技术---C18发动机.doc

此文档收集于网络，如有侵权请联系网站删除ACERTTM Technology for 0ff-Highway C18 Engines ACERTTM 技术-C18发动机 What does ACERT stand for? ACERT 代表什么? Advanced 高级 Combustion燃烧 Emission排放 Reduction减少 Technology技术 What is ACERT Technology? ACERT技术是什么? Multiple technologies多重技术 Varies by engine family随发动机系列而变化 Varies by engine application随发动机应用而变化 -Medium duty specs,change,new design中速 -Heavy duty-specs,change,new design重型 What engines are affected? 发动机受什么影响? C-18 is based off the C15 plateformC18是脱离于C15 平台的 Displacement changes from 15.2 to 18.1ltr排量从15.2变化至18.1升 Bore increase from 137mm to 145mm Stroke increases from 171mm to 183mm How is ACERT Technology Different?ACERT 技术有什么区别? What does ACERT Technology look like? ACERT 技术看起来像什么? How does ACERT Technology work? ACERT 技术是如何工作的? What are the advantages of ACERT Technology?ACERT 技术的优点是什么? Is extra maintenance required?需要哪些额外的维修?C18 Engine power band performance2100rpm provide widest operating range easiest match in changover2100rpm 提供了最广泛的运行范围,在转化上更佳匹配1800rpm provide best fuel economy,best heat rejection,less noise1800rpm 提供了最佳的燃油经济性,最佳的热量散发,低躁音Design strategy设计策略The core strategy for the C18 machine ACERT engine was to build off of the already successful C15. In appearance, the C18 machine ACERT engine is visually similar to the C15 and consumes the same footprint. A displacement increase was achieved with a bore and stroke change. The compression ratio has changed and can be either 16.3:1 or 18:1 based on the rating. Generally, the high HP engines have the lower compression ratio with higher boost than the standard HP ratings. Standard HP ratings usually employ higher compression ration with lower boost settings. The increase in compression ratio has beneficial effects on cold start and white smoke.C 18机具ACERT 发动机核心的设计是脱离于成熟的C15 发动机的.在外观上,C18ACERT 发动机看起来与C15非常相似.排量的增加是通过缸径和冲程变化来取得的.压缩比变化到16.3:1或18:1.通常,大功率发动机具有低压缩比,高增压.然而标准马力设定用高压缩比和低增压.增加的压缩比对冷起动和冒白烟效果更好.ACERT Multiple injection-多重喷射One of the key features of ACERT technology is increased sophistication in the fuel injection system. A more powerful ECM is able to more precisely control the fuel injection event.Camshaft Changes-凸轮轴变化The camshaft has changed slightly in the C18 machine ACERT engine. The injector lobe profile has been ground to include an additional ramp that is used when the ECM determines the need for a pilot injection. This is a very subtle change to the lobe profile and is more easily felt than seen. The lobe profile may vary as well for different HP ratings, making the cams non-interchangeable.C18 机具ACERT 发动机的凸轮轴有轻微变化.喷油器凸缘轮廓被磨过还包括另外的坡道,这被ECM用来决定何时予喷射.这是个微妙的变化,很难看到,可是容易感觉. 凸缘轮廓还会随不同马力级别而变化,使得凸轮轴不可互换.Areas of Higher Roller Contact The technicians will see two area of higher contact in the roller track on the injector lobe. The more obvious heavy contact pattern would be nearly at the nose from the main injection event (similar to Tier II) The secondary location will be 15 to 20 mm before the primary contact area that is generated from the main injection. The technicians should not mistake this normal 2 patch contact pattern as a bad cam. This second contact patch will vary in size and “severity” with each machine engine application since the main and pilot injected quantity will be different depending on the machine. This feature cam be felt as a discontinuity if the technician runs a finger over the cam lobe up from the base circle. 