Efficient transport of materials and personnel is crucial for an efficient operation of a mining plant. Transport powered by diesel engines is widely used in mines due to its mobility. This article outlines the requirements that diesel engines operating underground must meet. These requirements particularly impact the design of engines operating in mine workings with a potentially explosive atmosphere. Due to operation in confined spaces, the quality of the engine's exhaust gases is also crucial, and increasingly stringent requirements have been imposed over the years. This article discusses the design of a diesel engine intended for operation in potentially explosive atmospheres, in light of the current requirements. Commonly used methods for improving the exhaust gases quality in surface engines are discussed, as well as the technical challenges associated with adapting them to engines operating underground. An example engine introduced to the market by a leading mining machinery manufacturer is presented.
Assessing vehicle emissions is crucial for understanding their environmental impact and developing effective emission reduction strategies. This article discusses modern research tools that combine traditional laboratory measurements on chassis dynamometers with advanced theoretical models. Probabilistic methods, including stochastic processes based on Markov and semi-Markov chains, are important tools for modelling driving cycles, considering the variability of road conditions and driver behaviour. The article also presents mathematical approaches to emission data analysis, considering both the states of the technical system and the transitions between them, which allows for precise modelling of real vehicle operating conditions. Ultimately, the synergy of experimental measurements with computational modelling offers a more complete and accurate tool for assessing pollutant emissions, which is crucial in global efforts to improve air quality.
Issues related to the various driving gears of the valve trains were discussed, along with the factors affecting them. The study was focused on the effect of disassembling the toothed pulley shrink-fitted to the crankshaft journal, followed by their assembly via pressure fitting. The roughness parameters for surfaces of a new and worn toothed pulley and worn crankshaft journal, as well as their hardness values, were measured. The model for calculations of friction coefficient, contact pressure, and friction torque carried by the contact zone was developed. It was found that the disassembling and assembling of the analyzed components can significantly weaken the interference between them. The weakening was accompanied by a decreased contact pressure. The plastic saturation occurred in the contact zone. The corresponding values of the friction coefficient were much higher than those for elastic stress in the contact zone. The friction coefficient values for the plastic saturation conditions differ from each other by up to 10%. Although all values of torque loading the worn toothed pulley exceed values of friction torque carried by the contact zone under plastic saturation, the displacement of the toothed pulley about the crankshaft journal can occur due to possible changes in the friction coefficient in the contact zone. The friction coefficient values can be lowered due to the presence of oxides, impurities, and engine oil droplets introduced into the contact zone by way of the oil mist present inside the engine block.
In response to the growing problems associated with road transport emissions, increasing emphasis is being placed on biofuels and bio-additives as a more ecological alternative to traditional fossil fuels. Biofuels, produced from renewable raw materials such as oil plants, cereals, or organic waste, aim to reduce greenhouse gas emissions and limit the consumption of non-renewable raw materials. The introduction of additives to fuels can have a positive effect on reducing harmful substances in exhaust gases. Still, the effectiveness of this solution depends on many factors, such as the type of bio components and the design of the engines. The article discusses research on bio-additives impact on exhaust emissions, with particular emphasis on combustion processes and the formation of harmful substance emissions. It presents two complementary modelling methods: COPERT, which allows for estimating emissions in real conditions, and Diesel-RK, which simulates engine combustion processes for a detailed analysis of emission mechanisms. The combination of these tools allowed for a precise assessment of the impact of biofuels on pollutant emissions and may be an essential step towards optimising engine designs for more ecological solutions. Despite certain technological and economic limitations, using bio-additives to fuels can significantly reduce emissions from road transport, accelerating the implementation of global environmental protection and sustainable development goals.
Przedstawiono model matematyczny układu napędowego pojazdu, który składa się z silnika spalinowego o zapłonie iskrowym i czterech suwach pracy oraz pięciostopniowej skrzyni biegów i przekładni głównej. W modelu silnika spalinowego wykorzystano równania dynamiki oraz podstawowych procesów chemicznych. Uwzględniono uproszczony model matematyczny nadwozia pojazdu w celu weryfikacji poprawności działania całego układu. Zaprojektowano system sterowania skrzynią biegów. Przedstawiono wyniki badań symulacyjnych.
