Numerical and experimental study of a boosted uniflow 2-stroke engine

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel UniversityEngine downsizing is one of the most effective ways to reduce vehicle fuel consumption. Highly downsized (>50%) 4-stroke gasoline engines are constrained by knocking combustion, thermal and mechanical limits as well as high boost. Therefore a research work for a highly downsized uniflow 2-stroke engine has been proposed and carried out to unveil its potential. In this study, one-dimensional (1D) engine simulation and three-dimensional (3D) computational fluid dynamic analysis were used to predict the performance of a boosted uniflow 2-stroke DI gasoline engine. This was experimentally complemented by the in-cylinder flow and mixture formation measurements in a newly commissioned single cylinder uniflow 2-stroke DI gasoline engine. The 3D simulation was used to assess the effects of engine configurations for engine breathing performance and in order that the design of the intake ports could be optimised. The boundary conditions for 1D engine simulation were configured by the 3D simulation output parameters, was employed to predict the engine performance with different boost systems. The fuel consumption and full load performance data from the 1D engine simulation were then included in the vehicle driving cycle analysis so that the vehicle performance and fuel consumption over the NEDC could be obtained. Based on the modelling results, a single cylinder uniflow 2-stroke engine was commissioned by incorporating a newly designed intake block and modified intake and exhaust systems. In-cylinder flow and fuel distribution were then measured by means of Particle Image Velocimetry (PIV) and Planar Laser Induced Fluorescence (PLIF) in the single cylinder engine. The numerical analysis results suggested that a 0.6 litre two-cylinder boosted uniflow 2-stroke engine with an optimised boosting system was capable of delivering comparable performance to a NA 1.6 litre four-cylinder 4-stroke engine yet with a maximum 23.5% improvement potential on fuel economy. Furthermore, simulation results on in-cylinder flow structure and fuel distribution were then verified experimentally

Optimal air and fuel-path control of a diesel engine

The work reported in this thesis explores innovative control structures and controller design for a heavy duty Caterpillar C6.6 diesel engine. The aim of the work is not only to demonstrate the optimisation of engine performance in terms of fuel consumption, NOx and soot emissions, but also to explore ways to reduce lengthy calibration time and its associated high costs. The test engine is equipped with high pressure exhaust gas recirculation (EGR) and a variable geometry turbocharger (VGT). Consequently, there are two principal inputs in the air-path: EGR valve position and VGT vane position. The fuel injection system is common rail, with injectors electrically actuated and includes a multi-pulse injection mode. With two-pulse injection mode, there are as many as five control variables in the fuel-path needing to be adjusted for different engine operating conditions. [Continues.

14th International Conference on Turbochargers and Turbocharging

14th International Conference on Turbochargers and Turbocharging addresses current and novel turbocharging system choices and components with a renewed emphasis to address the challenges posed by emission regulations and market trends. The contributions focus on the development of air management solutions and waste heat recovery ideas to support thermal propulsion systems leading to high thermal efficiency and low exhaust emissions. These can be in the form of internal combustion engines or other propulsion technologies (eg. Fuel cell) in both direct drive and hybridised configuration. 14th International Conference on Turbochargers and Turbocharging also provides a particular focus on turbochargers, superchargers, waste heat recovery turbines and related air managements components in both electrical and mechanical forms

