R6160zc Diesel Engine Turbocharging System Optimization Design

In this paper, the simulation calculation of diesel' s working process used in R6160ZC diesel which made in Weichai Power Co., Ltd. The calculation software is BOOST of AVL. In calculation process, the optimum matching plan is made through the method of orthogonal experiment by taking performance of power, economy and emission as optimum target; structure parameters of turbocharger, intake/exhaust pipe, valve timing and cam lift rate as selective parameters of optimum performance; the better heat release rate in similar diesel and other structure parameters as limited condition.As the original cam profile approaches the tangent-circle arc, the motion will be discontinuous. In many parameters, the optimum valve train is emphasis. A new high power cam profile is designed according to the change of valve timing. For determining whether the new cam profile is satisfied or not, the calculation of dimensional train and contact stress of valve train is made. The results show that the continuity of velocity and acceleration of the new cam profile is good and contact stress can meet the request.The best matching schema of turbocharger is made according to the result of simulation calculation, commissions Weichai Power Co., Ltd. to performing the improved design and machining the sample diesel according to schema, then, testing the sample diesel. By analyzing the experimental data and simulation results, we can find that the fuel economy and power performance of sample diesel are better than original diesel. Its experience can support similar research.Finally, We can make these conclusions according to the results of simulation calculation and experimental data:The simulation calculation of diesel's working process is accurate on the whole and diesel's performance data can be reflected. As a toolof simulation calculation, Boost software was completely workable and the period and cost was reduced through simulation calculation.The performance curve shows that Datong turbocharger is more suited than Fuyuan turbocharger. The experimental performance of diesel used Datong turbocharger is better than Fuyuan turbocharger. It shows that a diesel which matching a high efficiency turbocharger is essential.The different diameters of exhaust pipe which influence the diesel' s performance are analyzed. From the calculation results, we can find the effect is not noticeable.The new cam profile can completely fulfill the demand. The motion continuity is improved and noise is reduced. It makes know that high power cam profile used in marine medium/low speed diesel is suitable.