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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

stanislav.lindak@gmail.com

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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