University of Pitesti

Faculty of Mechanical Engineering and Technology

RELIABILITY OF COMBUSTION ENGINE
ELECTRIC EQUIPMENT
Supervisor: prof.
PhD. BOO!U "le#andru
1
Student: B!$"
$ornel
SUMM"%:
&. !'TODU$T!O'
(. T)E SU*E% OF E+E$T!$ "'D E+E$TO'!$ S%STEMS
(.&. Functional "nalysis $oncerning the Starting Syste, elia-ility
(.(. Functional "nalysis $oncerning the $harging Syste, elia-ility
(... Functional "nalysis $oncerning the !gnition Syste, elia-ility
(./. Functional "nalysis $oncerning the !n0ection Syste, elia-ility
.. E1PE!ME'T"+ STUD!ES
/. E+!"B!+!T% MODE+S OF E+E$TO'!$ E'2!'E E3U!PME'T $)OSE'
E+EME'TS
4. $O'$+US!O'S
2
!n recent years5 fast develop,ent of auto,otive industry has -een o-served.
The progress in the 6eld of auto,otive electrotechnics plays an i,portant part in
this develop,ent. Fro, year to year5 the proportional share of electric ele,ents in
auto,otive vehicle e7uip,ent increases5 and such a 7uantitative increase is
acco,panied -y constant analysis of 7uality and relia-ility.
The develop,ent of relia-ility engineering proceeds at di8erent pace
depending on the 6eld of technology it pertains to. !ts fastest develop,ent is
o-served in car electronics5 9hich is the su-0ect ,atter of the present paper.
The purpose of the paper is to analyse the relia-ility of vehicle co,-ustion
engine electric e7uip,ent together 9ith the structural analysis of engine relia-ility.
The present paper co,prises:
The survey of engine electric and electronic syste,s
The structural analysis of engine relia-ility
+a-oratory relia-ility tests : a passive e#peri,ent.
1. INTRODUCTION
!n technical science5 relia-ility5 -oth in theory and in practice5 is considered one
of the ,ost i,portant features of each vehicle. The notion of relia-ility 9as
understood intuitively and su-0ectively. The pro-le, is approached in a 7uantities
9ay -y using the notion of availa-ility5 i.e. vehicle readiness for 9or;5 and the notion
of dependa-ility. The nu,-er of vehicles at 9or; as related to the total <eet of
vehicles of a given ;ind is registered. !ntensive develop,ent of space5 nuclear and
che,ical technologies5 -oth ,ilitary and peaceti,e5 in 9hich the criteria of ha=ard
and dependa-ility played an i,portant part5 in<uenced the develop,ent of
,otori=ation5 9here the need for strict assess,ent of vehicle relia-ility5 even in the
stage of designing5 arose.
The area of relia-ility co,prises5 generally spea;ing5 three interconnected
6elds:
elia-ility conditions5
elia-ility ,odelling5
elia-ility assess,ent.
The 6eld of science ;no9n as the theory of relia-ility5 -ased ,ainly on the
theory of pro-a-ility and the theory of rando, >stochastic? processes5 is today a
fully developed for,al discipline 9ith e#panded ,athe,atical apparatus. "
technical discipline ;no9n as relia-ility technology or engineering is -eing
developed.
2. THE SURVEY OF ELECTRIC AND ELECTRONIC SYSTEMS
Functional Analysis Conc!nin" t# Sta!tin" Syst$ Rlia%ility
Electric starters generating very -ig ,o,ents are used for starting co,-ustion
engines. Such a starter consists of: a series or co,pound direct current engine5 a
coupling ,echanis, and a pinion 9hich couples 9ith a co,-ustion engine toothed
<y9heel ri, for the ti,e of starting. @hile constructing ne9 types of starters5 an
e8ort should -e ,ade to decrease their di,ensions and ,ass and to increase their
relia-ility. Engines 9ith co,pound e#citation are often used in starters.
