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Reverse engineering as a modern methods of test bed modernization

Cieślik Wojciech, Mielcarzewicz Dawid, Rawecki Michał

Combustion Engines

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2024

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R. 63, nr 1

66--72

EN

The main purpose of the work is to demonstrate the individual stages involved in the reverse engineering process by using a dynamometer equipped with a single-cylinder research engine AVL 5804 as an example. The project entails theoretical and practical aspects of measurements using 3D scanners. The Scantech KSCAN Magic hand-held optical scanner was used to obtain measurements of the geometry of the dynamometer. The CAD model was created in the Autodesk Inventor program, and its accuracy was verified by comparing it to the scan and generating a scale of deviations along with a color-coded representation of their size in the GOM Inspect program. The work was summarized with an example of upgrading the current stand based on a previously made design, which significantly shortened the process of modifying the intake system.

2

Reverse engineering of research engine cylinder-head

Cieślik Wojciech, Szwajca Filip, Wisłocki Krzysztof

Combustion Engines

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2022

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R. 61, nr 2

73--82

EN

The pursuit of increasing the efficiency of internal combustion engines is an ongoing engineering task that requires numerous research efforts. New concepts of injection or combustion systems require preliminary investigation work using research engines. These engines, usually single-cylinder, make it possible to isolate a single variable in a complex combustion mixture preparation process, thus enabling analysis of the changes being made. However, these engines are relatively expensive and their designs are offered by a limited number of manufacturers. The authors of this paper have successfully undertaken the engineering task of modifying an existing research engine cylinder head in such a way as to implement an electronically controlled variable valve timing system of the intake system. The process of reverse engineering, together with design assumptions that finally contributed to the construction of the assumed solution has been described in this paper.

3

The possibility of energy consumption reduction using the ECO driving mode based on the RDC test

Cieślik Wojciech, Szwajca Filip, Golimowski Jacek

Combustion Engines

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2020

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R. 59, nr 3

59--69

EN

The greenhouse effect and overall climate changes are the main reasons for developing ecological powertrain units dedicated to road vehicles. An electrical drivetrain without using conventional combustion engines fueled by hydrocarbon fuels is an effective method to significantly reduce CO2 emissions from the fleet. It is particularly vital in 2020 emission regulations aspects, and continuously the number of vehicles increasing. In this paper battery electric drive system of a small size passenger car was analyzed in terms of two different drive modes in cooperation with two recuperative braking modes. The research was carried out with real driving condition test requirements and driving parameters recording. Based on data obtained from OBD signals, energy flow and torque distribution have been specified. In results, overall reducing energy consumption has been achieved with ECO mode compared to normal mode. Selection of the driving mode ECO has a positive impact on reducing the state of charge saving more than 5%, taking into account the whole RDC test; greater energy consumption reductions were observed in selected test areas.