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MODERNIZATION OF LEARNING FACILITIES ON EVALUATION OF COMBUSTION
PROCESSES
STANISLAV LINDAK, IVAN JANOSKO, PETER KUCHAR, MAREK HALENAR
Department of Transport and Handling Slovak University of
Agriculture in Nitra
Tr. A. Hlinku 2, 949 76 Nitra Slovak Republic
[email protected]
Abstract: The paper focuses on modernization of learning
facilities on evaluation of combustion processes, parameters and
graphic indication of limiting states. Primal part of device was
older type of dynamometer used for measuring power of tractors,
which was redesign and modernized for measuring the power about 140
kW and torque about 450 Nm of small vehicle’s engines. For data
acquisition and calculations was designed new software in
programming language. The control of hydrodynamic brake was
automatised and all important parameters of learning facilities and
engine was recorded in PC and visualized on the main monitor.
Designed and modernized learning facilities can measure basic
parameters: engine torque, engine power, RPM, fuel consumption with
gravimetric method and other numerous internal engine parameters,
that can be set “on line” through a special engine control unit.
The whole modernized learning facilities are designed on open
platform with free access for administrator.
Key Words: combustion processes, modernization, engine
parameters, learning facilities.
INTRODUCTION Monitoring of performance and technical parameters
of internal combustion engines is an
important part of the scientific research process. It is mainly
used to verify the theoretical knowledge and practical assumptions
(Janoško et al. 2013).
In order to reliably and securely verify the effects of
different technical solutions, settings or operating conditions on
the performance parameters of the engine, the most suitable
location of engine is on a test device that allows to simulate
different operating conditions and to read the greatest number of
motor parameters in real-time (Chrastina et al. 2014).
The market offers number of more or less complex devices, which
allowing monitoring various parameters of internal combustion
engines. Their complexity is reflected in their price (Uhrinová et
al. 2013).
By utilizing existing facilities, their modernization and
expansion of the new features can save a substantial part of the
funds (Jablonický et al. 2015).
We have therefore decided to modify and modernize existing
equipment to measure performance of tractors through the P.T.O.
shaft whereby can be monitored and simultaneously modify selected
parameters of conventional internal combustion engines for
passenger cars. Designed device combines the feature of a chassis
hydrodynamic brake with the possibility not only of monitoring
engine parameters but it also allows control and modify of the
activity of the internal combustion engine in real-time.
MATERIAL AND METHODS Hydrodynamic brake was constructed by
rebuilding of older type of dynamometer that are used
to measure the performance of the tractor through P.T.O. shaft.
From the initial dynamometer was used water brake with the driven
and a reaction turbine without reduction gearbox (Figure 1),
allowing to measure high torque at low speed through the P.T.O.
shaft. Its technical parameters are shown in Table 1.
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Figure 1 Hydrodynamic brake with mounted an internal combustion
engine
Table 1 Technical parameters of the original dynamometer Maximum
measurable power (kW) 140 Maximum rpm of P.T.O shaft (min-1) 2,000
The maximum measurable torque (Nm) 1,500 The gear ratio between the
input shaft and turbine (-) 0.3036 The maximum allowable torque of
input shaft at maximum power and maximum rpm (Nm)
668
Basic parameters of hydrodynamic brakes Before starting
conversions were carried out basic calculations to determine the
suitability of
using a dynamometer for the purpose of measuring power and
torque of conventional combustion engines. Calculation of the
maximum permissible rpm of the turbine nt max based on the maximum
permissible rpm of the drive shaft of dynamometer and from gear
ratio of reduction gearbox of initial dynamometer. From equation
(1) results, that the maximum permissible rpm of the drive turbine
of dynamometer are about 6,600 min-1. This limit of the maximum
permissible rpm is fully sufficient for diesel and most common
petrol engines for passenger cars. 𝑛𝑛𝑡𝑡 𝑚𝑚𝑚𝑚𝑚𝑚 =
𝑛𝑛ℎ 𝑚𝑚𝑚𝑚𝑚𝑚𝑖𝑖
, (1)
Where: nt max – the maximum permissible rpm of turbine (min-1),
nh max – the maximum permissible rpm of the drive shaft (min-1), i
– Gear ratio of reduction gearbox (-).
