Handbook of Diesel Engines PDF
Preview Handbook of Diesel Engines
Klaus Mollenhauer (cid:2) Helmut Tschoeke Handbook of Diesel Engines Klaus Mollenhauer (cid:2) Helmut Tschoeke Handbook of Diesel Engines With584Figuresand86Tables 1 3 Editors Prof.Dr.-Ing.KlausMollenhauer Prof.Dr.-Ing.HelmutTschoeke OrberStr.25 OttovonGuerickeUniversityMagdeburg 14193Berlin InstituteofMobileSystems Germany Universita¨tsplatz2 [email protected] 39106Magdeburg Germany [email protected] Translator KristerG.E.Johnson Otto-von-Guericke-Strass56b 39104Magdeburg Germany ISBN978-3-540-89082-9 e-ISBN978-3-540-89083-6 DOI10.1007/978-3-540-89083-6 SpringerHeidelbergDordrechtLondonNewYork LibraryofCongressControlNumber:2010924045 #Springer-VerlagBerlinHeidelberg2010 Thisworkissubjecttocopyright.Allrightsarereserved,whetherthewholeorpartofthematerialisconcerned,specificallytherightsof translation,reprinting,reuseofillustrations,recitation,broadcasting,reproductiononmicrofilmorinanyotherway,andstorageindata banks.DuplicationofthispublicationorpartsthereofispermittedonlyundertheprovisionsoftheGermanCopyrightLawofSeptember9, 1965,initscurrentversion,andpermissionforusemustalwaysbeobtainedfromSpringer.Violationsareliabletoprosecutionunderthe GermanCopyrightLaw. Theuseofgeneraldescriptivenames,registerednames,trademarks,etc.inthispublicationdoesnotimply,evenintheabsenceofaspecific statement,thatsuchnamesareexemptfromtherelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. Coverdesign:WMXDesignGmbH,Heidelberg Printedonacid-freepaper SpringerispartofSpringerScience+BusinessMedia(www.springer.com) Preface This machine is destined to completely revolutionize cylinderdieselengineupthroughlargelowspeedtwo- engine engineering and replace everything that exists. stroke diesel engines. An appendix lists the most (From Rudolf Diesel’s letter of October 2, 1892 to the importantstandardsandregulationsfordieselengines. publisherJuliusSpringer.) Furtherdevelopmentofdieselenginesaseconomiz- Although Diesel’s stated goal has never been fully ing,clean,powerfulandconvenientdrivesforroadand achievable of course, the diesel engine indeed revolu- nonroad use has proceeded quite dynamically in the tionizeddrivesystems.Thishandbookdocumentsthe last twenty years in particular. In light of limited oil currentstateofdieselengineengineeringandtechnol- reserves and the discussion of predicted climate ogy. The impetus to publish a Handbook of Diesel change, development work continues to concentrate Engines grew out of ruminations on Rudolf Diesel’s onreducingfuelconsumptionandutilizingalternative transformation of his idea for a rational heat engine fuelswhilekeepingexhaustascleanaspossibleaswell into reality more than 100 years ago. Once the patent as further increasing diesel engine power density and wasfiledin1892andworkonhisenginecommenced enhancing operating performance. Development is thefollowingyear,RudolfDieselwaitedanother4years oriented toward the basic legal conditions, customer until the Association of German Engineers provided demands and, not least, competition with gasoline himaplatformtopresenthisenginetothepublicatits engines, which are still considered the benchmark car convention in Kassel on June 16, 1897. The engine engineinmanysectors. came to bear the name of its ingenious inventor soon Thetopicstobetreatedwereweighedwithallthisin thereafter. mind: In addition to engine internal measures that The editors and publisher intend this English edi- reduceexhaustemissionswiththeaidofnewcombus- tion of the handbook to furnish readers outside Ger- tionsystemsandnewfuels,thesectiononExhaustGas man-speakingregionsascholarlyandpracticalpresen- Aftertreatmentdeservesparticularmention.Theoxida- tation