Table Of ContentKlaus Mollenhauer (cid:2) Helmut Tschoeke
Handbook of Diesel Engines
Klaus Mollenhauer (cid:2) Helmut Tschoeke
Handbook of Diesel
Engines
With584Figuresand86Tables
1 3
Editors
Prof.Dr.-Ing.KlausMollenhauer Prof.Dr.-Ing.HelmutTschoeke
OrberStr.25 OttovonGuerickeUniversityMagdeburg
14193Berlin InstituteofMobileSystems
Germany Universita¨tsplatz2
[email protected] 39106Magdeburg
Germany
[email protected]
Translator
KristerG.E.Johnson
Otto-von-Guericke-Strass56b
39104Magdeburg
Germany
ISBN978-3-540-89082-9 e-ISBN978-3-540-89083-6
DOI10.1007/978-3-540-89083-6
SpringerHeidelbergDordrechtLondonNewYork
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Preface
This machine is destined to completely revolutionize cylinderdieselengineupthroughlargelowspeedtwo-
engine engineering and replace everything that exists. stroke diesel engines. An appendix lists the most
(From Rudolf Diesel’s letter of October 2, 1892 to the importantstandardsandregulationsfordieselengines.
publisherJuliusSpringer.) Furtherdevelopmentofdieselenginesaseconomiz-
Although Diesel’s stated goal has never been fully ing,clean,powerfulandconvenientdrivesforroadand
achievable of course, the diesel engine indeed revolu- nonroad use has proceeded quite dynamically in the
tionizeddrivesystems.Thishandbookdocumentsthe last twenty years in particular. In light of limited oil
currentstateofdieselengineengineeringandtechnol- reserves and the discussion of predicted climate
ogy. The impetus to publish a Handbook of Diesel change, development work continues to concentrate
Engines grew out of ruminations on Rudolf Diesel’s onreducingfuelconsumptionandutilizingalternative
transformation of his idea for a rational heat engine fuelswhilekeepingexhaustascleanaspossibleaswell
into reality more than 100 years ago. Once the patent as further increasing diesel engine power density and
wasfiledin1892andworkonhisenginecommenced enhancing operating performance. Development is
thefollowingyear,RudolfDieselwaitedanother4years oriented toward the basic legal conditions, customer
until the Association of German Engineers provided demands and, not least, competition with gasoline
himaplatformtopresenthisenginetothepublicatits engines, which are still considered the benchmark car
convention in Kassel on June 16, 1897. The engine engineinmanysectors.
came to bear the name of its ingenious inventor soon Thetopicstobetreatedwereweighedwithallthisin
thereafter. mind: In addition to engine internal measures that
The editors and publisher intend this English edi- reduceexhaustemissionswiththeaidofnewcombus-
tion of the handbook to furnish readers outside Ger- tionsystemsandnewfuels,thesectiononExhaustGas
man-speakingregionsascholarlyandpracticalpresen- Aftertreatmentdeservesparticularmention.Theoxida-
tation of the current state of the diesel engine and its tioncatalyticconvertersintroducedinthecarsectoras
largerangeofapplications.Thehandbookhasnotonly standard in the 1990s will soon no longer meet the
been conceived for diesel experts but also ‘‘diesel lay- mountingrequirementsforairhygiene;particulatefil-
persons’’ with prior knowledge of engineering or at tersandnitrogenoxidereductionsystems,e.g.SCRand
least an interest in technology. Furthermore, it is storagecatalysts,havebecomestandard.
