Salient Characteristics_SCTE_Head.doc

Salient Characteristics

Commercial Availability Certification:

I have evaluated the commercial marketplace and determined that all of the salient characteristics documented below are available in products/services offered in the commercial marketplace.

Signature (typed name):

Kurt M Kruger Technical Point of Contact (TPOC) or Contracting Officer’s Representative (COR) C.1 The CCDC Army Research Laboratory (ARL) currently uses a Ricardo Hydra Single Cylinder Thermal Engine (SCTE) for research and experimentation purposes in its Small Engine Combustion Research Lab (SECRL) at Aberdeen Proving Ground (APG) MD. ARL is now seeking proposals for the design, manufacture, test and delivery of a new custom engineered cylinder head to connect to and integrate with its SCTE. The new head will replace the existing aftermarket head (Ford P/N 4S7Q-6090-CC) and shall provide new features:

C.1.1 Generic / Universal fuel injector mounting to allow the installation of multiple different diesel, CRIN2 & CRIN3 fuel injectors. (List of injectors to be provided) C.1.2 Generic / Universal glow plug mounting to allow the installation of multiple different glow plugs and energy assistive devises. (List of glow plugs to be provided) C.1.3 Variable Valve Timing (VVT) to allow intake and exhaust valve timing adjustments while the engine is running.

C.2 The cylinder head shall accommodate an internal, direct mount in-cylinder dynamic pressure sensor: Kistler Model 6125. One (1) in-cylinder pressure sensor for combustion analysis (Kistler 6125) shall be included with the head.

C.3 The cylinder head shall bolt on to and integrate with existing SCTE block: Ricardo Hydra S/N 184 according to specifications listed in Tables 1-4 below.

C.4 The cylinder head shall be made from a casting such that surfaces of the intake air and exhaust gas passages replicate surface texturing of a cast part.

C.5 The new head shall not significantly modify or alter the existing SCTE block and shall allow ARL the ability to revert back to the original head configuration if desired.

C.6 All necessary valves, tappets, valves springs, and retainers, and other cylinder head internal components will be provided as part of the final delivered head.

C.7 The contractor shall create a cylinder head design from the provided specifications and design constraints and submit the final solid 3D-CAD model for approval from ARL before manufacturing the head.

C.8 The contractor shall develop and use the cylinder head 3D-CAD model and specifications to design and optimize the cooling water jacket design around the head and validate by CFD simulation. Results of CFD simulation will be provided to ARL prior to manufacturing for final approval.

C.9 The contractor shall validate the global head design accounting for heat transfer, combustion pressure and internal stresses. Results of global model validation shall be provided to ARL prior to manufacturing for final approval.

C.10 The contractor shall provide results of the reverse engineering of existing COTS cylinder head (Ford P/N 4S7Q-6090-CC) and reconstruction of the combustion system. Starting from the existing cylinder head, the tomography and digitization work shall be done in order to model the combustion system and in particular:

C.10.1 the position and size of the valves.

C.10.2 the position of the camshafts.

C.10.3 the water core.

C.10.4 the oil core.

C.10.5 the position of the glow plug.

C.10.6 the position and size of the injector.

C.11 The contractor shall conduct the following validation and quality control tests. Results of these quality tests shall be provided to ARL for documentation.

C.11.1 Flow Bench Testing to check the permeability of the ports on the new cylinder head conforms to that of the original cylinder head.

C.11.2 Valve Lift Tests conducted after assembly to check that the valve lift law conforms to that of the original cylinder head.

C.11.3 Leakage Test, after assembly, to check that the cylinder head is leakproof.

C.12 The contractor shall provide the following documentation for all machined parts:

C.12.1 Metallurgical certificate.

C.12.2 Radiography certificate.

C.12.3 Die Penetrant certificate.

C.12.4 Tensile report.

C.12.5 Dimensional report.

C.12.6 Heat treatment certificate.

C.13 The contractor shall provide a 3D CAD model of the SECRL Single Cylinder Thermal Engine (SCTE) head adapted to the engine block.

C.14 The contractor shall provide two (2) cylinder head gaskets with the new head

Ricardo Hydra S/N 184 - Reference Photos and Engine Specifications:

Table 1: Ricardo Hydra SCTE Operating Limits

Maximum speed

4500 rev/min

Minimum oil pressure

3.5 bar gauge

Maximum cylinder pressure

160 bar

Maximum exhaust port temperature

800 C

Maximum inlet port temperature

100 C

Maximum coolant temperature

110 C

Maximum fuel pressure

1350 bar (Increase to 1800 bar)

Table 1: SCTE Operating Limits

Table 2: SCTE Technical Specification Summary

Bore

86 mm

Stroke

86 mm

Displacement

500 cc

Compression ratio

16.5:1

Camshaft

DOHC via cam followers

Valves

4 per cylinder

Valve Timing

Fixed

Piston to cylinder head clearance

0.72mm

Induction

NA or externally boosted

Fuel Injection

DI common rail with engine driven fuel pump

Fuel pressure

350 to 1350 bar (Increase to 1800 bar)

Maximum engine speed

4500 rpm

Minimum engine speed

1200 rpm

Maximum torque

Dependent on build and operating limits

Maximum power

Dependent on build and operating limits

Combustion chamber geometry/ layout

4 valve central vertical injector

Maximum cylinder pressure (continuous operation)

160 bar

Fuel types

Diesel

High pressure fuel pump

8200659759 (Bosch Part No)

Fuel injector

VSTI22M Part No

Table 2: SCTE Technical Specification Summary

Table 3: Lubrication System Specification

Lubrication System Type

Wet Sump

Oil

15w40 API SL/CF, ACEA A3/B4

Working Temperature

90°C nominal

Normal Working Pressure

4 to 4.5 bar

Oil Pressure Relief Valve Setting

5 bar (nominal)

Oil flow rate

17 l/min (at 4.5 bar)

Table 3: Lubrication System Specifications

Table 4: Cooling System Specification Cooling System Type Pressurised closed circuit Engine Coolant De-mineralised water plus 50% solution Ethylene Glycol or any commercially available anti-freeze solution, with corrosion inhibitors.

Working temperature 90°C Maximum pressure 1 bar Coolant flow rate:

30 l/min

Table 4: Cooling System Specification

Figure 8: Potential sensor location (Example only) Contracting Officer:

Potential pressure sensor location

Exhaust valve

Injector Hole

Intake Valve

Head Bolt Hole

Water Jacket

Glow Plug Hole

Template last updated 07/28/2016