of the current state of the diesel engine and its tioncatalyticconvertersintroducedinthecarsectoras largerangeofapplications.Thehandbookhasnotonly standard in the 1990s will soon no longer meet the been conceived for diesel experts but also ‘‘diesel lay- mountingrequirementsforairhygiene;particulatefil- persons’’ with prior knowledge of engineering or at tersandnitrogenoxidereductionsystems,e.g.SCRand least an interest in technology. Furthermore, it is storagecatalysts,havebecomestandard. intended to benefit students desiring a firsthand New combustion systems with a larger share of comprehensive and sound overview of diesel engine premixed, homogeneous combustion than normal engineering and technology and its state of diffusion combustion are just as much the subject of development. this handbook as the refinement of supercharging to These aims are reflected in the book’s five-part enhancethepoweroutput,increasethepeakcylinder structure. Part I provides a brief history of the diesel pressureandthuslimitloadasthebrakemeaneffec- engine followed by sections on the fundamentals, tivepressureincreases.Quicklyemergingastheopti- including supercharging systems, diesel engine com- mal injection system when the car sector switched bustion,fuelsandmoderninjectionsystems.PartsII– from indirect to direct injection at the end of the IVtreattheloadinganddesignofselectedcomponents, 1990s, the common rail system also came to be used diesel engine operation, the pollution this causes and – initially only experimentally – for larger diesel theincreasinglyimportantmeasurestoreduceit.Part engines at the start of the new millennium. The Vpresentstheentirerangeofenginesfromsmallsingle commonrailsystemisnowstandardindieselengines V VI Preface of virtually every size. Hence, reflecting current but We would like to thank all the authors – whether by far not yet finalized development, this handbook experts workinginindustrywheretheutmostdedica- treats the different designs, e.g. with solenoid valve- tionisdemandedorourcolleaguesinacademiawhere controlled or piezo-actuated injectors, in detail. the days of creative leisure have long since become a Amplespace hasaccordinglyalsobeengiventoelec- thing of the past – for their collaboration, their ready tronicswithitsdiverseoptionstocontrolprocessesin acceptance of our ideas and the many fruitful discus- the engine. sions.Wewouldalsoliketoextendourgratitudetothe To be able meet the expectations and demands companiesthatallowedtheiremployeestoworkonthe connected with a Handbook of Diesel Engines, we side, supported the compilation of texts and master relied as much on the collaboration of outstanding illustrationsandprovidedmaterial.Acknowledgement engineersfrom theengineindustryasontheresearch is also due the many helpers at companies and insti- findingsofprofessorsatuniversitiesofappliedsciences tutes for their contributions without which such an and universities. After all, a particularly close connec- extensive book manuscript could never have been tionhasexistedbetweentheoryandpractice,between produced. academia and industry, in engine research since Die- ParticularlyspecialthanksgototheDieselSystems sel’s day, his invention itself being based on the engi- DivisionatRobertBoschGmbHforthetechnicaland neeringofhisday. financial support, which made it possible to complete Thanks to the work of many generations of engi- thisextensiveworkinthefirstplace. neers, scientists, researchers and professors, the diesel Despitethesometimeshecticpaceandconsiderable enginecontinuestobethemostcosteffective internal additional work, the editors tremendously enjoyed combustion engine and has evolved into an advanced theircollaborationwiththeauthors,thepublisherand high-techproduct. alltheothercollaborators. Berlin,Germany, KlausMollenhauer Magdeburg,Germany HelmutTschoeke September2009 Myenginecontinuestomakegreatadvances.... (FromRudolfDiesel’sletterofJuly3,1895tohiswife.) Contents Contributors . . . . . . . . . . . . . . . . . . . . . IX 5.2 InjectionNozzlesandNozzleHolders . . . 