Model-based pre-ignition diagnostics in a race car application

Since 2014, Formula 1 engines have been turbocharged spark-ignited engines. In this scenario, the maximum engine power available in full-load conditions can be achieved only by optimizing combustion phasing within the cycle, i.e., by advancing the center of combustion until the limit established by the occurrence of abnormal combustion. High in-cylinder pressure peaks and the possible occurrence of knocking combustion significantly increase the heat transfer to the walls and might generate hot spots inside the combustion chamber. This work presents a methodology suitable to properly diagnose and control the occurrence of pre-ignition events that emanate from hot spots. The methodology is based on a control-oriented model of the ignition delay, which is compared to the actual ignition delay calculated from the real-time processing of the in-cylinder pressure trace. When the measured ignition delay becomes significantly smaller than that modeled, it means that ignition has been activated by a hot spot instead of the spark plug. In this case, the presented approach, implemented in the electronic control unit (ECU) that manages the whole hybrid power unit, detects a pre-ignition event and corrects the injection pattern to avoid the occurrence of further abnormal combustion

0-D Dynamic Performance Simulation of Hydrogen-Fueled Turboshaft Engine

In the last few decades, the problem of pollution resulting from human activities has pushed research toward zero or net-zero carbon solutions for transportation. The main objective of this paper is to perform a preliminary performance assessment of the use of hydrogen in conventional turbine engines for aeronautical applications. A 0-D dynamic model of the Allison 250 C-18 turboshaft engine was designed and validated using conventional aviation fuel (kerosene Jet A-1). A dedicated, experimental campaign covering the whole engine operating range was conducted to obtain the thermodynamic data for the main engine components: the compressor, lateral ducts, combustion chamber, high- and low-pressure turbines, and exhaust nozzle. A theoretical chemical combustion model based on the NASA-CEA database was used to account for the energy conversion process in the combustor and to obtain quantitative feedback from the model in terms of fuel consumption. Once the engine and the turbomachinery of the engine were characterized, the work focused on designing a 0-D dynamic engine model based on the engine’s characteristics and the experimental data using the MATLAB/Simulink environment, which is capable of replicating the real engine behavior. Then, the 0-D dynamic model was validated by the acquired data and used to predict the engine’s performance with a different throttle profile (close to realistic request profiles during flight). Finally, the 0-D dynamic engine model was used to predict the performance of the engine using hydrogen as the input of the theoretical combustion model. The outputs of simulations running conventional kerosene Jet A-1 and hydrogen using different throttle profiles were compared, showing up to a 64% reduction in fuel mass flow rate and a 3% increase in thermal efficiency using hydrogen in flight-like conditions. The results confirm the potential of hydrogen as a suitable alternative fuel for small turbine engines and aircraft

Development of a Control-Oriented Ignition Delay Model for GCI Combustion

Increasingly stringent pollutant emission limits and CO2 reduction policies are forcing the automotive industry toward cleaner and decarbonized mobility. The goal is to achieve carbon neutrality within 2050 and limit global warming to 2 degrees C (possibly 1.5 degrees C) with respect to pre-industrial levels as stated in both the European Green Deal and the Paris Agreement and further reiterated at the COP26. With the aim of simultaneously reducing both pollutants and CO2 emissions, a large amount of research is currently carried out on low-temperature highly efficient combustions (LTC). Among these advanced combustions, one of the most promising is Gasoline Compression Ignition (GCI), based on the spontaneous ignition of a gasoline-like fuel. Nevertheless, despite GCI proving to be effective in reducing both pollutants and CO2 emissions, GCI combustion controllability represents the main challenge that hinders the diffusion of this methodology for transportation. Several works in the literature demonstrated that to properly control GCI combustion, a multiple injections strategy is needed. The rise of pressure and temperature generated by the spontaneous ignition of small amounts of early-injected fuel reduces the ignition delay of the following main injection, responsible for the torque production of the engine. Since the combustion of the pre-injections is chemically driven, the ignition delay might be strongly affected by a slight variation in the engine control parameters and, consequently, lead to misfire or knocking. The goal of this work was to develop a control-oriented ignition delay model suitable to improve the GCI combustion stability through the proper management of the pilot injections. After a thorough analysis of the quantities affecting the ignition delay, this quantity was modeled as a function of both a thermodynamic and a chemical-physical index. The comparison between the measured and modeled ignition delay shows an accuracy compatible with the requirements for control purposes (the average root mean squared error between the measured and estimated start of combustion is close to 1.3 deg), over a wide range of operating conditions. As a result, the presented approach proved to be appropriate for the development of a model-based feed-forward contribution for a closed-loop combustion control strategy

CFD Methodology to Capture the Combustion Behavior of a Conventional Diesel Engine Retrofitted to Operate in Gasoline Compression Ignition Mode

