Fault Detection of Fuel Injectors Based on One-Class Classifiers

Fuel injectors are considered as an important component of combustion engines. Operational weakness can possibly lead to the complete machine malfunction, decreasing reliability and leading to loss of production. To overcome these circumstances, various condition monitoring techniques can be applied. The application of acoustic signals is common in the field of fault diagnosis of rotating machinery. Advanced signal processing is utilized for the construction of features that are specialized in detecting fuel injector faults. A performance comparison between novelty detection algorithms in the form of one-class classifiers is presented. The one-class classifiers that were tested included One-Class Support Vector Machine (OCSVM) and One-Class Self Organizing Map (OCSOM). The acoustic signals of fuel injectors in different operational conditions were processed for feature extraction. Features from all the signals were used as input to the one-class classifiers. The one-class classifiers were trained only with healthy fuel injector conditions and compared with new experimental data which belonged to different operational conditions that were not included in the training set so as to contribute to generalization. The results present the effectiveness of one-class classifiers for detecting faults in fuel injectors.

Experimental study of a heavy fuel oil atomization by pressure-swirl injector in the application of entrained flow gasifier

The available SMD(Sauter mean diameter) correlations on pressure-swirl injectors predict droplet sizing very different from each other, especially for heavy fuels. Also there was a lack in the literature for comparing available correlations. So an experimental study was conducted on a heavy fuel oil(HFO) spray, Mazut 380. A pressure swirl injector was designed and fabricated. The experiments for Mazut at 40℃ and 80℃ were compared with the results for water, including spray half cone angle, breakup length and mean droplet diameter,at different injection pressures. Lower spray angle, higher breakup length and larger droplets were observed for lower injection pressures and higher liquid viscosity. SMD was about 75 μm for water and about 87 μm for Mazut at 80℃. The results for droplet mean diameter were also compared with correlations from previous studies on pressure swirl atomizers. The SMD results show that for water spray, LISA method was in good agreement,also Babu and Ballester correlations were successful when high viscosity fluid was injected.

Numerical simulation of heavy fuel oil atomization using a pulsed pressure-swirl injector

It is known that increasing the injection pressure reduces the breakup length and the droplet size.Adding pulses,on the other hand,helps to atomize the liquid into finer droplets,similar to airassisted injectors but without altering the airtofuel concentration.To further reduce the droplet size and breakup length,a novel injector type,called''Pulsed PressureSwirl"(PPS),is introduced in this work,which is a combination of pressureswirl and ultrasonic pulsed injectors.A pressureswirl atomizer was designed and fabricated specifically for Mazut HFO(Heavy Fuel Oil).The droplet formation process and droplet size distribution have been studied experimentally(by shadowgraphy high speed imaging)and numerically(with the opensource VolumeofFluid code Gerris).Changing liquid injection pressure effect on the spray angle and film thickness has been quantified.These simulations have been used to study the primary breakup process and quantify the droplet size distributions,using different injection pulse frequencies and pressures.The numerical results have revealed that the new injector concept successfully produces finer droplets and results in a decrease in the breakup length,especially when applying high pulse frequencies,with no significant changes in the spray angle.

Effect of pulsed laser process parameters on welding quality of automobile fuel injector

In this research, pulverization plate and base of a fuel injector in an automobile electronic-controlled engine was joined by pulsed laser welding. The different welding parameters were evaluated and effect of process parameters on joint characteristics was analyzed. The optimal process parameters were obtained as follows： welding current 120 A, welding speed 600 ram/rain, pulse duration 1.80 ms and pulse frequency 60 Hz. The microstructure of weld metal was investigated. Results show that the fusion zone is austenitic dendrite, the weld center is equiaxed grain, while the transition zone between fusion zone and weld center is mixed crystal with austenitic dendrite and equiaxed grain. The weld layered phenomenon was observed, and eddy caused by keyhole effect is the main reason for the formation of layered structure in molten pool.

