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Development of high speed diesel engine

JAIKIRAT SINGH

Abstract:
for the valve train and cam shaft
covers are replaced by aluminium
High speed 600 V12 twin charged , nickel alloy metal. The usual racing
direct fuel injection ,4 valve DOHC manifolds made of stainless is
mid longitudinal engine, 5,964 cc , replaced by a denser light metal
direct multi point fuel injection , which is used on space shuttles saves
603.46 BHP/ 450 kW . 101.2 bhp / weight and does not deform under
liter torque figures of about 859.4 high engine exhaust gasses. This
Nm . The stroke value is 150 mm and significantly high powered engine is
the bore value is 225 mm. The the first of its kind light weight-high
engine weight is reduced by output engine.
replacing all engine components As standards for durability and
from cast steel to magnesium parts automobile
which offer better strength to weight designs become more complex, steel
ratio. The air intake is changed to simply can't deliver on higher
carbon fibre from the regular plastic performance expectations. Light
or aluminium pipes. All engine weight magnesium requires far less
mountings are taken off and stripped energy during the entire die cast
down and is bolted directly to the production process and designs can
monocouque shell. It is further be far more elaborate without
reduced by using special light weight sacrificing strength. Tolerances are
turbos with lighter bearings and tighter and the fit and finish in the
using a prototype material which has final product is vastly superior
higher heat dissipating properties.
The unnecessary cover
Introduction: taken in equal volume. Magnesium
The engine built serves the offers great versatility. It can be run
importance for the Le mans racing in both hot (conventional and
where the engine needs to have multi-slide machines) and cold
higher output at lower speeds and chamber die cast machines. This
faster acceleration relative to the makes is suitable for castings that
endurance required to last 24 hours are small in size (less than an
of constant running at high speeds. ounce) to very large (up to sixteen
motive to win the next le mans and pounds or larger).
take the world by storm with the
high output diesel engine was the
main motivation to build this General overview :
prototype engine .
OBJECTIVES OF DEVELOPMENT
Large scale modifications have been AND
done to the existing engine TECHNOLOGIES USED
technology . from replacing bolts to
changing engine firing . To ensure that the v12 engine
achieved simultaneous
Magnesium is 33% lighter than improvement of output, fuel
aluminum, 60% lighter than consumption, and reliability, while
titanium, and 75% lighter than meeting Category 2 regulations, the
steel. Yet for many applications it's following were set as primary
stronger per unit volume than all development objectives:
three of those structural metals
(1) increasing the performance of
the diesel engine.

(2) Decreasing the fuel


consumption or in other words
increasing fuel economy.
(3) increasing the durability and
reliability of the vehicle as it has to
Sustain harsh conditions from
extreme hot to extreme cold so the
engine should give same
Magnesium weighs 1.5 times less
performance in all the terrains.
than aluminium when both are
ENGINE SPECIFICATIONS Bore: 225 mm
Configuration: 600 V12
D/L: 1.5
Location: Mid longitudinally
mounted Cooling system: Liquid cooled
Construction: Engine block made up Ignition system: Electronically
of light weight magnesium steel controlled
alloys.

Displacement: 5964 cc Advantages of using V12engine:

Valve train: 4 valve DOHC V12 engines have minimal


vibrations because they are
Fuel feed: Multi point injection two 6 straight sixes which are
balanced by a single crankshaft
Lubrication: Dry sump and are balanced by Vs. I m
using 600 angle between the Vs
Aspiration: Twin charger ( so that the engine is much
supercharger + turbo charger ) more compact.
Power: 450 Kw . The power delivery in case of v
12s are the smoothest and it
Torque: 860 Nm gives a smooth ride as we are
using a diesel engine.
Compression ratio: 26:1 .

BHP/Liter: 102hp/liter
Rpm redline: 5100
Stroke: 150 mm
Role of Bore/Stroke consideration because ,there are
Ratio various advantages of this type
of design , as the bore is bigger
than the stroke then the piston
In order to getting high rpms speed will be relatively low and
the effect of bore/stroke ratio as a result of which there will be
should be taken in less stress on the crankshaft and
the combustion process will I have invented a new kind of
be more effective if we take swirl technology in which there
multi point injection system will be grooves present in the
and as we are using enhanced cylinder above the top dead
swirl technology so we will center which will be in the
get better flame propagation shape of helix help the air to
which helps the engine to have better swirl so that the
reach higher rpms. As we complete combustion process
have larger bore we can takes place giving the engine
easily fit in 4 valve much better performance and
technology and we can have
larger valves for better air As the engine speed increases
intake and hence increasing so there is less time to burn the
the rpm of the engine. fuel and injection process
should also be spontaneous so
this kind of swirl technology
helps when the engine is
CERMET COATING ON INTERIOR running at higher rpms.
SURFACES OF PISTON CYLINDER

