The main direction for the further development of internal combustion engines (ICEs) in the context of the global climate change problem relies on integrating power units, which will still have a carbon footprint for a certain period, into a circular carbon economy with zero carbon emissions throughout their full life cycle, coupled with intensive implementation of renewable energy sources. This publication analyzes existing global trends, challenges, and proposed promising ways for this transformation. Using examples from statistical data, analytical reports from research institutions, and information on investment projects, three key problems are examined, towards whose effective resolution efforts of researchers has to be directed. They constitute finding feasible means to achieve the desired effect from an entirety of coordinated measures within a circular carbon economy, addressing the challenges of using renewable energy sources whose electricity generation is characterized by daily and seasonal non-periodic cycles, and identifying scientifically sound directions for the further development of ICEs under the outlined conditions. It is shown that the use of ICEs in a circular economy should be considered carbon-neutral, regardless of the presence or absence of a carbon footprint. Removing ICEs from use complicates the achieving carbon neutrality. Carbon-based bio- and synthetic fuels, as well as carbon-free fuels for ICEs, can and should be viewed as methods for accumulating energy from renewable sources and converting it into other forms suitable for efficient storage, transportation and use. Five independent directions for the development of ICEs in a circular economy are considered: replacing traditional fuels in existing ICEs with carbon-neutral ones, improving designs to enhance their efficiency, applying additional onboard systems and devices, transitioning to the use of carbon-free fuels, and minimizing greenhouse gas emissions throughout the ICE life cycle. It is proven that the continuous improvement of ICEs directly contributes to meeting sustainable development requirements amidst the undeniable demands of transitioning to a climate-neutral economy.
The article considers the impact of the use of alternative fuels of plant origin on energy efficiency, environmental performance and combustion processes in a motor-tractor diesel engine. The relevance of the topic is due to the need to reduce the carbon footprint of diesel engines in the context of tightening requirements for greenhouse gas emissions, increasing energy independence and ensuring fuel autonomy of critical sectors of the economy. The main attention is paid to the evaluation of diesel engine performance when running on fuel mixtures containing fatty acid methyl esters (FAME) and hydrogenated vegetable oil (HVO) in comparison with traditional petroleum diesel fuel. A review of the physicochemical properties of these fuels, in particular: density, specific lower heating value, cetane number, viscosity, flash point, oxygen content, and carbon-to-hydrogen mass ratio, was carried out. Design and technological limitations on their use in modern diesel engines are discussed. The efficiency of internal oxygen in FAME in the combustion process is evaluated based on the analysis of the chemical structure, thermal stability of ester groups, and kinetic conditions in the combustion chamber. The mathematical modeling of the 4CHN10.7/12.4 diesel engine's operating process was carried out in the Blitz-PRO software package using the real properties of the mixtures and the calculated parameters of the fuel equipment. Changes in the indicator and effective efficiency, specific fuel consumption, maximum cycle pressure, cylinder pressure rise rate, ignition delay period, and specific CO2 emissions were analyzed. It was found that with an increase in the proportion of HVO in the mixture, a significant decrease in the rigidity of the working process (up to 30%) was observed due to the high cetane number. At the same time, a slight decrease in efficiency is mainly due to a decrease in the volumetric heat of combustion and a shift in the heat release law to the later phases of the cycle. CO2 emissions were analyzed for different blends: a reduction of up to 6% is possible when using pure HVO. The full life cycle from raw material cultivation to fuel production has the potential to reduce emissions by 15-55% compared to petroleum-based diesel, according to the UK government. The results confirm the feasibility of using fuels from renewable sources in diesel engines as a tool for reducing the carbon footprint without significant losses in energy efficiency.
The publication deals with the methodology for conducting motor experiments to study the effect of diesel intake system air filter fouling on the economic and environmental performance of the engine. The methodology also makes it possible to track the influence of changes in the air excess ratio on these indicators within the operating modes of the diesel engine. In modern internal combustion engines with electronic control units, air supply processes are controlled automatically. In this case, based on the program laid down in the control unit, the consumption of both fuel and air charge is adjusted, and the engine operating modes are considered for the development of such a program, which are determined, in turn, by the type of internal combustion engine, its purpose, boost level, and operating conditions. At the same time, the main goal is to select the optimal consumption of both fuel and air, depending on the operating mode. In particular, the air consumption, the excess air ratio can be adjusted both upward in forced modes to improve the processes of mixture formation, the completeness of fuel combustion, and downward in partial modes to reduce pumping costs and increase mechanical efficiency. Thus, modeling the processes of air filter fouling, limiting the air flow through the diesel engine can be considered in a broader sense by conducting certain experimental evaluations for both forced and partial load modes. The proposed experimental methodology is characterized by simplicity and can be used in the educational process to consolidate the relevant theoretical provisions, in particular, in the course “Operation and Repair of Internal Combustion Engines”.