intended to benefit students desiring a firsthand New combustion systems with a larger share of
comprehensive and sound overview of diesel engine premixed, homogeneous combustion than normal
engineering and technology and its state of diffusion combustion are just as much the subject of
development. this handbook as the refinement of supercharging to
These aims are reflected in the book’s five-part enhancethepoweroutput,increasethepeakcylinder
structure. Part I provides a brief history of the diesel pressureandthuslimitloadasthebrakemeaneffec-
engine followed by sections on the fundamentals, tivepressureincreases.Quicklyemergingastheopti-
including supercharging systems, diesel engine com- mal injection system when the car sector switched
bustion,fuelsandmoderninjectionsystems.PartsII– from indirect to direct injection at the end of the
IVtreattheloadinganddesignofselectedcomponents, 1990s, the common rail system also came to be used
diesel engine operation, the pollution this causes and – initially only experimentally – for larger diesel
theincreasinglyimportantmeasurestoreduceit.Part engines at the start of the new millennium. The
Vpresentstheentirerangeofenginesfromsmallsingle commonrailsystemisnowstandardindieselengines
V
VI Preface
of virtually every size. Hence, reflecting current but We would like to thank all the authors – whether
by far not yet finalized development, this handbook experts workinginindustrywheretheutmostdedica-
treats the different designs, e.g. with solenoid valve- tionisdemandedorourcolleaguesinacademiawhere
controlled or piezo-actuated injectors, in detail. the days of creative leisure have long since become a
Amplespace hasaccordinglyalsobeengiventoelec- thing of the past – for their collaboration, their ready
tronicswithitsdiverseoptionstocontrolprocessesin acceptance of our ideas and the many fruitful discus-
the engine. sions.Wewouldalsoliketoextendourgratitudetothe
To be able meet the expectations and demands companiesthatallowedtheiremployeestoworkonthe
connected with a Handbook of Diesel Engines, we side, supported the compilation of texts and master
relied as much on the collaboration of outstanding illustrationsandprovidedmaterial.Acknowledgement
engineersfrom theengineindustryasontheresearch is also due the many helpers at companies and insti-
findingsofprofessorsatuniversitiesofappliedsciences tutes for their contributions without which such an
and universities. After all, a particularly close connec- extensive book manuscript could never have been
tionhasexistedbetweentheoryandpractice,between produced.
academia and industry, in engine research since Die- ParticularlyspecialthanksgototheDieselSystems
sel’s day, his invention itself being based on the engi- DivisionatRobertBoschGmbHforthetechnicaland
neeringofhisday. financial support, which made it possible to complete
Thanks to the work of many generations of engi- thisextensiveworkinthefirstplace.
neers, scientists, researchers and professors, the diesel Despitethesometimeshecticpaceandconsiderable
enginecontinuestobethemostcosteffective internal additional work, the editors tremendously enjoyed
combustion engine and has evolved into an advanced theircollaborationwiththeauthors,thepublisherand
high-techproduct. alltheothercollaborators.
Berlin,Germany, KlausMollenhauer
Magdeburg,Germany HelmutTschoeke
September2009
Myenginecontinuestomakegreatadvances.... (FromRudolfDiesel’sletterofJuly3,1895tohiswife.)
Contents
Contributors . . . . . . . . . . . . . . . . . . . . . IX 5.2 InjectionNozzlesandNozzleHolders . . . 129
5.3 InjectionSystems . . . . . . . . . . . . 137
5.4 InjectionSystemMetrology . . . . . . . . 170
Part I The Diesel Engine Cycle . . . . Literature . . . . . . . . . . . . . . . . . . 173
1
FurtherLiterature . . . . . . . . . . . . . . 173
FurtherLiteratureonSection5.2 . . . . . . . . 174
1 HistoryandFundamentalPrinciplesofthe
DieselEngine(KlausMollenhauerand
6 FuelInjectionSystemControlSystems(UlrichProjahn,
KlausSchreiner) . . . . . . . . . . . . . . . . 3
HelmutRandoll,ErichBiermann,Jo¨rgBru¨ckner,
1.1 TheHistoryoftheDieselEngine . . . . . . 3
KarstenFunk,ThomasKu¨ttner,WalterLehle,and
1.2 FundamentalsofEngineEngineering . . . . 7
JoachimZuern) . . . . . . . . . . . . . . . 175
1.3 CombustionCycleSimulation . . . . . . . 18
6.1 MechanicalControl . . . . . . . . . . . 175
Literature . . . . . . . . . . . . . . . . . . . 29
6.2 ElectronicControl . . . . . . . . . . . . 176
6.3 Sensors . . . . . . . . . . . . . . . . . 184
2 GasExchangeandSupercharging(HelmutPucher) . . 31
6.4 Diagnostics . . . . . . . . . . . . . . . 186
2.1 GasExchange . . . . . . . . . . . . . . . 31
6.5 ApplicationEngineering . . . . . . . . . 189
2.2 DieselEngineSupercharging . . . . . . . . 38
Literature . . . . . . . . . . . . . . . . . . 191
2.3 ProgrammedGasExchange
FurtherLiterature . . . . . . . . . . . . . . 191
Simulation . . . . . . . . . . . . . . . . 56
Literature . . . . . . . . . . . . . . . . . . . 59
Part II Diesel Engine Engineering . .
