controls. GET's main field of interest is to combine their knowledge about engines and electronics in order to design and manufacture new controls. These control systems not only offer economic benefits to the user but also contribute to the protection of the environ- ment. One of GET's successful products is their anti-knock control. In this field, GET is European market leader. G a s
E n g i n e
T e c h n o l o g y
B V Gas Engine Technology Engine Knock During a combustion cycle a spark-plug starts-up the ignition, resulting in a propagating flame front. Within a normal combustion cycle this flame front runs through the cylinder with a normal propagation speed, gradually burning almost all mixture available. Because of the lower temperature at the walls, the flame front is extinguished short before reaching the cylinder wall. This phenomenon is called "flame quenching". This causes a so called "quenching bar- rier" or "boundary layer". This boundary layer isolates the piston, cylinder head and cylinder wall against excessive heat pick up resulting in a high thermal load. If the methane number of (natural)gas (similar to the octane number of petrol) drops, pre-reactions can start to occur in areas which are not yet reached by the flame front. In case of engine knocking, these pre-reactions result in an un-controlled mode of com- bustion of unburned mixture with extreme high flame propagation velocity. The onset of very high conversi- on rate causes the excitation of the natural frequen- cies of the cylinder charge inside the cylinder. The resulting "pressure waves" and the coupling of flame propagation with these pressure waves subse- quently squeeze the isolating boundary and expose the vital engine components to a high combined mechanical and thermal stress. This will destroy the piston - see picture- and can subsequently destroy other components such as the cylinder liner as well. a) Piston damage due to knock. b) Surface structure damaged due to high thermal load Knocking combustion can be caused by e.g. un-sta- ble methane numbers of the gas, a higher intake-air temperature or a changing air-fuel ratio. G a s
E n g i n e
T e c h n o l o g y
B V Analog versus Digital filtering Knocking combustion results in vibrations propaga- ted within the engine structure. These vibrations can be sensed by Piezo electric transducers also called knock-sensors. The signals coming from these trans- ducers contain both knock-relevant frequencies and background-noise. There can be multiple knock-relevant frequencies due to the several natural frequencies 1 of the cylinder charge. Especially with pre-chamber engines it can be hard to distinguish knock-frequencies from back- ground-noise. The filtering capability of an analog band pass filter is very limited and will not enable a knock detection system to be sensitive to all relevant knock frequencies in the first place. It will also mess up knock frequencies and back ground noise fre- quencies. The principal limitations of analog filtering techniques do result in an unsafe engine operation with less power and a lower efficiency. For this very reason GET, opposite to their competi- tors, does not use analog-, but the much more sophi- sticated digital-techniques, using a DSP based knock detection system with real time - cycle by cycle- FFT spectral analysis. By using such analysis techniques it is possible to exactly determine the 'signal energy' of the knock- relevant frequencies. Even when these frequencies are positioned in multiple frequency bands. Using these techniques allows the engine to run very close to the knock-limit; the engine will run with improved power and fuel efficiency in a guaranteed safe mode. 1 Natural frequencies can be calculated using the Bessel function GET anti-knock control The GET anti-knock control analyses each individual cycle of each individual cylinder. The cylinder indivi- dual ignition timing is being changed, before the fol- lowing cycle. In case the applied ignition system requires that igni- tion timing is being changed engine-globally, the igni- tion timing of all cylinders is being retarded according to the knock-level in the 'worst-case' cylinder. With use of the GET anti-knock control it's possible to optimize the ignition timing of each individual cylinder resulting in improved power and a higher overall efficiency. Previously anti-knock controls only functioned as a safety device to avoid damage. But, during the last decade these have evolved into closed loop control systems enabling the engine to run with the best pos- sible fuel economy under changing gas quality and ambient air temperature conditions. If an engine is running under these conditions, it's critical to detect knocking the best way possible. The GET anti-knock controls are designed around the best filtering - and analyzing techniques available today. The analog signal from the knock-sensor runs through an anti-aliasing filter after which it is digitized. This digitized signal is filtered and analyzed by a Digital Signal Processor (DSP). The DSP uses a spectral analysis technique called Fast Fourier Transformations (FFT) in order to convert the signal from the time domain to the frequency domain. After the signal has been processed, the knock-relevant frequencies are extracted with ultimate accuracy after which they are compared against certain thres- holds. After this analysis, the knock-control parame- ters, e.g. engine global timing, cylinder individual timing, load reduction, diesel injection timing (dual- fuel operation) are adjusted accordingly. Result of Fast Fourier Transformation By analyzing the signals coming from the knock-sen- sors, the GET knock-control unit can also detect mis- fire. Depending on e.g. the condition of ignition system a spark not necessarily starts a normal com- bustion. If for whatever reason there is no combusti- on, the GET anti-knock control detects that and informs the engine management. This feature is optionally available. G a s