Experimental and Numerical Analysis of Ethanol Fueled HCCI Engine

Presently, the research on the homogeneous charge compression ignition (HCCI) engines has gained importance in the field of automotive power applications due to its superior efficiency and low emissions compared to the conventional internal combustion (IC) engines. In principle, the HCCI uses premixed lean homogeneous charge that auto-ignites volumetrically throughout the cylinder. The homogeneous mixture preparation is the main key to achieve high fuel economy and low exhaust emissions from the HCCI engines. In the recent past, different techniques to prepare homogeneous mixture have been explored. The major problem associated with the HCCI is to control the auto-ignition over wide range of engine operating conditions. The control strategies for the HCCI engines were also explored. This dissertation investigates the utilization of ethanol, a potential major contributor to the fuel economy of the future. Port fuel injection (PFI) strategy was used to prepare the homogeneous mixture external to the engine cylinder in a constant speed, single cylinder, four stroke air cooled engine which was operated on HCCI mode. Seven modules of work have been proposed and carried out in this research work to establish the results of using ethanol as a potential fuel in the HCCI engine. Ethanol has a low Cetane number and thus it cannot be auto-ignited easily. Therefore, intake air preheating was used to achieve auto-ignition temperatures. In the first module of work, the ethanol fueled HCCI engine was thermodynamically analysed to determine the operating domain. The minimum intake air temperature requirement to achieve auto-ignition and stable HCCI combustion was found to be 130 °C. Whereas, the knock limit of the engine limited the maximum intake air temperature of 170 °C. Therefore, the intake air temperature range was fixed between 130-170 °C for the ethanol fueled HCCI operation. In the second module of work, experiments were conducted with the variation of intake air temperature from 130-170 °C at a regular interval of 10 °C. It was found that, the increase in the intake air temperature advanced the combustion phase and decreased the exhaust gas temperature. At 170 °C, the maximum combustion efficiency and thermal efficiency were found to be 98.2% and 43% respectively. The NO emission and smoke emissionswere found to be below 11 ppm and 0.1% respectively throughout this study. From these results of high efficiency and low emissions from the HCCI engine, the following were determined using TOPSIS method. They are (i) choosing the best operating condition, and (ii) which input parameter has the greater influence on the HCCI output. In the third module of work, TOPSIS - a multi-criteria decision making technique was used to evaluate the optimum operating conditions. The optimal HCCI operating condition was found at 70% load and 170 °C charge temperature. The analysis of variance (ANOVA) test results revealed that, the charge temperature would be the most significant parameter followed by the engine load. The percentage contribution of charge temperature and load were63.04% and 27.89% respectively. In the fourth module of work, the GRNN algorithm was used to predict the output parameters of the HCCI engine. The network was trained, validated, and tested with the experimental data sets. Initially, the network was trained with the 60% of the experimental data sets. Further, the validation and testing of the network was done with each 20% data sets. The validation results predicted that, the output parameters those lie within 2% error. The results also showed that, the GRNN models would be advantageous for network simplicity and require less sparse data. The developed new tool efficiently predicted the relation between the input and output parameters. In the fifth module of work, the EGR was used to control the HCCI combustion. An optimum of 5% EGR was found to be optimum, further increase in the EGR caused increase in the hydrocarbon (HC) emissions. The maximum brake thermal efficiency of 45% was found for 170 °C charge temperature at 80% engine load. The NO emission and smoke emission were found to be below 10 ppm and 0.61% respectively. In the sixth module of work, a hybrid GRNN-PSO model was developed to optimize the ethanol-fueled HCCI engine based on the output performance and emission parameters. The GRNN network interpretive of the probability estimate such that it can predict the performance and emission parameters of HCCI engine within the range of input parameters. Since GRNN cannot optimize the solution, and hence swarm based adaptive mechanism was hybridized. A new fitness function was developed by considering the six engine output parameters. For the developed fitness function, constrained optimization criteria were implemented in four cases. The optimum HCCI engine operating conditions for the general criteria were found to be 170 °C charge temperature, 72% engine load, and 4% EGR. This model consumed about 60-75 ms for the HCCI engine optimization. In the last module of work, an external fuel vaporizer was used to prepare the ethanol fuel vapour and admitted into the HCCI engine. The maximum brake thermal efficiency of 46% was found for 170 °C charge temperature at 80% engine load. The NO emission and smoke emission were found to be below 5 ppm and 0.45% respectively. Overall, it is concluded that, the HCCI combustion of sole ethanol fuel is possible with the charge heating only. The high load limit of HCCI can be extended with ethanol fuel. High thermal efficiency and low emissions were possible with ethanol fueled HCCI to meet the current demand

