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In-cylinder Flow
Section 4
Valve Flow
At WOT the most significant gas flow restriction in an IC engine is the flow
through the intake and exhaust valves
Pv
Pcyl
2 Pv Pv
m = c f o Av co
k 1 Po Po
m , Po , o
Po k + 1
=
Pv 2
2
m cr = c f o Av co
k + 1
k
k 1
k +1
k
k +1
2 ( k 1)
= c f Av
k Po 2
R To k + 1
k +1
2 ( k 1)
Valve Flow
Minimum areas:
low lift - Av = A1= dl
high lift - Av= A2=
d2/4
A1
A2
High lift
Low lift
flow coefficient (c f ) =
discharge coefficient (c d ) =
Set: Av
Measure: mi, Ti, Pi
Calculate: cf
1
2
2
k +1
m 2 Pv k Pv k
cf =
o Av co k 1 Po Po
Valve Sizing
In order to avoid choked flow the intake valves are sized based on:
(U p )max
2
Av 1.3b
ci
where Av is the average valve area, b is the cylinder bore, U p is average
piston velocity at max engine speed, ci speed of sound of gas in intake port.
Exhaust valves can be smaller since the speed of sound of the exhaust
gas expelled is significantly larger.
Since there is only so much room available for valves it is common to
have multiple intake and exhaust valves per cylinder. This increases
valve area to piston area ratio permitting higher engine speeds.
Valve Sizing
Heads are often wedge-shaped or domed, this permits Av/Ap up to 0.5.
Valve Sizing
Double overhead cams per cylinder bank are used to accommodate
multiple valves, one cam for each pair of intake and exhaust valves
EVO
IVO
IVC
EVC
180o
Duration
Valve starts
to open
BC
TC
CA
Valve completely
closed
8
Valve Overlap
In real engines in order to ensure that the valve is fully open during a stroke,
for high volumetric efficiency, the valves are open for longer than 180o.
The exhaust valve opens before BC and closes after TC
The intake valve opens before TC and closes after BC.
At TC there is a period of time called valve overlap where both the intake
and exhaust valves are open.
EVO
4
IVO
IVC
5
1
EVC
180o
TC
BC
BC
TC
BC
CA
Valve overlap
When the intake valve opens bTC the cylinder pressure is at roughly Pe
Part throttle (Pi < Pe): residual gas flows into the intake port. During intake
stroke the residual gas is first returned to the cylinder then fresh gas is
introduced. Residual gas reduces part load performance.
WOT (Pi = Pe): some fresh gas can flow out the exhaust valve scavenging
residual (increases power but reduces fuel efficiency and increases emissions)
Supercharged (Pi > Pe): fresh gas can flow out the exhaust valve
Pe
Pi
Throttled
Pi < Pe
Pi
Pe
WOT
Pi = Pe
Pi
Pe
Supercharged
Pi > Pe
10
Engine load
WOT bmep
sfc
Engine speed:
Idle - 1000 rpm
Economy - 2500 rpm
Performance - 4000 rpm
11
Valve Timing
Conventional
Performance
EVO
EVO
IVO
IVO
e
i
IVC
EVC
TC
180o
BC
e
i
TC
IVC
EVC
180o
BC
Valve Overlap
Overlap
15o
65o
At high engine speeds less time available for fresh gas intake so need more
crank angles to get high volumetric efficiency large valve overlap
At low engine speed and part throttle want to minimized valve overlap
Variable Valve Timing (VVT) used to obtain optimum performance over
a wide range of engine speeds and load
Variable valve lift: high speed want high lift to increase air mass flow rate,
low speed want low lift to minimize overlap effects
13
Camshaft
Follower
During high-rpm operation a pin locks the three rocker arms and the valves
High rpm lobe has longer duration and higher lift raises max to 8000 rpm
giving higher peak power (good for racing) no benefit below 4500 rpm 15
16
no pin
pin 1
med-cam
low-lift
med-lift
med-lift
pin 2
high-cam
high-lift
Stage 1 (low speed): left valve left rocker arm driven by the low-lift left
cam. Right valve right rocker arm driven by the medium-lift right cam
Stage 2 (medium speed): left and right valve right rocker arm driven by
