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At least 1,513 records · Page 84

Durability Study of a High-Pressure Common Rail Fuel Injection System Using Lubricity Additive-Dosed Gasoline-Like Fuel—Improved Endurance with Upgraded Hardware

Gasoline compression ignition (GCI) is a promising combustion technology that can help the commercial transportation sector achieve operational flexibility and meet upcoming criteria pollutant regulations. However, high-pressure fuel injection systems (>1000 bar) are needed to enable GCI and fully realize its benefits compared to conventional diesel combustion. This work is a continuation of previous durability studies that identified three key technical risks after running gasoline-like fuel through a heavy-duty, common rail injection system: (i) cavitation damage to the inlet check valve of the high-pressure pump, (ii) loss of injector fueling capacity, (iii) cavitation erosion of the injector nozzle holes. Upgraded hardware solutions were tested on a consistent 400- to 800-hour NATO durability cycle with the same gasoline-like fuel as previous studies. The upgraded pump showed no signs of abnormal wear or cavitation damage to the inlet check valve. In contrast to previous studies, there were no signs of pump performance degradation observed after 400 hours of testing. Material selection and design upgrades were also made to the injector which, only showed a 6.5% loss in fueling capacity after 800 hours of durability testing compared to 49.3% previously. Finally, geometric nozzle hole features such as higher inlet radius of curvature and higher K-factor were found to correlate with reduced cavitation erosion. However, mitigation of eccentric radial needle motion (i.e., wobble) is likely needed to further suppress cavitation. In general, the results from this study indicate there are viable hardware-based solutions for improving the endurance of high-pressure systems when running with gasoline-like fuel.

33 ADVANCED PROPULSION SYSTEMS↗

Influence of Injector Location on Part-Load Performance Characteristics of Natural Gas Direct-Injection in a Spark Ignition Engine

Interest in natural gas as an alternative fuel source to petroleum fuels for light-duty vehicle applications has increased due to its domestic availability and stable price compared to gasoline. With its higher hydrogen-to-carbon ratio, natural gas has the potential to reduce engine out carbon dioxide emissions, which has shown to be a strong greenhouse gas contributor. For part-load conditions, the lower flame speeds of natural gas can lead to an increased duration in the inflammation process with traditional port-injection. Direct-injection of natural gas can increase in-cylinder turbulence and has the potential to reduce problems typically associated with port-injection of natural gas, such as lower flame speeds and poor dilution tolerance. A study was designed and executed to investigate the effects of direct-injection of natural gas at part-load conditions. Steady-state tests were performed on a single-cylinder research engine representative of current gasoline direct-injection engines. Tests were performed with direct-injection in the central and side location. The start of injection was varied under stoichiometric conditions in order to study the effects on the mixture formation process. In addition, exhaust gas recirculation was introduced at select conditions in order to investigate the dilution tolerance. Relevant combustion metrics were then analyzed for each scenario. Experimental results suggest that regardless of the injector location, varying the start of injection has a strong impact on the mixture formation process. Delaying the start of injection from 300 to 120°CA BTDC can reduce the early flame development process by nearly 15°CA. While injecting into the cylinder after the intake valves have closed has shown to produce the fastest combustion process, this does not necessarily lead to the highest efficiency, due to increases in pumping and wall heat losses. When comparing the two injection configurations, the side location shows the best performance in terms of combustion metrics and efficiencies. For both systems, part-load dilution tolerance is affected by the injection timing, due to the induced turbulence from the gaseous injection event. CFD simulation results have shown that there is a fundamental difference in how the two injection locations affect the mixture formation process. Delayed injection timing increases the turbulence level in the cylinder at the time of the spark, but reduces the available time for proper mixing. Side injection delivers a gaseous jet that interacts more effectively with the intake induced flow field, and this improves the engine performance in terms of efficiency.

