Modernization of the Mechanical Fuel System of a Diesel Locomotive Engine through Physical and Numerical Modeling

Reducing harmful emissions from exhaust gases and increasing energy efficiency are urgent tasks when designing reciprocating internal combustion engines. In this experimental work, the fuel system of a diesel locomotive engine operating on the Miller cycle is improved. The purpose of the study is to improve the environmental and economic indicators of diesel engines at minimal financial cost. The article provides an overview of the main research on improving fuel supply, mixing and combustion. The features of engine operation are also briefly described. Numerical simulation of the diesel engine operating cycle was performed before the bench tests. The experiments were performed on a full-size diesel engine with a power of 1200 kW. The measuring equipment and experimental technique are described in the article. The technical solutions that made it possible to improve the fuel supply are described. A new design for the high-pressure fuel pump drive is proposed. The optimal fuel injection advance angles are determined. An original design for the fuel pump plunger was developed. The proposed technical solutions made it possible to reduce fuel consumption by up to 3% (from 217.8 to 211.4 g/kW·h) and NOx emissions two-fold (from 19.4 to 8.8 g/kW·h).

Fracture failure analysis on drive shaft component of diesel locomotive

Failure analysis is a systematic method of investigation to find the cause of the failure mechanism of a component or equipment. This research describes the fracture analysis of driveshaft components in a diesel locomotive. The drive shaft which is a connecting component around the compressor in the locomotive engine has failed. The methods used in this study include literature studies, visual observations, data collection, material characteristics through chemical composition tests, hardness tests, tensile tests, microstructure observations, fractographic observation, data processing, and analysis of test results. Based on the results of chemical composition testing and mechanical testing shows that the drive shaft is classified as plain carbon steel, specifically AISI 1025 steel. Visual observations and microstructure observations show that the driveshaft failure occurred at the connection part, which is the connection around the welded region. From the fractography results show a visible pattern of deformation plastic that showing the fracture occurred since the connection cannot bear the load given.

Team durability test of a 1.3 MW locomotive diesel engine with prototype piston rings

Objective of this work was to realize a test of durability of railway engine EMD645 with power about 1300 kW. Within the framework of this test were investigated a prototyped piston’s rings with diamond embankment. Piston rings are made of chromium layer with including of diamond powders technology with a porous chromium coating, where in pores is deposited on said diamond powder with a grain size about 1 micron. The work will be carried out of an analysis of collaboration piston – piston rings – cylinder unit in internal combustion engine and an analysis of the use of hard materials (diamond powder) in friction pairs. During work of this unit we can observe wear of piston rings, precisely - of coating which is deposited on ring to prolong service life. After testing of the locomotive engine EMD645 on the basis of the collected results are developed conclusions of the wearing intensity on piston ring and relating them to the requirements for coatings. The work aims to show the possibilities and benefits of the application of new protective coatings on structural elements of the internal combustion engine in order to reduce their wearing, which is consistent with the observed trend of technology development.

Modelling and Simulation of the Performance and Combustion Characteristics of a Locomotive Diesel Engine Operating on a Diesel–LNG Mixture

The article describes a compression-ignition engine working with a dual-fuel system installed in diesel locomotive TEP70 BS. The model of the locomotive engine has been created applying AVL BOOST and Diesel RK software and engine performance simulations. Combustion characteristics have been identified employing the mixtures of different fuels. The paper compares ecological (CO2, NOx, PM) and energy (in-cylinder pressure, temperature and the rate of heat release (ROHR)) indicators of a diesel and fuel mixtures-driven locomotive. The performed simulation has shown that different fuel proportions increased methane content and decreased diesel content in the fuel mixture, as well as causing higher in-cylinder pressure and ROHR; however, in-cylinder temperature dropped. CO2, NOx and PM emissions decrease in all cases thus raising methane and reducing diesel content in the fuel mixture.

Improved method of processing the output parameters of the diesel locomotive engine for more efficient maintenance

Modernization of aged rolling stock is one of the possibilities to adapt it to the current requirements for better environmental friendliness and economy of railway transport. However, some vehicle upgrades lead to new failures that were not observed in the original vehicles. The cause is the so-called “hybrid design”, built on a combination of original and selected new components. The aim of the work was to improve the situation with frequent failures and unavailability that occur on the modernized locomotive where a new diesel engine and new electronic control system was installed. Within the work, a simplified methodology for evaluating the outputs of diagnostic equipment was developped based on and applied to specific locomotive type and its diesel engine. The methodology resulted in a significant reduction of the time for assessing the condition of the vehicle’s diesel engine and more effective maintenance. The paper also presents other possibilities in the analysis of big data in the maintenance of rolling stock e.g. using fuzzy logic.

Improved method of processing the output parameters of the diesel locomotive engine for more efficient maintenance

Modernization of aged rolling stock is one of the possibilities to adapt it to the current requirements for better environmental friendliness and economy of railway transport. However, some vehicle upgrades lead to new failures that were not observed in the original vehicles. The cause is the so-called “hybrid design”, built on a combination of original and selected new components. The aim of the work was to improve the situation with frequent failures and unavailability that occur on the modernized locomotive where a new diesel engine and new electronic control system was installed. Within the work, a simplified methodology for evaluating the outputs of diagnostic equipment was developped based on and applied to specific locomotive type and its diesel engine. The methodology resulted in a significant reduction of the time for assessing the condition of the vehicle’s diesel engine and more effective maintenance. The paper also presents other possibilities in the analysis of big data in the maintenance of rolling stock e.g. using fuzzy logic.

Impact of a locomotive engine modernization on fuel consumption

Vehicles used in rail transport are characterized by a long service life, which is caused, among others, by the high cost of their purchase. In Poland, the average age of freight diesel locomotives exceeds 40 years. Increasing the wear and tear of vehicles has an impact on many aspects of machine operation, including environmental pollution. Significant wear and degradation of the powertrain components contributes to the increase in pollutant emissions and fuel consumption, which is closely correlated with the production of carbon dioxide. Modernizations involving the replacement of the drive unit are performed in order to reduce the negative impact of rail vehicles on the environment. The article compares the energy consumption of the ST44 locomotive prior to and after modernization. The older 14D40 two-stroke internal combustion engines were replaced with a more modern engine unit 12CzN26/26. Fuel consumption tests were carried out on a test bench using a OW6300 water resistor.