The experimental study of mechanical losses in the modern diesel engine

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Abstract

BACKGROUND: Amid the tightening of the CO2 emission requirements as well as high level of competition on the commercial truck market, the focus area of the internal combustion engine (ICE) development is as follows: high engine efficiency and fuel economy, minimization of internal losses and engine cycle optimization for all operation modes. Engine performance factors of modern 12–13-liter diesel engines, existing on the global market, are as follows: the minimal specific fuel consumption is 179–182 g/kWh, effective efficiency is 46–48%. Decreasing of mechanical losses is one of the features that made the achievement of such factors possible. The relevant issue for choosing the strategy of mechanical losses decreasing is formation of balance in losses distribution between main ICE groups of components. Moreover, considering the mechanical losses dependence on engine operating speed, engine cycle parameters and engine design features, it is important to determine the pattern of change in mechanical losses.

AIMS: Assessment of mechanical losses of modern diesel engine with high effective efficiency in an experimental way. Formation of mechanical losses balance.

METHODS: The study object is the 6ChN 13/15 inline six-cylinder diesel engine with the operation volume of 11.95 liters. The mechanical losses assessment was performed with the engine, propelled by a dynamometric machine on a testing facility with fully stabilized conditions, with the method of sequential disassemble of main groups of components.

RESULTS: Relevant data of mechanical losses level of the modern diesel engine with the distribution between main groups of components is obtained. Mechanical losses dependence on operation speed, oil and coolant liquid temperatures is formed.

CONCLUSIONS: Practical value of the study lies in assessment of contribution of each group of components in the total friction as well as in assessment of the degree of design and technological development of ICEs. According to the study results, areas of possible improvement of friction for each group of components and engine as a whole will be formed.

About the authors

Marat D. Khannanov

Naberezhnye Chelny Institute of the Kazan Federal University; Research and Development Center of PJSC “KAMAZ”

Author for correspondence.
Email: marhan87@mail.ru
ORCID iD: 0000-0001-9816-0691
SPIN-code: 9825-8736

Postgraduate of the Automobiles, Automobile Engines and Design Department

Russian Federation, Naberezhnye Chelny; Naberezhnye Chelny

Irek F. Gumerov

Research and Development Center of PJSC “KAMAZ”

Email: gumerov@kamaz.ru
ORCID iD: 0000-0002-5538-8693
SPIN-code: 3475-4219

Cand. Sci. (Engin.); Deputy General Director - Development Director

Russian Federation, Naberezhnye Chelny

Lenar I. Fardeev

Research and Development Center of PJSC “KAMAZ”

Email: Lenar.Fardeev@kamaz.ru
ORCID iD: 0000-0002-2508-5915
SPIN-code: 4034-8695

Deputy Chief Engine Designer for Advanced Engines

Russian Federation, Naberezhnye Chelny

Andrey S. Kulikov

Research and Development Center of PJSC “KAMAZ”

Email: Andrey.Kulikov@kamaz.ru
ORCID iD: 0000-0003-4005-1112
SPIN-code: 1525-7860

Chief Engine Designer of R&D Center

Russian Federation, Naberezhnye Chelny

Eduard R. Alimgulov

Research and Development Center of PJSC “KAMAZ”

Email: Eduard.Alimgulov@kamaz.ru
ORCID iD: 0000-0002-7808-8327
SPIN-code: 8738-3647

Head of the Design Group of Advanced Engines, R&D Center

Russian Federation, Naberezhnye Chelny

References

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  7. Shchukina VN. Analysing methods of determining mechanical losses for their subsequent use in operation process. Vestnik of Federal State Educational Establishment of Higher Professional Education “Moscow State Agroengineering University named after V.P. Goryachkin” 2016;(5):18–21. (In Russ).
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Supplementary files

Supplementary Files
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1. JATS XML
2. Fig. 1. Distribution of mechanical losses shares between units and assemblies of an ICE: 1 – cylinder-piston group (CPG); 2 – crank gear assembly (CGA); 3 – gases exchange (pumping losses); 4 – valve gear assembly (VGA); 5 – accessories.

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3. Fig. 2. The sketch of losses distribution depending on engine operation speed.

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4. Fig. 3. The simplified scheme of the testing facility: 1 – a driving dynamometric machine; 2 – a torque sensor; 3 – a jointed shaft with an adapter flange; 4 – main oil distributing passage, oil and pressure gauge; 5 – an oil filter; 6 – an air intake system; 7 – an oil pump; 8 – a coolant liquid pressure and temperature gauge at the outlet; 9 – a heat exchanger; 10 – a coolant liquid conditioning unit; 11 – an oil conditioning unit; 12 – a water pump, a coolant liquid pressure and temperature gauge at the inlet; 13 – an oil pan.

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5. Fig. 4. Evaluation of average indicator pressure: a) the indicator diagram calibration; b) the P-V diagram plotting.

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6. Fig. 5. Shares of groups of components from ICE total losses for oil and coolant liquid temperatures of 90 °C and crankshaft rotation speed of 900 and 1900 rev/min.

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7. Fig. 6. The graph of mechanical losses power of main groups of components depending on crankshaft rotation speed.

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8. Fig. 7. The graph of mechanical losses percentage of main groups of components depending on crankshaft rotation speed.

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9. Fig. 8. The graph of mechanical losses of the assembled engine depending on temperatures of oil and coolant liquid.

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