This article presents the results of a comparative study on the operation of a small-displacement diesel engine 3ChN 8.8/8.2 within a hybrid powertrain system of a transport vehicle. The research was conducted by developing simulation models in the Simcenter Amesim environment for two basic hybrid drive architectures — parallel and series configurations. Currently, governments of many countries are implementing stringent emission standards for harmful substances (particularly NOx, CO, CO2, HC), which requires vehicle manufacturers to implement innovations in powertrain technology. The developers of the Euro 7 standard, which is set to come into force in 2025, clearly understand that tightening certain requirements, such as particulate matter emissions, has practically reached its limits, while establishing even stricter NOx emission limits for diesel vehicles remains possible, which also required attention. Therefore, within the scope of this research, the impact of each configuration on fuel economy, emission levels of harmful substances (CO, HC, NOx), and overall powertrain efficiency during typical urban and mixed driving modes (NEDC cycle) was analyzed. Special attention was given to the technical and functional feasibility of using a small-displacement diesel engine as an energy source in modern hybrid power systems, considering its design features, load characteristics, and adaptability to environmental constraints. The obtained results demonstrate comparable fuel efficiency of both configurations, significant advantage of the series architecture in reducing CO and NOx emissions, and lower HC levels in the parallel configuration. Meanwhile, the parallel configuration demonstrates higher dynamic flexibility and adaptability under variable driving conditions. The research has practical applications and is aimed at developing energy-efficient technologies in the field of specialized vehicles for military, expeditionary, or commercial purposes, where the combination of reliability, autonomy, and environmental compliance is particularly relevant. It was determined that the 3ChN 8.8/8.2 diesel engine demonstrated satisfactory technical and operational performance and adaptation potential to modern hybridization requirements. Its application is also feasible in the context of specialized transport, where economy, autonomy, and reliability are priorities.
Based on foreign sources, the article systematises and summarises the results of recent studies on the possibilities of using synthesised electronic fuels (e-fuels) in land transport for the gradual decarbonisation of the industry. The article focuses on liquid e-fuels for transport diesel engines. Diesel engines remain a relevant subject of research for Ukraine today, as they are used in vehicles not only for transporting goods, but also for the mobility of the defence sector and technological processes in food production. EU countries plan to reduce greenhouse gas emissions by 55 % by 2030 and achieve carbon neutrality by 2050. In this context, e-fuels have become a promising solution for reducing greenhouse gas emissions in transport. Classic e-fuels are synthesized from CO2 captured from the air and renewable hydrogen obtained by electrolysis of water. The energy for electrolysis comes from renewable sources of wind, solar, geothermal, tidal, or hydroelectric power. The main advantages of e-fuels are that they are produced from renewable energy sources and use existing fuel infrastructure with minimal changes. E-fuel production is not yet available on a large scale. Its use will gradually increase thanks to a phased increase in its concentration in blended fuels. At the same time, other similar carbon-neutral technologies will be introduced in transport. The first step towards carbon-neutral e-fuels is the introduction of paraffin fuels obtained from bio-raw materials using renewable energy sources. Such introduction in transport diesel engines ensures a reduction in CO2, soot and other harmful emissions. This is an intermediate stage until the mass production of purely synthetic paraffin e-fuels. The use of synthesised OMEx and DME e-esters in diesel engines as low-carbon fuels is possible in the short and medium term. This is the second step towards the spread of carbon-neutral e-fuels and technologies in transport. Before introducing such fuels, additional research is needed on their compatibility with diesel materials. Ukraine has an outdated fleet of vehicles that cannot be instantly replaced with new, more efficient ones. Research and development aimed at the phased introduction of carbon-neutral e-fuels in transport should minimise the harmful impact of existing motor vehicles on the environment.
