Towards Centrifugal Compressor Stages Virtual Testing

Flow features inside centrifugal compressor stages are very complicated to simulate with numerical tools due to the highly complex geometry and varying gas conditions all across the machine. For this reason, a big effort is currently being made to increase the fidelity of the numerical models during the design and validation phases. Computational Fluid Dynamics (CFD) plays an increasing role in the assessment of the performance prediction of centrifugal compressor stages. Historically, CFD was considered reliable for performance prediction on a qualitatively level, whereas tests were necessary to predict compressors performance on a quantitatively basis. In fact "standard" CFD with only the flow-path and blades included into the computational domain is known to be weak in capturing efficiency level and operating range accurately due to the under-estimation of losses and the lack of secondary flows modeling. This research project aims to fill the gap in accuracy between "standard" CFD and tests data by including a high fidelity reproduction of the gas domain and the use of advanced numerical models and tools introduced in the author's OEM in-house CFD code. In other words, this thesis describes a methodology by which virtual tests can be conducted on single stages and multistage centrifugal compressors in a similar fashion to a typical rig test that guarantee end users to operate machines with a confidence level not achievable before. Furthermore, the new "high fidelity" approach allowed understanding flow phenomena not fully captured before, increasing aerodynamicists capability and confidence in designing high efficiency and high reliable centrifugal compressor stages.

Development and testing of methodologies for the control and diagnosis of innovative combustion systems

In pursuit of aligning with the European Union's ambitious target of achieving a carbon-neutral economy by 2050, researchers, vehicle manufacturers, and original equipment manufacturers have been at the forefront of exploring cutting-edge technologies for internal combustion engines. The introduction of these technologies has significantly increased the effort required to calibrate the models implemented in the engine control units. Consequently the development of tools that reduce costs and the time required during the experimental phases, has become imperative. Additionally, to comply with ever-stricter limits on 〖"CO" 〗_"2" emissions, it is crucial to develop advanced control systems that enhance traditional engine management systems in order to reduce fuel consumption. Furthermore, the introduction of new homologation cycles, such as the real driving emissions cycle, compels manufacturers to bridge the gap between engine operation in laboratory tests and real-world conditions. Within this context, this thesis showcases the performance and cost benefits achievable through the implementation of an auto-adaptive closed-loop control system, leveraging in-cylinder pressure sensors in a heavy-duty diesel engine designed for mining applications. Additionally, the thesis explores the promising prospect of real-time self-adaptive machine learning models, particularly neural networks, to develop an automatic system, using in-cylinder pressure sensors for the precise calibration of the target combustion phase and optimal spark advance in a spark-ignition engines. To facilitate the application of these combustion process feedback-based algorithms in production applications, the thesis discusses the results obtained from the development of a cost-effective sensor for indirect cylinder pressure measurement. Finally, to ensure the quality control of the proposed affordable sensor, the thesis provides a comprehensive account of the design and validation process for a piezoelectric washer test system.