TY - THES

T1 - Development of a connecting rod concept for a power-increased gas engine

AU - Hopp, Sebastian

N1 - embargoed until 01-10-2024

PY - 2019

Y1 - 2019

N2 - Stationary gas engines have undergone a revival in recent years, as they are regarded as an environmentally friendly and efficient way of generating electricity. The constant further development of these engines with the aim of achieving a higher power output, better efficiency and lower fuel consumption has led to ever higher demands being placed on core engine components in particular. In addition to some other core engine components, a new connecting rod has to be developed for a power-increased Type 6 gas engine of the company INNIO Jenbacher GmbH & Co OG. Connecting rods are complex components that are subject to many different requirements in terms of reliability, functionality, design and production. Experience has shown that most failure mechanisms on a connecting rod occur in the area of the connecting rod head as a result of insufficient stiffness. Too little stiffness can lead to excessive deformation of the big end during engine operation and must therefore be avoided. In the course of this master's thesis, a methodology is developed with which criteria for the design and dimensioning of a connecting rod for large gas engines can be derived. The aim is to identify those product features that enable a functional and modern connecting rod design and fulfill defined requirements. Particular attention is paid to the performance of the big eye. Using the finite element analysis and a parametric analysis, possibilities for the evaluation and optimization of the stiffness and deformation behaviour under load are determined and geometric influences identified. On the basis of the gained knowledge finally a concept design is derived, which serves as a starting model for the development of a new connecting rod for a power-increased gas engine of the INNIO Jenbacher GmbH & Co OG. In order to confirm the correctness of the conclusions, the stiffness and deformation behaviour of the concept design and the current baseline model under load are compared and discussed.

AB - Stationary gas engines have undergone a revival in recent years, as they are regarded as an environmentally friendly and efficient way of generating electricity. The constant further development of these engines with the aim of achieving a higher power output, better efficiency and lower fuel consumption has led to ever higher demands being placed on core engine components in particular. In addition to some other core engine components, a new connecting rod has to be developed for a power-increased Type 6 gas engine of the company INNIO Jenbacher GmbH & Co OG. Connecting rods are complex components that are subject to many different requirements in terms of reliability, functionality, design and production. Experience has shown that most failure mechanisms on a connecting rod occur in the area of the connecting rod head as a result of insufficient stiffness. Too little stiffness can lead to excessive deformation of the big end during engine operation and must therefore be avoided. In the course of this master's thesis, a methodology is developed with which criteria for the design and dimensioning of a connecting rod for large gas engines can be derived. The aim is to identify those product features that enable a functional and modern connecting rod design and fulfill defined requirements. Particular attention is paid to the performance of the big eye. Using the finite element analysis and a parametric analysis, possibilities for the evaluation and optimization of the stiffness and deformation behaviour under load are determined and geometric influences identified. On the basis of the gained knowledge finally a concept design is derived, which serves as a starting model for the development of a new connecting rod for a power-increased gas engine of the INNIO Jenbacher GmbH & Co OG. In order to confirm the correctness of the conclusions, the stiffness and deformation behaviour of the concept design and the current baseline model under load are compared and discussed.

KW - Gasmotor

KW - Pleuel

KW - Pleuelstange

KW - Finite Elemente Analyse

KW - FEM

KW - Design of experiments

KW - DoE

KW - Motorkernbauteil

KW - Entwicklung

KW - Gas engine

KW - Conrod

KW - Connecting rod

KW - Finite element analysis

KW - FEA

KW - FEM

KW - Design of experiments

KW - DoE

KW - Core engine component

KW - Development

M3 - Master's Thesis

ER -