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)igh rotational speed of starter 9ith a series of e#citation 9hile itAs 9or;ing in
noBload state lead to -earings 9ear and rotor da,age. The introduction of additional
shunt 9inding ,a;es it possi-le to decrease rotational speed at 9or; in noBload
state considera-ly and conse7uently to ensure relia-le starter 9or; for a longer
ti,e.
!n starters 9ith planetary gears5 a planetary gear is used for reducing the
rotational speed of the rotor of the direct current electric ,otor. The coupling lever
,eshes the pinion in the sa,e 9ay as in a conventional starter.
Three planet 9heels and a <anged 9heel 9ith internal teeth are responsi-le
for reducing the rotational speed of the ar,ature shaft of the direct current electric
engine. @hile the electric ,otor ar,ature shaft is rotating5 the planet 9heels are
rotating in the opposite direction trying to turn the <anged 9heel. "s the <anged
9heel is i,,o-ili=ed5 the planet 9heels have to roll do9n the ring gear ,ounted on
the ar,ature shaft. !n this case5 the planet 9heels turn the gear output shaft -y
,eans of the -as;et. The ratios in this gear are5 for e#a,ple5 the follo9ing: &&:&4:/.
>ring gear: planet 9heels: <anged 9heel?. Thus5 the total ratio is 4. This ,eans that
the speed of the output shaft is a-out 6ve ti,es lo9er than the speed of the electric
,otor ar,ature shaft.
"t regular 9or;5 the <anged 9heel is i,,o-ili=edC ho9ever5 if the tor7ue in the
starter is too -ig5 the <anged 9heel 9ill turn causing the loss of tor7ue surplus. !n
this 9ay5 -oth the ar,ature and other parts ,ating 9ith it are protected against
da,age. The <anged 9heel carries the load to the clutch plate that is pressed
against the 9heel -y the dis; spring. @hen the tor7ue is too -ig to -e carried5 the
circu,ferential force on the 9heel overco,es the friction force generated -y the
spring pressure and the <anged 9heel -egins to rotate. !n this 9ay5 the tor7ue
surplus is a-sor-ed as the ,o,ent of friction.
Functional Analysis Conc!nin" t# C#a!"in" Syst$ Rlia%ility
The alternator is a -asic source of electric energy in any auto,otive vehicle. The
current it generates can charge the -atteryC it can also5 together 9ith the -attery or
9ithout the -attery5 supply vehicle electrical syste, receivers.
$onstantly changing operating conditions of the alternator during auto,otive
vehicle ,otion 9ould lead to its voltage changes in a too 9ide range if so,e
ele,ents 9ere not used5 and that 9ould have a negative in<uence on -oth the
-attery and other electric energy receivers.
egulators are responsi-le for regulating voltage in vehicle electrical syste,.
Silicon diodes as a part of alternating current rectifying syste, serve as a reverse
current -rea;er. The syste, diodes5 9hich are a constituent part of alternatorB
-attery circuit5 condition current <o9 in the circuit if the alternator voltage value
increases a-ove the -attery voltage. Then5 current <o9s in the circuit fro, the
alternator to the -attery. $urrent <o9 in the opposite direction >reverse current? is
practically i,possi-le due to the diode 9hich functions as a -arrier.
" co,pact alternator is &4D s,aller and (4D lighter than a conventional
alternator. Decreasing the ,ass and di,ensions of this ;ind of alternator and
i,proving its ,aintenance properties could -e done than;s to the ,odi6cation of
,agnetic e#citation circuit that consisted in decreasing the clearance si=e and the
shape of pole -odies. Besides5 its rotational speed has -een increased considera-ly
through ,oving the fan fro, the place outside the case to the place inside it5 9here
it constitutes an integral part of the rotor. Such a solution i,proved cooling
eEciency.
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The rotor set consists of ,agnetic cores5 9inding coils5 slip rings5 a shaft and a
fan. Unli;e in conventional alternators5 on the shaft5 there are t9o integral fans
,ounted on -oth sides of the rotor. !n the case5 there are holes ,a;ing air <o9
possi-le and at the sa,e ti,e increasing cooling eEciency. EEciency can -e
i,proved at higher rotational speeds -y ,a;ing use of a grooved pulley 9hich
increases -elt trans,ission ratio -y a-out (54D.