EN
A math. model of a vehicle’s drive system was presented, which consists of a 4-stroke combustion engine with spark ignition and a 5-speed gearbox with main transmission. Dynamics eqns. and simple chem. processes were used in the model of the combustion engine. A simplified math. model of the vehicle body was included and the control system for the gearbox was designed.
Artykuł prezentuje wykorzystanie systemów CAD w projektowaniu układu wydechowego motocyklowego silnika spalinowego. Autorzy prezentują znaczenie zastosowania skanowania przestrzennego oraz modelowania 3D do wykonania układu wydechowego motocykla Yamaha YZ 85. Zaprezentowane zostały również badania trakcyjne silnika na hamowni motocyklowej z użyciem zaprojektowanego wydechu.
EN
The article presents the use of CAD systems in the design of the exhaust system of a motorcycle combustion engine. The authors present the importance of using spatial scanning and 3D modeling to create the exhaust system of the Yamaha YZ 85 motorcycle. Engine traction tests using the designed exhaust on a motorcycle dynamometer were also presented.
The article describes the process of selecting the design parameters of the electromagnetic actuator, which was used to regulate the compression pressure in the cylinder of an internal combustion engine. The electromagnetic actuator was installed in the timing system of a single-cylinder internal combustion engine, which forced its basic design parameters in terms of force and frequency of operation. For the electromagnetic actuator in question, field calculations of the esign variants of the linear electromagnetic actuator for two types of materials were conducted. The finite element method was applied to the computer-aided design of electromagnetic actuators. The influence of the magnetic circuit and the dimensions of the windings on the distribution of the magnetic field were analyzed. The thickness and height of the magnetic field induces, and the dimensions of the stator poles have been changed while maintaining the same external dimensions of the actuator for design reasons. All this work was aimed at improving the performance of the internal combustion engine in terms of improving efficiency in terms of partial engine loads. In this area, the internal combustion engine is characterized by low efficiency, significantly deviating from the maximum, and at the same time, during normal operation of vehicles is the area most often exploited.
PL
W artykule opisano proces doboru parametrów konstrukcyjnych siłownika elektromagnetycznego, który posłużył do regulacji ciśnienia sprężania w cylindrze silnika spalinowego. Siłownik elektromagnetyczny został zamontowany w układzie rozrządu jednocylindrowego silnika spalinowego, co wymusiło jego podstawowe parametry konstrukcyjne w zakresie siły i częstotliwości pracy. Dla omawianego siłownika elektromagnetycznego przeprowadzono obliczenia porównawcze wariantów konstrukcyjnych liniowego siłownika elektromagnetycznego dla dwóch rodzajów materiałów. Do komputerowego wspomagania projektowania siłowników elektromagnetycznych zastosowano metodę elementów skończonych. Przeanalizowano wpływ obwodu magnetycznego i wymiarów uzwojeń na rozkład pola magnetycznego. Grubość i wysokość indukowanego pola magnetycznego oraz wymiary biegunów stojana zostały zmienione przy zachowaniu tych samych wymiarów zewnętrznych siłownika ze względów konstrukcyjnych. Wszystkie te prace miały na celu poprawę osiągów silnika spalinowego w szczególności poprawy sprawności w zakresie częściowego obciążenia silnika. W tym obszarze silnik spalinowy charakteryzuje się stosunkowo niską sprawnością, znacznie odbiegającą od maksymalnej, a jednocześnie w czasie normalnej eksploatacji pojazdów jest obszarem najczęściej eksploatowanym.
The article discusses issues related to the behavior of powertrains understood as monuments of engineering art. The theoretical part analyzed the most important issues related to the maintenance and renovation of vehicles, their share in Poland in the age category, as well as the regulations regarding the classification of historic vehicles. The next part of the article presents the renovation process of two powertrains - the K-750 motorcycle and the Volkswagen Type 117 passenger car, along with a short production history. Then, recommended procedures for unique objects were discussed in the context of their state of preservation and occurrence based on the authors' experience.