According to equation (2) we can determine the maximum
measurable brake torque of turbine Mkt, which represents the value
in the level Mkt max = 455 nm, which is sufficient for most
conventional diesel and petrol engines. 𝑀𝑀𝑘𝑘𝑡𝑡 𝑚𝑚𝑚𝑚𝑚𝑚 = 𝑖𝑖.𝑀𝑀𝑘𝑘ℎ,
(2) Where: Mkt max – torque on the turbine (Nm), Mkh – torque of
input shaft of the dynamometer (Nm), i – Gear ratio (-).
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The maximum permissible power of measured engine may be
determined by the equation (3) to the level of Pt max = 139.6 kW
(at 6600 min-1), which is sufficient for most existing, common,
especially small-volume petrol and diesel engines of passenger
cars.
𝑃𝑃𝑡𝑡 𝑚𝑚𝑚𝑚𝑚𝑚 =2𝜋𝜋.𝑀𝑀𝑘𝑘𝑘𝑘 𝑚𝑚𝑚𝑚𝑚𝑚.𝑛𝑛𝑘𝑘 𝑚𝑚𝑚𝑚𝑚𝑚
60 , (3)
Where: Pt max – the maximum allowable braking performance of
dynamometer (W), Mkt max – maximum permissible safe torque of
turbine (Nm), nt max – the maximum permissible rpm of turbine
(min-1), (Janoško et al. 2014).
Mechanical construction of equipment Proposal of test device for
braking of engines (Figure 2) consists of a base plate, frame and
body
of hydrodynamic brake with turbines, reaction and calibration
arm, main mounting flange, mechanism of adjustment load, water
management and accessories with other components.
Figure 2 Assembly scheme of hydrodynamic brake - major parts
1 - base plate, 2 - combustion engine, 3 - control unit of
engine, 4 - auxiliary frame, 5 - flange for mounting the internal
combustion engine, 6 - front pivoting of body brakes, 7 - rpm
sensor, 8 - frame of dynamometer, 9 - hydrodynamic brake, 10 - rear
pivoting of body dynamometer, 11 - sensor of eject position
reaction turbine, 12 - belt gear, 13 - force sensor, 14 -
electromotor at adjusting the position of the reaction turbine
The electronic part of the device The electronic part of the
proposed facility consists of two main parts, sensors and
actuators. The
sensing part through input-output card LabJack converts signals
from the sensors to the computer. The reading of the other
parameters is using control unit VEMS, which sends the measured
values via the RS232 interface to the PC. The control part using
the appropriate action and switching actuators executes commands
sent from the computer. Using the designed software, it is possible
fully automated to control the load of the hydrodynamic brake. By
using a sensing electronics of hydrodynamic brake it is now
possible read the following parameters:
• Rpm of engine, • Torque, • The air temperature in the room, •
Air pressure in the room, • Position of eject reaction turbine of
hydrodynamic brake, • Fuel consumption, mass method.
By using the control unit of engine can measure and record the
following parameters: • The oil temperature of engine, • The
temperature of the coolant,
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• The temperature of exhaust gases in two places, • The air
temperature in the intake manifold, • Air pressure in the intake
manifold, • The position of the throttle, • The richness of the
fuel mixture, (Janoško and Chrastina 2014).
Modernization of equipment consisted inter alia in modification
of mechanism adjustment of burden. Originally hand-operated
mechanism was replaced by electromechanical system with automatic
regulation. Electromotor by using worm gear and by belt gear
(Figure 3) changes the position of driven and driving turbines of
hydrodynamic brake.
Figure 3 Load setting mechanism of the hydrodynamic brake with
the feedback
Operating of the electromotor is solved by using electronic
switching unit (Figure 4) controlled
by hydrodynamic brake software. Load adjustment can be performed
in a manual or automatic mode.
Figure 4 Schematic diagram of the control electronics load
setting of the hydrodynamic brake
Control and measurement software
For operating of the hydrodynamic brake, data collection and
data visualization was designed and created personal computer
software.
Following of monitored parameters provides the user overview of
actual measured values of performance, rpm, torque and fuel
consumption in numeric and graphic form (Szabó et al. 2013).
The measured values can be saved and exported to a file in
*.csv. format. The software enables step, continuous and automatic
control of braking performance of hydrodynamic brake with the
feedback sized load of internal combustion engine. Software has
except operating and display functions also protective functions.
In the event that any value exceeds the permitted limit value, the
program immediately notifies the operator, respectively depending
on the significance of safety occurs interruption of a measurement.
The software was developed in C# on the platform of Microsoft®
Visual Studio 2013 by using some freely available dynamically
linked library. After starting the program, user
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can immediately see the value of each measured variables and
control settings of regulation in the graphics, respectively
alphanumeric form (Figure 5).