Sevik, James↗

Effects of Heat of Vaporization and Octane Sensitivity on Knock-Limited Spark Ignition Engine Performance

Knock-limited loads for a set of surrogate gasolines all having nominal 100 research octane number (RON), approximately 11 octane sensitivity (S), and a heat of vaporization (HOV) range of 390 to 595 kJ/kg at 25 degrees C were investigated. A single-cylinder spark-ignition engine derived from a General Motors Ecotec direct injection (DI) engine was used to perform load sweeps at a fixed intake air temperature (IAT) of 50 degrees C, as well as knock-limited load measurements across a range of IATs up to 90 degrees C. Both DI and pre-vaporized fuel (supplied by a fuel injector mounted far upstream of the intake valves and heated intake runner walls) experiments were performed to separate the chemical and thermal effects of the fuels' knock resistance. The DI load sweeps at 50 degrees C intake air temperature showed no effect of HOV on the knock-limited performance. The data suggest that HOV acts as a thermal contributor to S under the conditions studied. Measurement of knock-limited loads from the IAT sweeps for DI at late combustion phasing showed that a 40 vol% ethanol (E40) blend provided additional knock resistance at the highest temperatures, compared to a 20 vol% ethanol blend and hydrocarbon fuel with similar RON and S. Using the pre-vaporized fuel system, all the high S fuels produced nearly identical knock-limited loads at each temperature across the range of IATs studied. For these fuels RON ranged from 99.2 to 101.1 and S ranged from 9.4 to 12.2, with E40 having the lowest RON and highest S. The higher knock-limited loads for E40 at the highest IATs examined were consistent with the slightly higher S for this fuel, and the lower engine operating condition K values arising from use of this fuel. The study highlights how fuel HOV can affect the temperature at intake valve closing, and consequently the pressure-temperature history of the end gas leading to more negative values of K, thereby enhancing the effect of S on knock resistance.

33 ADVANCED PROPULSION SYSTEMS↗

Total Thermal Management of Battery Electric Vehicles (BEVs)

The key hurdles to achieving wide consumer acceptance of battery electric vehicles (BEVs) are weather-dependent drive range, higher cost, and limited battery life. These translate into a strong need to reduce a significant energy drain and resulting drive range loss due to auxiliary electrical loads the predominant of which is the cabin thermal management load. Studies have shown that thermal subsystem loads can reduce the drive range by as much as 45% under ambient temperatures below -10°C. Often, cabin heating relies purely on positive temperature coefficient (PTC) resistive heating, contributing to a significant range loss. Reducing this range loss may improve consumer acceptance of BEVs. The authors present a unified thermal management system (UTEMPRA) that satisfies diverse thermal and design needs of the auxiliary loads in BEVs. Demonstrated on a 2015 Fiat 500e BEV, this system integrates a semi-hermetic refrigeration loop with a coolant network and serves three functions: (1) heating and/or cooling vehicle traction components (battery, power electronics, and motor) (2) heating and cooling of the cabin, and (3) waste energy harvesting and re-use. The modes of operation allow a heat pump and air conditioning system to function without reversing the refrigeration cycle to improve thermal efficiency. The refrigeration loop consists of an electric compressor, a thermal expansion valve, a coolant-cooled condenser, and a chiller, the latter two exchanging heat with hot and cold coolant streams that may be directed to various components of the thermal system. The coolant-based heat distribution is adaptable and saves significant amounts of refrigerant per vehicle. Also, a coolant-based system reduces refrigerant emissions by requiring fewer refrigerant pipe joints. The authors present bench-level test data and simulation analysis and describe a preliminary control scheme for this system.

Chowdhury, Sourav↗

Respiratory transfer value has fail-safe feature

Quick-acting, remote controlled valve connects either one of two oxygen or air supplies to a breathing tube. The valve, which is fall-safe, incorporates a cammed piston arrangement that is driven by a remote controlled reversible rotary solenoid or reversible electric motor.