技师会发现在喷 油器凸缘滚轮轨迹上有两块主要接触面积.最显然的一块是在鼻子上,另一块是第一块之前1520mm.技师不能误会有两块补钉接触的模式作为作为坏凸轮.第二块接触补钉会严格随发动机应用而不同,因燃油主和予喷射数量会有所区别.如果用手指从基圆摸到凸缘,你就可以感觉到不连续性的特征.Fuel System燃油系统The mechanical actuated, electronically controlled (MEUI) injection system is similar to current C15 but has many internal changes to give it greater flexibility. Mechanical and electronic changes allow the system to inject multiple times during the combustion event. Not only can the number of injections be varied, but the RATE at which the fuel is injected may be varied as well. 19878-bitPEEC II1991Advanced8-bitPEEC III1993Two 8-bitADEM II1998 32-bitADEM III机械执行,电子控制的喷油系统与流行的C15相似,是具有很多内部的变化,给它更大的灵活性.机械和电子的变化允许系统在燃烧时喷射多次.不只数量上有变化,而在速率上有也变了.2004 32-bitADEM 4ADEM 4 Electronic Engine ControlGenerations of Experience更新换代的历程During the past decade, advanced designs have played a major role in improving the operation of diesel engines. Customer needs for better performance along with new standards for lower emissions have required more sophisticated engine controls. Caterpillar has taken the challenge and has met and exceeded these demands with the development of electronic engines.Since 1986, more than 500,000 advanced Caterpillar electronic engines have been put in service in truck, marine, petroleum, industrial, and locomotive applications. The above controls show the advancement of Caterpillar electronic controls beginning with PEEC that was introduced in the on-highway truck market in 1987. ADEM III was introduced in trucks in 1998 and will be available for industrial in 2001.在以往的十年中,先进的设计在改进发动机的运行中扮演了一个重要的角色.客户对更好的性能即低排放的新标准需要更复杂的发动机的控制.卡特皮勒接受了挑战,符合并超过了电喷发动机发展的这些要求.从1986年以来,超过500,000先进的电喷发动机服务在卡车,船舶,石油平台,工业和火车头.以上的图展示了卡特皮勒电控发动机的发展始于1987年投放到市场的高速公路卡车上.Extreme temperature test极限温度的测试Extreme temperature test vibration test salt spray test electrostatics test温度测试 震动测试 盐分雾化测试 静电测试Just like a home computer, the processing power of the ADEM4 has increased significantly over the ADEM3. This allows the greater sophistication needed to control the increasingly complex injection event. The easiest way to recognize an ADEM4 control unit is the 120 pin engine side connector. (Previously was a 70 pin connector). The ECM also has a little larger cross section along the bottom (thicker) although the control unit itself covers the same footprint as the ADEM3.ADEM 4 具有与发动机相连的120插针的接口(保留以往70插针),可比ADEM 3 控制更复杂的喷射事件.CAT ET functions with the ADEM4 just as it did with the ADEM3. The ADEM4 platform will be used from the C6.6 up through the C32. The ADEM4 allows many more options than the ADEM3 thanks to its increased computing power. CAN (Controller Area Network) J1939 data link allows high speed communications.CAT ET与ADEM 4 的功用就象跟ADEM 3 一样.ADEM 平台被用来从C6.6上升至C32.,由于增加的计算功率,允许更多的选项.Head bolt torque sequence缸头螺栓扭矩上紧顺序Tighten bolts 1-26 in sequence to 270+/-15NMTighten bolts 1-26 in sequence to 450+/-15NMTighten bolts 1-26 sequence to 450+/-15NM /Retighten按顺序紧螺栓1-26至450+/-15NM按顺序紧螺栓1-26至450+/-15NM;按此扭矩再紧一遍Turbocharger涡轮增压器The turbocharger(s) now incorporate Wastegated boost control. The wastegate enables higher boost for better performance without the danger of over-boosting.