On the development of novel telemetry systems for online monitoring of highly stressed components

The energy and transportation sector are one of the biggest contributors to greenhouse gas emissions worldwide. While there are potentially cleaner and easily to apply options available for the operation of passenger cars, the usage of internal combustion engines in power generation and transportation systems such as ships and locomotives is still increasing. Consequently, there is a growing need for research focused on enhancing efficiency, reducing emissions, and minimizing life cycle costs of these large engines. To achieve these goals, it is necessary to develop advanced measurement methods capable of quickly and precisely capturing difficult-to-measure parameters. Despite the simplifications provided by simulations, it is essential to validate these results through empirical measurements and to provide accurate input and boundary conditions for simulations.

This paper presents innovative telemetry systems developed for real-time monitoring of critical variables in highly stressed components such as valves, bearings, pistons, piston rings and others, even under harsh environmental conditions typical for internal combustion engines. These systems can measure multiple parameters such as temperatures, pressures or kinetic variables of mechanical components, providing invaluable data for engine optimization. The telemetry systems' design, including sensor placement, boundary conditions, mechanical considerations, and iterative design phases, will be thoroughly discussed.

Additionally, the paper will showcase results from experiments where multiple novel measurement technologies were employed, providing comprehensive insights into engine processes. These insights are crucial for the ongoing transition to alternative, carbon-free fuels and for further extending the service life of large engines.