Design of air filter box and duct bellow for range extender engine in medium/heavy duty applications
Publicerad
Författare
Typ
Examensarbete för masterexamen
Master's Thesis
Master's Thesis
Modellbyggare
Tidskriftstitel
ISSN
Volymtitel
Utgivare
Sammanfattning
This study focuses on designing an air filter box for REX (range extender) engine
applications in medium/heavy duty trucks. The aim is to meet the technical re quirements set by Aurobay and design an air filter box and duct bellow that fulfill
the necessary criteria. The research questions addressed include identifying current
designs and filters used in the automotive industry and establishing technical re quirements. Along with exploring design possibilities, and evaluating how the new
designs can meet and exceed expectations. By comparing existing designs, establish ing requirements, and exploring design possibilities, this study provides a design for
an air filter box and duct bellow that meet the requirements and can be produced.
It also provides Aurobay with a foundation for future air filter box designs.
The study includes a literature review and benchmarking of existing air filter system
designs in the automotive industry. Technical requirements are established through
interviews, considering factors such as airflow, air quality, pressure drop, leakage,
durability, and space constraints. CAD (Computer Aided Design) modeling and
CFD (Computational Fluid Dynamics) simulations are conducted to evaluate the
design parameters’ impact. The results highlight the significance of inlet placement,
inlet angle, guides, distance between the inner wall and filter, filter thickness, radius
on the outlet, and inlet design on the air filter box’s performance.
Two significant findings emerge from the study. The radius on the inlet and outlet
are important factors that affects the UI (uniformity index) over the outlet and the
air filter. Additionally, placing the bellows on the duct at a greater distance from
the box improves uniformity over the MAF (mass flow sensor).
The recommended final concept is a rectangular air filter box with a flat-shaped
filter. It incorporates a short duct bellow for cost benefits and the inlet is positioned
near the top of the engine to create a shorter path for a dirty side duct. The air filter
box is divided into two parts for optimal placement and replacement of the air filter
and is securely fastened using screws. Hexagonal pattern ribs on the top lid and
outer surface of the bottom part enhance structural integrity, while rounded corners
and edges prioritize safety. The recommended concept fulfills the requirements and
serves as a guide for Aurobay’s future air filter box designs.
Beskrivning
Ämne/nyckelord
Air filter box, air filter, duct bellow, limited space, CAD, CFD, REX