Microsoft Word - A_26_Titrik_R.doc HUNGARIAN JOURNAL OF INDUSTRIAL CHEMISTRY VESZPRÉM Vol. 39(1) pp. 35-40 (2011) DATA DETERMINATION OF AN INTERNAL COMBUSTION ENGINE FOR MODEL SET-UP I. LAKATOS , Á. TITRIK, T. ORBÁN Széchenyi István University, Department of Automotive and Railway Engineering Egyetem tér 1, 9026 Győr, HUNGARY E-mail: lakatos@sze.hu To make the model of the vehicle power train modelling firstly we have to make the engine (uncharged, 4-cylindrical, 8 valve four stroke engine) model with the help of GT Suite software. In terms of building and identification of the model we need to define several geometrical and mechanical values. Some of mentioned values are not given in available mending directive of the car. Some of them (e.g. the intake and exhaust-system) are too complex they can’t be exactly defined with simple measurement-technique. To define these geometries a computer tomography and methods with limited-element have been used. In the lecture we are introducing some interesting examples. Keywords: GT Suite, model, intake pipe, valve lift, Computer Tomography, straight pipe, bent pipe, Y-connector Introduction The research and development project set target to build the vehicle power train. The first important step is to build the internal combustion engine model. To build this model important data of the chosen engine are required. There are only a few of these as base data available. Therefore most of the geometrical sizes have to be defined by measurements. The engine chosen for modelling is a 1.6-liter 8-valve gasoline engine. Table 1: The main dates of chosen engines are as it follows: Construction 4-cylinder line engine Engine capacity 1595 cm3 Bore Ø81.0 mm Stroke 77.4 mm Compression ratio 10.3:1 Max. power 75 kW, 5600 min-1 Max. torque 148 Nm, 3800 min-1 The characteristic curves are shown on Fig. 1 and Fig. 2. Figure 1: Engine torque Figure 2: Engine power 36 Data validation for the model For the modelling it is necessary to know the elements of the intake and exhausting system details. Hereinafter we show the method of the measuring process. Defining the valve-lift chart We measured the valve moving chart with disassembled cylinder head. For this measuring we use inductive way and angle signaller. With this measuring technique we get the chart which is based on camshaft rotation. Figure 3: Measuring the valve movement chart (movement measure) Figure 4: Measuring the valve movement chart (angle signaller) Figure 5: The valve movement chart from the measure Definition of the mass data of the crank gear As an example, measurements of the mass of the piston are presented: Table 2: Results of the measurements Connecting-rod mass 539.63 g Mass without pin 286.6 g Mass with pin 348.7 g Piston + pin + connecting rod mass 886.86 g Figure 6: Measuring the piston mass Definition of geometrical data of the crank gear We present the measurements of the data of the piston and combustion chamber measured on the components of the given engine. Figure 7: Piston geometrical dimensions ● Piston Cup Diameter Ø 62.4 mm ● Maximum Piston Cup Depth 2.5 mm ● Piston Cup Diameter (Edge) Ø 62.4 mm ● Piston Cup Centre Depth 2.5 mm ● Piston Height 51 mm ● Deck Thickness 9.7 mm ● Average Ring Thickness 3 mm 37 Figure 8: Piston and combustion chamber dimensions ● Head Region Diameter (max.) Ø80.6 mm ● Head Region Diameter (edge) Ø 80.6 mm ● Head Region Height 8 mm Data of the intake system With the computer tomography we can control the outside and inside geometries with high accuracy. The external profile can be measured with ATOS optical measuring system, and the 3D digitalizing system is creating a polygon-mesh with high resolution. The system converts these data to CAD data using reverse engineering method. The