The purpose of the work is to analyze the features of the working process in internal combustion engines when using synthetic gas with significant hydrogen content. At present, the effective use of synthetic gas allows you to use the energy resources of alcohol fuels and significantly increase the environmental performance of engines. In addition, the production of synthetic gas on board a vehicle in a certain way allows you to increase the fuel efficiency of the engine by using the energy of exhaust gases. The article considers the features of the combustion process of synthesis gas in the working cylinder of an internal combustion engine with spark ignition. The purpose of the study is also to estimate the parameters of heat release of synthesis gas. The most significant result is to obtain dependencies for determining the current values of the combustion character indicator m and the combustion duration φz in the heat release in professor's I. I. Wiebe model for spark-ignition engines operating on synthesis gas with a range of changes in the excess air coefficient α (1.0...2.2) and a variation in the hydrogen content in the fuel composition of 30...100% by volume. The variability of the combustion index m (1.6...5.5) in the semi-empirical heat release in professor's I. I. Wiebe model has been established, which largely corresponds to the real law of heat release in experimental studies. The proposed dependencies for determining m and φz allow us to take into account the peculiarities of the combustion process of synthesis gas in spark-ignition engines and thereby significantly increase the accuracy of determining the indicator pressure in the working cylinder (the relative root-mean-square error does not exceed 4.5%). The conducted studies and mathematical modeling of various engine sizes allowed us to establish a possible range of changes in the combustion character index m in professor's I. I. Wiebe model, which is 1.6…5.5. The obtained research results can be used in the design and construction of new spark-ignition engines operating on alternative fuels, or the conversion of existing ones, as well as to refine the mathematical model of the combustion process.
Internal combustion engines installed on agricultural machinery, as well as on transport and stationary installations, are subject to mandatory examination by competent institutions and organizations to confirm compliance with the standards in force in the country. However, circumstances may arise in the technological process of production when it becomes necessary to determine the level of environmental performance of the engine directly at the enterprise. In this case, the studies must be carried out in a short time and with minimal costs. The data and features of the norms currently in force in Ukraine are presented, which take into account a comprehensive approach to the implementation of European requirements for pollutant emissions from agricultural and forestry vehicles and are designated by the environmental classes "Stage". To determine the level of environmental indicators in production conditions using the example of research on the engine of an agricultural tractor intended for operation in Ukraine, a methodology has been proposed, which is based on the analysis of the current regulatory documentation regulating the emissions of harmful substances with exhaust gases of engines, the generalization of the data of the performed research and tests carried out directly in production conditions, the analysis of the influence of design and chemical factors, the operating mode of the diesel engine on the emission indicators of harmful substances with exhaust gases. The object of the study was the WP6T180E200 diesel engine, which is intended for installation on the KhTZ-159K.010 tractor of category E and is widely used in Ukrainian agriculture. The assessment of the level of environmental performance of the engine for compliance with the established requirements was carried out taking into account and generalizing the change in mass emission of harmful substances characteristic of engines of this purpose depending on the load for the nominal crankshaft speed, the speed corresponding to the maximum torque and the minimum idle mode. In studies on determining the environmental performance of a diesel engine in production conditions, an analogy method was proposed, which is based on the presence of characteristic features in the studied object, corresponding to the features of the object chosen as an analogue. The methodology and results of the performed calculation and experimental studies are presented. An assessment is given of the compliance of the environmental performance of the engine with the standards in force in the country.
Electronic control units control the vast majority of internal combustion engine systems. In the future, the maximum automation of engines must necessarily include full self-acting control of gas exchange in the cylinders. An innovative idea for the design of the gas exchange mechanism is the electromagnetic drive of the camshafts. Such innovations are being actively studied in automotive engines, but there is little information about their application to low-power internal combustion engines, which are basic for small mechanization and, in wartime, sometimes have a dual purpose. The physical model considered by the authors assumes that, instead of a camshaft, very fast electromagnetic actuators at the command of an electronic control unit control the opening and closing of the valves. The input to the unit comes from sensors and transducers that monitor the crankshaft position, intake manifold pressure, engine temperature and crankshaft speed. The output is used to control the position of the intake and exhaust valves. The technology allows you to change the valve opening and closing moments relative to the engine's dead points and operating cycles, influence the duration of the open and closed valve states, vary the valve overlap time (simultaneous open state), perform a stroke-by-stroke phase shift, etc. The C# programming language was used for modelling the gas exchange system in low-power internal combustion engines with electronic valve control using an object-oriented approach. The results of the model presented in the article are in agreement with the data of recent open publications. The study was carried out on prototypes created by an experimental selection of operating parameters. The system requirements for the power supply of the electronic control unit are quite low - it is possible to operate from a 12 V electrical network. The research has demonstrated that the drive achieves the desired power, play and performance requirements.