193
3 DieselEngineCombustion(KlausB.Binder) . . . . . 61
3.1 MixtureFormationandCombustion . . . . 61 7 EngineComponentLoading(DietmarPinkernelland
3.2 DesignFeatures . . . . . . . . . . . . . . 69 MichaelBargende) . . . . . . . . . . . . . . 195
3.3 AlternativeCombustionProcesses . . . . . . 73 7.1 MechanicalandThermalLoading
3.4 ProcessSimulationofInjectionCharacteristic ofComponents . . . . . . . . . . . . . 195
andRateofHeatRelease . . . . . . . . . . 74 7.2 HeatTransferandThermalLoads
Literature . . . . . . . . . . . . . . . . . . . 75 inEngines . . . . . . . . . . . . . . . 202
Literature . . . . . . . . . . . . . . . . . . 217
4 Fuels(GerdHagenow,KlausReders,Hanns-Erhard
FurtherLiterature . . . . . . . . . . . . . . 219
Heinze,WolfgangSteiger,DetlefZigan,andDirk
Mooser) . . . . . . . . . . . . . . . . . . . . 77 8 CrankshaftAssemblyDesign,Mechanics
4.1 AutomotiveDieselFuels . . . . . . . . . . 77 andLoading(EduardKo¨hler,EckhartSchopf,and
4.2 AlternativeFuels . . . . . . . . . . . . . 94 UweMohr) . . . . . . . . . . . . . . . . . 221
4.3 OperationofMarineandStationary 8.1 DesignsandMechanicalPropertiesof
EngineswithHeavyFuelOil . . . . . . . 103 CrankshaftAssemblies . . . . . . . . . . 221
4.4 FuelGasesandGasEngines . . . . . . . 114 8.2 CrankshaftAssemblyLoading . . . . . . 228
Literature . . . . . . . . . . . . . . . . . . 124 8.3 BalancingofCrankshaftAssemblyMasses . 236
8.4 TorsionalCrankshaftAssembly
5 FuelInjectionSystems(WalterEgler,RolfJu¨rgen Vibrations . . . . . . . . . . . . . . . 250
Giersch,FriedrichBoecking,Ju¨rgenHammer, 8.5 BearingsandBearingMaterials . . . . . . 259
JaroslavHlousek,PatrickMattes,UlrichProjahn, 8.6 Piston,PistonRingsandPistonPins . . . . 270
WinfriedUrner,andBjo¨rnJanetzky) . . . . . . 127 Literature . . . . . . . . . . . . . . . . . . 287
5.1 InjectionHydraulics . . . . . . . . . . . 127 FurtherLiterature . . . . . . . . . . . . . . 290
VII
VIII Contents
9 EngineCooling(KlausMollenhauerand 15.2 EmissionControlLegislation . . . . . . 426
JochenEitel) . . . . . . . . . . . . . . . . . 291 15.3 PollutantsandTheirProduction . . . . . 443
9.1 InternalEngineCooling . . . . . . . . . 291 15.4 In-EngineMeasuresforPollutant
9.2 ExternalEngineCoolingSystems . . . . . 309 Reduction . . . . . . . . . . . . . . . 449
Literature . . . . . . . . . . . . . . . . . . 336 15.5 ExhaustGasAftertreatment . . . . . . . 455
15.6 EmissionsTesting . . . . . . . . . . . 469
10 MaterialsandTheirSelection(JohannesBetz) . . . . 339 Literature . . . . . . . . . . . . . . . . . . 483
10.1 TheImportanceofMaterialsforDiesel FurtherLiterature . . . . . . . . . . . . . . 485
Engines . . . . . . . . . . . . . . . . 339
10.2 TechnicalMaterialsforEngineComponents . 339 16 DieselEngineNoiseEmission(BrunoM.Spessert
10.3 FactorsforMaterialSelection . . . . . . 348 andHansA.Kochanowski) . . . . . . . . . . 487
10.4 ServiceLifeConceptsandMaterialData . . . 348 16.1 FundamentalsofAcoustics . . . . . . . 487
10.5 ServiceLifeEnhancingProcesses . . . . . 349 16.2 DevelopmentofEngineNoise
10.6 TrendsinDevelopment . . . . . . . . . 352 Emission . . . . . . . . . . . . . . . 487
Literature . . . . . . . . . . . . . . . . . . 354 16.3 EngineSurfaceNoise . . . . . . . . . . 489
FurtherLiterature . . . . . . . . . . . . . . 355
16.4 AerodynamicEngineNoises . . . . . . . 498
16.5 NoiseReductionbyEncapsulation . . . . 499
Part III Diesel Engine Operation . .