涡轮增压器现包括废气门增压控制. 废气门用高增压使性能更佳,没有过分增压的危险.The hose running from the compressor side to the canister opens a gate and dumps exhaust energy. The hose is a high temperature (bright blue) silicon material (painted yellow in this picture). Some Tier III machines will have a silver reflective sleeve on the portion of the wastegate line that is closest to the turbine housing. This will vary by application. The sleeve provides further thermal protection of the wastegate hose. The reflective sleeve material will be serviceable and cannot be painted. Painting the sleeve will destroy its thermal protection properties.从压缩机侧去罐的管子释放了废气能量.管子是高温的硅材料.有些Tier III机具有个银反射套装在废气门管路的口上,靠近透平壳体,随发动机应用而变化.这个套提供了更多的热保护,耐用的但不用油漆.油漆这个套会坏它的热保护特性.Higher HP C18 machine ACERT ratings will have two turbochargers. These turbochargers are in parallel. That is, each turbo is fed off of 3 cylinders. They are NOT in series (one turbo feeding the other) as in the on-highway ACERT engines.高马力的C18 机具ACERT 级别会有两个涡轮增压器.这两个透平是并联的.也就是说,每个透平由3个缸供给.不是串联的. With a Wastegated turbocharger, boost pressure is reduced or “blown off” at higher RPMs to keep cylinder pressure within safe limits. With a Wastegated turbo, the benefits of increase boost at lower RPMs are achieved while the engine is protected from over-boosting at higher RPM.具有废气门的透平,增压压力会在高转速时减小或放出来保持缸内的压力在安全限制内.而在低转速时能保持增加的增压压力.Water Cooled Center Section-水冷中芯区域水泵供水至透平A majority of Tier III machines will have a water cooled center section turbocharger. Water cooling the center section will extend the turbo shaft seal and bearing life by keeping the shaft seal cooler during operation and not allowing the formation of oil carbon deposits on the seal or bearings after a hard/hot shutdown. The water supply line to the turbo is from the high pressure side of the water pump. The water line returns the coolant from the turbo to the radiator top tank hose.多数Tier III机具会有水冷中芯部分的涡轮增压器.水冷芯子会延长透平轴的密封和轴承的寿命,在突然停车时不会形成热机油积碳在密封和轴承上.去透平的供水管来自于水泵的高压侧.透平的回水管去散热器顶部的管子.JWPC Jacket Water Pre-cooler used to cool the air before it enters the ATAAC.Used to reduce the air temperature from the HP stage turbo. The JWAC is not used at low idle or under low loads, the cooling system temperature would drop causingengine overcooling. The engine coolant diverter valve is normally open. 缸套水予冷却器用来冷却空气在它进入ATAAC(用来减小来自于高压级透平的进气温度)之前.JWAC 不是被用在低怠速或低负荷下的,这会引起发动机过冷.发动机冷却转换伐通常是开启的.-C15ENGINEJacketWaterPre-coolerThe engine coolant diverter valve stops coolant flow through the JWPC when the airtemperature and the engine coolant is cold.当空气温度和发动机冷却液还是冷时,发动机转换伐阻止冷却液流经JWPC.Engines use a low pressure turbocharger, a high pressure turbocharger and theJWPC.发动机使用一个低压的透平,一个高压的透平和缸套水予冷器.在C15 发动机中,废气门安装在高压的透平侧.C18 Compression Brake Oil Flow Schematic /C18压缩刹车机油流动路径图The actuator valve is a normally open valve.Engine oil is directed to the piston assemblies at all times. The path for the oil to escape is blocked when the actuator valve is energized. The slave piston will then open the exhaust valves when the unit injector rocker arm comes into contact with the master piston and pushes the master piston into its bore causing the slave piston to extend out of its bore and come into contact with the exhaust rocker arm.When the ECM shuts off the actuator valve, the pressurized oil will drain back to the oil sump causing the slave piston and the master piston to return to their normal position. 