In modern global diesel engine manufacturing, the possibilities for improving the efficiency of in-cylinder working processes in automotive small-displacement diesel engines have been largely exhausted. At the same time, the issue of optimizing diesel engine operation across the entire range of operating modes – from idle speed to rated crankshaft rotational speed – remains insufficiently researched. Ukrainian engine manufacturing potential, despite the absence of mass production, has significant developments in the field of research into operating modes of such diesels, including the development of criteria for forming external speed characteristics and an innovative approach to designing supercharging systems for modern automotive diesel engines. The proposed approach is based on air charge pressure speed characteristics and involves the use of a combination of modern software tools for solving research problems and developing connection schemes for supercharging system components. The developed solutions have potential for implementation in the global market for modern automotive diesel design and for increasing the competitiveness of domestic developments in this field. As an example of the viability of the proposed approach, optimization has been conducted based on the obtained analytical dependence for the domestic automotive six-cylinder diesel engine 6DTNA1 (6ChN 8.8/8.2), and necessary graphs of dependencies between optimal brake mean effective pressure and rational supercharging pressure versus crankshaft rotational speed under external speed characteristic conditions have been constructed. Based on these dependencies, a progressive supercharging system has been selected for the domestic small-displacement diesel engine 6DTNA1, and a proposed connection scheme for its components has been developed.
The study presents the results of research on the implementation of Industry 4.0 technological approaches in the manufacturing of cast internal combustion engine (ICE) components, which continues the discourse on transforming strategies for using Product Lifecycle Management (PLM) systems in the context of achieving sustainable development goals. Given that the foundry industry is a key supplier of metal components for the automotive and energy sectors, particular attention is paid to the integrated application of computer modeling, additive technologies, and microstructure control of alloys, which are considered essential for ensuring sustainability in this field. It is noted that the implementation of the proposed approach enables the minimization of waste, improvement of mechanical properties of components, enhancement of energy efficiency in manufacturing processes, and reduction of the product development life cycle for new designs. Research in this area opens up new prospects for realizing circular economy principles and creating more environmentally responsible production in engine manufacturing. Technological casting processes for producing the cylinder of a two-stroke engine were modeled to analyze crystallization characteristics and phase transformations during the cooling of the casting. As a result of numerical simulations, data were obtained regarding mold filling, temperature field distribution, cooling and solidification sequences, and the kinetics of phase transitions, with an assessment of the areas prone to shrinkage-related defects. Control over these processes made it possible to prevent crystal growth irregularities in the transition zones of the casting, thus mitigating their negative impact on the mechanical properties of the component during operation. Conclusions were drawn on the application of simulation within PLM systems for automating the improvement of casting technologies. The integration of additive manufacturing into technological stages of shape formation in ICE casting production was also examined. It was determined that the implementation of these technologies in engine manufacturing allows for the creation of components with optimized designs that meet the requirements of sustainable development. As a model tooling case, a printed cast cylinder part was developed, and the key parameters of the 3D printing process were presented. Directions for future research on the use of additive technologies were outlined. The study also highlights the enhancement of microstructure control using machine learning and artificial intelligence as a promising area for future research in sustainable manufacturing. The paper proposes fundamental steps for a methodology for the comprehensive application of Industry 4.0 technologies in the sustainable production of cast ICE components. An interaction algorithm between major production stages was developed, placing the concept of the digital twin at the center as the core management unit. It is concluded that the proposed approach enables systematic improvements of technological processes, ensuring production adaptability to sustainable development challenges through the comprehensive integration of Industry 4.0 technologies and laying the foundation for the transition to Industry 5.0.
