Final Year Project Proposal 1

2

- To design and build up a new Pressure

Pulsation Test Machine using control

system

Available resources :

- CAD software: Solidworks

- Dasylab

OBJECTIVE

Objective

3

ENGINE

Gasoline, Diesel, LPG, etc…

4

INTAKE SYSTEM

Outline

The intake system provides the necessary volume of clean air to the engine

Air cleaner

Throttle body

Intake Manifold

Intake System

5

INTAKE MANIFOLD

An intake manifold consists of

several pipes that supply air to each cylinders

Intake Manifold

Air intake Manifold

6

Natural Aspirated Engine

Intake

manifold

air

Air filter

A: ≤ 100°C

Air pipes Temperature

A ≤ 100°C

Engine

Exhaust

Pipe

Layout of the natural aspirated engine

7

Pressure

Tank

Vacuum

Tank

Pressure pulsation test with air with climate chamber for under-the-hood applications

Current Testing Layout

Pressure pulsation test diagram

8

Vacuum Pressure to Over Pressure (absolute)

3 bar

0.2 bar

Normal variation frequency

9

Vacuum Pressure to Over Pressure (absolute)

3 bar

0.2 bar

15

Holding Pressure

5

10

Vacuum Pressure to Over Pressure (absolute)

3 bar

0.2 bar

Pressure ramp-up and –down time

51

11

Function of the New Pressure Pulsation Test Machine

Function Current Test Machine New Test Machine

Pressure holding time control at peak to peak Y Y

Vacuum to over pressure Y Y

Vacuum to atmosphere pressure

Y

(Mechanical)

Y

(Electrical and Mechanical)

Atmosphere to over pressureY

(Mechanical)

Y

(Electrical and Mechanical)

Vacuum to vacuum pressure

Y

(Mechanical)

Y

(Electrical and Mechanical)

Over pressure to over pressure

Y

(Mechanical)

Y

(Electrical and Mechanical)

Pressure ramp up and down control

Y

(Mechanical)

Y

(Electrical and Mechanical)

Air flow speed control N Y

Compressed air temperature control N Y

12

Function Current Test Machine New Test Machine

Pressure holding time control at peak to peak Y Y

Vacuum to over pressure Y Y

Vacuum to atmosphere pressure

Y

(Mechanical)

Y

(Electrical and Mechanical)

Atmosphere to over pressureY

(Mechanical)

Y

(Electrical and Mechanical)

Vacuum to vacuum pressure

Y

(Mechanical)

Y

(Electrical and Mechanical)

Over pressure to over pressure

Y

(Mechanical)

Y

(Electrical and Mechanical)

Pressure ramp up and down control

Y

(Mechanical)

Y

(Electrical and Mechanical)

Air flow speed control N Y

Compressed air temperature control N Y

Function of the New Pressure Pulsation Test Machine

13

Modern turbo charged engine

Charged air system

Charged Air System

14

Air filter

Turbo charger

Clean air duct

“Hot side”

“Cold side”

BMW Mini: clean air and charged air system

Modern turbo charged engine

15

Turbo Engine

Layout of the engine with turbo charger

inte

rco

ole

r

Exhaust

gas

air

Air filter

Turbo ChargerA: ≤ 100°C

B: 80-150°CC: 130-220°C

D: 80-160°CAir pipes Temperature

A ≤ 100°C

B 80 – 150°C

C 130 – 220°C

D 80 – 160°C

Intake

Manifold

16

PressureTank

Vacuum

Tank

Pressure pulsation test with air with climate chamber for under-the-hood applications

New testing layout with temperature control

Heater

Pressure pulsation test diagram

17

Achievement

Multi-discipline application knowledge

- To design and build up a new Pressure

Pulsation Test

- Pneumatic

- Control system

- Thermal fluid dynamic

Other experience

- Souring

- Material Selection for PV test machine

• Set up a Air flow measurement and control

system

• Set up a Air pressure measurement and control system

• Set up a Compressed air temperature measurement and control system

Target Deliverables

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Technical data− pressure change between 0,2 bar to 3 bar abs.

− cycles time: at least 1.0 s (1 Hz)

− typical inner volume of parts: 1 liter to 15 liters

� Measuring of pressure with electronic pressure transmitters

� Counting of cycles passed(typical test duration: 105 to 106 cycles)

� Fatigue resistance against cyclic loading

(change between over and under pressure) with constant amplitude and constant frequency

� Typical tested parts:

− air intake manifolds (AIMs)

− pipes,

− etc.

Pressure Pulsation Test Machine

Proprietary pressure and climatic test

19

Equipment data

� Volume of test space: 600 liters

� Temperature range: -75οC to 200οC

� Climate test range: +10οC to + 95οC, 10% r. h. to 98% r. h.

� Compressed air dryer

� Powerful vacuum pumps: 140 m³/h for big part volumesand short cycle times

Climate Chamber

Proprietary pressure and climatic test

Final Year Project Proposal 2

21

Available resources :

- CAD software, eg. Solidworks or CATIA

- CAE software, eg. Abaqus (solver) and ANSA

(pre-processing) and META (post-processing)

- Universal Testing Machine

- Graphic Workstations

- Calculation servers with min. 96GB memory

Verification of material model through testing and simulation of baby stroller mechanical plastic parts

- To design and setup fixture for testing using

CAD software.

- To test part using in-house Universal

Testing Machine.

- To verify test results with virtual simulation

using CAE software.

Objective

22

Verification of material model through testing and simulation of baby stroller mechanical plastic parts

- Correlation of the test and simulation

results.

- Verification of the existing material property

card with static test results.

- Set up of standard simulation technique for

static loading of the assembled parts.

Target Deliverables

23

Tension and compression testing of structural parts with universal testing machine*

Purpose

� Testing of parts in terms of

– Strength

– Stiffness

– Failure mode

– Durability

Performance data

� Mounting area (W x H): 2,500 x 4,000 mm

� Nominal force bottom unit: 100 kN

� Nominal force top unit: 2 kN

� High test speed 0,0001 ~ 1500 mm/min

UTM with dual load cells for all kinds of testing of

structural parts

* Co. Zwick