Diesel Engine

Diesel engines, also known as CI engines, possess a wide field of applications as energy converters because of their higher efficiency. However, diesel engines are a major source of NOX and particulate matter (PM) emissions. Because of its importance, five chapters in this book have been devoted to the formulation and control of these pollutants. The world is currently experiencing an oil crisis. Gaseous fuels like natural gas, pure hydrogen gas, biomass-based and coke-based syngas can be considered as alternative fuels for diesel engines. Their combustion and exhaust emissions characteristics are described in this book. Reliable early detection of malfunction and failure of any parts in diesel engines can save the engine from failing completely and save high repair cost. Tools are discussed in this book to detect common failure modes of diesel engine that can detect early signs of failure

Design and investigation of a diesel engine operated on pilot ignited LPG

This thesis explores the idea of igniting LPG in a compression ignition diesel engine using pilot diesel injection as spark ignition medium. The main advancement in using this technology on current diesel engines is the establishment of a better balance between NOx and PM emissions without losing too much of the CO2 benefits of diesel. With the advent of common rail diesel engines, it is now possible to get control of pilot diesel injection and make the LPG and diesel control systems work together. Combined diesel and LPG operation is a new subject for engine research, so the thesis moves on to consider the results from detailed engine simulation studies that explore the potential benefits of the mix. Subsequent simulations of a modern four cylinder dCi engine suggest that with closer control over the pilot diesel injection, diesel like performance can be obtained, hopefully with less emissions than currently expected from diesel only operation. A single cylinder variable compression ratio research engine was developed to explore diesel /LPG dual fuel operation. A second generation common rail injection rig was also developed for the engine and for fuel spray characterisation. Engine experiments proved the concept of using a modest charge of pilot injected diesel for igniting a larger dose of port injected LPG. The experimental work results suggest that combining diesel common rail injection technology with the state of the art LPG injection systems, it is possible to establish a better balance between NOx/ PM emissions without losing too much of the CO2 benefits from the diesel operation

Real-time predictive model for reactivity controlled compression ignition marine engines

Model-based design is proven to be essential for the development of control systems. This paper presents a real-time predictive control-orientated model (COM) for low-temperature combustion (LTC), dual-fuel, reactivity-controlled compression ignition (RCCI) engines. A comprehensive model-based design methodology must be capable of constructing an RCCI control-orientated model with high accuracy, high noise immunity, good response, predictivity in governing mechanisms, and low computation time. This work attains all of these for the first time for a cutting-edge RCCI marine engine. The real-time model (RTM) captures the key sensitivities of RCCI by controlling the total fuel energy and the blend ratio (BR) of two fuels, while also considering uncertainties arising from variations of inlet temperature and the gas exchange process. It provides not only the cycle-wise combustion indicators but also the crank-angle-based cylinder pressure trend. The RTM is derived by direct linearisation of a physics-based model and is successfully validated against experimental results from a large-bore, RCCI engine and the previously acknowledged UVATZ (University of Vaasa Advanced Thermo-kinetic Multi-zone) model. Validation covers both steady-state and transient modes. With high accuracy in several case studies representing typical load transients and air-path disturbance rejection tests, the model predicts maximum cylinder pressure (Pmax), crank-angle of 5 % burnt (CA5), crank-angle of 50 % burnt (CA50) and indicated mean effective pressure (IMEP) with root means square (RMS) errors of 8.6 %, 0.3 %, 0.6 %, and 0.6 % respectively. The average simulation time without any code optimisation is around 5 ms/cycle, offering sufficient real-time surplus to incorporate a semi-predictive emission submodel within the current approach.© 2023 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).fi=vertaisarvioitu|en=peerReviewed

Powertrain Systems for Net-Zero Transport

The transport sector continues to shift towards alternative powertrains, particularly with the UK Government’s announcement to end the sale of petrol and diesel passenger cars by 2030 and increasing support for alternatives. Despite this announcement, the internal combustion continues to play a significant role both in the passenger car market through the use of hybrids and sustainable low carbon fuels, as well as a key role in other sectors such as heavy-duty vehicles and off-highway applications across the globe. Building on the industry-leading IC Engines conference, the 2021 Powertrain Systems for Net-Zero Transport conference (7-8 December 2021, London, UK) focussed on the internal combustion engine’s role in Net-Zero transport as well as covered developments in the wide range of propulsion systems available (electric, fuel cell, sustainable fuels etc) and their associated powertrains. To achieve the net-zero transport across the globe, the life-cycle analysis of future powertrain and energy was also discussed. Powertrain Systems for Net-Zero Transport provided a forum for engine, fuels, e-machine, fuel cell and powertrain experts to look closely at developments in powertrain technology required, to meet the demands of the net-zero future and global competition in all sectors of the road transportation, off-highway and stationary power industries

