Session C8 Paper #50 Disclaimer—This paper partially fulfills a writing requirement for first year (freshman) engineering students at the University of Pittsburgh Swanson School of Engineering. This paper is a student, not a professional, paper. This paper is based on publicly available information and may not provide complete analyses of all relevant data. If this paper is used for any purpose other than these authors’ partial fulfillment of a writing requirement for first year (freshman) engineering students at the University of Pittsburgh Swanson School of Engineering, the user does so at his or her own risk. THE FUTURE OF INTERNAL COMBUSTION: CAMLESS ENGINES Anthony Barca, [email protected], Budny 10:00, Scott Moskal, [email protected], Budny 10:00 Abstract—For years, the internal combustion engine has dominated the transportation industry. Today, many of the components of the internal combustion engine - from fuel injectors to turbochargers - have improved tremendously since their creation. Despite this, one of the most important components of the engine, the valvetrain, is yet to be totally reinvented. As greenhouse gases continue to create more issues for our environment, many automotive engineers are trying to develop new ways of achieving higher efficiency from their engines. The most promising new piece of technology is the camless engine, an innovation that will change the way the engine operates. Camless engines employ a computer aided system that controls each individual valve in the cylinder of an internal combustion engine via a mechanical device such as a pneumatic or electromagnetic actuator. This can result in the best optimization currently available in engine efficiency, possibly leading to a downward trend in emissions if widely implemented. Such a downward trend could also pay dividends towards the sustainability and protection of the earth’s resources and the health of all citizens. However, before proper implementation can occur, much more research, design, and testing must be performed to make the system practical for real world application. Key Words—Camless engine, Electromagnetic actuators, Engine emissions, Internal combustion engine, Pneumatic actuators, Valvetrain, Variable valve timing. have increased power outputs and emission ratings, but they cannot afford to stop there. Innovations must keep surfacing in the automotive world, and engineers are developing a technology that has the potential to take the refinement of the ICE to a whole new level. The technology that can change the future of the ICE technology (and the future of the environment) is known as the camless engine. The camless engine is a special kind of ICE that does not need camshafts over each bank of cylinders to actuate the valves for each cylinder. Instead, it uses a system of mechanically operated valves programmed to activate at a specific frequency and depth into the cylinder. This new technology will provide potential gains to the automotive world. Alternative sources of power for automobiles usually come in the form of electric, hydrogen, or even air-powered vehicles. While these new technologies are currently being designed and implemented without the use of fossil fuels, they are still in development and will take many years until they are as reliable, practical, and affordable as their internal combustion counterparts. Until then, the use of fossil fuels is required for most automobiles, and must be optimized using the latest technologies to ensure that our society is using as little of these resources as possible. THE INTERNAL COMBUSTION ENGINE Components INTERNAL COMBUSTION TODAY Every day, greenhouse gases such as the carbon dioxide emissions that result from the combustion of fuels in internal combustion engines (ICE) are accountable for a large portion of the pollutants in our environment. The main effects of increased greenhouse gases are global warming and adverse health problems. With emissions at their highest levels in the last decade and an increasing number of vehicles on the road, global warming requires special attention. Since the creation of the ICE, engineers have been researching new ideas to produce more power and less emitted pollutants with the same amount of fuel. Efforts include the use of multiple valves, electronic fuel injection, and variable valve timing. The effects of these developments on the ICE University of Pittsburgh Swanson School of Engineering 1 31.03.2017 There are a few main components of an ICE that must be introduced to explain its function. A visual representation of the internal combustion engine can be viewed in Figure 1. Starting at the top of the diagram, the intake manifold (referred to as the intake), pulls in air from the atmosphere, filters it, and channels it to the cylinders. Next, the valvetrain controls the valves of the cylinders, opening and closing them to allow the air to flow into the cylinder, and allowing exhaust gases to exit out of the exhaust system. The fuel injector, located in the cylinder, sprays a fine mist of fuel in with the incoming air to prime the mixture for combustion. Spark plugs then create an arc of electricity to ignite the mixture, which causes the gases to expand in the cylinder. The force from these expanding gases then pushes a piston down in the cylinder, connecting to Anthony Barca Scott Moskal the crankshaft to turn the force into rotational motion. From there, the power is sent through the flywheel, transmission