Floating Clamping Mechanism of PT Fuel Injector and Its Dynamic Characteristics Analysis

PT fuel injector is one of the most important parts of modern diesel engine.To satisfy the requirements of the rapid and accurate test of PT fuel injector,the self-adaptive floating clamping mechanism was developed and used in the relevant bench.Its dynamic characteristics directly influence the test efficiency and accuracy.However,due to its special structure and complex oil pressure signal,related documents for evaluating dynamic characteristics of this mechanism are lack and some dynamic characteristics of this mechanism can＇t be extracted and recognized effectively by traditional methods.Aiming at the problem above-mentioned,a new method based on Hilbert-Huang transform（HHT） is presented.Firstly,combining with the actual working process,the dynamic liquid pressure signal of the mechanism is acquired.By analyzing the pressure fluctuation during the whole working process in time domain,oil leakage and hydraulic shock in the clamping chamber are discovered.Secondly,owing to the nonlinearity and nonstationarity of pressure signal,empirical mode decomposition is used,and the signal is decomposed and reconstructed into forced vibration,free vibration and noise.By analyzing forced vibration in the time domain,machining error and installation error of cam are revealed.Finally,free vibration component is analyzed in time-frequency domain with HHT,the traits of free vibration in the time-frequency domain are revealed.Compared with traditional methods,Hilbert spectrum has higher time-frequency resolutions and higher credibility.The improved mechanism based on the above analyses can guarantee the test accuracy of injector injection.This new method based on the analyses of the pressure signal and combined with HHT can provide scientific basis for evaluation,design improvement of the mechanism,and give references for dynamic characteristics analysis of the hydraulic system in the interrelated fields.

基于网格搜索和投票分类模型的喷油器故障诊断研究

为了提高高压共轨试验台对喷油器检修效率,提出一种基于网格搜索和投票分类模型的喷油器故障自动诊断方法。由于压电喷油器故障数据采集困难,使用AMESim软件模拟不同轨压和脉宽状态下压电喷油器可能出现的多种故障情况。随后,将采集到的1 760组数据使用由随机森林、支持向量机和GBM组成的投票分类模型进行训练,并使用网格搜索法优化各分类器的超参数。实验结果表明:该模型对压电喷油器的5种故障状态及正常状态诊断时的准确率、精确率、召回率和F1-score分别为98.86%、99.13%、98.56%、98.83%,表现出较高的准确性和稳定性。该方法能够快速高效地对喷油器故障情况进行定位。

迈腾B8高压喷油器常见故障诊断

迈腾B8不仅在中国中级车辆的销售市场占有率较高,还是全国汽车技术技能竞赛的主选车型之一。在各类汽车故障中,高压喷油器是故障高发区域之一,对于高压喷油器常见故障及时进行精准诊断,是把握故障原因,做好有效处理的关键。本文主要结合燃油控制电路,对迈腾B8发动机喷油器的喷油过程进行分析,最后以案例的形式,讲解其高压喷油器常见故障的分析诊断过程,最后对于高压喷油器的故障诊断提供几点有效方法参考。通过理论联系案例分析,为更好的把握迈腾B8高压喷油器故障问题提供指导,为高压喷油器的故障诊断和处理提供一些思路和借鉴。

基于PISO算法的汽车喷油器优化仿真研究

通过三维数值模拟软件Converge结合PISO算法,针对重型直喷柴油机,研究喷油器的不同孔径、孔深和喷油倾角对发动机燃烧和排放性能的影响,得到柴油发动机最佳热效率的喷油器参数设置方案。结果表明:相较于喷孔深度和喷孔倾角,喷孔直径的改变对发动机热效率的影响更大,且可有效改善发动机的NO_(x)和碳烟排放。当喷孔直径为0.179 mm、0.219 mm及0.259 mm时,分别能实现1.4%、3.4%、和2.8%的增幅,热效率提升较为显著。

