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Engine motoring torque estimation 1 Sudarshan Mundhe 13 th October 2014

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Page 1: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

Engine motoring torque estimation

1

Sudarshan Mundhe

13th October 2014

Page 2: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

Objective

2

The goal is to determine net engine torque at crank shaft for cranking at low oil temperatures.

Speed range: 0 to 500 rpm.

Temperature range: -400 C to 00C

Engine: Inline 4 cylinder 4.5L

Page 3: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

Analysis Approach

3

The torque required to motor the engine can written as:

The total friction torque for engine is sum of frictional torque observed at following components.

1 Piston-ring assembly frictional

2 Cam bushing friction

3 Valve train friction

4 Idler bushing friction

5 Small end bushing friction

6 Rod bearing friction

7 Main bearing friction

In this project cylinder torque and the friction torque at different engine speed are estimated. The

friction torque is calculated for small end bush, rod bearing and main bearing.

GT suite is used to calculate the gas torque and the friction torque for bearings. The GT bearing

analysis is completed without heat balance (i.e input temperature is used as it is for the bearing

performance calculation).

Tm = Tc +Tf + I (∂ω/ ∂t)

Tm = Motoring Torque

Tc = Cylinder torque (Gas torque + Reciprocating inertia torque)

Tf = Friction Torque

I = Engine moment of inertia

(∂ω/ ∂t) = Angular acceleration

Page 4: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

Inputs

4

-50 0 50 100 150 200

Kin

em

atic

vis

cosi

ty (

cSt)

Temperature (deg C)

Oil Properties

Kin Vis (cSt)

The oil viscosity data below 0 deg C is required for the analysis.

Oil Properties: Viscosity data

Motoring curve pressure will be used for all rpm’s from 50-500 rpm

Cylinder Pressure Data

Page 5: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

5

GT Suite: Crankshaft Model GT crank Model

Note: The GT bearing analysis is completed without heat balance (i.e input temperature is used as it is for the bearing performance calculation).

main bearing

small end bushing

Rod bearing

Page 6: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

6

Main Bearing Friction Torque (50 rpm and -40 deg C)

M friction Torque Nm

µ viscosity of the oil. N-s/m^2

U omega* R (velocity of the journal) m/s

L bearing width m

R Journal radious m

C radial clearance m

Main1 average friction torque from GT x Nm

Main2 average friction torque from GT x Nm

Main3 average friction torque from GT x Nm

Main4 average friction torque from GT x Nm

Main5 average friction torque from GT x Nm

Total average friction torque from GT =5x Nm

Following equation can be used to verify the average friction torque analysis results .

Note: The GT bearing analysis is completed without heat balance (i.e input temperature is used as it is for the bearing performance calculation).

Page 7: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

7

Rod Big End Bearing Friction Torque (50 rpm and -40 deg C)

BE1 average friction torque from GT y Nm

BE2 average friction torque from GT y Nm

BE3 average friction torque from GT y Nm

BE4 average friction torque from GT y Nm

Total average friction torque from GT 4y Nm

Note: The GT bearing analysis is completed without heat balance (i.e input temperature is used as it is for the bearing performance calculation).

The rod bearing friction torque follow the relative speed curve.

30

35

40

45

50

55

60

65

70

0 90 180 270 360 450 540 630 720

spe

ed

Crank angle (deg)

Relative Speed (BE1)

Speed

Page 8: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

8

Small End Bushing Friction Torque (50 rpm and -40 deg C)

0

5

10

15

20

25

30

35

40

45

50

0 100 200 300 400 500 600 700

Smal

al E

nd

Bu

shin

g To

tal

Fric

tio

n T

orq

ue

(N

m)

Crank angle (deg)

Total Torque

Total-SE-Nm

SE1 average friction torque from GT z Nm

SE2 average friction torque from GT z Nm

SE3 average friction torque from GT z Nm

SE4 average friction torque from GT z Nm

Total average friction torque from GT 4z Nm

Bushing rotational velocity

Note: The GT bearing analysis is completed without heat balance (i.e input temperature is used as it is for the bearing performance calculation).

Page 9: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

-1000

-500

0

500

1000

1500

2000

2500

3000

0 100 200 300 400 500 600 700 800

Torq

ue (N

m)

Crank angle (deg)

Total-Friction-Nm

CylinderTorque

Total_ENG_torque-Nm

0

5

10

15

20

25

30

35

40

45

50

0 100 200 300 400 500 600 700

Smal

al E

nd

Bu

shin

g To

tal

Fric

tio

n T

orq

ue

(N

m)

Crank angle (deg)

Total Torque

Total-SE-Nm

9

Total Torque (friction + cyl torque): 50 rpm at -40 deg C

-800

-600

-400

-200

0

200

400

600

800

0 200 400 600 800

GasTorque-TVSIM

GasTorque-TVSIM

Average torque = 28Nm

Total Torque

Main bearing friction torque

Rod big end bearing friction torque

Small end bushing friction torque

Total Engine Torque

Total Engine Friction Torque

Cylinder Torque

Cylinder torque

Page 10: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

10

0

200

400

600

800

1000

1200

1400

1600

1800

2000

-40 -30 -20 -10

Fric

tio

na

l To

rqu

e (N

m)

Oil Inlet temperature (deg C)

Frictional Mean Torque Nm

Fric. Mean Torque - Main Bearings Nm

Fric. Mean Torque- Large End Bearings Nm

Fric. Mean Torque- Small End Bearings Nm

Oil inlet Temp deg C -40 -30 -20 -10 0

Average Engine Ang. Vel. RPM 50 50 50 50 50

Fric. Mean Torque - Main Bearings Nm 64% 65% 64% 64% 64%

Fric. Mean Torque- Large End Bearings Nm 34% 34% 34% 34% 35%

Fric. Mean Torque- Small End Bearings Nm 1% 1% 1% 1% 2%

Frictional Torque

Each bearing friction torque contribution is same at all speeds. Friction increases

with speed and reduces as oil temperature increases.

Page 11: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

-1000

-500

0

500

1000

1500

2000

2500

3000

0 100 200 300 400 500 600 700 800

Torq

ue (N

m)

Crank angle (deg)

Total-Friction-Nm

CylinderTorque

Total_ENG_torque-Nm

11

Max Motoring Torque

Max motoring torque = Max cylinder torque + mean friction torque

Max motoring torque

Page 12: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

12

Torque-Summary

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

50 100 150 200 250 300 350 400 450 500

Ma

x M

oto

rin

g To

rqu

e (

Nm

)

Engine Speed (rpm)

Max Motoring Torque

-40 deg C

-30 deg C

-20 deg C

-10 deg C

0 deg C

Note: The GT bearing analysis is completed without heat balance (i.e input temperature is used as it is for the bearing performance calculation).

Page 13: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

13

Power Loss Comparison

Example plot : Inline 6 cylinder engine power loss comparison using GT and other tool.

Oil inlet temperature 90 deg C

Cylinder pressure : zero cylinder pressure

T

T

GT suite results are comparable with other simulation tool.

Page 14: Sudarshan Mundhe 13th October 2014 - gtisoft.com · 45 50) 0 100 200 300 400 500 600 700 Crank angle (deg) Total Torque Total -SE Nm SE1 zaverage friction torque from GT Nm SE2 zaverage

Summary

GT Suite is capable to calculate bearing friction torque.

GT suite results are comparable with other tools and it is faster way to get the

friction calculation.

14

Future action items Simulation of piston and cam bushing frictional power loss using GT Suite

Estimate torque required to accelerate the engine (I (∂ω/ ∂t))


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