357 16.6 EngineSoundproofing . . . . . . . . . 502
Literature . . . . . . . . . . . . . . . . . . 502
11 LubricantsandtheLubricationSystem
(HubertSchwarze) . . . . . . . . . . . . . . 359 Part V Implemented Diesel
11.1 Lubricants . . . . . . . . . . . . . . . 359
Engines . . . . . . . . .
505
11.2 LubricationSystems . . . . . . . . . . 370
Literature . . . . . . . . . . . . . . . . . . 376
17 VehicleDieselEngines(FritzSteinparzer,Klaus
12 StartandIgnitionAssistSystems(WolfgangDressler Blumensaat,GeorgPaehr,WolfgangHeld,and
andStephanErnst) . . . . . . . . . . . . . . 377 ChristophTeetz) . . . . . . . . . . . . . . . . 507
12.1 ConditionsfortheAuto-IgnitionofFuel . 377 17.1 DieselEnginesforPassengerCars . . . . 507
12.2 FuelIgnitionAids . . . . . . . . . . . 378 17.2 DieselEnginesforLightDuty
12.3 StartandIgnitionAssistSystems . . . . . 379 CommercialVehicles . . . . . . . . . . 521
12.4 ColdStart,ColdRunningPerformance 17.3 DieselEnginesforHeavyDutyCommercial
andColdRunningEmissionsforCars . . 383 VehiclesandBuses . . . . . . . . . . . 528
12.5 Conclusion . . . . . . . . . . . . . . 386 17.4 HighSpeedHighPerformance
Literature . . . . . . . . . . . . . . . . . . 386 DieselEngines . . . . . . . . . . . . . 544
FurtherLiterature . . . . . . . . . . . . . . 386 Literature . . . . . . . . . . . . . . . . . . 556
FurtherLiterature . . . . . . . . . . . . . . 557
13 IntakeandExhaustSystems(OswaldParr,
JanKru¨ger,andLeonhardVilser) . . . . . . . 387
18 IndustrialandMarineEngines(Gu¨nterKampichler,
13.1 AirCleaners . . . . . . . . . . . . . . 387
HeinerBu¨lte,FranzKoch,andKlausHeim) . . . 559
13.2 ExhaustSystems . . . . . . . . . . . . 393
Literature . . . . . . . . . . . . . . . . . . 398 18.1 SmallSingleCylinderDiesel
FurtherLiterature . . . . . . . . . . . . . . 399 Engines . . . . . . . . . . . . . . . . 559
18.2 StationaryandIndustrialEngines . . . . 568
14 ExhaustHeatRecovery(FranzHirschbichler) . . . . 401
18.3 MediumSpeedFour-Stroke
14.1 BasicsofWasteHeatRecovery . . . . . . 401
DieselEngines . . . . . . . . . . . . . 576
14.2 OptionsofWasteHeatRecovery . . . . . 404
18.4 Two-StrokeLowSpeed
Literature . . . . . . . . . . . . . . . . . . 413
DieselEngines . . . . . . . . . . . . . 592
Literature . . . . . . . . . . . . . . . . . . 607
Part IV Environmental Pollution
by Diesel Engines . . . . . StandardsandGuidelinesforInternalCombustionEngines . 609
415
Index . . . . . . . . . . . . . . . . . . . . . . 621
15 DieselEngineExhaustEmissions(HelmutTschoeke,
AndreasGraf,Ju¨rgenStein,MichaelKru¨ger,Johannes
Schaller,NorbertBreuer,KurtEngeljehringer,
andWolfgangSchindler) . . . . . . . . . . . 417
15.1 GeneralBackground . . . . . . . . . . 417
Contributors
MichaelBargende, Prof.Dr.-Ing.,Universita¨tStuttgart, Hanns-ErhardHeinze, Dr.-Ing.,Magdeburg,Germany,
Stuttgart,Germany,[email protected] [email protected]
JohannesBetz, MTUFriedrichshafenGmbH, WolfgangHeld, Dr.-Ing.,MANNutzfahrzeugeAG,