the medium-lift right cam
Stage 3 (high speed): left and right valve middle rocker arm driven by the
high-lift right cam
i-VTEC (2001): VTEC + continuously variable camshaft phasing for
benefit even at lower speeds
17
Most systems provide inlet, two-stage discrete phasing (0o and 30o), others
provide continuous phasing (0o - 30o)
At low speed, 0o phasing is used so as to minimize valve overlap to minimize
residual gas backup into intake (good idle performance)
At high speeds, max phasing so as to increase valve overlap high-speed
exhaust gas inertia pulls in fresh gas purging residual gas out of cylinder
(improves volumetric efficiency)
18
Cap moves towards or away from the cam based on engine speed and gas
pedal position by varying hydraulic pressure in the two chambers
Valvetronic also permits continuously variable intake valve lift, from ~0 to
10 mm, on the intake camshaft. This eliminates the need for a throttle valve
reducing pumping losses (10% improvement in power and fuel economy).
19
LP
HP
20
Toyotas VVTL
VVTL uses cam phasing and two cam profiles for duration
At low rpm: long duration cam not engaged, short duration cam runs on
roller follower to reduce friction
At high rpm: long duration cam engaged by sliding pin and locking
follower height also increases the lift (for Honda VTEC, both the
duration and lift are implemented by the cam lobes)
21
22
EVO
P = cylinder pressure
Lv = valve displacement
P, Lv
1
Lv, exh
Exhaust
Lv, int
Ppoo
Intake
Po
WOT
Part throttle
e
i
TC
1st
BC
TC
4
2
BC
23
Valve Float
The valve spring normally keeps the top of the valve stem in contact with
the cam lobe
At very high engine speeds, and thus high camshaft speeds, it is difficult to
maintain contact between the cam lobe and the top of the valve stem as a
result the valves stay open longer than desired and slam into valve seat.
Spring
24
Po, To
Cylinder
Po
Muffler
25
Exhaust manifold used to duct the exhaust gases from each cylinder to
a point of expulsion such as the tail pipe.
26
Manifold Pressure
3000 rpm
6000 rpm
27
Win
28
P1
P2
Pressurization occurs in the manifold when the air flow rate supplied
is larger than that ingested by the cylinders.
Produces constant flow rate independent of boost pressure (P2)
29
Roots
Dynamic Compressors
Dynamic compressor has a rotating element that adds tangential
velocity to the flow which is converted to pressure in a diffuser.
Most common is the radial (or centrifugal) type
32
Aftercooler
The peak pressure in the exhaust system is only slightly greater than
atmospheric small P across turbine
In order to produce enough power to run compressor the turbine speed
must be very fast (100k-200k rev/min) long term reliability an issue
Takes time for turbine to spool up to speed, so when the throttle is opened
suddenly there is a delay in achieving peak power - turbo lag
EXHAUST
FLOW
INTAKE
AIR
34
Waste gate valve used to bypass exhaust gas flow from the turbine
It is used as a full-load boost limiter and in new engines used to control
the boost level by controlling the amount of bypass using proportional
control to improve drivability
Engine
WASTE GATE
Proportional
valve
AIR
Patm
Exhaust
Patm
Turbine
WASTE GATE
Compressor
35
36
37
Guide vane
38
2006 Porche 911 Variable Turbine Geometry uses temperature-resistant materials
39
Holset VGT
40
Volumetric Efficiency
a ,cylVd ,a
ma
=
Recall volumetric efficiency is defined as: v =
a ,oVd
a ,oVd
Pcyl
Tcyl
=
Po
To
Vd ,a
Vd
N = ( S / 2) U p
41
Factors affecting v
Fuel evaporation:
In naturally aspirated engines (no supercharging) the volumetric efficiency
will always be less than 100% because fuel is added and the fuel vapour
will displace incoming air.