To enhance performance and


wear resistance in order to
reduce friction, all the inner
surfaces are rubbed by the
gas seals which are coated
with chrome and carbide ECU
based cermets(Composite of
Fuel pump and injector sensors
ceramic and sintered metals)
: it manages the injections
also the inner lining of the timing for each cylinder , ie; the
cylinder are coated with ECU sends signals to the
cermet in order to reduce injector depending on the
wear and tear and have timing and the amount of fuel
higher heat resistance. needed per degree of the crank
shaft

Swirl technology: Variable coolant pressure


controller:
The ECU controls the input amount of air intake varies to
coolant pressure in relation to get a smooth and a fast ride.
the pressure needed by the
engine. i.e.; if the engine
temperature increases which
is detected by a thermostat, so
it will increase the pressure of MAGNESIUM ALLOY PARTS
the coolant which will help in
cooling the engine faster. A vast majority of magnesium
applications are covered by AZ91, a
Waste gate valves of twin diecasting alloy. This alloy has
charger : insufficient creep resistance for
many desirable applications at
temperatures above 130C.
The ECU controls the valve
position of the twin
chargers at different The characteristics of magnesium are:
speeds. i.e.; the ECU Lightest of all structural materials
controls the valve to open
33% lighter than aluminum
the supercharger valve at
75% lighter than steel
lower speeds closing the
High Strength to weight ratio
turbo charger valve and
Excellent dimensional stability
spots the supercharger
Large alloy section
valve at higher speeds and
High Impact resistance
only uses the turbo charger
Abundant material supply
at higher speeds
100% recyclable

Throttle sensor:

The ECU controls the


amount of air coming
through the turbo into the
cylinder by a variable flap
valve . its value varies upon
the engine curve at
different rpms and
different torques the
ACKNOWLEDGEMENT

The technologies employed in References


this engine to improve the
engines output, fuel [1] Magnesium imp Wettbewerb,
consumption, and EUROFORUM-Konferenz, Bonn,17
18.02, 1998. [1]B.L. Mordike, T. Ebert
durability/ reliability. It is a Department of Material Science and
valuable contribution and support Engineering, Technical Uni6ersity of
from the various members and Clausthal, Sachsenweg 8, 38678
Clausthal-Zellerfeld, Germany .
many outside organizations portals
on the internet that made the, 2 Braess, Zielkonflikte in der
Technological developments Automobiltechnik, in: BMBF Workshop
Werkstoff- und produktionstechnische
possible. We thank them all and, Potentiale fursparsame, umweltvertragliche
with their continued assistance and und wettbewerbsfahige
Kraftfahrzeugskonzepte, Bonn, 31.0101.02,
guidance, we will continue our 1997.
efforts to further upgrade and
improve our racing engines. 3 K.U. Kainer, Potential von
Magnesium in der Karosserie
Moglichkeiten und
Entwicklungsbedarf, in: Stahl,
Aluminium und [4]B.L. Mordike, W. Henning,
Creep and high temperature propertiesof
magnesium based alloys,
4 The New Generation of
High Speed DI Diesel 10 Fast Prototyping of a Racing Diesel Engine
Engine with High Specific Control System
Power and Durability Published on : 2008-12-02
Published on: 1995-10-01 Authors: H. Waras,
V.Kordesch Authors : Enrico Corti, Giulio Cazzoli ,Matteo
Rinaldi ,Luca Solier

5 The effect of structure


11 Diesel Engine Noise Reduction by Combustion
design on high speed automotive diesel
and Structural Modifications
engine noise
Published on : 1973-02-01
Published on : 1979-02-01
Authors: D. Anderton, J. Dixon,
C.M.P. Chan, S. Andrews
12 Multi-Valve High-Speed Direct
Injection Diesel Enginesthe
Design Challenge
6 Studies on Combustion and Exhaust Authors : I P Gilbert, , A R Heath, I D Johnstone
Emissions in a High Speed DI Diesel Engine
Published on : October 1, 1993
Published on: 1990-09-01
Authors: Masahiro Ishida,
Hironobu Ueki, Yoshihiro
Yoshimura, Noboru 13 An example of Development of Automotive
Matsumura small high speed diesel engine. Published on1965-
02-01 Author: Shotaro Tanaka, Shinji Seki,
Hirokazu Nakamura

7 Developmental Work of High Speed 3.0


Litre Diesel Engine
Published on: 1980-09-01 Authors: Shigefumi
Nakata, Koji Yoshizu, Koichi Hatamura.

8 Dynamic Behaviour of a High Speed Direct


Injection Diesel Engine.
Published on: 1999-03-01
Authors: R. S. Wijetunge, C. J. Brace, J. G. Hawley,
N.D
Vaughan, R. W. Horrocks, G.
L. Bird

9 A New High Speed Light Duty DI Diesel Engine


Published on: 1988-08-01
Authors: Otto Freudenschuss