• Dynamic modeling of a transient engine test cell for cold engine testing applications

      Souflas, Ioannis; Pezouvanis, Antonios; Mason, Byron A.; Ebrahimi, Kambiz M. (2014)
      The increasing complexity in the development and manufacturing process of internal combustion engines leads to a higher demand for more effective testing and monitoring methods. Cold engine testing becomes progressively the main End-of-Line test which is used nowadays from automotive engine manufacturers with the purpose of determining the integrity of engine assembly. The present work is focused on the development of a detailed physics-based, lumped-parameter, dynamic model of a single cylinder internal combustion engine coupled with an alternating current transient dynamometer for cold engine testing applications. The overall transient engine test cell model is described based on a two-inertia system model consisting of the engine, the dynamometer and the coupling shaft. The internal combustion engine is modelled based on First Law of Thermodynamics and Second Newton’s Law for rotational bodies. The transient dynamometer is actually an alternating current three-phase induction motor which is modelled according to direct-quadrature axis approach, and its drive unit which is responsible for controlling the speed of the motor using indirect field orientation scheme. The engine and dynamometer are connected through a coupling shaft which is modelled as a compliant member with damping. The model is validated against experimental measurements such as engine cylinder pressure, engine excitation torque and alternating currents of the induction motor. All of the experimental measurements were recorded from an identical single cylinder transient engine test cell using a highly advanced instrumentation system. The described model serves as an ideal platform for developing innovative model-based fault detection and diagnosis techniques for cold engine testing applications. In conclusion, this is presented successfully for two simulated fault cases, a process fault and a sensor fault, proving the functionality and usefulness of the model.
    • Piston data telemetry in internal combustion engines

      Ebrahimi, Kambiz M.; Lewalski, Antosh; Pezouvanis, Antonios; Mason, Byron A. (2014)
      Measuring piston crown temperature and pressure during engine development cycle is paramount. This paper presents a new development in short distance telemetry system which includes an on board power generation device. A mechatronic data acquisition system is developed whereby signal conditioning is performed by a module inside the piston and the signal passed to a Bluetooth transmitter module for wireless telemetry to a Bluetooth receiver located in very close proximity, connected to an external host PC. The Data Acquisition Bluetooth module integrates a microcontroller that reads the conditioned sensor signal and performs any other required functionality. The microcontroller firmware includes a server that collates the data and transmits them via Bluetooth to the host PC to display via a client interface. An independent power supply consisting of a rotor incorporating NdFeB magnets and a wire wound stator. As the crankshaft rotates the rotor induces an AC voltage into the stator. A rectifying circuit converts the AC voltage into a regulated DC output voltage that drives the signal conditioning and embedded Bluetooth circuits.
    • Rotary compact power pack for series hybrid electric vehicle

      Amirian, Hossein; Pezouvanis, Antonios; Mason, Byron A.; Ebrahimi, Kambiz M. (2013)
      This paper presents a new-designed compact power pack for a series hybrid vehicle. A new type of rotary induction machine with an outer rotor construction is designed to be coupled with the novel rotary internal combustion engine (ICE) with cylindrical crankcase in order to form the compact power unit. The starting and generation performance of the designed machine as well as the overall vehicle performance is analysed. Results show that the proposed power pack has the best performance in terms of fuel economy, emissions and battery charging compared to the existing power units in ADVISOR. Over a city cycle, fuel economy is increased by up to 47% with emissions reduced by up to 36% and over the highway cycle, fuel economy is increased by up to 69% with emissions reduced by up to 42%.
    • Turbine blade vibration measurement methods for turbocharges

      Janicki, Grzegorz; Pezouvanis, Antonios; Mason, Byron A.; Ebrahimi, Kambiz M. (2014)
      This paper presents and compares the most important and often used methods to measure turbine blade vibrations: use of strain gauges and telemetry system which is an intrusive method or, on the other site. The Blade Tip Timing (BTT) method known as Non-Intrusive Stress Measurement (System) NSMS. Both methods have advantages and disadvantages which are described below. This paper focused on synchronous vibrations, which are more important in terms of turbine blades fatigue prediction and design optimization.