Ennsuring the reliable and efficient operation of a diesel engine is impossible without accurate control of key parameters of the fuel system. One of the most important parameters is the fuel pressure in the high-pressure rail, whose dynamic fluctuations reflect the technical condition of the injectors and high-pressure fuel pump. Modern electronic engine control systems, including IIoT solutions, operate with large volumes of data, requiring high-precision, high-speed data acquisition and real-time analysis. The pressure sensor, as a critical element of such systems, must meet strict requirements: wide measurement range (up to 180 MPa or higher), high frequency response (≥ 1 kHz), accuracy of at least ±1 %, and stability under temperature and mechanical stresses. Compatibility with microcontrollers (such as Arduino Portenta H7) is equally important to ensure flexibility for use in both modern Common Rail and older mechanical diesel systems. For accurate diagnostics of pressure pulsations generated by injector operation, a sampling rate of at least 24 kHz is required at engine speeds up to 4000 rpm. This imposes additional requirements on the performance of both the microcontroller and the ADC. The use of edge computing technologies allows for the reduction of transmitted data volumes and enables preliminary signal processing at the data acquisition level, reducing network and server load. This paper presents the selection process, calibration methodology, and experimental validation of a piezoresistive Bosch 0281006188 pressure sensor for diesel engine fuel system condition monitoring. The calibration procedure using an Arduino Portenta H7 microcontroller is described, along with the results of linearity assessment and measurement uncertainty analysis. The system achieves a total measurement error of approximately 1–2 %, which is sufficient for reliable injector diagnostics and integration into advanced IIoT-based engine monitoring systems.
The study of the performance of the bearings of the crank-shaft mechanism of ship low-speed engines is aimed at increasing the operational reliability and reducing the operating costs of the ship's power plant. Modern economic requirements and environmental restrictions on the emission of harmful substances with exhaust gases from ship diesel engines have led to changes in the conditions of the working process in the cylinders of diesel engines, which, in combination with the use of economic vessel speeds, create new conditions for loading the bearing assemblies of the crank-shaft mechanism of low-speed engines. To create modern systems for monitoring and diagnosing the performance of the crosshead bearings and predicting their resource, it is necessary to develop appropriate criteria for their evaluation. To determine the indicators that characterize the loading conditions of the crankshaft bearings, it is necessary to collect data for modeling the working process in the engine cylinders and the dynamic characteristics of the crankshaft. This will provide an opportunity to analyze the current loading conditions of the bearing assembly and, if possible, avoid long operating times. The paper studies the influence of the working processes of the low-speed diesel engine 8K90MC-C manufactured by MAN B&W, operating at the nominal propeller characteristic, on the loading conditions of the crosshead bearings. An analysis of the limiting characteristics of the main engine was performed taking into account the selected mode of the design maximum continuous power (SMCR). A method for conducting dynamic calculations using solid-state modeling of the mass characteristics of the connecting rod is presented. As criteria for assessing the performance, the characteristics of the total force acting on the crosshead bearing, the average load and the bearing characteristic pm∙vb are selected. An assessment of the effectiveness of the application of the above indicators and the pm∙vb criterion is provided. The feasibility of using the pm∙vb criterion is indicated for indirect assessment of the thermal load regime of bearings. Directions for further research are given in the direction of developing methods and criteria for assessing and predicting the performance of the bearing assemblies of the low-speed engines.
The work describes the solution of an urgent and important scientific and applied problem: the development of methods and means of discrete and continuous strengthening in the restoration of military and technical elements for strategic sectors of the national economy. The work is designed to meet the urgent need to restore samples of military and important civilian equipment in a short time and with high intensity. This equipment, under conditions of intensive loads during operation and the performance of combat missions in conditions of combat operations, wears out quite quickly as a result of contact interaction and mutual relative motion. At the same time, the processes of loading, contact, friction and wear develop according to a progressive scenario during the service life. And this leads to the failure of valuable objects. To eliminate these problem situations, the basics of technology and means of discrete and continuous strengthening have been developed. It consists in discrete processing of one of the contacting parts and continuous processing of the other. The conducted studies of processes and states during contact interaction of hardened parts made it possible to create a device on this basis that implements the technology of discrete hardening and makes it possible to determine rational technological modes during discrete and continuous strengthening of military and technical elements for strategic sectors of the national economy. Such device makes it possible to significantly increase the hardness, wear resistance and strength of machined structural parts. All effects that lead to an improvement in the technical characteristics of parts strengthened in this way are based on the effects of profile changing of contacting surfaces. This profile becomes hilly. Contact pressure is localized on these hills. Due to this, stresses are shifted to the material of discretely strengthened zones. Taking into account the high mechanical characteristics of material of these zones, the overall strength increases. In addition, tribological characteristics also increase. Efficiency increases, durability extends, and friction is reduced in such connection.
