12th GT-Suite Users Conference

Performance Analysis of a Decompression Brake System for a Diesel Engine

Ivan Miguel Trindade Vinicius J. M. Peixoto

MWM International Motores

November, 10th 2008

Presentation overview
Introduction and objective of the engine brake Engine Brake Systems MWM Brake System GT-Power: Engine Brake Model Engine Brake Simulations Conclusion

Performance Analysis of a Decompression Brake System for a Diesel Engine

Introduction
Motivation of analysis f
High loads on hydraulic brake system during downhill routes Continuous brake applications can lead to excessive wear between brake rotors and brake pads t db k d Increasing of repair and stand still costs Low engine brake capacity leads to more robust system, heavier and more expensive

Objective:
Analyze the brake system dynamics and predict engine y y y p g performance
Performance Analysis of a Decompression Brake System for a Diesel Engine
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Exhaust Brake Systems

Concept
Engine is converted from a power-source to a powerabsorbing machine b bi hi Mechanism based on exhaust gases pressure rising Pressurized gases force the engine piston down during compression stroke summing with the power generated by engine friction Engine brake systems can achieve braking power so high as the engine output

Performance Analysis of a Decompression Brake System for a Diesel Engine

Current MWM Engine Brake System

Exhaust brake
Flap valve with a drilled hole at the beginning of exhaust system blocks the gases from escaping Maximum brake power limited by exhaust valve bounce occurrence at intake stroke and also structural i t t l issues If not avoided, bouncing can , g result in valve and valve seat damages

Performance Analysis of a Decompression Brake System for a Diesel Engine

MWM Brake System

Engine braking power using brake flap system can achieve p y values 3 times the engine friction Braking power achieved using the decompression system can be 5 times the engine friction, mainly at high speeds
Engine Friction Motored Exhaust Brake Flap Hyper Brake System

50%

158%

Curves of a 6 cylinder Diesel engine.

Performance Analysis of a Decompression Brake System for a Diesel Engine

MWM Brake System

State-of-art
Hydraulic actuation of the exhaust valves Valve brake can be controlled to actuate at any engine speed Requires excessive room package in the cylinder head for the hydraulic device Costs are expensive due to controlled actuation

INTAKE

COMPRESSION

POWER

EXHAUST
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Performance Analysis of a Decompression Brake System for a Diesel Engine

MWM Brake System

Operation
Developed by MAN AG Just one of the valves is actuated Valves actuated by exhaust pressure waves Hydraulic system keeps the valve opened y y Costs are lower than Jacobs brake
Normal valve lift / Valve Lift locked through hydraulic actuation Gradual return to cam shape Valve opening due to high back pressure (bouncing)

Performance Analysis of a Decompression Brake System for a Diesel Engine

MWM Brake System

Actuator follows the exhaust valve during bounce movement Ch k valve l k th actuator position and oil Check l locks the t t iti d il pressure avoid it to return During normal valve lift an oil passage is opened allowing the actuator returns to its original position

Nut Pivot Pivot Seat Bracket + bolt Check valve Check valve spring Lock Pin Actuator Spring Actuator

Performance Analysis of a Decompression Brake System for a Diesel Engine

MWM Brake System

Bouncing movement Unbalance between
Actuator

Valve spring Cylinder pressure Actuator inner spring p g

Valve top/ Valve spring

Back pressure and Actuator oil pressure generates bounce in the exhaust valve h l

Performance Analysis of a Decompression Brake System for a Diesel Engine

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MWM Brake System

Operation
Exhaust flap with torsional spring can provide high backpressure even under l b k d low engine speeds i d Gases are dissipated through exhaust system during the compression stroke, decreasing the pressure area in power stroke
Exhaust brake: Spring effect of pressurized gases Decompression brake: Higher effective brake area

Performance Analysis of a Decompression Brake System for a Diesel Engine

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Engine Brake Model

GT-Power model
Predict the engine brake operation E l t it effects on engine performance Evaluate its ff t i f
Investigation of bouncing g g mechanism was necessary to evaluate performance of the system parameters y p Model includes engine brake components, intake and exhaust systems Fuel injection is shut off
Performance Analysis of a Decompression Brake System for a Diesel Engine
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Engine Brake Model

Valve train components: Modeled using GT-Power templates Rocker Arm Ground (imposed movement) Valve and actuator Linked masses Connections Calibration to reproduce the same contact behavior Spring connections simulate valve and actuator spring