执行器伐是常开的.发动机的机油在所有时刻被供在活塞上.当执行器伐被增能时,机油释放回路受堵.当喷油器摇臂接触到主动活塞时,推动主动活塞进入缸内,促使从动活塞伸出缸外与排气摇臂接触,从动活塞就会开启排气伐.当ECM 切断执行器伐时,压力油会泄回油底壳促使从动活塞和主动活塞回位.C18 Cat Brake Oil Feed PathOil feed3/4 in.Hex Heads on 1/2 in.Threaded Fasteners 5 palaces英寸的头1/2英寸的牙的螺栓锁紧5处9/16 in.HeX heads on 3/8 in.Threaded Fasteners 2 places oilfeed bolt oil feed 供油螺栓4个双头螺栓打上装饰标识用于锁紧“studded”bolts,4 locations,used w/cat Brake only/ 4Brake and Non-brake Rockers 排气摇臂喷油器摇臂 The same injector rocker arms and valve rocker arms are used on all C15 and C18 engines (on-highway truck, machine, industrial, marine, gen-set). The intake and exhaust valve rocker arms are a common part number. Some ACERT machine engines use EVA (exhaust valve actuation) also known as the CAT brake. The master piston is in contact with the machined pocket in the injector rocker arm and the valve rocker arms have a machined flat near the valve bridge adjustment nut where the CAT brake slave piston pushes open the exhaust valve in the case of the machine ACERT engines.同样的喷油器摇臂和气伐摇臂应用在所有C15和C18发动机上(高速公路卡车,整机,工业,船舶,发电机组).进气和排气摇臂是一个普通的组件.有些ACERT 机具用EVA(排气伐执形器)被称之为CAT 刹车.主动活塞与喷油器摇臂的加工过的口接触,而气伐摇臂有个加工过的平面(邻近于伐桥调节螺冒),在那里CAT 刹车从动活塞打开了排气伐.The tightening sequence when installing the CAT compression brake must be followed. 当安装CAT压缩刹车时上紧螺栓的顺序必须被遵循.C15/ Use a feeler gauge in between the rocker arm and the actuation pin and set the clearance to 0.50 +/- .08 mm (0.020 +/- 0.003). Then torque the jam nut to 50 +/- 10Nm.Follow inlet valve adjustment procedure (number 1 cylinder on TDC compression stroke, set intake valve actuation clearance on cylinders 1,2,4. Rotate engine 360degrees and set intake valve actuation clearance on cylinders 3, 5, 6).用塞尺测摇臂与执行器销处,设定间隙为0.50 +/- .08 mm (0.020 +/- 0.003).上锁紧螺冒的扭矩至50 +/- 10Nm.调节进气伐的布骤按以下L(置发动机与NO.1缸TDC 压缩上死点, 调节NO.1,2,4进气伐执行器间隙.沿发动机旋向转过360度, 调节NO.3,5,6进气伐执行器间隙Injector and Valve Lash Setting Notes喷油器和气伐间隙设定注意/C18Valve lash set with engine cold and stopped气伐调整要在发动机停车冷却下来后Valve lash set adjusting screw locknut torqued to 30+/-7NM气伐调整锁紧螺冒上纽矩至30+/-7NMInjector height gauge 9u-7227喷油器高度表9u-7227Injector height adjusting screw locknut torqued to 100+/-10NM喷油器高度锁紧螺冒上纽矩至100+/-10NMInjector and Valve Lash Setting Procedure喷油器和气伐间隙设定步骤Set number 1 cylinder on TDC compressionstroke, L置发动机与NO.1缸TDC 压缩上死点set unit injector on cylinder 3,5,6 调节喷油器3,5,6Turn crankshaft 360 degrees 将曲轴转过360度set unit injector on cylinder 1,2,4 调节喷油器1,2,4PistonSteel piston across the board. Piston varies for different compression ratios. Notice large wrist pin diameter.单体式活塞是铸钢设计的,活塞随不同压缩比而不同,注意活塞销直径变大. Be certain to pay attention to the markings on the rings and the ring orientation when installing the ring package. The ACERT on-highway and off-highway pistons will look very similar, but the major difference is that the machine engine has a second (or intermediate) compression ring that is a keystone ring and a rectangular section top ring. On-highway truck has a rectangular cross section intermediate compression ring and a keystone cross section top ring. This makes on-highway and off-highway pistons non-interchangeable, even though they may look the same. The Keystone Ring has its sides tapered inwardly toward the back. The piston groove in which it is used must have its sides tapered with an angle similar to that used on the ring. This construction permits the piston designer to strengthen the lands between the grooves. During engine operation, relative movement between the ring and piston piston breaks up the formation of carbon. 