Design and Simulation of Camless Engine Electro-mechanical Valve Actuation System for Four Stroke Single Cylinder Engine

The current engine technology relies on mechanically driven camshafts, which lack flexibility and real-time modification capabilities. To overcome this limitation, the thesis proposes integrating individually controlled valves into the ICE, leading to the development of camless engine technology. Electromechanical valve actuators (EMVAs) have been considered one of the most promising technological solutions to develop this novel engine technology. The aim of this thesis research is to experience engineering design science by taking an idea from a concept and then modeling it using software. Existing literature reveals that conventional camless engine valve actuation systems involve complex designs and numerous components, which can increase manufacturing costs and pose challenges for mass production. These challenges are related to the temperature sensitivity and characteristics of hydraulic fluids used in camless engine valve actuation systems, as well as practical implementation difficulties. Successfully addressing these gaps will result in the advancement of camless engine valve actuation systems. In this thesis work, an attempt has been made to integrate the concepts of mechanics, mechatronics, and electronics for designing an economical, lowemission, high-performance single-cylinder Cam-less engine. The concept is that by using sensors, an electric signal will be sent to the ECU. The ECU analyzes the signal and determines what to do on the actuator depending on the pre-sated programming, and then it automatically directs the actuator what to do on the valve. The methodology that is used in this thesis work is analytical analysis as well as a model and simulation of a work using ANSYS workbench/space claim and solid works 2022 for modeling mechanical system components and ANSYS workbench for simulation, MATLAB/Simulink for actuator model, and PROTEUS SUIT DESIGN 8.6 with Arduino IDE for simulating electrical systems functionality testing. The study reveals that the total weight of the analyzed system is 2.729 kilograms, compared to the 3.4 kilograms of the conventional valve actuation components of the selected model. These results in a 20% weight reduction, mainly due to the reduction of valve train components and camshaft itself. This results in improved engine efficiency and reduced fuel consumption. Also as seen from cost analysis the design is cost effective which means the design system has less expensive as compared to conventional camshaft engine with current market Value. Additionally these research findings indicate that the system achieves a maximum valve lift of approximately 6mm, which is comparable to conventional valve lift mechanisms. Through the PROTUES simulation, it is observed that the valve timing can infinitely vary based on control programming, enabling the decoupling of valve lift, timing, and actuation speed from the crankshaft position. Thus based on design results system can be implemented with technical adjustments, offering weight reduction, improved engine efficiency, and reduced fuel consumption.