and axles, until it reaches the wheels. possess a valvetrain that is responsible for the opening and closing of the intake and exhaust valves [2]. They accomplish this task by using fixed lobes on a spinning shaft known as the camshaft, which actuates the valves and pushes them into the cylinder to let air and fuel in and exhaust gases out. For years, engineers in the automotive industry have been finding ways of perfecting this system, modifying the location of the camshaft and valves in the engine, and turning to modern electronics to create systems that can adapt to changing engine speeds. In more recent history, engineers have created a system using variable valve timing (VVT), which combines the best arrangement of the valvetrain and advanced electronics to get the best performance from an ICE. What makes VVT technology the best out of any current techniques is its use of cam phasors that electronically or hydraulically change the cam that each valve is using, effectively increasing the airflow at the necessary speeds [3]. Due to the focus on the valvetrain and its best possible configuration, automotive companies are going beyond these simple cam phasors to create a system that can better adjust to an ICEs changing speeds and conditions. This is where the idea of a camless system comes into play. From extensive testing, automotive engineers have discovered that camshafts are limited in their customization, so the next step in realm of the valvetrain is to completely remove the camshaft altogether and replace it with a fully customizable system [4]. FIGURE 1 [1] Internal Combustion Engine Diagram Combustion ROOM FOR IMPROVEMENT Behind every ICE in an automobile, there is the same basic principle: to convert as much potential energy stored in fuel into mechanical energy that can be used to propel the vehicle. This is achieved through the combustion process, in which air from the atmosphere is drawn into the engine, mixed with a vapor of fuel, and ignited with enough force to drive the piston down in the cylinder. This is also the first place that engineers look for improvements, altering the amount of fuel that the fuel injector sprays each time and how much air is let into the engine, creating the best air to fuel ratio. An air to fuel ratio can be created to fit the needs of any specific engine, whether it is a high-performance engine with a high ratio or an economically focused engine with a lower ratio. Engineers also fine tune this process by increasing the efficiency in converting chemical energy to mechanical energy by using techniques that reduce the temperature of the incoming air. Reducing the temperature of the gases in the cylinder will allow more oxygen to be mixed in with the fuel, creating a more powerful reaction without burning any excess fuel. This is one way that emissions can be reduced in automobiles. The most critical component for optimizing the ICE and its combustion process, however, is the valvetrain. Greenhouse Gas Emissions One of the most significant challenges facing us today is the protection of the environment from pollution. Having grown so rapidly in the last century, the human population has caused the number of vehicles on the road to continuously increase at a high rate. In Jerry Hirsch’s 2014 Los Angeles Times’ article on increasing vehicle usage, he reports that we have “reached a record level of 253 million, an increase of more than 3.7 million” in one year [5]. Vehicle usage also continues to soar due to the economy and the increasing quality of automobiles. These automobiles are one of the major causes of global warming, accounting for a large portion of all emissions in the United States, affecting health, security, and many other human needs. With the rise in the number of vehicles on the road, increasing levels of pollution continue to harm our environment and the protection of the earth’s resources. Other sources of power, such as electricity or hydrogen, need more time to become truly practical. This means that ICEs will remain dominant for many years to come. Therefore, it is necessary to understand this problem and learn ways to minimize pollution. Focusing on transportation, the main greenhouse gas emitted is carbon dioxide, which results from the combustion of gasoline in an ICE. According to the United States Environmental Protection Agency (EPA) in “The Sources of Greenhouse Gas Emissions,” about a fourth of all Valvetrain The valvetrain controls several key components that directly affect its performance, and is the area that can potentially see the most improvement. Presently, most ICEs 2 Anthony Barca Scott Moskal greenhouse gas emissions come from transportation. The EPA also reports that greenhouse gas emissions have continued to rise over the last several years due to an “increased demand for travel and the limited gains in fuel efficiency” [6]. These emissions in the United States have continued to increase since the 1990s. Many people also tend to be on the road more often, as well as traveling further to a destination than in the past [6]. The growing number of people on the road is largely due to the rising population growth, economic growth and low gas prices at the beginning of the twenty-first century. With all these parts in the ICE moving faster, the air and fuel mixture also follows this pattern, causing turbulence in the cylinder. If the valves do not adapt to open widely enough, the necessary amount of air and fuel will