E n g i n e
T e c h n o l o g y
B V Misfire detection Dual-fuel engines GET anti-knock controls are not only being used on dedicated gas engines. They've also been installed on dual-fuel engines in order to change e.g. the substitution rate or the diesel injection timing when knocking combustion is detected. With the GET anti-knock control, the pay-back time of a dual-fuel retrofit will be reduced since the sub- stitution rate is continuously optimized under changing gas conditions. Advantages of GET anti-knock control A solid base for engine protection, Based upon the best filtering techniques available, Increased thermo dynamic efficiency, Reduced loss of KWh-output during drop of methane index of fuel, Knock-detection from cylinder to cylinder and cycle to cycle, After 1 knocking cycle of 1 individual cylinder, the cylinder individual timing of that specific cylinder is cor- rected before the next cycle (under the condition that the ignition system supports this functionality), Interfaces to all common ignition systems available in the market place (e.g. 4-20mA, CAN, RS-485) Misfire detection available within the same anti-knock control, Based upon a expandable platform, Proven technology, over 1800 units supplied to almost all major European gas engine manufacturers. Integration of AKC in GET engine management GET has a total gas-engine management available including e.g. air-fuel ratio control and speed-con- trol. Such an integration of functionality not only results into a large cost reductions, it also helps with the optimization of all control-loops. If knocking is detected, mixture can also be made leaner in order to stop the knocking. Such optimization steps are more difficult if different systems from multiple manufacturers are controlling the engine. Please contact GET with all off your engine control questions, we will be happy to assist! References GET has supplied over 1800 anti-knock controls to OEM's like GE Jenbacher, Perkins, Deutz MWM, MAN B&W, BVI, Caterpillar/MAK and Wrtsil. A detailed list containing all engine types is available upon request. The GET anti-knock controls are designed around the best filtering - and analyzing techniques available today. The design of the anti-knock control is based upon more than 10 years of experience with AKC application and calibration on more then 45 different engine types with cylinder bores ranging from 120 mm up to 440 mm. GET has developed a proprietary vibration analysis software package by which engine application of the GET AKC can be realized with a minimum of test bench capacity and/or down time of the engine. G a s
E n g i n e
T e c h n o l o g y
B V GET `s wide experience with AKC application GET proprietary vibration analysis software package G a s
E n g i n e
T e c h n o l o g y
B V Specifications Please note that these are 'general specifications'. GET designs tailored-made knock-controls which suit seamlessly within the rest of the gas-engine or dual-fuel management. GET can adapt to your requirements. Dimensions 130 mm x 300 mm x 240 mm Box position The knock-control box must be mounted off the engine Weight 4.15 kg Max allowable temperature during normal operation -40C - 85C Power supply 24VDC Power supply range 18VDC - 32VDC Connector Cannon type connectors Conforms to following directives EN55014, EN55022, IEC60529-IP65 Knock sensor Bosch sensor with Cannon connector 1 sensor per cylinder or 1 sensor per 2 cylinders (double sen- sed mode) Wiring between knock-sensors and knock control must be according to GET specifications. Maximum quantity sensors 20 Communication CAN, J1993 based protocol RS232 / RS485 Data content Through the communication link the system status of the knock-control and all individual cylinder knock-levels are being communicated. Input 2-stroke engine 1 pick-up sensing tooth on flywheel 4-stroke engine 1 pick-up sensing tooth on flywheel 1 pick-up sensing camshaft speed Analysis technique DSP performing spectrum analysis of the knock-sensor signal using Fast Fourier Transformations Capability Cylinder individual and cycle specific knock-detection and con- trol Speed Various speeds are supported ranging from 500 - 1800 RPM Ignition Cooperates with all industrial ignition systems available in the market Additional functionality Misfire detection optionally available Knock history diary short term and long termDiagnosis diary Gas Engine Technology BV Economiestraat 39 NL-6433 KC Hoensbroek Phone +31 (0)45 56 30 584 Fax +31 (0)45 56 30 287 Internet http://www.get-bv.com E-mail info@get-bv.com
Gas-Engines and Producer-Gas Plants
A Practice Treatise Setting Forth the Principles of Gas-Engines and Producer Design, the Selection and Installation of an Engine, Conditions of Perfect Operation, Producer-Gas Engines and Their Possibilities, the Care of Gas-Engines and Producer-Gas Plants, with a Chapter on Volatile Hydrocarbon and Oil Engines
Ignition, Timing And Valve Setting: A Comprehensive Illustrated Manual of Self-Instruction for Automobile Owners, Operators, Repairmen, and All Interested in Motoring.