当安装活塞包时,请注意活塞上的标记和凸出.ACERT 高速公路和非高速公路的活塞看起来非常相似,但主要的区别在于车用发动机第二道压缩环是a keystone环和顶环剖面是矩形的.高速公路卡车有一个矩形横剖面中间环和一个keystone的横剖面顶环.这使高速公路和非高速公路的活塞不可互换,尽管它们看起来非常相似.关键的活塞环有个倒角朝向背部.活塞环槽必须也有个环形的倒角以便跟所用的活塞环相配.这种结构设计加强了环槽与槽边的强度.在发动机运行时,在活塞和活塞环之间的相对运动破除了积碳的形成.C18 uses a one piece steel piston. Connecting rod has four cap bolts and a oil hole through the beam to lubricate the wrist pin. Since a main part of ACERT technology is increased cylinder pressure, the piston and connecting rod have been beefed up to withstand the greater forces placed on them. C18用单体式铸钢活塞.连杆有4个瓦盖螺栓和一个钻孔通道以润滑活塞销.既然ACERT 技术的主要部分是增加的缸内压力,活塞和连杆能忍受作用在它们上面的爆压.The connecting rod has a longitudinal drilling to improve oiling to the wrist pin. The beefed up cap is now attached with 4 bolts.连杆有一个纵向的钻孔通道以润滑活塞销The connecting rod uses four bolts on the crankpin end. Follow the correct tightening sequence in the specification manual.连杆用4个螺栓绑在曲轴上,须按服务手册上的顺序和纽矩来上螺栓.Hardened Plateau Honed LinerSmooth surfaceImproved ring seating and better oil control are benefits of plateau honed liners. The proper procedure must be followed if re-honing is performed. Consult the service manual.Deep cuts缸套两级的塘磨改进了活塞环密封和机油控制:上部平滑利于减小磨损和更好接触,下部切了深度网纹利保持机油,减小了下排气,增加了机油消耗控制.Leak Free DesignImproved joints through out the engine:Oil pan seal,timing cover,block to flywheel housing . All fluid connection sealed with the standard thread “0” ring design 改进的接口贯穿在发动机中:油底壳密封,正时盖,缸体与飞轮壳之间.所有的流体接口密封采用标准锯齿”O”形设计.Aftertreatment C15 Diffuser Can ConverterWhat does it look like? Catalytic Converter Muffler(CCM) 接触反应转化器Independent catalytic converterA catalytic converter is used in order to reduce the unburned hydrocarbons from the exhaust.一个接触反应的转化器被用来减小排气中未燃烧的碳.Exhaust going into converterHC = HydrocarbonCO = Carbon MonoxideNox = Nitrogen Oxide or Oxides of NitrogenPM (soot+SOF+sulfates)O2 = OxygenExiting the converterCO2 = Carbon DioxideH2O = WaterNox = Nitrogen Oxide or Oxides of NitrogenPM (soot+sulfates)O2 = Oxygen(Al2O3) = Aluminum OxideSpecifications/C18 Power CurveModel C18Rated RPM 1800-2100Displacement 18.1 L (1104 cu.in)Bore 145 mm (5.7 in.)Stroke 183 mm (7.2 in.)Full power is available from 1800.在1800 RPM时能获得满功率.C18 ACERT vs. 3408C3412EC18 ACERTMaintenance InformationOil chance interval has been standardized at 500 hours. S.O.S. oil sampling is recommended to ensure confirmation of oil cleanliness. Oil should meet CAT ECF-1 specifications. (CH or CI rated oil with a maximum of 1.5% ash meets these specifications) High load factors and high fuel sulfur as well as a TBN of less than 10 will decrease the change interval.换油间隔周期标准在500小时. . S.O.S.定期油样分析被推荐来确认机油特性.机油应该符合CAT ECF-1的性能.(CH或CI 级别的机油含灰分最大值是1.5%符合此特性)高功率因素和高的TBN含硫量少于10%会减少换油间隔.High Efficiency Oil FiltersRevolutionary filter design,increased contamination control,double