Figure 5 The main screen of the hydrodynamic brake software
The software allows you to view in the chart a time frame of
power, torque, rpm and volume of
the fuel at tank. Furthermore, it is possible to record and
portray also the rpm curves of engine.
Optimization of engine parameters By use the fully configurable
universal control unit VEMS, integrated into the system of the
hydrodynamic brake is possible except the recording parameters
of the internal combustion engine also manage his operations. The
unit is useful for any petrol engine with a maximum of eight
cylinders. By using VEMS control unit we can change the parameters
of the combustion process, such as the richness of the fuel
mixture, ignition advance, or turbo boost pressure. This change is
possible due a rewritable memory of control unit transferred in
real time and on the fly of the internal combustion engine. For
monitoring and adjustment of all key parameters of the internal
combustion engine is used software VemsTune (Figure 6).
Figure 6 Program for the monitoring and management of data in
the control unit
RESULTS AND DISCUSSION The operation of hydrodynamic brake is
also on base an open platform of setting the parameters
required not only for spot cycles but also in automatic mode
according to a programmed load. The learning facility was designed
as an open system, which allowing complements various modules for
measuring other parameters. The device can be easily extended at
the measurement of emissions or
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thermo vision testing. This characteristic is specific to the
hydrodynamic brake, which is different from commercial
facilities.
CONCLUSION Despite the fact that designed the test equipment is
still in development, already now can be a
good instrument in the education process, or may be use for
scientific experiments in short-term or long-term measurement of
internal combustion engines of cars. By using the integrated, fully
configurable control unit it can manage the operation of a petrol
combustion engine and change the combustion parameters in real
time.
ACKNOWLEDGEMENT This paper was prepared with the support of the
project KEGA No. 044 SPU-4/2014 ’Environmental technologies and
engineering’ and project VEGA No 1/0337/15 ‘Research aimed at
influence of agricultural, forest and transport machinery on
environment and its elimination on the basis of ecological measures
application’.
REFERENCES Chrastina, J., Janoško, I., Kangalov, P. 2014.
Monitoring the operating parameters of municipal vehicles. Ruse:
Angel Kanchev University of Ruse, Bulgaria. Jablonický, J., Hujo,
Ľ., Tkáč, Z. 2015. Motorové vozidlá. Mechanizmy motorových
vozidiel. 1 vyd. Nitra : Slovenská poľnohospodárska univerzita v
Nitre. Janoško, I., Polonec, T., Chrastina, J. 2013. Assessment of
monitoring of commercial vehicle’s technical parameters. Machines,
technologies, materials. [Online], 6: 15–17. Available at:
http://mech-ing.com/journal/Archive/2013/6/dokladi/27_Janosko.pdf.
[2016-04-06]. Janoško, I., Chrastina, J. 2014. Monitorovanie
parametrov komunálnych vozidiel. 1. vyd., Slovenská
poľnohospodárska univerzita v Nitre. Janoško, I., Lindák, S.,
Kosiba, J. 2014. Monitoring of the impact of operating personnel on
the transportation efficiency in the intercity bus transport. In
Naučni trudove, Ruse, Bulgaria. tom 53, seria 1.1, p. 145–152.
Szabó, M., Majdan, R., Tkáč, Z., Čápora, R., Hujo, Ľ. 2013.
Evaluation of fuel consumption in road freight transport. Acta
technologica agriculturae. vol. 16(1): 17–20. Uhrinová, D.,
Jablonický, J., Hujo, Ľ., Kosiba, J., Tkáč, Z., Králik, M.,
Chrastina, J. 2013. Research of limited and unlimited emission
effect on the environment during the burning of alternative fuels
in agricultural tractors. Journal of Central European Agriculture
online. [Online], 14(4): 1419–1431. Available at:
https://jcea.agr.hr/articles/774439_research_of_limited_and_unlimited_emission_effect_
on_the_environment_during_the_burning_of_alternative_fuels_in_agricultural_tr_en.pdf.
[2016-04-05].
Figure 3 Load setting mechanism of the hydrodynamic brake with
the feedbackConclusionAcknowledgementThis paper was prepared with
the support of the project KEGA No. 044 SPU-4/2014 ’Environmental
technologies and engineering’ and project VEGA No 1/0337/15
‘Research aimed at influence of agricultural, forest and transport
machinery on environment and ...
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