Changing the ignition advance angle has a significant impact on the performance of a combustion engine. Optimization of ignition advance angle is a major task of adjusting the engine concerning emission standards, fuel consumption, torque value, etc. The results of the research showed that the process of optimizing the ignition advance curve can noticeably increase engine efficiency, as well as torque and power output from the engine while reducing fuel consumption as a result of lower indications of the air flow mass per second from MAF sensor (mass air flow sensor). The highest impact of the ignition advanced angle modifications can be seen in the area of the highest volumetric efficiency of the tested combustion engine. Almost no impact is observed within high engine speed levels. Simultaneously increasing engine load and rotation speed increases the possibility of engine knocking, which has a devastating effect on engine durability.
This scientific article presents an innovative concept of a hybrid power unit designed for ultralight aircraft, with the aim of improving energy efficiency and operational flexibility. As part of the development of the system, the construction of the combustion unit and the electric motor / generator, which are the key elements of this solution, was described. The advanced internal combustion engine controller and the bi-directional energy conversion converter have been developed and built to enable optimal cooperation of both energy sources. In order to carry out experimental research on the developed system, a special test stand was built on which a prototype drive unit was mounted. The results of the research include preliminary performance characteristics of the prototype drive unit and an analysis of the achievements that indicate the potential benefits of using such a hybrid drive unit. The article also summarizes the conclusions and recommendations for further work on improving this innovative solution.
Vehicle coolant is one of the most important operating fluids. Along with changes in the design of engines, the composition of the coolant has also changed. The main function of the coolant is heat transfer (HT). It absorbs up to one-third of the heat energy generated by the engine. The coolant is also responsible for protecting the cooling system from damage caused by corrosion, scaling and deposits. The unfavorable working environment of the engine is also affected by smaller capacities of the cooling systems (CSs) of the drive units, extreme temperatures and increased pressure in the CS, enhancing the importance of the fluid composition. The coolant must be replaced every three years or 100,000 kilometers or every five years or 250,000 kilometers with the Organic Acid Technology (OAT). It is worth remembering that coolant of unknown composition or low quality used for a long time can expose the system to engine overheating, corrosion, deposits and restriction of liquid flow. This can lead to engine failure, in extreme cases even engine seizure. Currently, many types of fluids, including nanocoolants with different compositions, are available on the cooling market. The article presents these fluids, describe the most common failures of CSs, present the currently used methods of fluid replacement in the engine and proposes an innovative method based on the pressure method, which allows both replacing the fluid in the entire system and cleaning it.
The paper presents an analysis of the experimental results of direct hydrogen injection in a dual-fuel diesel engine. The test object is a four-cylinder, four-stroke ADCR engine. The parameters like: indicated mean effective pressure, peak pressure, angle of maximum pressure and released heat were analyzed. Statistical analysis of the obtained results was carried out for each cylinder separately for four different hydrogen doses. Both early and late direct hydrogen injection were analyzed. The significance of the differences for each of the analyzed parameters and type of injection was determined. The stability of the combustion process was evaluated using the coefficient of variation CoV(IMEP).
This paper presents a method for the precise diagnosis of a diesel engine in an agricultural tractor based on the analysis of efficiency changes and parameters characterizing the process of fuel-air mixture preparation. We proposed that the technical condition be identified based on available data from the engine controller, as this enables the implementation of precise online diagnostics of an agricultural tractor. The method was verified using the original cycle, during which we simulated several engine defects leading to a change in conditions and quality of the processes of creating and burning the fuel/air/flue gas mixture. In the paper, we justified the selection of the points at which the engine parameters were measured, as they provide the most information and allow for efficient identification of damage. These results indicate the possibility of damage identification without the use of the diagnostic cycle in the operation of operator-driven vehicles and autonomous vehicles.