not occupy the cylinder, drastically reducing top-end performance and efficiency. This is where the idea of a camless valvetrain could improve the process of combustion that engineers have been developing for years, to ultimately reduce the impact of ICEs on the environment. THE CAMLESS VALVETRAIN This revolutionary new type of valvetrain and its promising test data show that it has the potential to be the future of internal combustion. However, as with any new technology, there also arises many new challenges that automotive engineers must overcome to make the camless system reliable and cost-effective enough to replace the current version of the ICE. The design and implementation of the camless engine is crucial to providing better efficiency and protection of the environment. Basic Components While the technology behind the function of the camless engine is quite complicated, its theory is simple: remove the camshafts and replace them with a fully customizable system that controls each valve individually. This will reduce emissions and fuel consumption without the loss of power and reduce its influence on the environment. To create a camless engine, three main components must work together in an efficient and flawless way. The first and most important element of a camless engine is the valve actuator. One actuator must sit above each set of intake and exhaust valves, so that they can be controlled independently from the others. It must use one of several possible techniques for physically pushing the valve down in the cylinder in a controlled manner, using either an electromechanical system or a hydraulic system [2]. Another component of the camless engine is the way in which the engine generates enough electrical energy to run the valve actuators. In order for the engine to be more efficient, it must not lose too much energy in operating the electronics that control its components [3]. A low friction generator and very advanced electronics must be employed to create the large amount of power required to run all its actuators simultaneously. The third main component of a camless valvetrain is the control system required to tell the actuators when to operate and how far to push the valve down in the engine, according to engine speed. This will require lots of programming by engineers and computer scientists to fully optimize the system. These three main components of the valvetrain are the basis for a camless engine, which becomes much more complicated when designing them to function efficiently. FIGURE 2 [6] Greenhouse Gas Emissions from Transportation Figure 2 depicts a graph of the greenhouse gases emitted from transportation alone in the United States, showing that the greenhouse gas emissions continue to increase each year. During the Great Recession in 2007, the carbon dioxide emissions fell at a high rate because of the cutbacks in consumer spending everywhere, along with a lower number of drivers on the road. However, once the Recession ended, carbon dioxide emissions continued to increase over the next few years. The Limits of the Camshaft To decrease the greenhouse gases emitted from the transportation industry, the camshaft of the ICE will need modification. This part of the ICE has been around since its creation, being one of the most critical components of the engine by opening and closing the valves. For the combustion process to occur as efficiently as possible, the intake and exhaust valves must open at the right time. According to Francois Badin’s book Hybrid Vehicles From Components to System, “the height and duration of valve lift is fixed, being determined by the profile of the cam” [3]. These camshafts are unable to properly adjust to the increasing speeds of the engine. Just like the speedometer measures the speed of a car, the tachometer measures the revolutions per minute (RPM) of the crankshaft. Increasing the RPM causes the valves to open and close even faster along with the pistons. 3 Anthony Barca Scott Moskal In fact, the standard automobile currently operates on a 12V system, which would not be able to run all the components in a camless engine. Rather, the automobile needs at least a 42V system to operate all components tied into the battery [2]. In creating all the necessary power to run the system using more powerful electronics, it is important that the efficiency of the engine is not affected by the added strain of more rotating components from extra generators and alternators [3]. The Valve Actuator To physically move the valves individually at high speeds with pinpoint precision is the job of the valve actuator. Many engineers have implemented existing technologies to actuate the valves in camless engines, starting with electromechanical actuators. These devices use a “spring system” to hold the valve in its middle position, and two coils that are “energized alternately to attract an armature,” as seen in Figure 3 [2]. Due to the powerful electromagnetic force between the coils and armature, the valve can be operated at high speeds, and at various depths. In camless engine development thus far, the electromechanical system has been the best for speed and control, but there are alternate methods being developed that can also control valve depth. Providing Full Control As promised by the development of a camless valvetrain, the valves must operate independently of each other, creating the need for a dynamic control system. Similarly, all new ICEs have computerized