Test rig description

The test rig consist of JCB 444T2 diesel engine with a 4.4 litre, four-cylinder, four-stroke, 16-valve, in-line, turbocharged, direct injection configuration and an AC dynamometer for loading applications. The test rig is controlled by a control panel which is used to start/stop the engine, adjust engine speed, fuel supply, and monitor the engine temperature etc.

Instrumentation

Various sensors and transducers are employed for measuring and obtaining different signals. A Cylinder pressure sensor which measures the in-cylinder combustion pressure; optical encoder for engine synchronisation which measures the angular position of crankshaft.  Thermocouples which measures the temperature of lubricating oil and coolant; Torque sensor to measure the load applied to engine; AE sensor and accelerometers to measure AE and vibration signals, respectively. These signals are obtained by the Data Acquisition system (DAQ) for further signal processing.

Typical fault simulation

The test rig can stimulate various kind of combustion related and mechanical engine faults. Typical combustion related faults include faults associated with engine misfire, fuel injector faults, valve clearance faults. Typical mechanical faults experimented with this engine include, Piston slap faults, Bearing knock faults (oversized clearance faults) and lubrication oil faults.

Key publications

• [1] F. Elamin, F. Yibo, F. Gu and A. Ball (2010) Diesel Engine Valve Clearance Detection Using Acoustic Emission. Journal of Advances in Mechanical Engineering, 2010. ISSN 1687-8132.
• [2] F. Elamin, F. Gu and A. Ball (2010) Diesel Engine Injector Faults Detection Using Acoustic Emissions Technique. Journal of Modern Applied Science, 44 (9). pp. 3-13. ISSN 1913-1844
• [3] B.C. Tesfa, R. Mishra, F. Gu, N. Powles. Prediction models for density and viscosity of biodiesel and their effects on fuel supply system in CI engines. Renewable Energy, 2010,35(12), pp.2752-2760.
• [4] Tesfa, Belachew, Mishra, Rakesh, Gu, Fengshou and Ball, Andrew (2009) Condition Monitoring of CI engine running on Biodiesel using Transient Process. Key Engineering Materials, 413-414. pp. 495-503. ISSN 1013-9826
• [5] Singh, D., Gu, F., Fieldhouse, J. D., Singh, N., & Singal, S. K. (2014). Prediction and analysis of engine friction power of a diesel engine influenced by engine speed, load, and lubricant viscosity. Advances in Tribology, 2014, [928015]. https://doi.org/10.1155/2014/928015
• [6] B.C. Tesfa, R. Mishra, F. Gu, A.D. Ball. ‘Combustion Characteristics of CI Engine Running with Biodiesel Blends, ICREPQ’11, Canaria, Spain, 13 -15 April 2011.
• [7] F. Elamin, O. Glikes, F. Gu, A. Ball (2010) The Analysis of Acoustic Emission Signals from the Cylinder Head of a Diesel Engine for Fault Detection. In: CM 2010 and MFPT 2010: The Seventh International Conference on Condition Monitoring and Machinery Failure Prevention Technologies, 22-24 June 2010, Stratford-upon-Avon, UK
• [8] B.C. Tesfa, R. Mishra, F. Gu, A.D. Ball. ‘NOx Emission Prediction Based on Cylinder Pressure Measurement for Engine Emission Monitoring, COMADEM 2011 ISBN 0-9541307-2-3, Norway 30 May 1st Jun 2011 [9] F. Elamin, F. Gu and A. Ball (2011) Diesel engine lubricating oil condition and performance monitoring using acoustic emission measurements. In: 24th International Congress on Condition Monitoring and Diagnostics Engineering Management (COMADEM 2011), 30th May – 1st June 2011, Stavanger, Norway