Compliance with modern environmental standards and fuel efficiency requirements is a key challenge facing diesel engine manufacturers. To meet these challenges, measures are being taken to intensify fuel supply and enable flexible control of its parameters. To a large extent, these requirements are fulfilled by modern accumulator-type fuel systems (Common Rail (CR) systems). However, in such systems, a portion of the fuel delivered by the high-pressure fuel pump (HPFP) to the rail is excessive and is discharged back to the fuel tank through a pressure control valve. Consequently, part of the mechanical energy consumed to drive the HPFP is lost, which negatively affects the engine’s efficiency and environmental performance. These power losses are especially significant in small-displacement engines, which necessitates measures to reduce them. This article presents the results of a literature review on the level of mechanical losses in the drive of high-pressure fuel pumps in diesel engines, the methods of regulating HPFP output under various engine operating conditions, and the rationale for controlling the delivery rate of the HPFP in accumulator-type fuel systems to reduce mechanical drive losses. Based on the conducted analysis, it is concluded that in order to reduce power losses in the HPFP drive and thus increase the mechanical and overall efficiency of diesel engines with accumulator fuel systems it is necessary to include a device in the fuel system that enables delivery adjustment independently of pump shaft speed and accumulator pressure. Future work will focus on developing a conceptual design of an HPFP that enables reduction of mechanical losses through controlled delivery, as well as on creating mathematical models required to describe and study processes within the diesel fuel system.
S.Zh. Bodu, A.V. Novoshytskyi, O.P. Shumilov, V.A. Polishchuk A systematic engineering-scientific analysis has been conducted of a complex set of technological factors that directly determine the durability, operational performance, and reliability of the components of diesel internal combustion engine fuel equipment. The primary focus is on the injector nozzle holes as critical zones operating under significant thermal, hydrodynamic, mechanical, and chemical loading conditions. An in-depth assessment of the influence of microgeometry, internal surface roughness, residual stresses, as well as the condition of the inlet and outlet edges of the holes on the development of degradation processes—specifically cavitation, erosion, coking, fatigue, and thermochemical destruction—is conducted. The research methodology is based on a comprehensive synthesis of current theoretical approaches, numerical modeling, experimental observations, and detailed analysis of actual equipment failures. The work compares the effectiveness of various finishing methods: traditional mechanical (drilling, grinding, lapping) and non-contact (electroerosion, electrochemical, anodic-mechanical). It is demonstrated that non-contact technologies ensure high dimensional accuracy, reduction of roughness (down to Ra ≤ 0.02 µm), geometric stability, and minimization of surface damage. It is established that initial defects formed at early manufacturing stages are not eliminated by subsequent operations and significantly reduce the injector’s reliability. Quantitative data on changes in hole diameter, fuel leakage coefficient, hydrodynamic stability, and fuel spray symmetry under real operating conditions are provided. Recommendations are formulated regarding the optimization of the technological processing route, material selection, microrelief control, and residual stress management. The proposed solutions can be implemented in serial production to increase service life, reduce failure frequency, and ensure long-term operational stability of diesel fuel equipment. The presented results have practical applied value for mechanical engineering, and the proposed approach can be adapted to other types of highly loaded components.