W artykule przedstawiono rys historyczny odlewania tłoków silników spalinowych na przykładzie 50. lat doświadczenia Federal-Mogul (FM) Gorzyce sp. z o.o. Zwrócono szczególną uwagę na zmiany w konstrukcji układu chłodzenia kokilarek, które obecnie są sprzężone z robotami zalewającymi ciekły stop tłokowy Al-SiCu-Ni-Mg. To rozwiązanie zapewnia równomierną krystalizację tłoków i optymalną wydajność procesu ich odlewania. Na skutek konieczności poprawy sprawności silnika, a tym samym zmniejszenia zużycia paliwa i emisji substancji szkodliwych dla środowiska, zmianie uległa również budowa tłoków. W zależności od rodzaju silnika, obecne tłoki posiadają różny kształt denka, którego krawędzie są przetapiane laserowo, niższą tzw. „koronę” tłoka i odchudzone ścianki wewnętrzne. Dla zapewnienia mniejszych strat tarcia układu: tłok-pierścienie-cylinder i wzmożonego chłodzenia części pierścieniowej, nowoczesne tłoki są wyposażone w komponenty (kanały solne, alfinowane wkładki pierścieniowe), a płaszcz tłoka jest poddawany zabiegom obróbki powierzchniowej. Stosowanie innowacyjnych rozwiązań w Federal-Mogul Gorzyce Sp. z o.o. zapewnia uzyskanie kompromisu pomiędzy produkcją silników o zmniejszonej pojemności skokowej i dużej mocy, przy jednoczesnym zachowaniu trwałości i niezawodności odlewanych dziś tłoków ze stopów aluminium.
EN
The article presents a historical overview of the casting of combustion engine pistons on the example of 50 years of experience of Federal-Mogul (FM) Gorzyce Ltd. Particular attention was paid to the changes in the design of the cooling system of the mold making machines, which are currently coupled with robots pouring liquid Al-Si-Cu-Ni-Mg piston alloy. This solution ensures uniform crystallization of the pistons and optimal efficiency of the casting process. As a result of the need to improve engine efficiency, and thus reduce fuel consumption and emissions of substances harmful to the environment, the design of the pistons has also changed. Depending on the type of engine, the current pistons have a different shape of the bottom, the edges of which are melted by laser, the lower, so-called „crown” of the piston and slimmed down inner walls. To ensure lower friction losses of the piston-rings-cylinder system and increased cooling of the annular part, modern pistons are equipped with various components (salt channels, and alfinated ring inserts), and the piston skirt is subjected to surface treatment. The use of innovative solutions at Federal-Mogul Gorzyce Ltd provides a compromise between the production of engines with reduced displacement and high power, while maintaining the durability and reliability of today’s cast aluminum alloy pistons.
The article presents the concept of a hybrid propulsion unit for ultralight aircraft. A combustion unit and an electric motor/generator were presented. As part of the research, a dedicated combustion engine controller and a two-way converter for energy conversion were built. The prototype drive unit was installed on a test stand and its initial characteristics were determined. The results of research and conclusions related to the construction of a hybrid drive unit are presented.
PL
W artukule przedstawiona została koncepcja hybrydowej jednostki napędowej dla ultralekkich statków powietrznych. Przedstawione zostały jednostka spalinowa a także silnik/generator elektryczny. W ramach badań zbudowany został dedykowany sterownik silnika spalinowego i dwukierunkowa przetwornica do konwersji energii. Prototypowy zespół napędowy zabudowano na stanowisku badawczym i wyznaczono jego wstępne charakterystyki. Przedstawiono wyniki badań i wnioski związane z budową hybrydowej jednostki napędowej.
The present study was focused on the combustion engine with a variable compression ratio (VCR), namely the four-stroke air-cooled engine with the active combustion chamber (ACC). An indicated pressure, torque, power, and specific fuel consumption of that engine were investigated experimentally as a goal of the present study. Experiments were conducted using two versions of an engine. Two parameters particularly influencing the ACC engine performance including the maximum compression ratio CRmax and the indicator γfm determining the correct operation of the ACC system, were described. It was found that the ACC engine allowed avoiding detonation combustion without changing the amount and composition of the combustible mixture, and even without delaying the ignition advance angle. In addition, the possible range of control of the combustion process allowed the ACC engine to operate with different types of hydrocarbon fuels, for example, in the form of petrol with various alcohol admixtures. The very intense flow of the combustible mixture inside the cylinder of the ACC engine allowed describing the combustion in the ACC engine with zero-dimensional mathematical models with the dual Vibe function providing the proper characterization of the heat release process. The use of very high maximum compression ratios allows the ACC engine to operate to a certain extent as a Homogeneous Charge Compression Ignition (HCCI) engine with high lambda coefficients.