Friedrichshafen,Germany,[email protected] Nu¨rnberg,Germany,[email protected]
ErichBiermann, Dr.-Ing.,RobertBoschGmbH,Diesel FranzHirschbichler, Dr.,Mu¨nchen,Germany,
Systems,Stuttgart,Germany, [email protected]
[email protected] JaroslavHlousek, Dipl.-Ing.,KEFICOCo,Gunpo,Korea
KlausB.Binder, Prof.Dr.-Ing.,Deizisau,Germany, (RoK),[email protected]
[email protected] Bjo¨rnJanetzky, Dr.-Ing.,RobertBoschGmbH,Diesel
KlausBlumensaat, VolkswagenAG,Wolfsburg,Germany, Systems,Stuttgart,Germany,
[email protected] [email protected]
FriedrichBoecking, RobertBoschGmbH,DieselSystems, Gu¨nterKampichler, Dipl.-Ing.,Ruhstorf,Germany
Stuttgart,Germany,[email protected] FranzKoch, Dr.-Ing.,MANDiesel&TurboSE,Augsburg,
NorbertBreuer, Dr.-Ing.,RobertBoschGmbH,Diesel Germany,[email protected]
Systems,Stuttgart,Germany, HansA.Kochanowski, Dr.-Ing.,Ruhstorf,Germany
[email protected] EduardKo¨hler, Prof.Dr.-Ing.habil.,KSAluminium
Jo¨rgBru¨ckner, Dr.,RobertBoschGmbH,DieselSystems, TechnologieGmbH,Neckarsulm,Germany,
Stuttgart,Germany,[email protected] [email protected]
HeinerBu¨lte, Dr.-Ing.,DeutzAG,Ko¨ln,Germany, JanKru¨ger, Dr.-Ing.,J.Eberspa¨cherGmbH&
[email protected] Co.KG,Esslingen,Germany,
WolfgangDressler, Dr.,RobertBoschGmbH,Diesel [email protected]
Systems,Stuttgart,Germany, MichaelKru¨ger, Dr.-Ing.,RobertBoschGmbH,Diesel
[email protected] Systems,Stuttgart,Germany,
WalterEgler, Dr.-Ing.,RobertBoschGmbH,DieselSystems, [email protected]
Stuttgart,Germany,[email protected] ThomasKu¨ttner, Dipl.-Ing.,RobertBoschGmbH,Diesel
JochenEitel, BehrGmbH&Co.KG,Stuttgart,Germany, Systems,Stuttgart,Germany,
[email protected] [email protected]
KurtEngeljehringer, AVLListGmbH,Graz,Austria, WalterLehle, Dr.rer.nat.,RobertBoschGmbH,Diesel
[email protected] Systems,Stuttgart,Germany,[email protected]
StephanErnst, Dr.-Ing.,RobertBoschGmbH,Diesel PatrickMattes, Dr.,RobertBoschGmbH,DieselSystems,
Systems,Stuttgart,Germany,[email protected] Stuttgart,Germany,[email protected]
KarstenFunk, Dr.-Ing.,RobertBoschGmbH,Diesel UweMohr, Dr.,MahleGmbH,Stuttgart,Germany,
Systems,Stuttgart,Germany,[email protected] [email protected]
RolfJu¨rgenGiersch, Dipl.-Ing.,RobertBoschGmbH,Diesel KlausMollenhauer, Prof.Dr.-Ing.,Berlin,Germany,
Systems,Stuttgart,Germany, [email protected]
[email protected] DirkMooser, Dr.-Ing.,CaterpillarMotorenGmbH&Co.
AndreasGraf, Dipl.-Ing.,DaimlerAG,Stuttgart,Germany, KG,Kiel,Germany,[email protected]
[email protected] GeorgPaehr, Dr.,VolkswagenAG,Wolfsburg,Germany,
GerdHagenow, Dr.,ShellGlobalSolutions(Deutschland) [email protected]
GmbH,Hamburg,Germany OswaldParr, Dr.-Ing.,Ludwigsburg,Germany
Ju¨rgenHammer, Dr.-Ing.,RobertBoschGmbH,Diesel DietmarPinkernell, MANDiesel&TurboSE,Augsburg,
Systems,Stuttgart,Germany, Germany
[email protected] UlrichProjahn, Dr.-Ing.,RobertBoschGmbH,Diesel
KlausHeim, Wa¨rtsila¨SwitzerlandLtd,Winterthur, Systems,Stuttgart,Germany,
Switzerland,[email protected] [email protected]
IX