129 5.3 InjectionSystems . . . . . . . . . . . . 137 5.4 InjectionSystemMetrology . . . . . . . . 170 Part I The Diesel Engine Cycle . . . . Literature . . . . . . . . . . . . . . . . . . 173 1 FurtherLiterature . . . . . . . . . . . . . . 173 FurtherLiteratureonSection5.2 . . . . . . . . 174 1 HistoryandFundamentalPrinciplesofthe DieselEngine(KlausMollenhauerand 6 FuelInjectionSystemControlSystems(UlrichProjahn, KlausSchreiner) . . . . . . . . . . . . . . . . 3 HelmutRandoll,ErichBiermann,Jo¨rgBru¨ckner, 1.1 TheHistoryoftheDieselEngine . . . . . . 3 KarstenFunk,ThomasKu¨ttner,WalterLehle,and 1.2 FundamentalsofEngineEngineering . . . . 7 JoachimZuern) . . . . . . . . . . . . . . . 175 1.3 CombustionCycleSimulation . . . . . . . 18 6.1 MechanicalControl . . . . . . . . . . . 175 Literature . . . . . . . . . . . . . . . . . . . 29 6.2 ElectronicControl . . . . . . . . . . . . 176 6.3 Sensors . . . . . . . . . . . . . . . . . 184 2 GasExchangeandSupercharging(HelmutPucher) . . 31 6.4 Diagnostics . . . . . . . . . . . . . . . 186 2.1 GasExchange . . . . . . . . . . . . . . . 31 6.5 ApplicationEngineering . . . . . . . . . 189 2.2 DieselEngineSupercharging . . . . . . . . 38 Literature . . . . . . . . . . . . . . . . . . 191 2.3 ProgrammedGasExchange FurtherLiterature . . . . . . . . . . . . . . 191 Simulation . . . . . . . . . . . . . . . . 56 Literature . . . . . . . . . . . . . . . . . . . 59 Part II Diesel Engine Engineering . . 193 3 DieselEngineCombustion(KlausB.Binder) . . . . . 61 3.1 MixtureFormationandCombustion . . . . 61 7 EngineComponentLoading(DietmarPinkernelland 3.2 DesignFeatures . . . . . . . . . . . . . . 69 MichaelBargende) . . . . . . . . . . . . . . 195 3.3 AlternativeCombustionProcesses . . . . . . 73 7.1 MechanicalandThermalLoading 3.4 ProcessSimulationofInjectionCharacteristic ofComponents . . . . . . . . . . . . . 195 andRateofHeatRelease . . . . . . . . . . 74 7.2 HeatTransferandThermalLoads Literature . . . . . . . . . . . . . . . . . . . 75 inEngines . . . . . . . . . . . . . . . 202 Literature . . . . . . . . . . . . . . . . . . 217 4 Fuels(GerdHagenow,KlausReders,Hanns-Erhard FurtherLiterature . . . . . . . . . . . . . . 219 Heinze,WolfgangSteiger,DetlefZigan,andDirk Mooser) . . . . . . . . . . . . . . . . . . . . 77 8 CrankshaftAssemblyDesign,Mechanics 4.1 AutomotiveDieselFuels . . . . . . . . . . 77 andLoading(EduardKo¨hler,EckhartSchopf,and 4.2 AlternativeFuels . . . . . . . . . . . . . 94 UweMohr) . . . . . . . . . . . . . . . . . 221 4.3 OperationofMarineandStationary 8.1 DesignsandMechanicalPropertiesof EngineswithHeavyFuelOil . . . . . . . 103 CrankshaftAssemblies . . . . . . . . . . 221 4.4 FuelGasesandGasEngines . . . . . . . 114 8.2 CrankshaftAssemblyLoading . . . . . . 228 Literature . . . . . . . . . . . . . . . . . . 124 8.3 BalancingofCrankshaftAssemblyMasses . 236 8.4 TorsionalCrankshaftAssembly 5 FuelInjectionSystems(WalterEgler,RolfJu¨rgen Vibrations . . . . . . . . . . . . . . . 250 Giersch,FriedrichBoecking,Ju¨rgenHammer, 8.5 BearingsandBearingMaterials . . . . . . 259 JaroslavHlousek,PatrickMattes,UlrichProjahn, 8.6 Piston,PistonRingsandPistonPins . . . . 270 WinfriedUrner,andBjo¨rnJanetzky) . . . . . . 127 Literature . . . . . . . . . . . . . . . . . . 287 5.1 InjectionHydraulics . . . . . . . . . . . 127 FurtherLiterature . . . . . . . . . . . . . . 