20120225 Modelling Engine Torque
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The document discusses improving test benches used to test engine add-on parts and new concepts. It notes current test benches have limitations like indirect drives that do not correlate to field conditions and lack of protection systems. The main targets of the next generation test benches are to directly connect sample parts to an electrical engine to simulate real combustion engine torque and speed variations, and to design the test benches with explosion protection to test with field-relevant liquids. The focus is on simulating engine torque and speed behavior up to 10,000 rpm with speed gradients up to 12,000 rpm/s to directly test sample parts under improved security conditions.
![Simulation engine torque
Simulation of real combustion engine torque/speed
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150
n
140 2
130
360° (KW)
120
360° (elect. engine)
110
Frequenz_Unregelmäßigkeit [Hz]
100
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7](https://image.slidesharecdn.com/20120225modellingenginetorque-13302864193923-phpapp02-120226140514-phpapp02/85/20120225-Modelling-Engine-Torque-7-320.jpg)
![Simulation engine torque
Simulation of real combustion engine torque/speed
1
150.0
n
2
125.0
Drehzahl-Amplitude Verbrennungsmotor [1/min]
360° (KW)
360° (elect. engine)
100.0 Load [%]
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Engine speed [rpm]
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![Simulation engine torque
Summary: Simulation of real combustion engine torque/speed
1200 80
1100 70
Engine speed [rpm]
1000
load [%]
60
900
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30
600
speed-setpoint (1/min)
20
500 speed-nom.[1/min]
load [%]
400 10
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0,2 s 1,0 s time [s]
speed on test bench engine /electrical drive is varing in case of changes on:
Combustion engine load / nominal combustion engine speed / no. of cyclinders
10](https://image.slidesharecdn.com/20120225modellingenginetorque-13302864193923-phpapp02-120226140514-phpapp02/85/20120225-Modelling-Engine-Torque-10-320.jpg)
20120225 Modelling Engine Torque
- 1. Simulation engine torque Peter Heinrich engineering/business/consulting 1
- 2. overview test bench for engine add-on parts / new concept Current status on test bench concepts: •Indirect drive / samples driven by pulleys No correlation to used drives under field conditions Only redused speed gradients possible Wrong cross forces on sample drive shaft •Missing protection system Current protection system insufficient due to increased speed/torque/pressure/temperature/… •Missing environment simulation Test benches not always designed for runnig tests under “real” environment conditions like temperature, humidity, pressure, … 2
- 3. overview test bench for engine add on parts/new concept Main targets on next generation test bench: •Improved dynamic sample part drive no pulleys, no slipping main belt direct connection of sample parts to electrical engine •Simulation of real combustion engine torque/speed Alternating torque/speed at sample parts Constant speed •Using of field relevant test liquids Test bench designed with EX-protection (primary and/or secondary level) or using aged liquids varying speed 3
- 4. overview test bench for engine add on parts/new concept Main focus: simulation of engine torque/speed behaviour on test benches: • rated crankshaft speed speed up to 10000 1/min • speed gradients up to +/-12.000 rpm/s •direct connection to tested sample part •Torque/speed simulation of real combustion engines (1, 2, 4,…-cyl. Engine) •Equipment must run under improved security environment 4
- 5. Simulation engine torque Simulation of real combustion engine torque/speed real engine simulation n n + t t n t 5
- 6. Simulation engine torque Simulation of real combustion engine torque/speed Simulation of real combustion engine torque/speed parameter 1 = f (cyl., working process) simulation model cyl . 1 feng . felec.drive neng . 1 2 w n Cyl.: no. of Cylinder (1,2,3,4,…12 cylinder engine) W.: working process 360° (KW) (2, 4-stroke engine) 360° (elect. engine) 6
- 7. Simulation engine torque Simulation of real combustion engine torque/speed 1 150 n 140 2 130 360° (KW) 120 360° (elect. engine) 110 Frequenz_Unregelmäßigkeit [Hz] 100 1 90 2 3 80 4 70 5 6 No. of cylinder 60 8 50 40 30 20 10 0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000 Engine speed [rpm] 7
- 8. Simulation engine torque Simulation of real combustion engine torque/speed Simulation of real combustion engine torque/speed simulation model parameter 2 = f (eng.load, eng.speed, MOI) nmax.. n nN lN aeng . aelec.drive. n Δn 2 neng leng nN a: engine speed amplitude 360° (KW) neng, leng: engine speed, engine load at working point 360° (elect. engine) nN, lN: engine speed, engine load at nominal point 8
- 9. Simulation engine torque Simulation of real combustion engine torque/speed 1 150.0 n 2 125.0 Drehzahl-Amplitude Verbrennungsmotor [1/min] 360° (KW) 360° (elect. engine) 100.0 Load [%] 1 10 20 30 40 75.0 50 60 70 80 90 100 50.0 25.0 0.0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600 5800 6000 Engine speed [rpm] 9
- 10. Simulation engine torque Summary: Simulation of real combustion engine torque/speed 1200 80 1100 70 Engine speed [rpm] 1000 load [%] 60 900 50 800 40 700 30 600 speed-setpoint (1/min) 20 500 speed-nom.[1/min] load [%] 400 10 300 0 0,2 s 1,0 s time [s] speed on test bench engine /electrical drive is varing in case of changes on: Combustion engine load / nominal combustion engine speed / no. of cyclinders 10