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Free Valve Technology Free Valve Technology ØYVIND GUNDERSEN Master of Science Thesis Stockholm, Sweden 2009 Free Valve Technology – Utveckling av ett styrsystem för ett elektroniskt styrt pneumatisk-hydraulisk ventilsystem i en förbränningsmotor Øyvind Gundersen Examensarbete MMK 2009:75 MFM130 KTH Industriell teknik och management Maskinkonstruktion SE-100 44 STOCKHOLM Free Valve Technology – Development of a control system for an electronically controlled pneumatic-hydraulic valve actuation system for an automotive engine Øyvind Gundersen Master of Science Thesis MMK 2009:75 MFM130 KTH Industrial Engineering and Management Machine Design SE-100 44 STOCKHOLM Examensarbete MMK 2009:75 MFM130 Free Valve Technology – Utveckling av ett styrsystem för ett elektronisk styrt pneumatisk-hydraulisk ventilsystem på en förbränningsmotor Øyvind Gundersen Godkänt Examinator Handledare 2009-11-03 Hans-Erik Ångström Hans-Erik Ångström Uppdragsgivare Kontaktperson AVL SPEAB Richard Backman Sammanfattning Detta examensarbete är utfört på uppdrag från AVL Södertälje Powertrain Engineering AB. Målet med arbetet har varit att utveckla ett styrsystem för ett elektroniskt styrt pneumatisk- hydrauliskt ventilsystem på en encylindrig förbränningsmotor i en testcell. AVL är en oberoende firma som utvecklar drivlinor med förbränningsmotorer samt instrumenterings- och testsystem. Ventilsystemet, med ett fungerande styrsystem, ska användas i AVLs utvecklings- och forskningsarbete på förbränningsmotorer. Ventilsystemet, Free Valve Technology , är utvecklat av Cargine Engineering AB och består av elektroniskt styrda pneumatisk-hydrauliska aktivatorer som opererar en motorventil individuellt. Aktivatorernas styrsystem har utvecklats helt i Simulink och implementerats som en integrerad del i det av AVL utvecklade motorstyrsystemet Raptor. Hårdvaran och plattformen är ett rapid prototyping system från dSPACE GmbH. Systemet har visat sig fungera tillfredsställande i en testcellmiljö vid lyfthöjder större än 3 mm och varvtal lägre än 2500 rpm, även under förbränning. Under 2 mm lyft blir ventillyftet instabilt och över 2500 varv per minut kan ventillyftet bli lägre – beroende på duration – på grund av att ventilöppningshastigheten är konstant i tid, inte vevaxelgrader, och ventilen därmed inte hinner öppnas fullt före stängning. Systemets cykel till cykel-variationer på öppnings- och stängningstider samt ventillyft är i storleksordning på ca 10 procent inom ventilernas stabila område, med påföljande påverkning på gaväxlingsvariationerna. Systemets energiförbrukning tillsvarar ca 4 kW för en fyrcylindrig 16-ventils motor vid 6000 varv/min. Systemet har ett grafiskt gränssnitt som tillåter att ventiltider och -lyft kan bestämmas fritt och enkelt av användaren, men med en säkerhetsfunktion som begränsar ventiltider så att kollision med kolven undvikas. En funktion för att köra motorn i 8-takt finns, och nya funktioner, kan läggas till. Slutsatsen som kan dras är att – även med de utmaningarna som kvarstår – fungerar ventilsystemet tillfredsställande och kan användas i sin nuvarande form i testcellsmiljö. Examensarbetet har också visat att kombinationen av Raptor, RapidPro-systemet och friheten med pneumatiska ventiler öppnar för nästan obegränsade testmöjligheter. Det är en stark indikation på att detta system kan vara värdefullt i AVLs framtidiga arbete med utveckling och forskning inom förbränningsmotorteknologi. Master of Science Thesis MMK 2009:75 MFM130 Free Valve Technology – Development of a control system for an electronically controlled pneumatic-hydraulic valve actuation system for an automotive engine Øyvind Gundersen Approved Examiner Supervisor 2009-11-03 Hans-Erik Ångström Hans-Erik Ångström Commissioner Contact person AVL SPEAB Richard Backman Abstract This master thesis is a project commissioned by AVL Södertälje Powertrain Engineering AB. The purpose has been to develop a control system for an electronic pneumatic-hydraulic valve actuation system installed in a one cylinder test engine. AVL is an independent company which develops powertrain systems with internal combustion engines as well as instrumentation and test systems. The valve actuation system is to be used in their research and development of internal combustion technology. The valve actuation system, called Free Valve Technology , is developed by Cargine Engineering AB and consists of electronically controlled, pneumatic-hydraulic actuators operating each engine valve individually. The control system for the actuators has been developed entirely in Simulink and implemented as an integral part of the AVL developed engine control system, Raptor , on a dSPACE rapid prototyping system platform. The system has proved to be working satisfactorily in a test cell environment at lift heights above 3 mm and engine speeds below 2500 rpm, even during