The automatic speed control system (ASCS) is crucial for ensuring the stable operation of diesel engines, which are the most common prime movers on merchant fleet. Modern diesel installations are equipped with electronic speed governors (ESG) that can be adjusted upon changeable ship`s sailing conditions. However, in practice, governor parameters are typically set for a specific mode without considering the stochastic nature of external sailing conditions, leading to unsatisfactory speed regulation in other modes. This creates a problem of ensuring the optimal operation of the ASCS with ESGs during vessel`s operation, especially in rough weather conditions. In this regard, the study aims to optimize the adjustment ESG`s parameters, taking into account the stochastic nature of the load across the entire range of possible operational modes of marine diesel engine. The research methodology involves the use of numerical and mathematical modeling, allowing for the consideration of stochastic characteristics of disturbances caused by the propeller, fluctuations in gas pressure in the diesel cylinders, the dynamic properties of ESG components, and ASCS nonlinearities. The methodology was tested on the main diesel installation HYUNDAI-MAN B&W 6S60MC-C7 of the CATALAN SEA tanker under various operational modes and changing sailing conditions over a wide range. As a result of the study, optimal settings for the Nabtesco MG-800 electronic governor were determined based on the criterion of minimizing the amplitude instability of crankshaft speed oscillations while maintaining an acceptable level of thermal regime stability. This optimization improved diesel engine stability and reduced specific effective fuel consumption by 1.5 – 4.3 % in main operational modes. The recommendations presented in this work regarding ESG adjustment can be used in the operation of marine diesel engines to enhance their stability.
The article explores the transformation of approaches to the use of Product Lifecycle Management (PLM) systems in the context of Industry 4.0 technologies, aimed at achieving strategic goals of sustainable development. Using the example of creating a digital environment for the two-stroke engine cylinder model, the initial stage of integration with the 3DEXPERIENCE platform is presented, demonstrating the practical implementation of the digital twin concept. The study identifies key trends in addressing global environmental challenges, particularly the reduction of carbon emissions and the minimization of natural resource consumption—both of which represent critical tasks throughout all stages of the automotive product lifecycle. The application of sustainable manufacturing technologies is considered a key prerequisite for ensuring the long-term resilience of the industry by combining economic efficiency with social responsibility and environmental safety. As part of the research, a roadmap for adapting modern design and manufacturing principles of cast internal combustion engine (ICE) components within the framework of Industry 4.0 technologies was developed. A comparative analysis of existing PLM systems was carried out, covering a wide range of functional capabilities, each with its own strengths and limitations. Based on a thorough evaluation, the 3DEXPERIENCE platform was reasonably selected due to its support for the full product lifecycle, including the integration of digital design, simulation, and production management tools. Particular attention is paid to the platform’s functionality in enabling decentralized collaboration through cloud infrastructure and centralized data management. Within the digital twin concept, a virtual environment for the cast cylinder component of a two-stroke engine was created, ensuring continuous synchronization between the digital model and real-world manufacturing processes. Further steps for the modernization of the integrated digital model within the PLM system are discussed, including process simulation, stress-strain analysis, and the implementation of innovative materials with predefined physical and mechanical properties. The conclusions highlight the prospects for the development of next-generation, high-level autonomous digital twins that combine artificial intelligence, embedded sensor systems, and big data analytics—enabling significantly greater flexibility, adaptability, and sustainable efficiency in manufacturing systems within the context of Industry 4.0 and its evolution toward Industry 5.0.
Due to the introduction in Ukraine, as of May 1, 2025, of new environmental standards mandating the inclusion of at least 5% bioethanol in gasoline with an octane number below 98, the issue of adapting used automotive gasoline engines to operate on blended fuel has become increasingly relevant. Bioethanol, as a renewable energy source, possesses different physicochemical properties compared to gasoline, which affects the combustion process and, consequently, influences the engine's power output, fuel efficiency, and environmental performance. This study analyzes the impact of bioethanol addition on fuel–air mixture parameters, particularly changes in the air–fuel equivalence ratio, calorific value, and ignition boundaries. The stoichiometric ratios of gasoline–air and bioethanol–air mixtures differ, which can disrupt the quality of the prepared combustible mixture and, subsequently, alter engine performance indicators such as power and efficiency. The reduced calorific value of the bioethanol–gasoline mixture may lead to a decrease in engine power—potentially by up to 40%. When adding 25% bioethanol to gasoline, the calorific value of the fuel–air mixture decreases by 9%, which can result in a proportional reduction in engine power. At bioethanol concentrations of 30–60%, the mixture may fall outside the ignition range, rendering it ineffective without additional technical solutions. Modern approaches to engine adaptation are reviewed, including fuel delivery correction based on ethanol content sensors and oxygen sensors in the exhaust gases (closed-loop control), followed by calculations of bioethanol concentration. It is noted that most modern engines can operate on fuel containing up to 15% ethanol without modifications. However, higher ethanol concentrations require both hardware and software upgrades, such as the installation of devices like the Digital E85 Adapter or ECU software modifications. The findings emphasize the need for both theoretical and experimental research to ensure effective engine adaptation to the new fuel standards.