Puccinelli, A. A.↗

Circuit exhibits power efficiency greater than 75 percent

Variable duty cycle pulser increases circuit power efficiency by more than 75 percent when operating solenoid valves. The pulser provides a low-level holding current after a high-level current has actuated the solenoid valves.

Mankovitz, R. J.↗

Automatic protective vent has fail-safe feature

Delayed vent valve system in a mechanical backing pump in a vacuum system allows the pneumatic foreline valve to seal before the pump vent opens. The system is designed to be fail-safe and operate even though there is loss of electrical power.

Dameron, C. E.↗

Seal-off assembly permits rapid evacuation of air from containers

Seal-off assembly which permits rapid container evacuation using large diameter tubing has a vacuum valve that permits sealing plate transfer from the vacuum valve stem to the container after evacuation. The sealing plate can be reused repeatedly. This device can repump in case of a small leak without exposing the container to the atmosphere.

Demers, R. R.↗

System automatically supplies precise analytical samples of high-pressure gases

High-pressure-reducing and flow-stabilization system delivers analytical gas samples from a gas supply. The system employs parallel capillary restrictors for pressure reduction and downstream throttling valves for flow control. It is used in conjunction with a sampling valve and minimizes alterations of the sampled gas.

Langdon, W. M.↗

Improved cryogenic refrigeration system

Two-position shuttle valve simplifies valving arrangement and crank-shaft configuration in gas-balancing and Stirling-cycle refrigeration systems used to produce temperatures below 173 degrees K. It connects the displacer and regenerator alternately to the supply line or the return line of the compressor, and establishes constant pressure on the drive piston.

Higa, W. H.↗

High impact pressure regulator withstands impacts of over 15,000 g

High impact pressure regulator used with a high impact gas scannograph withstands impacts of over 15,000 g. By the passage of fluid through the first and second chambers of the regulator, the pressure of the scannograph is regulated from a specific input valve to the desired output pressure valve.

Biles, J. E., Jr.↗

Dynamic captive plastic seal

Fluoroplastic material held captive between valve sealing surfaces of 16 to 125 rms microinches provides zero leakage to a high-pressure line at high cryogenic temperatures, when the plastic material is subjected to sufficient stress. This sealing technique makes unnecessary the use of superfinished valve sealing surfaces.

Dryer, E. O.↗

Synchronized circuit improves accuracy of fluid transfer measurements

Shut-off valve at the destination of a transferred fluid, improves the accuracy of measurements determining the quantity of liquid transferred from a storage source to a remote location. By synchronizing this valve with the measuring device /totalizer/, the inaccuracies resulting from unfilled transfer lines can be reduced.

Vendl, C. J.↗

Ballast barge concept for underwater structures

Ballast barge for underwater structure consists of a reinforced concrete structure partitioned into watertight compartments. The barge structure includes a 3-way venting valve, a compressed air manifold, a master valve for connecting the manifold to an air line, and an open port in each compartment for admitting and expelling sea water.

Payne, V. E.↗

High-torque power wrench, a concept

High-torque power wrench is small enough to be handled by one or two men yet has sufficient torque to remove 1-1/2- to 4-inch nuts from high-pressure tanks and valves. The action can be made automatic by use of solenoid-operated valves and suitable switches.

Cox, E. F.↗

Automatic amino acid analyzer

Analyzer operates unattended or up to 15 hours. It has an automatic sample injection system and can be programmed. All fluid-flow valve switching is accomplished pneumatically from miniature three-way solenoid pilot valves.

Berdahl, B. J.↗

Hydraulic actuator motion limiter ensures operator safety

Device regulates action of hydraulic linkage to control column to minimize hazard to operator. Primary components of device are flow rate control valve, limiter accumulator, and shutoff valve. Limiter may be incorporated into other hydraulic systems to prevent undue wear on hydraulic actuators and associated components.

Steinmetz, C. P.↗