The earlier the fuel is added in the intake system the lower the volumetric
efficiency because more of the fuel evaporates before entering the cylinder.
In Diesels and GDIs the fuel is added directly into the cylinder after the
intake stroke so get higher volumetric efficiency.
42
Factors affecting v
Heat transfer:
All intake systems are hotter than ambient air, e.g., injection system and
throttle bodies are purposely heated to enhance fuel evaporation.
Therefore, the density of the air entering the cylinder is lower than
ambient air density.
Greatest problem at lower engine speeds more time for air to be heated.
Use cold air intake
Pcyl
m f
m a
43
Factors affecting v
Fluid friction:
The air flows through a duct fitted with an air filter, throttle and intake valve
Air moving through any flow passage or past a flow restriction undergoes a
pressure drop
The pressure at the cylinder is thus lower than atmospheric pressure
Greatest problem at higher engine speeds when the air flow velocity is high
44
Po = atmospheric pressure
Air cleaner
Po
Pair
Pu
Pthrottle
Pvalve
WOT
Part throttle
Cylinder
Muffler
Extreme case of flow restriction is when the flow chokes at the intake valve
as engine speed increases flow velocity remains the same have less fill 45
time.
Factors affecting v
Residual gas:
Residual gas takes up cylinder volume that would otherwise contain air
1
( Pe / P4 )1 / k
=
f
Recall the residual fraction given by
r
e
i
TC
1
BC
46
Factors affecting v
Opening intake valve before TC (valve overlap):
The longer the valve overlap, more exhaust gases rush into the
intake port.
Greatest problem at idle (part throttle and lower engine speeds) low
intake pressure and more time for exhaust gases to back up.
EO
IO
e
i
TC
IC
EC
BC
47
Factors affecting v
Closing the intake valve after BC (backflow):
P, Lv
Lv, exh
Lv, int
P
po
Factors affecting v
RAM Effect:
As the intake valve closes at higher engine speeds, the inertia of the air in
the intake system increases the pressure in the intake port, P + u 2 = Ps
allowing more air to be injected
This effect becomes progressively more important at higher engine speeds.
To take advantage of ram effect close intake valve after BC.
Pcyl
49
Factors affecting v
Intake tuning:
When the intake valve opens the air suddenly rushes into the cylinder and
an expansion wave propagates back to the intake manifold at the local speed
of sound relative to the flow velocity.
When the expansion wave reaches the manifold it reflects back towards to
intake valve as a compression wave. The time it takes for the round trip
depends on the length of the runner (L) and the flow velocity.
If the timing is appropriate the compression wave arrives at the inlet at the
end of the intake process raising the pressure above the nominal inlet
pressure allowing more air to be injected.
twave =
2L
c
2 2
tvalve
3 N
c
N
For fixed runner length the intake is tuned for one engine speed.
50
51
52
53
Swirl motion
Helical port
Tangential injection
Contoured valve
54
Swirl Theory
Swirl can be simply modelled as solid body rotation, i.e., cylinder of gas
rotating at angular velocity, .
Tangential flow velocity is v = r
The swirl ratio, Rs, is defined as the ratio of the gas angular velocity and
the crank shaft angular velocity, i.e.,
Rs =
2N
where N is the engine speed (revolutions per second)
is the air solid-body angular velocity (rad/s)
Most production engines have Rs in the range of 0.5 -1.0
55
Swirl Theory
The angular momentum, , and moment of inertia, I, of a rotating
volume of gas is:
= I
I = rdm
MB 2
for a cylinder I =
8
56
Engine Swirl
Many engines have a wedge shape cylinder head cavity or a bowl in the
piston where the gas ends up at TC.
57
58
Intake Flow
The intake process governs many important aspects of the flow within the
cylinder. The gas issues from the valve opening as a conical jet with radial
and axial velocities that are about ten times the mean piston velocity.