control of various components such as timing for the fuel injectors, spark plugs, and their VVT mechanisms. The same is true for a camless engine, which needs software similar to what is used now, except with much more complex programs to time the actuators rather than a VVT system. Extensive research must be done to determine the optimal depth and speed of a valve at any engine speed, which is to be programmed into the system. Another aspect to consider is the need of the software to regulate how much energy is going to each actuator so that no component is short on power. Once a well-developed and customizable software is created that can handle the high demands of control required by the system, the final tuning and optimization stages can begin. Techniques of Optimization The principals of combustion discussed earlier apply to every ICE, and the camless engine is no exception with regards to performance and efficiency. With several factors to balance, such as fuel economy, emissions, or power, finetuning an ICE is a lengthy technical process to fulfill the purpose of a specific engine. Over the years, automotive engineers have come up with several other ways of reducing emissions while increasing the power that the camless engine can take even more advantage of, revolutionizing each technique. The first technique stems back to the idea of getting the most power from the same amount of fuel, by controlling at what engine speed the most power or torque is produced. Torque in automobiles is most often referred to as the rotating force on the crankshaft to get the vehicle moving, while the power is the maximum rate at which the engine can perform this torque on the crankshaft. In most cases, the engineers specifically implement this maximum torque output at certain engine speeds for different purposes, to get the vehicle up to speed quicker if it has a larger mass. With the full valve control offered by a camless engine, fixing this range of maximum torque is much easier and allows for much finer adjustments. Not only can these adjustments place the power and torque peaks at more economical positions, but they are also engineered to be more “full,” creating more power, and Figure 3 [7] Operation of an Electromechanical Actuator One of these alternate methods includes the use of hydraulic controllers, in which the valve is controlled with a system of hydraulic fluids [2]. The fluids are pumped into the valvetrain, and the pressure that they create is enough to move the valves independently of one another. While this system is one of the most effective alternatives to an electromechanical actuator, it suffers from various drawbacks. Some of these drawbacks include its increased complexity and mass that it adds to the vehicle, and the fact that the viscosity of the fluids will change with the vastly changing engine temperatures, affecting performance and accuracy [2]. As developments in hydraulic systems are improved, they will become more practical for use in a camless valvetrain, but for now, the use of electromechanical actuators is optimal for performance. Powering the System To operate the very complex and powerful actuators in a camless engine, a large amount of electricity is required. According to IFP Energies Nouvelles expert Francois Badin, “considerable power” is required to move the valves down into the cylinder, even though they only move a short distance [3]. 4 Anthony Barca Scott Moskal accelerating the vehicle at a higher rate so that even less fuel is burnt in reaching the desired speed [3]. Another technique that will be more improved than ever before is increasing efficiency at low speeds. Taking a current example of an ICE at low engine speeds, the main flaw is that it only has one fixed valve travel depth and frequency. This is also the same valve travel and frequency as at much higher engine speeds, so the valves are not opening optimally for slow-speed situations, resulting in pumping loss. Pumping loss is caused by the suction force that the piston must use to pull air into the engine at low speeds, reducing the efficiency of the engine through energy loss [7]. A shorter travel depth and frequency can be assigned to each valve, making for much lower mechanical resistance at slow speeds and increased efficiency. Although there are many other possible techniques for optimizing the operation of a camless ICE, the final example discussed in this paper deals with the amount of pollutants emitted in every cycle of the engine. A fairly recent process has been engineered so that the engine does not pull in all new air from the atmosphere and expel the exhaust fumes produced in each cycle. This process is known as Exhaust Gas Recirculation (EGR), which effectively reduces the amount of exhaust gases and pollutants that leave the engine through the exhaust manifold [3]. Camless engines can make this process much simpler, by “regulating the overlaps” of the intake and exhaust valves [7]. As a byproduct of this technique, reducing the amount of air pulled in from outside of the engine will also result in a lower pumping loss [3]. Most of the techniques for optimization work closely with each other to create a truly remarkable machine that can adjust on the fly. This ability is created by advanced valve actuators, cutting-edge electronics, well-developed software, and the tuning of an ICE with a camless valvetrain that can greatly decrease the carbon footprint that automobiles create. FIGURE 