orbital heavy fuel engine technology
DESCRIPTION
Orbital is based in Perth, Western Australia and has a unique air-assisted direct injection system that has been used in the consumer market to reduce exhaust emissions on 2-stroke outboard, scooter, and personal water craft. It has also been evaluated by 4-stroke automotive applications by global auto OEM’s and several papers have been published by SAE highlighting the benefits of Orbital DI over other direct injection technologies. There are currently over 700,000 engines in the consumer market with this technology so the base hardware and control systems have been proven in the field making them very reliable. The air-assist technology is also used on defense outboard and UAV applications to enable operation on heavy fuels such as Jet A, JP5, and JP8. Orbital can develop a custom engine solution for your UAV application to meet package, weight, reliability and fuel consumption requirements. This technology has been flying in theater since 2012 and engines are being produced in Perth, Australia to support that activity. Orbital has design, prototype, validation and production capabilities to take your engine from concept to production. Key benefits of Orbital’s FlexDI technology for UAV’s is shown below: Multi-fuel capability with same hardware: gasoline, JP5, JP8, Jet A. Cold start capability down to -35C without the use of heaters. ~30% reduction in fuel consumption at cruise conditions because DI enables lean stratified operation – typical brake specific fuel consumption at cruise of 330g/kWh (0.543lb/hph). Lower fuel consumption that 2-stroke carbureted/EFI or gas turbine engines. Lower vibration signature and lower weight than compression ignition (diesel) solutions.TRANSCRIPT
Orbital Heavy Fuel Engine Technology
October 2014
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“ Leader in Specialised Engine and Vehicle Systems”
Diesel
Gasoline Alcohol LPG CNG/LNGHCNG
HydrogenKerosene
Transport MiningSmall Engines
Alternative Fuels & Engineering
Orbital’s Vision
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Our Track Record: Products to Market
Launch of Optimax
TRD Aurion
SeaDoo PWC
Dongan Minivan
JV Company Established
SanYang4S Scooter
V8 OEM Auto Applications
Ford
Aprilia. Piaggio and Peugeot FlexDI Scooters
2000 2010
Polaris JPMV800
Kymco KDI
Bajaj Autorickshaw
1990
Tohatsu Outboards UAS engines
Utility Engines (China)
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Orbital Businesses
Business Unit
Business Unit
Summary
Sector
Applications
Automotive (LPG), HD Trucks (NG)
UAS
Non Auto EMS
• LPG Supply– Ford– HSV– Aftermarket
• LNG Systems for Heavy Duty Trucks
• UAS (Unmanned Aircraft Systems)
• Royalties and licence fees
Services (Auto, non-Auto), R&D
• Services to the global engine and vehicle OEM’s, Gov’ts
• R&D
• Application support for FlexDI and Alt. Fuel products
Non Auto EMS global supplier
• Supply of DI and PI Engine Management Systems to Global Non Auto market
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Engine Design & Development
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Engine and Vehicle Testing
• Orbital’s testing capability is diverse:– Utility engines– All terrain vehicles– Snowmobiles – Outboard engines– Aircraft engines (UAV’s)– Light duty vehicles (petrol • diesel • LPG • CNG)– Heavy duty vehicles (diesel • dual fuel)
• Test cell capability: – 30cc small utility engines to
19litre heavy duty diesel engines
• Vehicle capability: from mopeds to light duty trucks3kW
600kW
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Heavy Fuel Challenge
• FlexDITM is direct fuel injection technology able to offer an advanced Spark Ignition solution for heavy fuel engines including Kerosene (JP5, JP8 and JetA1).
• FlexDITM is also able to seamlessly handle spark ignited Diesel applications for limp-home, etc.
