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Optimisation of reliability and maintenance plan of the high-pressure fuel pump system on marine engine

Knežević Vlatko, Stazić Ladislav, Orović Josip, Pavin Zoran

Polish Maritime Research

2022

nr 4

97--104

This paper presents a method of adjusting and designing the maintenance scheme for the high-pressure fuel pumps of a slow-speed two-stroke marine engine, MAN 6S70MC-C. The maintenance database for the marine fuel system was obtained from the planned maintenance software, and covered a period of 11 years. During this period, 29 failures occurred that required corrective actions. Our methodology includes failure mode analysis, risk analysis, reliability calculation and maintenance interval adjustment. Each failure is described using a failure mode analysis, based on a combination of the mode and cause of failure. The objective of this study is to recommend a new preventive maintenance interval based on the exponential reliability results and the analysed maintenance data. The initial maintenance plan for each fuel pump was set to 8,000 running hours, whereas in the modified plan, it is recommended to set this to 4,000 hours. Our results show an increase in the system reliability from 60% to 95% when the new modified maintenance plan is applied. In addition, the results and the recommended initial maintenance schedule are validated based on three similar types of engine with the same fuel pump system. The new maintenance approach can reduce the risk of component failure, which will lead to increased reliability of the fuel pump system and the optimisation of maintenance costs.

Modeling of selected design characteristics of cam and hypocycloidal drives of high-pressure fuel pumps

Bor Mateusz, Borowczyk Tomasz, Karpiuk Wojciech, Smolec Rafał

Advances in Science and Technology. Research Journal

2018

Vol. 12, no 2

128--136

The advancement of diesel fuel injection systems is forced by the increasingly stringent exhaust emissions limits. Modern injection systems must generate fuel pressure in excess of 200 MPa, which very often leads to premature wear of the mating components. Generating high pressures results in much force load acting on the pumps. In the case of frequently applied cam-driven pumps, high loads result in significant forces caused by friction. The friction force loads the piston perpendicularly to its axis, which rules out the application of super hard but fragile materials such as ceramics. One of the possible solutions of this problem is the application of unconventional drive systems, the example of which is the hypocycloidal drive. The paper presents the results of simulations comparing selected parameters of the piston motion of the cam-driven pumps and the pumps fitted with hypocycloidal drive. The use of the CAD software also enabled identification of the force acting on the piston (force perpendicular to the piston axis) in the cam-driven pump and its lack in the pump fitted with hypocycloidal drive.

Idea of use of hydraulic booster in high-pressure fuel pump with hypocycloid drive

Bor M., Borowczyk T., Idzior M., Karpiuk W., Smolec R.

Journal of KONES

2017

Vol. 24, No. 3

22--28

Common rail (CR) injection systems have been universally applied in passenger car engines for twenty years. Moreover, they are applied on a wide scale in trucks, machinery and stationary engines. They have many advantages such as very good fuel spraying due to high injection pressure, injection dose distribution to several smaller, or less heat generation compared to traditional systems. At the same time, the use of this type of system involves a number of problems. They are characterized, among other things, by the high cost of manufacturing and the high sensitivity to changes in the quality of the used fuel. The most important component of the common rail injection system is the high-pressure injection pump. The authors propose a new, alternative pump design with the hypocycloid drive – the article presents the issue of using this type of pump. Further sections describe the design of a pump utilizing a hypocycloid mechanism; demonstrate beneficial functional features and present selected results of the assembly's dynamic simulation. The pump is also characterized by the possibility of multiplying the piston's pitch while maintaining its diameter. It makes it possible to obtain much greater discharge per operating cycle. Taking into account the considerable quantity of fuel transferring by the pump, was also possible to propose an idea of use of hydraulic booster in such pump. In this field, the authors have presented schematic diagram of a pressure booster with a description of its operation.