290 VII VIII Contents 9 EngineCooling(KlausMollenhauerand 15.2 EmissionControlLegislation . . . . . . 426 JochenEitel) . . . . . . . . . . . . . . . . . 291 15.3 PollutantsandTheirProduction . . . . . 443 9.1 InternalEngineCooling . . . . . . . . . 291 15.4 In-EngineMeasuresforPollutant 9.2 ExternalEngineCoolingSystems . . . . . 309 Reduction . . . . . . . . . . . . . . . 449 Literature . . . . . . . . . . . . . . . . . . 336 15.5 ExhaustGasAftertreatment . . . . . . . 455 15.6 EmissionsTesting . . . . . . . . . . . 469 10 MaterialsandTheirSelection(JohannesBetz) . . . . 339 Literature . . . . . . . . . . . . . . . . . . 483 10.1 TheImportanceofMaterialsforDiesel FurtherLiterature . . . . . . . . . . . . . . 485 Engines . . . . . . . . . . . . . . . . 339 10.2 TechnicalMaterialsforEngineComponents . 339 16 DieselEngineNoiseEmission(BrunoM.Spessert 10.3 FactorsforMaterialSelection . . . . . . 348 andHansA.Kochanowski) . . . . . . . . . . 487 10.4 ServiceLifeConceptsandMaterialData . . . 348 16.1 FundamentalsofAcoustics . . . . . . . 487 10.5 ServiceLifeEnhancingProcesses . . . . . 349 16.2 DevelopmentofEngineNoise 10.6 TrendsinDevelopment . . . . . . . . . 352 Emission . . . . . . . . . . . . . . . 487 Literature . . . . . . . . . . . . . . . . . . 354 16.3 EngineSurfaceNoise . . . . . . . . . . 489 FurtherLiterature . . . . . . . . . . . . . . 355 16.4 AerodynamicEngineNoises . . . . . . . 498 16.5 NoiseReductionbyEncapsulation . . . . 499 Part III Diesel Engine Operation . . 357 16.6 EngineSoundproofing . . . . . . . . . 502 Literature . . . . . . . . . . . . . . . . . . 502 11 LubricantsandtheLubricationSystem (HubertSchwarze) . . . . . . . . . . . . . . 359 Part V Implemented Diesel 11.1 Lubricants . . . . . . . . . . . . . . . 359 Engines . . . . . . . . . 505 11.2 LubricationSystems . . . . . . . . . . 370 Literature . . . . . . . . . . . . . . . . . . 376 17 VehicleDieselEngines(FritzSteinparzer,Klaus 12 StartandIgnitionAssistSystems(WolfgangDressler Blumensaat,GeorgPaehr,WolfgangHeld,and andStephanErnst) . . . . . . . . . . . . . . 377 ChristophTeetz) . . . . . . . . . . . . . . . . 507 12.1 ConditionsfortheAuto-IgnitionofFuel . 377 17.1 DieselEnginesforPassengerCars . . . . 507 12.2 FuelIgnitionAids . . . . . . . . . . . 378 17.2 DieselEnginesforLightDuty 12.3 StartandIgnitionAssistSystems . . . . . 379 CommercialVehicles . . . . . . . . . . 521 12.4 ColdStart,ColdRunningPerformance 17.3 DieselEnginesforHeavyDutyCommercial andColdRunningEmissionsforCars . . 383 VehiclesandBuses . . . . . . . . . . . 528 12.5 Conclusion . . . . . . . . . . . . . . 386 17.4 HighSpeedHighPerformance Literature . . . . . . . . . . . . . . . . . . 386 DieselEngines . . . . . . . . . . . . . 544 FurtherLiterature . . . . . . . . . . . . . . 386 Literature . . . . . . . . . . . . . . . . . . 556 FurtherLiterature . . . . . . . . . . . . . . 557 13 IntakeandExhaustSystems(OswaldParr, JanKru¨ger,andLeonhardVilser) . . . . . . . 387 18 IndustrialandMarineEngines(Gu¨nterKampichler, 13.1 AirCleaners . . . . . . . . . . . . . . 387 HeinerBu¨lte,FranzKoch,andKlausHeim) . . . 559 13.2 ExhaustSystems . . . . . . . . . . . . 393 Literature . . . . . . . . . . . . . . . . . . 398 18.1 SmallSingleCylinderDiesel FurtherLiterature . . . . . . . . . . . . . . 399 Engines . . . . . . . . . . . . . . . . 559 18.2 StationaryandIndustrialEngines . . . . 568 14 ExhaustHeatRecovery(FranzHirschbichler) . . . . 401 18.3 MediumSpeedFour-Stroke 14.1 BasicsofWasteHeatRecovery . . . . . . 401 DieselEngines . . . . . . . . . . . . . 576 14.2 OptionsofWasteHeatRecovery . . . . . 404 18.4 Two-StrokeLowSpeed Literature . . . . . . . . . . . . . . . . . . 413 DieselEngines . . . . . . . . . . . . . 