The article provides a comprehensive analysis of the efficiency and prospects for the development of land transport power plants in the context of global challenges of climate change, energy transformation and the implementation of the Sustainable Development Goals. The authors consider the key role of the transport sector as one of the main sources of greenhouse gases, emphasizing the need to modernize internal combustion engines (ICE) and introduce alternative technologies taking into account international environmental standards. Particular attention is paid to hybrid power plants that combine a traditional ICE and an electric drive, which provides reduced fuel consumption and CO₂ emissions, especially in urban traffic conditions. As part of the work, a patent analysis of global trends in the development of transport technologies for the period 2010–2022 was performed. The results indicate a significant increase in the number of patents in the field of electric vehicles and hybrid plants, which indicates a shift of the global vector of innovations towards environmentally friendly solutions. At the same time, patent activity in the diesel and gasoline directions is decreasing, which confirms the gradual loss of relevance of traditional power systems. The NEDC driving cycle simulation was applied for the Volkswagen Golf in three configurations: gasoline, hybrid and electric. The models cover calculations of drag forces, power, fuel consumption, energy recovery and CO₂ emissions. The results obtained demonstrate the best environmental efficiency of the electric version when using "green" electricity (on the example of Berlin), while the hybrid version turned out to be optimal in regions with a high share of coal generation (on the example of Warsaw and Kyiv). The potential of using hydrogen additives to fuel as one of the directions for reducing toxic emissions and increasing the energy efficiency of hybrid systems was also analyzed. The conducted study allows us to formulate scientifically based criteria for choosing the type of power plant depending on regional energy supply conditions, environmental requirements, technological readiness of the infrastructure and long-term economic efficiency of vehicle operation.
The article presents a comparative analysis of modern laboratory and on-board technologies for monitoring the quality of diesel fuel, which are critically important for ensuring the stable operation of Common Rail fuel supply systems under operating conditions. The relevance of the research is due to the need to increase the reliability and environmental safety of diesel engines against the background of growing requirements for fuel efficiency and adaptation to the Industry 5.0 concept. The purpose of the work is to systematize knowledge about existing methods for assessing fuel quality and to justify the prospects of using on-board sensor systems as an element of preventive maintenance of diesel systems. The main tasks are: analysis of standard laboratory methods for measuring the physicochemical characteristics of fuel (cetane number, density, viscosity, sulfur content, FAME, water, and aromatic compounds), review of existing technologies for integrating diagnostic tools directly on board a vehicle, and evaluation of the accuracy, reliability, and practical applicability of such technologies. The study uses methods of comparative analysis of literature sources, standards, and patent documentation, as well as the methodology of technical evaluation of the design and operating principles of sensor systems. The novelty of the approach lies in the comprehensive comparison of the capabilities of traditional laboratory diagnostics with the results provided by modern on-board sensors based on tuning fork technology, near-infrared spectroscopy, ultrasonic, MEMS, and dielectric technologies. The research results show that most laboratory methods provide high accuracy, but are resource-intensive, poorly suited to real-time conditions, and not always informative for rapid response of engine control systems. At the same time, on-board sensors have demonstrated the ability to assess key physical parameters of fuel with sufficient reliability – particularly density, viscosity, dielectric constant, and FAME content. It was found that the most promising are systems that combine several sensor technologies with machine learning algorithms to create a complete fuel profile. It has been established that such hybrid solutions can adapt engine operation parameters to changes in fuel quality in real time, reducing the risk of malfunctions and lowering emission toxicity. The conclusions note that the transition to expanded use of on-board monitoring tools is a logical stage in the development of diesel injection systems. It is recommended to actively research and implement multiparameter sensors, which will make it possible to realize adaptive engine control strategies and prevent damage to fuel equipment. Several technical directions for improving sensor systems are proposed: improving thermal stability, self-cleaning surfaces, and expanding the spectral range of IR analysis. The results obtained may have long-term significance in the context of the environmental modernization of diesel transport and the development of reliable intelligent systems for monitoring fuel quality in the energy sector.