Functional Analysis Conc!nin" t# I"nition Syst$ Rlia%ility
!n all ,odern co,-ustion engines 9ith spar; ignition only electric ignition
syste,s are used. The -attery supplies all those syste,s. !gniting the ,i#ture 6lling
the cylinder consists in ,a;ing use of the pheno,enon of spar; discharge -et9een
the electrodes of the spar;ing plug placed in the cylinder co,-ustion cha,-er. The
course of co,-ustion depends on fuel che,ical constitution5 the choice of ignition
start ,o,ent5 and the shape of co,-ustion cha,-er and fuel ,i#ture 7uality. !n all
,odern uses of electronics in ,icroprocessor control syste,s5 all ,ova-le
,echanical parts have -een re,oved. This i,proved ignition syste, relia-ility and
decreased e,itted electro,agnetic interference.
!n engines 9ith an even nu,-er of cylinders5 in 9hich the pistons of one pair of
cylinders reach 2MP at the sa,e ti,e5 re,oving the distri-utor is possi-le -y
,a;ing use of a series connection of spar;ing plugs in each pair of cylinders5 e.g.&B/
and .B(. !n such a set5 the ends of secondary 9inding are isolated fro, ,ass
potential and connected to spar;ing plugs. The energy of high voltage pulse is
distri-uted to -oth cylinders: in the 6rst one5 it causes ,i#ture ignition in the
co,pression stro;eC in the second one5 the spar;Bover occurs during the e#haust.
The function of shaping the cran;shaft position signal has -een passed to the D!S
>Distri-utorless !gnition Syste,?. The D!S of the control syste, is an integrated
,icroprocessor ignition syste, consisting of t9o dipolar ignition coils5 a principal
electronic ,odule and a control unit. The ends of coil secondary 9indings isolated
fro, ,ass potential are connected to spar;ing plugs.
The functions of the D!S in the syste, are as follo9s:
&? it processes the signal fro, the rotational speed sensor into appropriate TT+
signal
trans,itted to the superordinate co,puter and into signal trans,itted to the revB
counterC
(? it generates ignition in ,o,ents deter,ined -y the superordinate co,puterC
.? it generates the spar; on the -asis of rotational speed signal in the event of
failure or
disconnection fro, the superordinate co,puterC
/? it controls the distri-ution of ignition to particular cylinder pairs.
The rotational speed signal >generated in the D!S? is a se7uence of rectangular
pulses 9hose a,plitude e7uals 4* and the 6lling factor : (F.. Signal fre7uency
depends on rotational speedC t9o pulses occur in one cran;shaft revolution.
!n order to control ignition advance angle5 the controller generates the
se7uence of rectangular pulses fed to the appropriate D!S entry. The a,plitude of
signals is 4*. For very s,all rotational speeds >e.g. during startBup?5 9hen proper
speed analysis is diEcult -ecause of the s,all nu,-er of ,ar;ers on the
,easure,ent dis;5 ignition advance angle is deter,ined -y the ignition syste,.
@hen engine speed e#ceeds /4G r.p.,.5 high state is esta-lished at ST e#it 9hich
infor,s the D!S that the controller ta;es over controlling the angle of advance.
Esta-lishing high state at ST e#it is very i,portant. !f high state does not appear at
the e#it5 ignition control is generated -y the D!S.
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Functional Analysis Conc!nin" t# In&ction Syst$ Rlia%ility
EE$B* in0ection syste, has -een used in FOD Fiesta since &HH4. !t is the
electronically controlled in0ection and ignition syste, reali=ed in digital electronics.
Fuel is in0ected into the suction ,anifold in a discontinuous 9ay. !gnition is
controlled -y characteristics stored in the central control syste,. Signal a-out the
de,and for fuel5 depending on the suc;ed air 7uantity5 is trans,itted to the central
control syste, as an electric signal co,ing fro, the air <o9 ,eter.