592 Literature . . . . . . . . . . . . . . . . . . 607 Part IV Environmental Pollution by Diesel Engines . . . . . StandardsandGuidelinesforInternalCombustionEngines . 609 415 Index . . . . . . . . . . . . . . . . . . . . . . 621 15 DieselEngineExhaustEmissions(HelmutTschoeke, AndreasGraf,Ju¨rgenStein,MichaelKru¨ger,Johannes Schaller,NorbertBreuer,KurtEngeljehringer, andWolfgangSchindler) . . . . . . . . . . . 417 15.1 GeneralBackground . . . . . . . . . . 417 Contributors MichaelBargende, Prof.Dr.-Ing.,Universita¨tStuttgart, Hanns-ErhardHeinze, Dr.-Ing.,Magdeburg,Germany, Stuttgart,Germany,[email protected] [email protected] JohannesBetz, MTUFriedrichshafenGmbH, WolfgangHeld, Dr.-Ing.,MANNutzfahrzeugeAG, Friedrichshafen,Germany,[email protected] Nu¨rnberg,Germany,[email protected] ErichBiermann, Dr.-Ing.,RobertBoschGmbH,Diesel FranzHirschbichler, Dr.,Mu¨nchen,Germany, Systems,Stuttgart,Germany, [email protected] [email protected] JaroslavHlousek, Dipl.-Ing.,KEFICOCo,Gunpo,Korea KlausB.Binder, Prof.Dr.-Ing.,Deizisau,Germany, (RoK),[email protected] [email protected] Bjo¨rnJanetzky, Dr.-Ing.,RobertBoschGmbH,Diesel KlausBlumensaat, VolkswagenAG,Wolfsburg,Germany, Systems,Stuttgart,Germany, [email protected] [email protected] FriedrichBoecking, RobertBoschGmbH,DieselSystems, Gu¨nterKampichler, Dipl.-Ing.,Ruhstorf,Germany Stuttgart,Germany,[email protected] FranzKoch, Dr.-Ing.,MANDiesel&TurboSE,Augsburg, NorbertBreuer, Dr.-Ing.,RobertBoschGmbH,Diesel Germany,[email protected] Systems,Stuttgart,Germany, HansA.Kochanowski, Dr.-Ing.,Ruhstorf,Germany [email protected] EduardKo¨hler, Prof.Dr.-Ing.habil.,KSAluminium Jo¨rgBru¨ckner, Dr.,RobertBoschGmbH,DieselSystems, TechnologieGmbH,Neckarsulm,Germany, Stuttgart,Germany,[email protected] [email protected] HeinerBu¨lte, Dr.-Ing.,DeutzAG,Ko¨ln,Germany, JanKru¨ger, Dr.-Ing.,J.Eberspa¨cherGmbH& [email protected] Co.KG,Esslingen,Germany, WolfgangDressler, Dr.,RobertBoschGmbH,Diesel [email protected] Systems,Stuttgart,Germany, MichaelKru¨ger, Dr.-Ing.,RobertBoschGmbH,Diesel [email protected] Systems,Stuttgart,Germany, WalterEgler, Dr.-Ing.,RobertBoschGmbH,DieselSystems, [email protected] Stuttgart,Germany,[email protected] ThomasKu¨ttner, Dipl.-Ing.,RobertBoschGmbH,Diesel JochenEitel, BehrGmbH&Co.KG,Stuttgart,Germany, Systems,Stuttgart,Germany, [email protected] [email protected] KurtEngeljehringer, AVLListGmbH,Graz,Austria, WalterLehle, Dr.rer.nat.,RobertBoschGmbH,Diesel [email protected] Systems,Stuttgart,Germany,[email protected] StephanErnst, Dr.-Ing.,RobertBoschGmbH,Diesel PatrickMattes, Dr.,RobertBoschGmbH,DieselSystems, Systems,Stuttgart,Germany,[email protected] Stuttgart,Germany,[email protected] KarstenFunk, Dr.-Ing.,RobertBoschGmbH,Diesel UweMohr, Dr.,MahleGmbH,Stuttgart,Germany, Systems,Stuttgart,Germany,[email protected] [email protected] RolfJu¨rgenGiersch, Dipl.-Ing.,RobertBoschGmbH,Diesel KlausMollenhauer, Prof.Dr.-Ing.,Berlin,Germany, Systems,Stuttgart,Germany, [email protected] [email protected] DirkMooser, Dr.-Ing.,CaterpillarMotorenGmbH&Co. AndreasGraf, Dipl.-Ing.,DaimlerAG,Stuttgart,Germany, KG,Kiel,Germany,[email protected] [email protected] GeorgPaehr, Dr.,VolkswagenAG,Wolfsburg,Germany, GerdHagenow, Dr.,ShellGlobalSolutions(Deutschland) [email protected] GmbH,Hamburg,Germany OswaldParr, Dr.-Ing.,Ludwigsburg,Germany Ju¨rgenHammer, Dr.-Ing.,RobertBoschGmbH,Diesel DietmarPinkernell, MANDiesel&TurboSE,Augsburg, Systems,Stuttgart,Germany, Germany [email protected] UlrichProjahn, Dr.-Ing.,RobertBoschGmbH,Diesel KlausHeim, Wa¨rtsila¨SwitzerlandLtd,Winterthur, Systems,Stuttgart,Germany, Switzerland,[email protected] [email protected] IX
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