Diesel Engine Experimental Design and Advanced Analysis Techniques THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Jonathan M. Davis Graduate Program in Mechanical Engineering The Ohio State University 2011 Master‘s Examination Committee: Shawn Midlam-Mohler, Advisor Dr. Giorgio Rizzoni Dr. Yann Guezzenec Copyright by Jonathan Michael Davis 2011 Abstract A new diesel engine control strategy has been developed. In order to successfully validate and implement this control strategy experimental design techniques were used which optimize the data collection process. This included the setup of cylinder pressure measurements as well as the creation of an automating testing program. This program automates engine testing, interfacing with key components such as the dynamometer and engine controller (ECU). Both steady state and transient testing algorithms were developed. Several advanced analysis techniques have been developed for the project. An in depth study on pegging cylinder pressure was completed, utilizing GT Power©. GT Power© was also used to analyze an experimental design to simulate altitude at sea level in the test cell. i Acknowledgements I would like to thank The Ohio State University and CAR for the facilities and opportunities provided. I would also like to thank Dr. Shawn Midlam-Mohler for the opportunity to participate in this research project as well as the guidance along the way. I would like to also thank Fabio Chiara and Jason Meyer, who were also on the project. ii Vita May 2005 .......................................................Dublin Scioto High School June 2010 .......................................................B.S. Mechanical Engineering, The Ohio State University June 2010 to present ......................................Graduate Research Associate, Center for Automotive Research, The Ohio State University i Table of Contents Abstract ................................................................................................................................ i Acknowledgements ............................................................................................................. ii Vita ....................................................................................................................................... i List of Tables ....................................................................................................................... i List of Figures ...................................................................................................................... i Chapter 1 ............................................................................................................................. 2 1.1 Introduction ......................................................................................................... 2 1.2 Literature Review................................................................................................ 2 1.2.1 Cylinder Pressure Pegging Methods ............................................................... 2 1.2.2 Combustion Noise ......................................................................................... 11 1.2.3 Altitude Testing ............................................................................................ 14 1.3 Motivation ......................................................................................................... 16 1.4 Project Objective ............................................................................................... 16 Chapter 2 : Experimental Setup ........................................................................................ 18 2.1 Engine Instrumentation ..................................................................................... 23 2.1.1 Factory sensor locations ................................................................................ 23 ii 2.1.2 Test cell specific sensor locations and descriptions ...................................... 25 2.1.3 Cylinder Pressure .......................................................................................... 34 2.2 Experimental Devices/Automation ................................................................... 38 2.2.1 Steady state automation ................................................................................ 39 2.2.2 Transient automation .................................................................................... 52 Chapter 3 : Advanced Analysis Techniques ..................................................................... 59 3.1 CO2 Distribution inside Intake Manifold .......................................................... 59 3.1.1 CO2 experimental setup ................................................................................ 60 3.1.2 CO2 experiment results ................................................................................. 65 3.1.3 CO2 experiment future recommendations ..................................................... 67 3.2 Combustion Noise ............................................................................................. 68 Chapter 4 : Simulation Enhancing Experiments ............................................................... 74 4.1 GT Power© model accuracy .............................................................................. 74 4.2 Cylinder Pressure Pegging ................................................................................ 82 4.2.2 GT Power© pegging analysis ........................................................................ 85 4.2.3 Experimental Pegging Results ...................................................................... 89 4.2.4 Impact of Pegging Method on Heat Release............................................... 102 iii 4.2.5 Pegging Methods Conclusions .................................................................... 124 4.3 Altitude Simulations ....................................................................................... 125 4.3.1 Altitude simulation – 85 kPa....................................................................... 127 4.3.2 Altitude simulation – 65 kPa....................................................................... 131 Chapter 5 : Future Work and Conclusions ...................................................................... 135 Bibliography ................................................................................................................... 137 Appendix A: CO2 Experiment Test Plan ........................................................................ 141 iv List of Tables Table Page Table 1: Sensor labels corresponding to Figure 9 ............................................................. 26 Table 2: Sensor labels corresponding to Figure 10 ........................................................... 27 Table 3: Sensor location table corresponding to Figure 11 .............................................. 28 Table 4: Labels corresponding to Figure 12 ..................................................................... 29 Table 5: Analysis of variance for baseline case ................................................................ 66 Table 6: Analysis of variance for CO2 injected into EGR pipe ........................................ 66 Table 7: Mean absolute pegging offset error from GT-Power© analysis.......................... 89 Table 8: Average experimental pegging offset for each cylinder (rounded) .................. 101 Table 9: Mean absolute pegging methods errors for ignition delay ............................... 109 Table 10: Mean absolute pegging methods errors for total cumulative heat release ...... 113 Table 11: CA50 and CA90 difference compared to true GT-Power© result .................. 118 Table 12: Average difference between pegging methods ignition delay ........................ 120 Table 13: Average absolute difference between pegging methods total heat release ..... 121 Table 14: Average absolute difference between pegging methods for CA50 and CA90 (Intake pegging method is baseline) ............................................................................... 122 Table 15: Well mixed case - CO2 injected after filter box .............................................. 141 i Table 16: EGR entering manifold through EGR pipe .................................................... 142 ii List of Figures Figure Page Figure 1: J plotted verses k (Tunestal) .............................................................................. 10 Figure 2: Lucas Industries structure response (Russell, Palmer and Young) ................... 13 Figure 3: Exhaust aspirator system (Culshaw and McClure) ........................................... 16 Figure 4: Engine encoder .................................................................................................. 19 Figure 5: DAQ system diagram ........................................................................................ 22 Figure 6: Factory engine sensors: 1 - Charge pressure and temperature 2 - Fuel rail pressure 3 – Intake air throttle .......................................................................................... 24 Figure 7: Factory engine sensors: 1 - Fresh air MAF sensor 2 - Compressor inlet 3 - Filter box..................................................................................................................................... 24 Figure 8: Factory engine sensors: 1 - EGR valve 2 - Turbocharger 3 - EGR cooler 4 - EGR piping