Comparative assessment and parametric optimisation of large marine two-stroke engines with exhaust gas recirculation and alternative turbocharging systems

Although the exhaust gas recirculation (EGR) technology has been proven effective to decrease the marine engine's nitrogen oxides (NOx) emissions, it is associated with a considerable fuel consumption increase and challenges to the engine−turbocharger matching. This study aims to parametrically optimise the EGR and turbocharging system settings of a large marine two-stroke engine with the objective of obtaining the highest engine efficiency whilst ensuring compliance with the prevailing NOx emissions limits. Two typical configurations of the investigated engine (baseline and alternative) are modelled in the GT-SUITE software. Parametric simulations are performed with EGR rates up to 40% along with cylinder bypass rates up to 50%, and the simulation results are analysed to quantify the impact of the engine operation with EGR on the performance and NOx emissions parameters. For the baseline engine configuration, the EGR rate increase considerably deteriorates the brake specific fuel consumption (BSFC), which is attenuated by opening the cylinder bypass valve. The optimal combinations of the EGR and cylinder bypass rates for each operating point are identified for both configurations. Following the comparative assessment between the two engine configurations, recommendations for the engine operating modes are proposed, leading to BSFC improvement in the region of 0.7 to 2.9 g/kWh. This study provides insights for the operational settings optimisation of two-stroke engines equipped with EGR systems, contributing towards the reduction of the associated environmental carbon footprint

Thermo-kinetic multi-zone modelling of low temperature combustion engines

Many researchers believe multi-zone (MZ), chemical kinetics–based models are proven, essential toolchains for development of low-temperature combustion (LTC) engines. However, such models are specific to the research groups that developed them and are not widely available on a commercial nor open-source basis. Consequently, their governing assumptions vary, resulting in differences in autonomy, accuracy and simulation speed, all of which affect their applicability. Knowledge of the models´ individual characteristics is scattered over the research groups´ publications, making it extremely difficult to see the bigger picture. This combination of disparities and dispersed information hinders the engine research community that wants to harness the capability of multi-zone modelling. This work aims to overcome these hurdles. It is a comprehensive review of over 120 works directly related to MZ modelling of LTC extended with an insight to primary sources covering individual submodels. It covers 16 distinctive modelling approaches, three different combustion concepts and over 60 different fuel/kinetic mechanism combination. Over 38 identified applications ranging from fundamental-level studies to control development. The work aims to provide sufficient detail of individual model design choices to facilitate creation of improved, more open multi-zone toolchains and inspire new applications. It also provides a high-level vision of how multi-zone models can evolve. The review identifies a state-of-the-art multi-zone model as an onion-skin model with 10–15 zones; phenomenological heat and mass transfer submodels with predictive in-cylinder turbulence; and semi-detailed reaction kinetics encapsulating 53-199 species. Together with submodels for heat loss, fuel injection and gas exchange, this modelling approach predicts in-cylinder pressure within cycle-to-cycle variation for a handful of combustion concepts, from homogeneous/premixed charge to reactivity-controlled compression ignition (HCCI, PCCI, RCCI). Single-core simulation time is around 30 minutes for implementations focused on accuracy: there are direct time-reduction strategies for control applications. Major tasks include a fast and predictive means to determine in-cylinder fuel stratification, and extending applicability and predictivity by coupling with commercial one-dimensional engine-modelling toolchains. There is also significant room for simulation speed-up by incorporating techniques such as tabulated chemistry and employing new solving algorithms that reduce cost of jacobian construction.© 2022 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).fi=vertaisarvioitu|en=peerReviewed