The central control syste, sends the signal to in0ectors. This 9ay5 it ensures the
opti,al point at 9hich air in0ection occurs. The har,fulness rate of e#haust gases is
considera-ly li,ited also due to the I pro-e 9hich ensures constant control of
opti,al fuel to air ratio. !nside the central control syste,5 there are integrated
circuits playing an i,portant part in proper functioning of the syste, in the event of
failures. @hen one of the sensors fail to function5 the central control syste,
auto,atically adapts for 9or;ing in failure conditions so that the engine can 9or;5
even if its 9or; is irregular5 until necessary repair is carried out.
'. E()ERIMENTAL STUDIES
!nfor,ation ac7uired to assess the relia-ility of engine electric e7uip,ent is 7uite
e#tensive and profound. This causes so,e diEculties 9ith its registration. )o9ever5
the -asic condition 9hose ful6l,ent is crucial in ac7uiring statistical data for
relia-ility testing is strict registration of ti,e ,o,ents in 9hich events i,portant to
us happen. "s it is necessary to ta;e into consideration the continuity of ti,e5
storing data ,ust -e a syste,atic and ,ost often auto,ated activity during 9hich
the continuity of ti,e <o9 9ill not -e lost. egistration consists in 9riting do9n
lengths of ti,e intervals connected 9ith par;ing or caused -y technical pro-le,s
and also infor,ation a-out the place of failure5 causes of failure5 sort of failure and
the ;ind of tas; -eing perfor,ed 9hen the failure occurred.
!n order to carry out relia-ility analysis of car engine electric e7uip,ent5 the
division into particular syste,s should -e esta-lished >starting syste,5 charging
syste,5 ignition syste,5 in0ection syste,?. Diagra,s of relia-ility structures of
particular syste,s are presented in Fig. ..&:..4.
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Figure 3.3. Diagram of charging system reliability structure
Figure 3.4. Diagram of electronic ignition system reliability structure
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Figure 3.5. Diagram of injection system reliability structure
The state,ent of electric e7uip,ent failures5 in 9hich Model F5 S5 M cars have
-een ta;en as e#a,ples5 is presented in Fig. ..J:..H.
Figure 3.6. The statement of starter failures
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Figure 3.7. The statement of alternator failures
Figure 3.8. The statement of control unit failures
9
Figure 3.9. The statement of engine control unit failures
4. RELIA*ILITY MODELS OF ELECTRONIC EN+INE E,UI)MENT
CHOSEN ELEMENTS
On the grounds of registered results and 9ith the use of the co,puter progra,
KStatisticaL have -een prepared relia-ility ,odels of vehicle electric ele,ents >see
Fig. /.&B/./?.
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Figure 4.1. ontrol unit ignition em!irical reliability function
Figure 4.". ontrol unit ignition reliability mo#el $e%!ecte# &alue'
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Figure 4.3. (ngine control unit em!irical reliability function
Figure 4.4. (ngine control unit reliability mo#el $e%!ecte# &alue'
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-. CONCLUSIONS
&. The conditions of auto,otive electronic syste,s ,aintenance are very diEcult
-ecause se,iconductor ele,ents are sensitive to te,perature and hu,idity
changes5 ,echanical shoc;s and vi-ration5 9ater5 grease and che,icals i,pactC
-esides they are very sensitive to electro,agnetic interference and e#cessive
voltage increase.
(. Electronic syste,s are su-0ect to te,perature changes in a very 9ide range
depending on the place in the car in 9hich they are installed. Te,perature changes
for engine space are assu,ed to range fro, : /G to M&(4N$. "s the range of
changes is so 9ide5 it is necessary to use se,iconductors designed for 9or;ing in
higher te,peratures and also to introduce te,perature co,pensation.
.. "s the role of ,echanical vi-ration generated -y the engine and the syste,s
connected to it is very i,portant5 a lot of innovative solutions concerning the
,ounting of engines and su-asse,-lies in the car -ody have -een 9or;ed out.
@hile driving on irregular surfaces5 shoc;s as strong as several do=en g 9ith
fre7uency of up to hundreds of )= arise. Therefore5 li,iting the nu,-er of soldered
connections and protecting the syste, -y ,eans of elastic 6lling ,ass precluding
vi-rations of particular su-asse,-lies is reco,,ended.
