As the world's largest automobile production and sales country, in 2014 China's various types of internal combustion engine production and sales reached 82 million units, completely complete and is the world's largest country in the production and sales of internal combustion engines. However, compared with the international advanced level, China is still not a strong country of internal combustion engines. Why? The biggest gap is the reliability of internal combustion engines. This is the statement made by Yan Dehui, Vice President of Weichai Power Co., Ltd., at the 4th International Symposium on Reliability Technology of Internal Combustion Engines held in Beijing on May 26, 2015. The seminar was co-organized by the Automotive Engines Branch of the China Association of Automobile Manufacturers and the International Technical Innovation Alliance of Internal Combustion Engine Reliability. More than a dozen experts from different angles and issues, around the increasingly stringent emission and fuel consumption regulations and their internal combustion engines. The challenge is to discuss and exchange technical aspects of the reliability of internal combustion engine and key components, the application of internal combustion engine and vehicle matching reliability technology, and the friction and wear of internal combustion engines.
Jiang Wenhu, director of the engine development department of the engine department of FAW Technology Center, believes that the reliability of the engine refers to the ability of the engine to operate according to the specified use and maintenance conditions and within the specified time. Generally, the failure rate is used for evaluation. The durability of the engine is the ability of the engine to run normally to the limit state under normal use and maintenance conditions. It is a special expression of engine reliability and is generally evaluated by B10 life. B10 life is the mileage or time when 10% of the engine has a serious fault during engine operation.
Jiang Wenhu said that defining the engine reliability and durability definition and evaluation indicators is the premise of engine reliability development. Specifically, in the case of FAW, in the planning stage of engine product development, the engine failure curve should be defined in detail, that is, the reliability level of the engine can be predicted in the planning stage. For example, in the component reliability target decomposition model based on the failure model of FAW, the cause of failure is analyzed and judged, such as structural design reasons, supplier technology and quality control level, improper materials or process does not meet design requirements and potential Failure analysis and other aspects. Jiang Wenhu believes that the market's true failure rate curve is the standard for evaluating engine development and quality assurance systems, and is also the input for next-generation product development. The reliability and durability development of the full life cycle engine, engine improvement, upgrade, and replacement are constantly modified. The process of the curve.
Also speaking of reliability issues, Professor Shuoshi Jin from the State Key Laboratory of Automotive Safety and Energy at Tsinghua University said that the service life of diesel engines varies according to the type of vehicle they match. Generally speaking, the higher the load mass of a diesel vehicle, the higher its life expectancy; the sixth-stage emission regulations in Europe require 40% to 60% more than the requirements of the fourth and fifth stages; In the United States, after the 2004 emission regulations, the mileage of light and medium-sized diesel engines has not been tightened, but the service life has increased by 2 years, and the mileage of heavy-duty diesel engines has been tightened by 50%. The life expectancy of diesel engines in China is based on the European system.
As the core of the diesel engine, the electronically controlled common rail fuel system, its wear diagnosis is closely related to engine reliability. Dr. Zhang Zhanteng, associate dean of Weichai Power Engine Technology Research Institute, introduced the nozzle hole wear control analysis software based on the speed oscillation of the fuel injector. When large, the corresponding software can identify the wear amount of the nozzle, and correct the actual fuel injection to protect the engine, and can prompt according to the degree of wear of the nozzle (such as alarm, limit torque, etc.). By setting the fuel injection amount to the fuel injection amount estimation, the injector wear amount analysis, the modified MAP self-learning, the correction factor, the external characteristic oil amount correction, and the engine protection strategy structure, the nozzle hole wear can be formed. Program. For example, when the degree of wear of the nozzle hole is small, the engine injection can be prevented from being damaged within a reasonable range by limiting the fuel injection amount outside the engine; and when the nozzle hole wear degree is large, the engine discharge and performance deterioration are serious. When the fuel injection amount cannot be effectively improved, the OBD (On-Board Diagnostic System) lights up or measures to limit the torque, and prompts to replace the new injector.
When talking about the verification of diesel injection system products, Qian Libin from the engineering test department of Bosch Automotive Diesel Injection Systems Co., Ltd. introduced reliability requirements analysis, simulation calculation, robustness verification and durability. A range of tasks including verification, customer verification and product reliability tracking. For example, in the product robustness assessment process, the robustness test based on load analysis can verify the robustness of diesel injection system components to oil lubricity, robustness to oil particle contamination, and robustness to extreme operating conditions. . Finally, high-quality and high-reliability products are formed through customer verification processes such as component testing, system durability testing, and vehicle testing.
Ms. Ilona Weber, a project manager from AVL, believes that the development of a system requires in-depth knowledge of the system's usage conventions. The system's focus is on typical usage in a variety of vehicle types, and vehicle usage practices determine the dynamics. The use of the system, and different parameters will affect the use of the vehicle. In the development of AVL, for the engine and its components, a load distribution analysis should give specific load details for a particular component. Through the load curve analysis, the load information of the relevant components can be obtained as early as possible, and a better load evaluation and system usage evaluation can be obtained early in the project to ensure the development progress and the accuracy of the layout.
Prof. Shuai Shijin introduced a large number of tests and studies on the durability of heavy-duty diesel aftertreatment systems, such as DOC (diesel oxidation catalyst), SCR (selective catalytic reduction), and DPF (in diesel aftertreatment systems). The main components such as diesel particulate traps include a series of tests and research including heat aging, sulfur poisoning, HC poisoning, high temperature deactivation, accumulation of sediment and ash, and proposed that the durability of DOC can directly affect the downstream DPF. And SCR performance, DOC needs to be designed according to DPF regeneration strategy, post-processing system layout scheme, etc.; and SCR durability has many influencing factors, pay special attention to SCR catalyst material selection and sediment control; for DPF, regeneration Control is important for its durability, and accurate and reliable DPF regeneration control can effectively improve the durability of the DPF.
Consistent with the issue of the reliability of internal combustion engines, Xing Min, executive vice president and secretary general of China Internal Combustion Engine Industry Association, pointed out that China's internal combustion engine industry "13th Five-Year" energy-saving emission reduction and green development ideas pointed out that facing the international advanced commercial diesel engine With a challenge of 1.6 million kilometers B10 level, China is studying a reliability scheme of more than 1 million kilometers, and will examine the entire life cycle of products from the perspective of sustainable development, emphasizing systematic development in the product development stage according to the whole life cycle point of view. Analysis and evaluation.
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