combustion. Below 2 mm lift height, the valve operation no longer is stable and dependable, and at engine speeds above 2500 rpm, valve lift may be truncated –depending on duration – due to the valve opening speed constant in time, not in crank angle degrees and thus does not manage to open fully before closing. The system’s cycle to cycle variations of valve timing and lift are around 10 percent inside the stable operation frame, with subsequent effect on gas exchange variations. Energy consumption of the system was found to be equivalent to 4 kW at 6000 rpm for a 16 valve four-cylinder engine. The system has a graphic user interface that allows the user to freely change valve timing and lift effortlessly, but with a safety function limiting timing to avoid valve and piston collision. A function for operating the engine at 8-stroke combustion mode exists, and new features can easily be added to the existing system. This thesis has reached the conclusion that even though a lot of problems and challenges still remain with this system the valve actuation system works satisfactorily and can be used in its present form in test cell conditions. This thesis has also shown that the combination of a rapid prototyping system together with the versatility in the free valve system opens almost endless testing possibilities. It shows a strong indication that the free valve technology will be valuable in AVL’s further research and development in internal combustion technology. Acknowledgements A lot of sweat, toil and frustration have gone into this project. Without the help of certain people, this thesis project could not have been completed. Some of them deserve a special mention. The author wishes to acknowledge the following people at AVL SPEAB: My supervisor, Richard Backman, for giving me this opportunity and his feedback and help. Henrik Dembinski for his helpfulness in just about everything, whether it was cell operation, control system development or problems in general. Jonas Cornelsen for his never-ending problem solving skills in dSPACE and cell equipment as well as essential tips and help during development of the control system. I also would like to thank my supervisor, Professor Hans-Erik Ångström, at the Royal Institute of Technology – Internal Combustion Engines division. Any flaws, of course, are my own. Contents 1 INTRODUCTION .......................................................................................................................................... 1 1.1 BACKGROUND ......................................................................................................................................... 1 1.2 OBJECTIVE ............................................................................................................................................... 1 1.3 LIMITATIONS ........................................................................................................................................... 2 1.4 METHOD .................................................................................................................................................. 2 2 VARIABLE VALVE ACTUATION............................................................................................................. 3 2.1 PNEUMATIC -HYDRAULIC VALVE ACTUATION ........................................................................................... 3 2.1.1 Free Valve Technology....................................................................................................................... 3 2.2 ADVANTAGES WITH VARIABLE VALVE ACTUATION ................................................................................ 6 2.2.1 Optimized valve timing and lift .......................................................................................................... 6 2.2.2 Advantages specifically for FVVT...................................................................................................... 9 2.3 DISADVANTAGES WITH PNEUMATIC VARIABLE VALVE ACTUATION ..................................................... 10 3 EXPERIMENTAL SETUP.......................................................................................................................... 11 3.1 CELL ...................................................................................................................................................... 11 3.2 ENGINE .................................................................................................................................................. 11 3.3 CONTROL UNITS .................................................................................................................................... 12 3.4 ACTUATORS ..........................................................................................................................................
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