The jet separates from the valve producing shear layers with large velocity
gradients which generate turbulence.
The jet is deflected by the cylinder wall down towards the piston and up
towards the cylinder head producing recirculation zones.
Additional turbulence is generated by the velocity gradient at the wall
in the boundary layer.
Shear layers
Large vortices become unstable
and eventually break down into
turbulent motion
59
Turbulent Flow
Turbulent flow is characterized by its transient and random nature that is
superimposed on a steady mean flow.
Steady flow
u(t2)
t1
t2
where u '2 =
1 t
2
t (u ' (t ) ) dt
t
2
61
Instantaneous
BC
Measurement
point
BC
TC
BC
TC
BC
CA
Individual cycle mean
In engines the flow is statistically periodic (the flow pattern changes with
crank angle) not steady.
The instantaneous velocity measured at a specific crank angle in a
particular cycle i is:
U ( , i ) = U ( ) + u ' ( , i )
62
Individual cycle
mean
Instantaneous
UEA
Ensemble average
CA
Flows that are statistically periodic are treated using ensemble average:
1n
U EA ( ) = U ( , i )
n i
The difference between the mean velocity in a particular cycle and the
ensemble average is defined as the cycle-by-cycle variation in mean velocity:
U ( , i ) = U ( , i ) U EA ( )
If the cycle-by-cycle variations are small then the cycle mean is equal to
the ensemble average.
Thus, the instantaneous velocity can be split into three components:
U ( , i ) = U EA ( ) + U ( , i ) + u ' ( , i )
ut ( ) = u ' ( , i )
n i =1
64
65
Turbulence Length-Scales
Turbulent flow is comprised of unsteady eddies (vortices) with a multitude
of length-scales and time-scales (turnover time).
The largest eddies in the flow are limited in size by the enclosure with
characteristic length-scale of L (e.g., large eddy associated with swirl).
The integral scale l represents the largest turbulent eddy, determined
by the fluctuating velocity frequency.
Most of the turbulent KE is contained in the large eddies that breakdown
into smaller size eddies via inviscid mechanisms.
The turbulent KE cascades from the larger structures to the smaller
structures where it is converted to thermal energy via viscous effects.
What scale eddy is required to dissipate energy?
66
Length-Scales of Turbulence
Reynolds number (Re) of an eddy with circulation velocity u' and size L is:
u '2 L2
3
inertia force per unit volume
u ' L
L
Re =
=
u ' L
viscous force per unit volume
Viscous forces are only important in the smallest scale where the Re 1
The eddy size at which the flow KE is dissipated by viscous effects is
known as the Kolmogorov scale, and the eddy dimension is .
There is one more length-scale between the integral and Kolmogorov scales
known as the Taylor microscale which represents the distance over which
viscous effects can be felt, or the mean spacing between dissipative eddies.
67
Length-Scales of Turbulence
The scales are: Integral (l), Taylor micro (l), Kolmogorov ()
68
15
= Re t1 2
l C
= (C )
1 4
Re t3 4
If the integral scale can be determined, so can all the other scales.
As the engine speed increases the Re increases, so the smaller scales
of turbulence decrease in size.
69
AIR
PROD
AIR
70
Scavanging Performance
Dr =
Delivery ratio, Dr
Trapping efficiency,
Scavenging efficiency, es
If the cylinder volume is completely filled with air the delivery ratio is
given by:
Dr =
a Vbc Vbc
r
>1
=
=
a Vd Vd r 1
71
Scavenging Models
A. Perfect scavanging no mixing, air displaces the products out the exhaust
if extra air is delivered (Dr > r/(r-1) ) it is not retained
B. Short circuiting the air initially displaces all the products within the path
of the short circuit and then flows into and out of the cylinder
Trapping efficiency
Scavenging efficiency
C. Perfect mixing the air that enters the cylinder mixes instantaneously
with the products, so immediately the gas leaving includes
both air and products
Delivery ratio
Delivery ratio
72