steps of this process are: ● cloud-model ● STL file(*.stl) only the surface is described with the help of 923.196 triangle elements ● Making the 3D model using the computer tomography geometries of lower part of the intake system ● Fitting the guideline to intake system and defining the length of the axis and the angle between the two connecting surfaces ● Using the section guideline we can measure the diameter of the intake system shown on Fig. 10 Figure 9: Lower intake system Figure 10: Dimensions of the lower intake system Data of exhaust system The geometric measures of the exhaust system have to be defined exactly. According to this the exhaust system pipes can be set up from the following model elements: 1. straight D=Ø45.4 mm l=40 mm 2. bent D=Ø45.4 mm 38°45’ r=45.4 mm 3. straight D=Ø45.4 mm l=530 mm 4. Y connector with 90° angle 5. straight D=Ø45.4 mm l=80 mm 6. D=Ø45.4 mm → Ø130 mm l=47 mm 7. straight D=Ø130 mm l=158 mm 8. D=Ø130 mm → Ø 54.4 mm l=47 mm 9. straight D=Ø54.4 mm l=960 mm 10. bent D=Ø54.4 mm 10° r=54.4 mm 11. straight D=Ø54.4 mm l=230 mm 12. bent D=Ø54.4 mm 55° r=54.4 mm 13. straight D=Ø54.4 mm l=210 mm 14. bent D=Ø54.4 mm 55° r=54.4 mm 15. straight D=Ø54.4 mm l=40 mm 16. catalyst 17. straight D=Ø54.4 mm l=40 mm 18. bent D=Ø54.4 mm 30° r=54.4 mm 19. straight D=Ø54.4 mm l=150 mm 20. bent D=Ø54.4 mm 45° r=54.4 mm 21. straight D=Ø54.4 mm l=260 mm 22. bent D=Ø54.4 mm 45° r=54.4 mm 23. muffler 24. exhaust pipe end 38 Figure 11: Dimensions of the exhaust system It is quite simple to model the straight sections if we know the geometric data. The bent pipe length can be defined with the measured angle (length of arc): 360 R2i α ⋅π⋅⋅= (1) Where: i – pipe length (mm) R – radius (mm) α – angle [°] To model the Y-connector we have to give the dimensions precisely. Beside this the volume has to be given according to changing size of the blue sphere on the model shown on Fig. 12. We have to measure the following dimensions to define the catalytic system: ● The section of the catalytic system (11959 mm2) ● Flow section (flow factor) from GT Suite, value 70% ● We choose the following parameters for cell density which is 400 cpsi (cells per square inch) = 62 cells/cm2 (this value is used for passenger car) For modelling the silencer we use the GT Suite sample model because we cannot disassembly the exhaust system. The silencer has a lot of parts like pipe and T connector, etc. which is shown on Fig. 14. Figure 12: Modelling the Y connector 39 Figure 13: Model of the catalytic system Figure 14: Model of the silencer Summary To carry out the model of the chosen four-cylinder, 8- valved, four stroke engine we have to get the rest of the dimensions. In this presentation we highlighted only some significant elements. ACKNOWLEDGMENT The financial support of this work by the Hungarian State and the European Union under the TAMOP-4.2.1/B- 09/1/KONV-2010-0003 project is kindly acknowledged. REFERENCES 1. A. RAHAMN, M. DZAIDIN: Optimal design of automobile exhaust system using GT-Power, International Journal of Mechanical and Materials Engineering (IJMME), 2(1), (2007), 40–47 2. U. KRAMER: Potentialanalyse des Direktstarts für den Einsatz in einem Stopp-Start-System an einem Ottomotor mit strahlgeführter Benzin- Direktein- spritzung unter besonderer Berücksichtigung des Motorauslaufvorgangs, Dissertation, Universität Duisburg – Essen, 2005 3. M. BOS: Validation Gt-Power Model Cyclops Heavy Duty Diesel Engine, MSc. Thesis, 2007 4. DR. I. LAKATOS Ph.D.: Gépjármű hajtáslánc modellezése és szimulációja, hajtáslánc optimális irányítása, Mobilitás és környezet: Járműipari, energetikai és környezeti kutatások a Közép- és Nyugat-Dunántúli Régióban TÁMOP 4.2.1/B- 09/1/KONV-2010-0003 Workshop, Győr, 2011.06.27. 