回油背压对高压共轨喷油器喷油特性影响的研究

高压共轨喷油器是柴油机高压共轨电控系统中最重要的一个部件,其喷油特性(如喷油器量)的优劣将直接影响发动机的性能表现。喷油器的喷射特性不仅受到喷油器的结构参数的影响,同时在喷射过程中还受到外界工作环境的影响,比如喷油器喷射时发动机缸内的背压,以及喷油器工作时的回油通道中的背压。本文主要对某高压共轨喷油器进行台架试验测试,研究喷油器回油背压对喷油特性的影响,并分析产生影响的原因,为开发新型的燃油喷射系统提供试验数据。

某船用发电辅机性能优化

为降低某船用发电辅机常用工况油耗,采用仿真分析确定最佳配气相位、压缩比、柱塞速度;通过负荷特性试验及正交试验,确定最佳喷油器方案;通过热怠速试验选择合适的机油泵、海水泵;通过台架负荷特性试验对比发电辅机优化前、后的油耗。结果表明:该发电辅机优化后,进气关闭角对应的曲轴转角为565°,排气开启角对应的曲轴转角为135°,压缩比为15.5,最高柱塞速度提高至2.54 m/s,选用喷孔直径为0.32 mm、喷孔锥角为158°的喷油器,机油泵、海水泵体积流量分别降低10、15 m^(3)/h,辅机常用工况区油耗比原机下降4~5 g/(kW·h),达到降低油耗的目的。

超磁致伸缩驱动高压共轨式喷油器的结构设计及喷油特性分析

针对现有喷油器存在的喷油速率低、喷油脉宽大、响应速率慢的问题,提出了一种超磁致伸缩驱动高压共轨式喷油器的设计方案。简述了该高压共轨式喷油器的整体设计及工作原理,并且在Jiles-Atherton磁滞模型和液压传动理论基础上建立数学模型;采用COMSOL建立了驱动部分仿真模型,并进行输出位移和应力特性分析,采用AMESim建立了喷油器整体模型,并进行喷油速率分析;搭建试验平台,验证了超磁致伸缩驱动高压共轨式喷油器设计方案的有效性。结果显示:当线圈电流为3.6 A时,超磁致伸缩棒的最大输出位移可达52μm;在160 MPa的压力下喷油最低脉宽从1 ms降低到0.15 ms,并且无论脉宽长短,其脉宽-喷油量均具有良好的线性度。结果表明,提出的设计方案可行,为研制出一种高性能的高压共轨式喷油器奠定了理论和技术基础。

基于SSA-VMD和ITFPF的喷油器信号去噪方法

由于柴油机工作环境复杂多变,喷油器信号中包含较多噪声,导致诊断率低。为降低噪声的影响,提高故障诊断率,提出一种麻雀算法优化变分模态分解(SSA-VMD)和改进时频峰值滤波(ITFPF)结合的信号去噪方法。针对VMD受分解参数制约的问题,以能量分解因子为目标函数,通过SSA自适应地将信号分解成一系列IMF,以解决参数设置不当导致的模态混叠问题。TFPF的窗长选择不当会影响其滤波效果,由于排列熵能够度量非平稳信号的复杂度,以排列熵为适应度函数寻到最优窗长,使ITFPF兼顾信号保真和噪声压制。仿真和试验结果表明:SSA-VMD和ITFPF结合的方法降噪效果优于其他方法,并使故障识别率相比未优化VMD提高了10.13%。

关于某喷油器CVO控制精度的研究

发动机喷油器是喷油系统的重要部件,对发动机的性能有很大的影响。文章结合对某发动机喷油器CVO自学习的失效案例,对喷油器CVO自学习、产生机理、常见问题改进措施进行详细的总结,希望对喷油器类高频高精密零件的控制软硬件匹配设计改进提供帮助。

关于喷油器头部积碳对燃油雾化的影响

喷油器对燃油的雾化是至关重要的,并且还影响着发动机的节能减排作用。通过试验数据对比,发动机喷油器其雾化效果变化较为明显,且积碳明显可见。通过对燃油雾化的影响分析得出,因在燃烧中产生积碳,并且粘附在喷油器头部,减小喷孔直径和喷孔数量,对喷油器燃油雾化效果有着直接性的影响,最终因积碳原因致使汽车无法启动,导致发动机故障灯亮,进而引发发动机怠速抖动,不能完全燃烧而产生一系列故障。

