CIMAC Congress - Schiff & Hafen

Tuesday, 15 June Wednesday, 16 June Thursday, 17 June
Monday, 14 June
the design process at an early stage to ensure right-first-time design
in the shortest possible project duration. The impact of
methodologies like concurrent engineering on the project, and the
continuous design process improvements are also outlined. The
result of this work is the development of a complete family of heavy
duty, high speed engines with bestin- class fuel consumption and a
good specific power output, demonstrating Technomots ability to
introduce new products working closely with its engine
manufacturing clients.
13:30 June 14th Room Scene GH
(8–1) Integrated Systems & Electronic Control –
Engines, Turbines & Applications –
Sensors & Actuators
Electronics for the safety-critical
application and control of combustion
engines
D. Eikemeier, T. Dauenhauer, MAN Diesel & Turbo
SE, Germany
In the recent years the reliability of modern diesel and gas engines
depend more and more on reliable and robust electronics. The
common rail injection is an example to meet current and future
regulations and standards for emissions. The following article gives
an insight to the new family of engine control electronics of MAN
Diesel SE (SaCoSone - Safety and Control System on engine) and
necessary considerations, implementation of processes and
advanced testing of these engine controllers. In the beginning of the
project, a very detailed FMEA of the complete system and each
electronic control module was carried out. This identified for
instance the need for redundancies in several places to always
remain in a safe and working condition of the engine in the case of
a failure. Regarding development processes, a detailed but still
flexible development process was not only implemented for the
software development, but for hardware development, too. This
included an automatic versioning management in combination
with a detailed and software supported change management process.
Of course also the sub-suppliers and development partners have to
be integrated into these processes. The control products are being
extensively tested. This included of course all necessary tests
according to standards like IEC or IACS: vibration, temperature,
EMC. Furthermore MAN Diesel SE has also carried out a more indepth
analysis of the different electronics parts both theoretically
and practically. The testing is done in the laboratory with HALT /
HASS (Highly Accelerated Life Testing / Highly Accelerated Stress
Screening) chambers. Faults are induced by a combination of
3D-vibration together with fast changing temperature cycles. The
following article gives a glance into the new SaCoSone control
system, together with experiences in implementing new development
processes. Certain test results are explained in more detail with
examples of critical electronic components, which can be replaced
by different parts or discrete circuits to result in a higher reliability.
Reducing fuel consumption on the field by
continuously measuring fuel quality on
electronically fuel injected engines
P. Flot, A. Meslati, Controle Mesure Regulation,
France,
T. Delorme, Ecole Centrale Marseille, France
In order to save crude oil worldwide resources and to reduce the
amount of GHG - green house gas - emissions resulting from
combustion inside engines, builders have to research new ideas
for further fuel consumption reduction, and cleaner exhaust
gas. That trend is not new but just more challenging and progress
is becoming seldom as modern engine performances are coming
closer to the Carnot efficiency. Although increasing use of
electronics on engine could support greater amount of
conditions and parameters in adjusting the engine actuators for
optimised combustion, like pressure and temperature of air,
coolant, lub-oil, and fuel, still fuel quality is not considered, so
that commercial engines are usually fine tuned for average
quality of fuels as found on the market. As a result, engine
performances on the field can be affected when locally purchased
fuel quality is far away from the average quality considered by
the engine builder. At the same time, engine builders and
authorities are asking for more stringent fuel specifications,
when oil companies, on the opposite, would like to enlarge fuel
specifications to help marketing and eliminating lower grades
of fuels. A smart fuel sensor has been developed and its
capability proven. This fuel sensor uses the patented
HydroCarbon Profiler technology, which measures the
molecular structure of the fuel. This information is continuously
transmitted to the Engine Control Unit allowing real time
optimization of injection, combustion and post treatment for
all possible fuel, including bio-fuels.
This fuel quality sensor is based on a smart combination of a
Near Infrared low cost hardware and powerful data treatment
software. That technology is in use since end of the years 90’s at
inlet, and outlet of crude oil refineries in order to continuously
adjust and control the chemical processes of the factory. But the
sensors are huge and expensive: 500 kg to 1000 kg, costing
nearly 1 M Euro! Although using the same principle, the new
sensor has been drastically reduced in size and cost from the
refinery experience, so that the sensor can be mounted on the
engine, not being bigger than a bottle of fruit juice! Then it went
through various marine approval type tests to prove its
robustness in engine ambient conditions, far away from those
quiet ones met inside refinery measurement room. The paper
will describe the sensor hardware and software technologies
and the expected engine combustion performance improvement
resulting from that new parameter input. This sensor can be
used as well to protect the engine against accidentally bad
quality of fuel.
Exhaust gas recirculation electric
actuation technology
A. Pintauro, Woodward Governor, USA
Exhaust gas recirculation (EGR) is an effective method to reduce
nitrogen oxide (NOx) emissions. There are many advantages to
using electric actuation technology for both metering EGR flow
and for waste gate control but this has been a challenge for the
heavy industrial engine market without using active cooling
because of the exhaust gas temperatures as high as 750°C. The
paper gives a general overview of an integrated package
comprising of a valve, rotary electric actuator, linkage, support
bracket, and actuation technology that solves this issue. The
system characteristics, technical data, models, as well as field life
test data are included. The modulating actuator relies on only
passive cooling due to its high ambient temperature rating as
well as having a unique linkage/bracket that is designed for
minimal heat transfer while allowing for relative motion due to
thermal expansion. This EGR electric actuation system allows for
precise metering control while simplifying the final installation
as no customer supplied linkage is required and the valve to
actuator position is pre-set at the factory. In addition, the actuator
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