4 [8] FreeValve Actuation System FreeValve’s technology, as shown in Figure 4, is a type of variable valve actuation that allows the timing of the valve to be programmed into the engine’s control system. According to FreeValve, they use “electro-hydraulic-pneumatic actuators combined with advanced sensor techniques” to control the valvetrain [8]. In 2009, FreeValve installed this system in a SAAB 9-5 to test its practicality, with very impressive results. After 55,000 kilometers of real-world use, the system has performed well, even down to temperatures of -20℃ [8]. Since then, FreeValve has created six generations of actuators that have improved dramatically over the past few years, with a “verified fuel consumption reduction of 12-17 percent” [8]. Another concept vehicle, named the Qoros, has partnered with FreeValve to create an engine that benefits from a 47% increase in torque and a 45% increase in horsepower compared to its unmodified 1.6-liter engine [8]. These numbers show some outstanding progress made over the years, and FreeValve hopes to continue the trend of reducing fuel consumption. Collin Woodard’s article on R&T.com illustrates how FreeValve’s technology functions and reduces pollution with benefits such as “better power, torque, efficiency, fuel economy, and emissions” [9]. Also, included in the article was a video made by Engineering Explained, which graphically demonstrated how the FreeValve system works, and explained some of the challenges faced by the company. These challenges included the cost of components in creating the FreeValve system, and how a lot of testing is still required to perfect the system [9]. With claims in the future of creating 30% more fuel efficiency and 50% less emissions, FreeValve is truly the frontrunner in implementing the camless engine that could potentially cut the automobile’s impact on the environment in half [9]. FREEVALVE In 1994, the Swedish automotive company Koenigsegg launched a new car company with a goal of producing worldclass sports cars. Koenigsegg’s success throughout the 1990s led to the creation of its sister company FreeValve, which began work on a new technology in the summer of 2000. Without much implementation of camless engines at the time, FreeValve was one of the first companies to include this new technology in its design. FreeValve’s goal was to reduce the greenhouse gas emissions and fuel consumption from the transportation industry by improving components for the ICE. During the early 2000s, FreeValve produced their first valve actuation system that modeled the process of a camless engine. SOCIETAL IMPACT Evaluating not only the performance and potential rewards of a technology, but its repercussions on society is also a concern of any innovation, and the engineers behind it. A large amount of research must also go into determining if the 5 Anthony Barca Scott Moskal benefits of the camless engine will outweigh any disadvantages in the real world. In this evaluation, a definition of what it means for a technology to encourage the sustainability of the earth is important. According to the EPA, sustainability is “to create and maintain the conditions under which humans and nature can exist” to “support present and future generations” [10]. Creating such an environment, therefore, is one of the most important things that scientists, engineers and diplomats can do for others in the future. Where the engineers behind camless engines will come into play is in the impact of the ICE on the ecosystems, resources, and overall health of the environment. As per section 7 of IEEE’s Code of Ethics, it requires an engineer “to accept responsibility in making decisions consistent with the safety, health, and welfare of the public” along with disclosing “factors that might endanger the public or the environment” [11]. Making ethical decisions that are for the benefit of all at the expense of none is what engineers as a whole must follow in their professional endeavors, and is the only way to truly accomplish this harmonious existence between citizens and nature. result would almost certainly counteract any increased power consumption and resource use from the production of the systems themselves [8]. Over time in fact, the resource conservation for future generations will be increasing more in the few years following the production of camless valvetrains “than in the previous one-hundred” [8]. This will make the investment pay off many times over, and save more fossil fuels for future generations. Although the current limitations of price on the implementation of the camless engine on the market may also make it appear impractical, it is important to remember that innovations in a particular field take time to develop and be properly tested so that they can be depended on. VVT systems in modern ICEs were developed in this way. Once these technologies are widely implemented, the costs will start to go down, making the technology more accessible to consumers. The more consumers that are able to purchase the technology the better, and will contribute to a healthier environment that will increase the sustainability of resources and ecosystems for years to come. WHEN WE WILL SEE MORE CAMLESS ENGINES Drawbacks While the camless engine and its various components are all still being developed to work together as effectively as possible, not many examples will reach the market for mass production for a few years. The reason for this delay is because