Performance Analysis of a Decompression Brake System for a Diesel Engine

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Engine Brake Model

Hydraulic system: Feed reservoir for oil availability in the cylinder head Ch k valve = b ll valve fl Check l ball l flow characteristics h t i ti Flow split performs like actuator chamber Leakage orifice reproduces clearance in the top of rocker arm

Performance Analysis of a Decompression Brake System for a Diesel Engine

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Engine Brake Model

Subassembly interaction
Inputs from the Main model: Valve train loads Cylinder pressure Exhaust pressure Output from the engine brake model Valve Lift

Exhaust system
Flap valve modeled as a throttle with variable diameter Exhaust pressure is kept in a constant value
Performance Analysis of a Decompression Brake System for a Diesel Engine
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Engine Brake Simulation

Backpressure waves on exhaust valves B k h t l
6 cylinder engine
Non interconnected exhaust manifold 3 main backpressure waves Necessity of avoid bouncing during intake stroke

4 cylinder engine
Interconnected exhaust manifold 4 backpressure waves resultant from all cylinders

Performance Analysis of a Decompression Brake System for a Diesel Engine

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Engine Brake Simulation

Bouncing at intake stroke small cylinder pressure Drop on lift curve Leakdown test predict actuator movement

Performance Analysis of a Decompression Brake System for a Diesel Engine

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Engine Brake Simulation

Mass flow rate through exhaust valve
Cylinder decompression at power stroke

Effect of cylinder pressure on actuator

Pressures are amplified High difference of surface area

Performance Analysis of a Decompression Brake System for a Diesel Engine

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Engine Brake Simulation - Correlation

Calibration of flap valve leakage Same back pressure valve of bench tests Same loads on exhaust valve similar performance from the engine test

Performance Analysis of a Decompression Brake System for a Diesel Engine

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Optimization studies
Variables: Spring pre-load and exhaust pressure Target lowest value for the spring pre-load However higher spring pre-load
Higher backpressure = higher braking power

Backpressure limited by turbocharger restriction

Performance Analysis of a Decompression Brake System for a Diesel Engine

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Optimization studies
Actuator Lift

1500 rpm

2600 rpm

Optimum lift change for every engine speed Small lifts exhaust gases remain trapped in the cylinder g y High lifts pressure is decreased and gases make less restriction on piston
Performance Analysis of a Decompression Brake System for a Diesel Engine
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Prediction of Braking Power

Braking Power Exhaust pressure

At low speeds valve may not open Reduction of spring pre-load

Can generate bounce under high speeds
Performance Analysis of a Decompression Brake System for a Diesel Engine
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Bounce investigation
Spring pre-load change backpressure level
High pre-load increases backpressure

Flap valve must release more gases to avoid bouncing or Spring pre-load must be increased
Performance Analysis of a Decompression Brake System for a Diesel Engine
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Conclusions
The developed numerical model is robust enough to predict the brake system performance and its components behavior The DOE study was able to identify the optimized spring preload that improves the brake power capacity Back pressure waves have strong influence on the dynamic of engine brake components
4 cylinder engine Firing order dictates interconnected manifold 6 cylinder engine Non interconnected manifold to prevent earlier bouncing and increase backpressure

Leakdown t t are suitable t correct evaluate valve lift L kd tests it bl to t l t l Holden valve lift has an optimum value for each engine speed Valve bouncing can still occurs at high speeds
Lower valve pre-load can bring high braking power at low speeds Higher valve pre-load can prevent bouncing at high speeds Softer flap valve pre-load can decrease the braking power at high speeds

Ball l B ll valve seat optimization and hi h oil pressure avoid d t ti i ti d high il id drop i th valve lift in the l To improve the model is necessary further calibration of the exhaust valve lift
Performance Analysis of a Decompression Brake System for a Diesel Engine
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Thanks
Special thanks to
Robert Wang and Shawn Harnish from Gamma Technologies

MWM International Motores Product Development Department

Performance Analysis of a Decompression Brake System for a Diesel Engine

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Thank You !
Ivan Miguel Trindade ivan.trindade@navistar.com.br Vinicius Peixoto vinicius.peixoto@navistar.com.br

Performance Analysis of a Decompression Brake System for a Diesel Engine

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