1. Simulation engine torque
Peter Heinrich
engineering/business/consulting
1

2. overview
test bench for engine add-on parts / new concept
Current status on test bench concepts:
•Indirect drive / samples driven by pulleys
No correlation to used drives under field conditions
Only redused speed gradients possible
Wrong cross forces on sample drive shaft
•Missing protection system
Current protection system insufficient due to increased
speed/torque/pressure/temperature/…
•Missing environment simulation
Test benches not always designed for runnig tests under “real”
environment conditions like temperature, humidity, pressure, …
2

3. overview
test bench for engine add on parts/new concept
Main targets on next generation test bench:
•Improved dynamic sample part drive
no pulleys, no slipping main belt
direct connection of sample parts to electrical
engine
•Simulation of real combustion engine torque/speed
Alternating torque/speed at sample parts
Constant speed
•Using of field relevant test liquids
Test bench designed with EX-protection
(primary and/or secondary level) or using aged
liquids
varying speed
3

4. overview
test bench for engine add on parts/new concept
Main focus: simulation of engine torque/speed
behaviour on test benches:
• rated crankshaft speed speed up to 10000 1/min
• speed gradients up to +/-12.000 rpm/s
•direct connection to tested sample part
•Torque/speed simulation of real combustion engines (1, 2, 4,…-cyl.
Engine)
•Equipment must run under improved security environment
4

5. Simulation engine torque
Simulation of real combustion engine torque/speed
real engine simulation
n n
+
t t
n
t
5

6. Simulation engine torque
Simulation of real combustion engine torque/speed
Simulation of real combustion
engine torque/speed parameter 1 = f (cyl., working process)
simulation model
cyl . 1
feng . felec.drive neng .
1
2 w
n
Cyl.: no. of Cylinder
(1,2,3,4,…12 cylinder engine)
W.: working process
360° (KW)
(2, 4-stroke engine)
360° (elect. engine)
6

7. Simulation engine torque
Simulation of real combustion engine torque/speed
1
150
n
140 2
130
360° (KW)
120
360° (elect. engine)
110
Frequenz_Unregelmäßigkeit [Hz]
100
1
90
2
3
80
4
70 5
6
No. of cylinder
60 8
50
40
30
20
10
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
3000
3200
3400
3600
3800
4000
4200
4400
4600
4800
5000
5200
5400
5600
5800
6000
Engine speed [rpm]
7

8. Simulation engine torque
Simulation of real combustion engine torque/speed
Simulation of real combustion
engine torque/speed
simulation model
parameter 2 = f (eng.load, eng.speed, MOI)
nmax..
n nN lN
aeng . aelec.drive. n
Δn 2 neng leng
nN
a: engine speed amplitude
360° (KW) neng, leng: engine speed, engine load at working point
360° (elect. engine) nN, lN: engine speed, engine load at nominal point
8

9. Simulation engine torque
Simulation of real combustion engine torque/speed
1
150.0
n
2
125.0
Drehzahl-Amplitude Verbrennungsmotor [1/min]
360° (KW)
360° (elect. engine)
100.0 Load [%]
1
10
20
30
40
75.0 50
60
70
80
90
100
50.0
25.0
0.0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
2600
2800
3000
3200
3400
3600
3800
4000
4200
4400
4600
4800
5000
5200
5400
5600
5800
6000
Engine speed [rpm]
9

10. Simulation engine torque
Summary: Simulation of real combustion engine torque/speed
1200 80
1100 70
Engine speed [rpm]
1000
load [%]
60
900
50
800
40
700
30
600
speed-setpoint (1/min)
20
500 speed-nom.[1/min]
load [%]
400 10
300 0
0,2 s 1,0 s time [s]
speed on test bench engine /electrical drive is varing in case of changes on:
Combustion engine load / nominal combustion engine speed / no. of cyclinders
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