The article analyzes and evaluates costs, transport time and CO2 emissions by selected vans. The research was carried out on the example of three models of Iveco Daily vehicles powered by: diesel oil, electricity and compressed natural gas (CNG). The result of the research presented in the article is the determination of the operating costs of vehicles powered by various energy sources and the level of CO2 emissions. The comparative analysis was carried out on real data for the established transport task. Vehicles with engines powered by compressed natural gas are characterized by the highest savings in terms of transport costs. As the authors pointed out, this may be due to the fact that this type of engines, despite the low interest of buyers at the moment, may gain much more popularity in the future. On the other hand, in relation to vehicles with electric motors, the cost of transport is the highest, which means that this type of technology is ineffective in relation to long-distance transport.
The flow of exhaust gases is the source of many physical processes, including thermal, acoustic, mechanical and chemical phenomena with high dynamics of changes. The study analyzes the impact of the entire structure of the exhaust system on the formation of acoustic energy, determining the transmission loss characteristics of its individual components and the entire system. On the example of a structure based on a proprietary solution of an adjustable reactive muffler, the possibilities of shaping the flow of acoustic waves in the process of designing and selecting exhaust systems for internal combustion engines were determined. The study was carried out with the use of the CFD method and a specialized package for advanced simulations AVL AST.
The article presents a method of determining the characteristics of exhaust emissions and fuel mass consumption in real driving conditions based on a single test using the Monte Carlo method. The exhaust emission characteristics used are the relations between the emissions and the average vehicle speed, and the characteristic of the fuel mass consumption is the dependence of the fuel mass consumption at the average vehicle speed. The results of empirical research of a passenger car with a spark-ignition engine in the RDE test were used. The use of the Monte Carlo method made it possible to select the initial and final moments of averaging the process values, thanks to which it was possible to determine the discrete values of the characteristics for various values of average vehicle speeds. The determined discrete characteristics of the particulate mass and number emissions and fuel mass consumption relative to the average vehicle speed were approximated by polynomial functions of the second and third degree. The determined discrete characteristics, presented as sets of points, were characterized by a relatively small dispersion in relation to their polynomial approximations. The average relative deviation of the points of discrete characteristics from the value of the polynomial was in most cases small – less than 4%, only in the case of the number of particles emitted deviated from this, as the average relative deviation of the measured points from the determined polynomial was nearly 14%. Combined with the results of RDE empirical studies, the Monte Carlo method proved to be an effective method for determining the characteristics of exhaust emissions, measured in real vehicle operating conditions. The main advantage of the proposed method was a significant reduction in the actual workload necessary to carry out the empirical research – where it became possible to determine the characteristics in a large range of vehicle average speed values with just one drive test. Using standard methods of measuring this type of data, it would be necessary to conduct multiple tests, driving at different average vehicle speeds.
The article deals with the study of exhaust emissions from a combustion engine in the Real Driving Emission (RDE) test. These tests are a simulation of real conditions of use of motor vehicles. Nowadays, RDE tests are mandatory for Light Duty Vehicle (LDV) and Heavy Duty Vehicle (HDV) vehicles and in the future, restrictive standard. Euro 7, which combines stricter limits with a comprehensive RDE test cycle, is becoming a challenge for current vehicle engineering. The paper presents the results of pollutant emission tests from a passenger car (PC). In the tests of LDV in the RDE test, the results of which are analyzed in the article, the Portable Emissions Measurement System (PEMS) mobile exhaust emission testing system was used. The processes describing the operating states of the vehicle and the combustion engine, as well as the processes of exhaust emission intensity and the intensity of the number of particulate (PN), were examined. The correlation between the considered processes was investigated. The emission of carbon monoxide, hydrocarbons, nitrogen oxides, particulate and carbon dioxide as well as the road PN were examined. The zero-dimensional statistical characteristics of the examined processes were also determined. The probability density and power spectral density of the processes were established. A great diversity was found in the properties of the process distributions, as well as in the dynamic properties of the processes. In the summary of the analysis of the results of the car speed process, the operating states of the combustion engine and the processes of exhaust emission intensity and the process of the intensity of PN in the RDE test, conclusions were formulated regarding, among others, course of the intensity of these compounds, correlation of the processes of pollution emission intensity and the intensity of the PN with the process of car speed, distribution of processes.
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