This paper presents a one-dimensional (1-D)/three-dimensional (3-D) simulation methodology for uprating a diesel engine to reduce production costs and improve fuel economy. The case study is carried out for a baseline multicylinder direct injection (DI) naturally aspirated (NA) diesel engine of 2945 cc, which meets the Central Pollution Control Board (CPCB)-II emission regulations and is used in a 25 kVA genset application. An uprated version of this NA engine is designed to replace a 30 kVA genset turbocharged engine, eliminating the expense of the turbocharger while reducing fuel consumption. The 1-D computational model was calibrated on the 25 kVA base engine and produced a good agreement with the airflow rate, power, brake-specific fuel consumption (BSFC), cylinder pressure, and oxides of nitrogen (NOx) emission levels. Exploratory work was done with the calibrated 1-D model to assess airflow rate requirements for the 30 kVA application, including a parametric analysis for compression ratio (CR), injection timing, and exhaust gas recirculation (EGR). To increase power in the uprated engine, new cylinder head ports were designed using the 3-D computational fluid dynamics (CFD) software Vectis from Ricardo. The newly designed ports compared well with predicted results and overall airflow through the engine, increased by approximately 3%. Piston bowl and fuel injection nozzle characteristics were optimized using the 3-D simulation. An acceptable agreement was found between predicted engine-out emissions and measurements of the 30 kVA genset engine, and good agreement between experiment and computation was found with BSFC. An overall 2-4% fuel efficiency improvement was achieved meeting the CPCB-II emission legislative norms along with a minimum number of experimental tests. Optimum configuration is also verified on the actual canopy where there is better fuel efficiency improvement with comparable overall engine liner surface temperature.


    Access

    Check access

    Check availability in my library

    Order at Subito €


    Export, share and cite



    Title :

    A Cost-Effective and Fuel-Efficient Solution to Uprating a Diesel Engine Using One-Dimensional/Three-Dimensional Simulation


    Additional title:

    Sae Technical Papers


    Contributors:
    Nain, Ajay (author) / Singh, Jaipal (author)

    Conference:

    Automotive Technical Papers ; 2022



    Publication date :

    2021-09-15




    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    English