Modeling of a New Generation Solenoid Common Rail Injector · PDF file17-10-2016 Andrea PIANO...
Transcript of Modeling of a New Generation Solenoid Common Rail Injector · PDF file17-10-2016 Andrea PIANO...
17-10-2016
Andrea PIANO, Federico MILLO
Politecnico di Torino
Lucio POSTRIOTI, Andrea CAVICCHI, Giulia BISCONTINI
Università degli Studi di Perugia
Francesco C. PESCE
General Motors – Global Propulsion System
Modeling of a New Generation
Solenoid Common Rail Injector European GT Conference 2016 - Frankfurt
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Agenda
Introduction
Experimental Setup
Test Matrix
Injection Rate Results
Conclusions
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Agenda
Introduction
Experimental Setup
Test Matrix
Injection Rate Results
Conclusions
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Common Rail FIS
The more and more stringent emission requirements along with the more demanding targets for fuel consumption reduction, are calling for enhanced fuel injection systems for diesel engines.
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Increased number of inj pulses (up to 12)
Increased inj pressure levels (up to 3000 bar)
Reduced dwell time between injections
Injection rate shaping
Large varieties of
systems with deep
specialization
Coupling between
different physical
domains
Wide range of
pressures
Main challanges for numerical simulation of FIS
Source: http://www.dieselnet.com
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
FIS Numerical Simulation Different approaches for the simulation of the injection systems:
3D-CFD – Focuses on detailed simulation of fluid domain.
1D-CFD – Navier-Stokes, Newton and Maxwell equations are computed to
model fluid, mechanical and electromagnetic parts using a 1D reduction.
Bond Graph –Network of 0D elements. This 0D schematization produces only
ODEs and DAEs.
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1. Multi-domain (differently from 3D-CFD)
2. Physically based representation of phenomena
(differently from Bond Graph)
3. Coupling with predictive combustion model DIPulse
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Agenda
Introduction
Experimental Setup
Test Matrix
Injection Rate Results
Conclusions
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Experimental Facilities In order to build a 1D-CFD model of a Common Rail injector, 2 crucial issues need to
be addressed:
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Source: http://www.boschautoparts.com
Internal
geometry
detection
Extensive
dataset of
experimental
injection rate
1. Piano, A., Millo, F., Postrioti, L., Biscontini, G. et al., "Numerical and Experimental Assessment of a Solenoid Common-Rail Injector Operation with Advanced Injection Strategies," SAE
Int. J. Engines 9(1):565-575, 2016, doi:10.4271/2016-01-0563.
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
STS Injection Analyzer For injection rates measurements, an STS Injection Analyzer, based on the Zeuch
method, was used.
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It consists of:
Injection in a close, fixed-volume chamber
filled with the same injected fluid
Pressure as primary measurement
∆𝑃 =𝑘
𝑉∆𝑉
Injection rate evaluation by differentiating
the pressure equation
𝑄 =𝑑𝑉
𝑑𝑡=𝑉
𝑘
𝑑𝑃
𝑑𝑡
1. L. Postrioti, G. Buitoni, F. C. Pesce, C. Ciaravino, Zeuch method-based injection rate analysis of a common-
rail system operated with advanced injection strategies, Fuel, Volume 128, 15 July 2014, Pages 188-198,
ISSN 0016-2361, http://dx.doi.org/10.1016/j.fuel.2014.03.006.
2. L. Postrioti, S. Malaguti, M. Bosi, G. Buitoni, S. Piccinini, G. Bagli, Experimental and numerical
characterization of a direct solenoid actuation injector for Diesel engine applications, Fuel, Volume 118, 15
February 2014, Pages 316-328, ISSN 0016-2361, http://dx.doi.org/10.1016/j.fuel.2013.11.001.