5. DR. I. LAKATOS: Töltetcsere-időzítés hatása a négy- ütemű feltöltetlen Otto-motorok üzemére, Ph.D. disszertáció, BME, 2002, 112 p. << /ASCII85EncodePages false /AllowTransparency false /AutoPositionEPSFiles true /AutoRotatePages /None /Binding /Left /CalGrayProfile (Dot Gain 20%) /CalRGBProfile (sRGB IEC61966-2.1) /CalCMYKProfile (U.S. Web Coated \050SWOP\051 v2) /sRGBProfile (sRGB IEC61966-2.1) /CannotEmbedFontPolicy /Error /CompatibilityLevel 1.4 /CompressObjects /Tags /CompressPages true /ConvertImagesToIndexed true /PassThroughJPEGImages true /CreateJobTicket false /DefaultRenderingIntent /Default /DetectBlends true /DetectCurves 0.0000 /ColorConversionStrategy /CMYK /DoThumbnails false /EmbedAllFonts true /EmbedOpenType false /ParseICCProfilesInComments true /EmbedJobOptions true /DSCReportingLevel 0 /EmitDSCWarnings false /EndPage -1 /ImageMemory 1048576 /LockDistillerParams false /MaxSubsetPct 100 /Optimize true /OPM 1 /ParseDSCComments true /ParseDSCCommentsForDocInfo true /PreserveCopyPage true /PreserveDICMYKValues true /PreserveEPSInfo true /PreserveFlatness true /PreserveHalftoneInfo false /PreserveOPIComments true /PreserveOverprintSettings true /StartPage 1 /SubsetFonts true /TransferFunctionInfo /Apply /UCRandBGInfo /Preserve /UsePrologue false /ColorSettingsFile () /AlwaysEmbed [ true ] /NeverEmbed [ true ] /AntiAliasColorImages false /CropColorImages true /ColorImageMinResolution 300 /ColorImageMinResolutionPolicy /OK /DownsampleColorImages true /ColorImageDownsampleType /Bicubic /ColorImageResolution 300 /ColorImageDepth -1 /ColorImageMinDownsampleDepth 1 /ColorImageDownsampleThreshold 1.50000 /EncodeColorImages true /ColorImageFilter /DCTEncode /AutoFilterColorImages true /ColorImageAutoFilterStrategy /JPEG /ColorACSImageDict << /QFactor 0.15 /HSamples [1 1 1 1] /VSamples [1 1 1 1] >> /ColorImageDict << /QFactor 0.15 /HSamples [1 1 1 1] /VSamples [1 1 1 1] >> /JPEG2000ColorACSImageDict << /TileWidth 256 /TileHeight 256 /Quality 30 >> /JPEG2000ColorImageDict << /TileWidth 256 /TileHeight 256 /Quality 30 >> /AntiAliasGrayImages false /CropGrayImages true /GrayImageMinResolution 300 /GrayImageMinResolutionPolicy /OK /DownsampleGrayImages true /GrayImageDownsampleType /Bicubic /GrayImageResolution 300 /GrayImageDepth -1 /GrayImageMinDownsampleDepth 2 /GrayImageDownsampleThreshold 1.50000 /EncodeGrayImages true /GrayImageFilter /DCTEncode /AutoFilterGrayImages true /GrayImageAutoFilterStrategy /JPEG /GrayACSImageDict << /QFactor 0.15 /HSamples [1 1 1 1] /VSamples [1 1 1 1] >> /GrayImageDict << /QFactor 0.15 /HSamples [1 1 1 1] /VSamples [1 1 1 1] >> /JPEG2000GrayACSImageDict << /TileWidth 256 /TileHeight 256 /Quality 30 >> /JPEG2000GrayImageDict << /TileWidth 256 /TileHeight 256 /Quality 30 >> /AntiAliasMonoImages false /CropMonoImages true /MonoImageMinResolution 1200 /MonoImageMinResolutionPolicy /OK /DownsampleMonoImages true /MonoImageDownsampleType /Bicubic /MonoImageResolution 1200 /MonoImageDepth -1 /MonoImageDownsampleThreshold 1.50000 /EncodeMonoImages true /MonoImageFilter /CCITTFaxEncode /MonoImageDict << /K -1 >> /AllowPSXObjects false /CheckCompliance [ /None ] /PDFX1aCheck false /PDFX3Check false /PDFXCompliantPDFOnly false /PDFXNoTrimBoxError true /PDFXTrimBoxToMediaBoxOffset [ 0.00000 0.00000 0.00000 0.00000 ] /PDFXSetBleedBoxToMediaBox true /PDFXBleedBoxToTrimBoxOffset [ 0.00000 0.00000 0.00000 0.00000 ] /PDFXOutputIntentProfile () /PDFXOutputConditionIdentifier () /PDFXOutputCondition () /PDFXRegistryName () /PDFXTrapped /False /CreateJDFFile false /Description << /ARA /BGR /CHS /CHT /CZE /DAN /DEU /ESP /ETI /FRA /GRE /HEB /HRV (Za stvaranje Adobe PDF dokumenata najpogodnijih za visokokvalitetni ispis prije tiskanja koristite ove postavke. 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