of the new and advanced electronics required to operate the system, which makes the production of the engine too expensive for the industry to produce in mass quantities. Also, additional testing must be done by automotive companies to ensure that camless engines are reliable and practical enough for everyday use, and that they can deal with the extreme weather conditions that they will be exposed to where they are sold. With the state of the environment in the spotlight recently, it is very important to continue improving every technology that is used so that its impact is minimal. Eventually, camless engines can be implemented into all kinds of transportation, such as locomotives or vessels, or in any instance that internal combustion is used. When considering the impact that the ICE has had on our past, it ranks among the greatest inventions in history because of how it changed the way people transitioned from place to place. The quality of life has also benefitted from the ICE, because of how much more one can accomplish in one day. Now that automotive engineers have taken one of the most crucial inventions in the past 200 years and reinvented it, the potential rewards with regards to the environment and quality of life everywhere can continue to climb. The camless engine, in design and testing has proven to be the next step for internal combustion, showing just how this new technology is truly an innovation not only for automobiles, but also for the course of history. Engineers will take these codes of ethics and other situations throughout history into consideration when examining the negative aspects of this new technology. Among the few drawbacks of the camless engine are the current costs of production and the increased resources that are needed to produce all the extra components for a camless valvetrain. High costs of production result from the fact that no automotive company has mass-produced a camless engine yet. Before companies like FreeValve can start production of their camless engine variant, a lot of testing remains before they can put it out on the market, which will lower production costs. Until then, consumers will not be able to purchase and spread this technology across the globe, so its impact will not be felt for a few years. Once production does start however, more energy and resources must be used to manufacture the components necessary to control the new valvetrain. This includes slightly more energy consumption from extra sections of factories and more materials used for the production of the actuators. Another question that is raised then, is if the benefits can outweigh these drawbacks and make the camless engine worth the effort. Outweighing the Disadvantages To address these concerns, engineers need to focus on the main reasons why this technology was created in the first place, which is to reduce emissions while increasing efficiency and performance. With the expected gains claimed by FreeValve of 50% less pollutants and 30% more power, this 6 Anthony Barca Scott Moskal SOURCES [1] “Internal Combustion Engine.” Britannica Online for Kids. 2017. Accessed 2.26.2017. http://kids.britannica.com/eb/art-66070/Cross-sectionshowing-one-cylinder-of-a-four-stroke-internal [2] R. Seethaler, J. Zhao. “A Fully Flexible Valve Actuation System for Internal Combustion Engines.” IEEE/ASME Transactions of Mechatronics. Vol. 16, No. 2. 4-2011. pp. 361-370 [3] F. Badin. Hybrid Vehicles From Components to System. Paris, France: Editions Technip. 2013. pp. 84-86 [4] W. S. Chang, J. G. Kassakian, T. A. Keim, T. A. Parlikar, D. J. Perreault, Y. H. Qiu, M.D. Seeman. “Design and Implementation of an Electromagnetic Engine Valve Drive.” IEEE/ASME Transactions of Mechatronics. Vol. 10, No. 5. 10-2005. pp. 482-494 [5] J. Hirsch. “253 million cars and trucks on U.S. roads; average age is 11.4 years.” Los Angeles Times. 6.9.2014. Accessed 1.26.2016. http://www.latimes.com/business/autos/la-fi-hy-ihsautomotive-average-age-car-20140609-story.html [6] “Sources of Greenhouse Gas Emissions.” US Environmental Protection Agency. 1.24.2016. Accessed 1.10.2017. https://www.epa.gov/ghgemissions/sources-greenhouse-gasemissions#transportation [7] E. Mohamed. “Modeling and performance evaluation of an electromechanical valve actuator for a camless IC engine.” International Journal of Energy and Environment (IJEE). Vol. 3, No. 2. 2012. pp. 276-294 [8] “FreeValve Technology.” FreeValve. Accessed 1.10.2017. http://www.freevalve.com/technology/freevalve-technology/ [9] C. Woodard. “Here’s How the Camless Engine of the Future Works.” R&T.com. 10.19.2016. Accessed 1.26.2017. http://www.roadandtrack.com/new-cars/cartechnology/videos/a31223/how-camless-engine-works/ [10] “Learn About Sustainability.” US Environmental Protection Agency. 10.18.2016. Accessed 3.26.2017. https://www.epa.gov/sustainability/learn-aboutsustainability#what [11] “IEEE Code of Ethics.” IEEE. Accessed 3.26.2017. http://www.ieee.org/about/corporate/governance/p7-8.html ACKNOWLEDGMENTS We would like to thank our co-chair Danielle Broderick for taking some time out of her busy schedule to revise parts of our paper. Special thanks also go out to our chair Jared Andes, who has provided very helpful professional feedback about the technical content of the paper. Finally, another big thanks to our writing instructor Michael Cornelius for giving us great feedback throughout the writing process. 7
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