V, P V, P+
Test fluid
V, P V,
P+ dP
dV
Injector
Inj
Rate
– N
eedle
lif
t
Time
IR Needle Lift
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Agenda
Introduction
Experimental Setup
Test Matrix
Injection Rate Results
Conclusions
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Test Matrix Selection
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Element Holes Nominal diameter Flow number
[-] [number] [mm] [cc/30s @∆p = 100 bar]
Nozzle #1 7 0.139 390
Nozzle #2 8 0.114 340
Single Injection Test
Nozzle #1
Nozzle #2
0
200
400
600
800
1000
1200
1400
0 200 400 600 800 1000 1200
Rail P
ress
ure
[bar]
Energizing Time [ms]
Energizing Time
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Test Matrix – Engine Patterns
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950 bar
700 bar
1050 bar
800 bar
850 bar
1000 bar
Typical Engine Injection Pattern Test
Nozzle #2
1500 rpm X 2 bar
𝑄1500𝑟𝑝𝑚 ≅ 7𝑚𝑚3
𝑠𝑡𝑟
2000 rpm X 8 bar
𝑄2000𝑟𝑝𝑚 ≅ 24𝑚𝑚3
𝑠𝑡𝑟
430 bar
360 bar
400 bar
370 bar
550 bar
460 bar
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Test Matrix – Innovative
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Innovative Injection Pattern Test
Nozzle #1
Hydraulic Fusion with Single and Double Pilot
MultiPilot events + After Injections
RailP = 400 bar
RailP = 1000 bar
RailP = 400 bar
RailP = 1000 bar
RailP = 400 bar
RailP = 1000 bar
RailP = 400 bar
RailP = 1000 bar
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Agenda
Introduction
Experimental Setup
Test Matrix
Injection Rate Results
Conclusions
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Results – Single Injection
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Injection Rate comparison
Nozzle #1
Nozzle #2
800 bar 600 bar
400 bar 600 bar
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Results – Single Injection Nozzle #2 – Total Injected Volume comparison
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y = 1.10 x
R2 = 0.99
y = 1.04 x
R2 = 0.99
y = 0.98 x
R2 = 0.99
y = 0.94 x
R2 = 0.99
y = 0.95 x
R2 = 0.99
y = 0.94 x
R2 = 0.99
Rail Pressure = 300 bar
Rail Pressure = 800 bar
Rail Pressure = 400 bar
Rail Pressure = 1000 bar Rail Pressure = 1200 bar
Rail Pressure = 600 bar
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Results – Engine Patterns
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Instantaneous injection rate profiles comparison for 2000 rpm X 8 bar operating
condition:
The 1D-CFD injector model is able to predict the injection rate with the correct
timing and also the pulse to pulse interaction for a conventional injection
strategies in a modern light duty diesel engine
700 bar 800 bar 1000 bar
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Results – Hydraulic Fusion
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Nozzle #1 – Injection Rate comparison
Single Pilot
Double Pilot
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Results – MultiPilot
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Nozzle #1 – Injection Rate comparison
With After
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Agenda
Introduction
Experimental Setup
Test Matrix
Injection Rate Results
Conclusions
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Conclusions
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A methodology for obtaining a complete characterization of a solenoid ballistic injector for a Light-Duty Common Rail diesel engine in GT-SUITE was presented
In literature it is possible to find different approaches for obtaining an accurate detection of the internal geometry
An extensive dataset of experimental measurements was used in order to validate the model. The injection rate profiles have been measured by means of STS Injection Analyzer based on Zeuch’s Method
In order to assess the predictive capabilities of the model, 2 different nozzles were tested and simulated for several single and multi-event operation strategies
The comparison between the experimental and simulated injection rates profiles showed a more than satisfactory accuracy of the model both for single and multiple injection events pattern
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Injector Model + DIPulse
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Burn rate and NOx emissions comparison
1500x2 1500x5 1500x8 2000x2 2000x5 2000x8 2000x12
NO
x E
mis
sions
[-]
Engine operating point [rpm x bmep]
NOx Emissions
Experimental Simulated
17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Virtual Test Rig in GT-SUITE
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17-10-2016 Andrea PIANO - Modeling of a new generation solenoid Common Rail injector
European GT Conference – Frankfurt 2016
Virtual Test Rig in GT-SUITE
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Injector Current Profile
DIPulse Predictive
Combustion model
BSNOx - BSFC CN - BSFC
17-10-2016
Andrea PIANO, Federico MILLO
Politecnico di Torino
Lucio POSTRIOTI, Andrea CAVICCHI, Giulia BISCONTINI
Università degli Studi di Perugia
Francesco C. PESCE
General Motors – Global Propulsion System
Modeling of a New Generation
Solenoid Common Rail Injector European GT Conference 2016 - Frankfurt