Defiance Technologies Limited A Hinduja Group Company

Design optimization and verification of

Compact Diesel Engine Systems –Air

Intake and Cooling system

Bharathan S

Cooling System Engineer

Powertrain- Defiance

Prashanth B

Air System Engineer

Powertrain-Defiance

Automotive diesel engines - Subsystems

2

Automotive diesel engines - Subsystems

3

Objective & Result

Objective

To have a complete understanding of the system fundamentals

To develop competency in system modelling

To verify and optimize system architecture

To develop a complete engine 1D model

Result

Indigenously developed system1D model

Scalable and is customized

Low cost and reliable model

4

Engine operating environment

0

1

2

3

4

5

Volumetric efficiency

Engine warm up time

P, T, m of intake air

Coolant temperature

Sensitivity

Key metrics

5

Modelling approach

Level – 1

Periodic (Event based)

Level – 2

Continuous (Time based)

Why Matlab?

Adaptation is easier

Customization

Modularity

Competency

Scalability

6

System interaction

System layout & Parameter diagram

Air intake system Model

8

Air intake outputs discussion

9

Test data

Predicted

DOE & Optimization

2 Valves vs. 4 Valves

Valve lift profiles

Con-rod length and piston travel

Valve seat angle

Robust air intake system

Higher volumetric

efficiency

Lesser variation with

respect to operating

conditions

Cooling system Model

Water Pump Engine overheat indicator

Cooling system - Results

Temperature vs. Time Flow vs. Time

DOE & Optimization

Thermostat characteristics

Water pump characteristics

Coolant flow ratio

Optimized coolant flow and heat rejection characteristics

Better thermal efficiency

16-Jun-14 Defiance Confidential 12

Summary

Cost reduction

Design optimization

Reduced time

Variation reduction

Robust

Easy decision making

www.defiance-tech.com

DISCUSSIONS

www.defiance-tech.com

THANK YOU