一款高性能重型柴油发动机的设计开发

介绍了一款配套重卡车型的直列6缸柴油发动机的设计开发过程。该发动机采用电控高压共轨系统和高效选择性催化还原(SCR)后处理系统,发动机本体采用蠕铁材料的气缸体和气缸盖。对比某款产品,该发动机动力更加强劲、燃油耗更低、经济性更好。此外,介绍了该发动机本体结构零件的开发设计、燃烧系统相关零件的设计和选型、性能开发策略,以及节能减排措施等。

东风4DD型内燃机车增压器喷油器故障及解决对策

为全面提升东风4DD型内燃机车用增压器的应用效益,延长其使用寿命,采用理论与实践相结合的方式,对以16V240ZJ型号为代表的柴油机增压器、喷油器运行原理以及常见故障进行分析。研究发现,在使用过程中,除了增压器、喷油泵和喷油器自身的故障外,气缸盖与活塞、增压器元件质量、油封质量、机油以及热交换器等各处的隐患均有可能影响喷油器的运行质量。为此,提出若干应对策略,以有效降低内燃机车增压器喷油器发生故障的概率。

两种不同大小喷孔直径喷油器对柴油机组经济性的影响

柴油机喷油器喷孔直径影响喷油器的雾化特性,而喷油器的雾化特性对柴油机热效率、燃油消耗率、有害物排放、机械故障等有着重要的影响。以某电控单体泵柴油机组为例,分别使用喷孔直径为0.28 mm和0.30 mm的2种喷油器进行负荷试验,对比2种喷油器柴油机组的燃油缸内爆发压力、燃油喷射压力、涡前排温及燃油消耗率。结果表明:使用喷孔直径为0.28 mm喷油器的柴油机组,其经济性优于使用喷孔直径为0.30 mm喷油器的柴油机组。

The Possibility of Active Attitude Control for Fuel Spray

The internal combustion engine (ICE) is an attractive power source for automobiles, with its superior storability, transportability, and suppliability of liquid fuel with high energy density. Compact ICEs with high performance and a low environmental load are greatly needed. In the future, smart active control of combustion by means of fuel spray injection must be considered as a breakthrough technology to address serious issues related to conventional ICEs, such as emissions. A designed fuel injection rate and spray pattern during the injection period have been technically developed, and combustion can be partially controlled in the conventional ICE. However, spatial fuel distribution is not progressing as desired in the field of combustion;thus, new and effective active control technologies for fuel spray are very necessary for the smart control of combustion. Cavitation, flash boiling, spray-to-spray interaction, spray-to-wall interaction, and air flow have potential as a basis for active attitude control of fuel spray. This article uses evidence from the literature to discuss the possibility of active spray attitude control for future fuel spray combustion technology in a smart compact ICE.

Thermal Modeling of a Novel Heated Tip Injector for Otto Cycle Engines Powered by Ethanol

This work presents a thermal modeling of a new cold-start system technology designed for Otto cycle combustion based on the electromagnetic heating principle. Firstly, the paper presents a state-of-the-art review and presents the context of automobile industry where heated injectors are necessary. The novel method of electromagnetic heating principle to solve the cold-start problem is still in the development phase and it enables engine starting at low temperatures in vehicles powered by ethanol or flex-fuel vehicles (FFV). This new system technology should be available as an alternative to replace the existing system. Currently, the cold-start system uses an auxiliary gasoline tank, which brings some inconvenience for the user. Secondly, the aim was also to create a physical model that takes into consideration all the parameters involved on the heating process such as power heating and average heat transfer coefficient. The study is based on the lumped system theory to model the ethanol heating process. From the analysis, two ordinary differential equations arise, which allowed an analytical solution. Particularly, an ethanol heating curve inside the injector was obtained, an important parameter in the process. Comparison with experimental data from other authors is also provided. Finally, a sensitivity analysis of controlling parameters such as heating power and heat transfer coefficient variation. The paper is concluded with suggestions for further studies.