/. Electronic syste,s ,ounted in engine space are su-0ect to hu,idity
resulting fro, condensation of vapour present in the air. @hen it rains5 they are
su-0ect to splashed 9ater and ,ud action. @hen the te,perature falls and air
hu,idity is high5 de9 or hoarB frost settle on car ele,ents. Besides5 the action of
salt and acids causes corrosion da,ages. To avoid che,ical e8ect5 galvanic coatings
of ,etal ele,ents5 appropriate siliconB-ased 6lling ,asses and airtight sealing of
syste,s are used.
4. Ensuring high relia-ility in a long period of ,aintenance re7uires ta;ing into
consideration the in<uence of ,aintenance environ,ent5 even at the stage of
designing5 and controlling relia-ility para,eters in the 9hole period of putting the
prototype into production and ,aintenance.
J. The follo9ing ;inds of protection against electric in<uence used in cars can
-e distinguished: anti super voltage5 over voltage5 over current5 anti distur-ance5
against connecting feeding 9ith reversed polarity.
O. The analysis of relia-ility of engine electric syste,s particular circuits
con6r,s the purposefulness of ,easuring -asic electric 7uantities.
P. @eather and ,aintenance conditions 9hich cause the loss of lea; tightness
in the inlet line and also ,aintenance 9ear of fuel pu,ps caused -y fuel i,purity
influence the relia-ility of vehicle electric e7uip,ent. I pro-e5 9hich is responsi-le
for controlling the in0ection process5 is very often su-0ect to da,age. The third of car
electric e7uip,ent ele,ents5 9hich are ,ost da,agea-le in ,aintenance5 is the
potentio,eter of throttling valveBopening angle.
H. On the grounds of the analysis of particular syste,s5 it can -e stated that
electric e7uip,ent is a very i,portant constituent ele,ent of the car and its
relia-ility ,ust -e high.
&G. !n order to o-tain results fro, the analysis of car electric e7uip,ent
relia-ility5 it is i,portant to analyse constantly and thoroughly the causes of
da,ages5 9hich occur during ,aintenance. )o9ever5 not all ;inds of da,ages can
-e o-served during relia-ility tests.
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&&. On the grounds of the passive e#peri,ent carried out to analyse engine
electric e7uip,ent relia-ility5 it can -e stated that the o-tained data con6r, the
QoR,ogoro9As test.
R.!ncs/
S&T D=iu-iUs;i M. elia-ility "spects in $onstructing *ehicle Electronic
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//B/P. >Prague?
S(T D=iu-iUs;i M. $o,puter $ontrol of "lternators Manufacture5 Manufacturing
Engineering5 /5 (GG.5 pp. 4OBJ&.
S.T D=iu-iUs;i M. !nvestigations of !gnition Syste,s elia-ility5 Vournal of
QO'ES !nternal $o,-ustion Engine5 (GG/5 pp. &.OB&/J. >@arsa9?
S/T D=iu-iUs;i M. elia-ility "spects in Manufacturing of Starter5 'e9 @ays in
Manufacturing Technologies5 (GG/5 pp..P4B.HG.
S4T Qrivtsov *. Practical E#tensions of 'on ho,ogeneous Poisson Process in
epaira-le Syste, elia-ility "nalysis. !n: The !nternational Sy,posiu, on
Stochastic Models in elia-ility5 Safety5 Security and +ogistics. Beer Sheva5 (GG45 pp.
(&OB((&.
SJT +evitin 2. Opti,ising Surviva-ility of Syste,s "cting in Battle Environ,ent.
!n: The !nternational Sy,posiu, on Stochastic Models in elia-ility5 Safety5 Security
and +ogistics. Beer Sheva5 (GG45 pp. (((B((4.
SOT %ats;iv !.5 2usarova +. The Di8erent "pproaches to *alidation of $luster
"nalysis esults. !n: The !nternational Sy,posiu, on Stochastic Models in
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