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Heavy Fuel Technology Comparison
Technology Application Issue
Gas Turbine • Expensive• High Fuel Consumption
Diesel • Heavy - poor power/weight• High vibration signature
Adding Heaters to 2-Stroke
• Needs external power source• Needs time to heat engine before starting
• No combustion knock control• Engine durability issues• No fuel consumption benefit
Piaggio Fast
• Limited ability to control combustion knock
• Package limitations due to belt system
• Limited redundancy• Compromise between power and fuel consumption
High Pressure Direct Injection
• Complex and heavy system including EMS and high pressure fuel pump
• Limited ability to control combustion knock
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• Air assisted direct fuel injection• Spray guided, stratified charge combustion system• Electronically controlled sophisticated engine
management system• Spark-Ignited combustion• Multi-fuel: Gasoline, JP5, JP8, Jet A
Direct Injected Mixture
Pressurised Fuel
DirectInjector
Pressurised
Air
Fuel (MPI)InjectorSuperior fuel atomization
What is Orbital FlexDI and How does it work?
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Orbital FlexDI Offers…
• Unique solution applicable to both 2 & 4 strokes
• Spark ignited Kerosene for UAVs: JP5, JP8, JetA, JetA1 and gasoline with no change to the engine calibration
• High specific power > 70kW/L• Cold start capability:
demonstrated to -35oC• Low combustion noise:
misfire free operation• Automatic altitude compensation• Up to 30% fuel consumption benefit;
cruise brake specific fuel consumption
of ~330 g/kWh (0.543lb/hph)
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PROVEN TECHNOLOGYOrbital FlexDI Consumer Products
Over 700,000 Orbital DI engines in the market
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Our Track Record: Heavy Fuel Engines
• 2002-2003
• Initial R&D development
• 2003-2004
• Barrus (50hp diesel-JP5-JP8-gasoline)
• Publication of technical capability papers
• 2005-2006
• Mercury JP Optimax Released http://www.mercurygovsales.com/technology/optimaxjp.php
• 2007-2008
• Polaris 4S MV800 (JP8/Gasoline)
• 2009+
• Various UAS customers (undisclosed)
• Internal R&D funded engine design
• AAI/Textron: Orbital HF on Aerosonde (2012)
• 2013
• Awarded contract from Boeing/Insitu to develop next generation Scan Eagle heavy fuel UAV engine.
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Orbital UAS Test and Validation Capabilities
Fully instrumented engine dynamometer facilities including durability dynamometer facilities
Propeller durability test stands to perform FAR 33 paragraph 49 UAV engine durability
Environmental dynamometers for cold start down to -35C and hot operation up to 60C
Altitude simulation up to 18,000 ft
Noise Vibration Harshness (NVH) for intake/exhaust optimization
CAE tools to optimize stress, heat management, flow, engine balance and vibration
Injector and fuel system bench test facilities
Compressor test stands flow & durability
Metrology lab for engine component measurements
Prototyping of hardware: produce, procure, build.
▲ Propeller durability test stands
▲ Altitude Simulation Chamber
▲ Instrumented Dynamometer
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NVH – Analytical capability
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NVH – Testing Capbility
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UAV Engine Testing – Prop Lab
▲ UAV Engine Development Facility
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NVH Data Logging and Software
• Equipment– PC Based National Instruments
PCI-4472 DAQ – 24bit 8 channel (110dB dynamic range), expandable to 130 channels
– Record to PC hard disk, playback, post processing or re-processing using raw acquired data
– Microphones,– Sound Level Meters,– Accelerometers, Pressure (Low) Transducers
for Intake And Exhaust Measurements.
• Software– 01dB FA Suite: Real-time monitoring and recording
of noise and vibration signals, real-time analysis (FFT, Octave to 1/48th octave, , order analysis transient/waterfall analysis, and much more), extensive reporting and post processing capabilities.
– Exhaust/Intake System Acoustic Modelling Software.
▲ National Instruments PCI-4472 DAQ – 24bit 8ch
▲ National Instruments LabVIEW Software
▲ Sample Results: Blue=before, Red=After
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Standards and Procedures
• CFR (US), UNECE (Euro), ADR (Aus)
• AS, ASTM, ISO, etc
• SAE Procedures
• MIL spec.
• Industry standards
• Customer specific and in-house
Orbital Engine Company
(Australia) Pty Ltd was assessed
and
certified as meeting the
requirements of AS/NZS ISO-
9001:2008.
Orbital Australia’s test facility has the following Department of Infrastructure and Transport Test Facility Number (TFN) T2335
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Contact Info
Go to www.uavpropulsiontech.com/orbitalFor more INFO