The need for a cleaner and more efficient transportation sector emphasizes the development of new technologies aimed at the integrated reduction of pollutant emissions and increases in efficiency. Among these, promising technologies such as low-temperature combustion (LTC) systems operate in the field of the combustion physics, combining the attributes of both spark-ignited (SI) and compression-ignited (CI) engines. In particular, in a gasoline compression ignition (GCI) engine, gasoline is injected in closely spaced multiple pulses near the top dead center (TDC), creating a highly stratified charge which locally auto-ignites based on the thermodynamic conditions. In this work, a sectorial mesh of the combustion chamber was built. Initial and boundary conditions were set according to a one-dimensional model of the engine from a GT-suite platform. Then, a dedicated Matlab R2023b code was used to capture the effect of the pressure wave propagation on the shape of the fuel mass rate in closely spaced multiple injection events. Finally, a 3D-CFD code was validated comparing pressure trace, rate of heat release (RoHR) and emissions with experimental data provided by the test bench. The results highlight the robustness of the tabulated combustion model, which is able to capture the auto-ignition delay with a considerably low amount of computational time compared to common detailed kinetic solvers

Review of combustion indexes remote sensing applied to different combustion types

This paper summarizes the main studies carried out by the authors for the development of indexes for remote combustion sensing applicable to different combustion types, i.e. conventional gasoline and diesel combustions, diesel PCCI and dual fuel gasoline-diesel RCCI. It is well-known that the continuous development of modern Internal Combustion Engine (ICE) management systems is mainly aimed at complying with upcoming increasingly stringent regulations throughout the world, both for pollutants and CO2 emissions. Performing an efficient combustion control is crucial for efficiency increase and pollutant emissions reduction. Over the past years, the authors of this paper have developed several techniques to estimate the most important combustion indexes for combustion control, without using additional cylinder pressure sensors but only using the engine speed sensor (always available on board) and accelerometers (usually available on-board for gasoline engines). In addition, a low-cost sensor based on acoustic sensing can be integrated to support combustion indexes evaluation and other engine relevant information. The real-time calculation of combustion indexes is even more crucial for innovative Low Temperature Combustions (such as diesel PCCI or dual fuel gasoline-diesel RCCI), mainly due to the high instability and the high sensitivity to slight variations of the injection parameters that characterize this kind of combustions. Therefore, the authors of this paper have applied the developed techniques not only to conventional engines (gasoline and diesel combustion), but also to engines modified for Low Temperature Combustions, with promising results in terms of validation and applicability for real-time combustion control. The developed methodologies have been tested and validated through a large amount of experimental tests. To run the estimation algorithms in real-time, they have been all implemented in a specifically designed rapid control prototyping system, the goal being to quantify the accuracy of the estimations and optimize the strategy implementations for the extensive use (in the near future) in modern Engine Control Modules (ECM)

Zero-Dimensional Model for Dynamic Behavior of Engineered Rubber in Automotive Applications

Abstract This paper presents a zero-dimensional model for the simulation of the mechanical behavior of automotive engineered rubber components, such as flexible couplings. The objective is to develop a real-time-capable model, able to simulate the behavior of a driveline containing elastomer components: the engineered rubber model has to correlate stretch to stress, the mechanical behavior being represented by means of a hysteresis cycle. The study presents the implementation of Maxwell and Voigt models, showing their limits in the representation of the material behavior: elastomers present a nonlinear response in the relationship stress-strain. A combination of Maxwell and Voigt models, with stiffness and damping variable according to the stress and strain rate, to represent nonlinear material responses, is coupled to a relaxation model, in order to represent the Mullins effect (the rubber mechanical behavior also depends on load history). Experimental tests have been carried out with different pre-load settings, stress amplitudes and stress frequencies. Tests results have been used to calibrate the parameters defining the simulation model, comparing the model outputs to experimental data: an optimization algorithm has been applied, with the aim of minimizing the results discrepancy with respect to experimental results. The optimization tool has been also used to reduce the number of parameters defining the model, in order to simplify the required computational power, avoiding at the same time over-parametrization. In the second section of the paper, the model is used for the simulation of a different rubber component, whose behavior is identified using quasi-static load ramps, frequency and amplitude sweeps, steps and random cycles. An alternative model formulation, minimizing the degrees of freedom is then applied to the new dataset. The model parameters are separately optimized using different tests, in order to capture the specific mechanical behavior. Finally, the identified parameters are used to simulate the elastomer response in random tests, comparing the results to experimental data, to evaluate the simulation quality in terms of RMSE

Development and simulation of a 3D printed liquid oxygen/liquid natural gas aerospike

One of the most difficult aspects to solve, in the development of an aerospike engine, is the cooling of the throat and base regions. This issue is addressed nowadays by relying on new capabilities offered by additive manufacturing techniques together with novel powder materials, that allow to design complex shapes while keeping the prototyping cost low. The following work shows the design and manufacturing process of DemoP1, an aerospike engine demonstrator developed by Pangea Aerospace, that applies the new capabilities offered by additive manufacturing. To validate the development, the engine has been tested at the P8.2 test stand of the Germany Space Agency (Deutsches Zentrum für Luft-und Raumfahrt, DLR) in Lampoldshausen. Finally, a numerical strategy has been implemented and validated to simulate the engine flowfield, therefore obtaining relevant information that would be impractical to measure during tests, such as the pressure distribution along the plug and in the plume and the estimation of the heat flux on the throat and spike walls to be used to guide and validate the design process

Innovative torque-based control strategy for hydrogen internal combustion engine

Over the past years, several efforts have been made to reduce greenhouse gas emissions coming from the transport sector. Due to the highly efficient CO2-free combustion and low manufacturing costs, Hydrogen Internal Combustion engines (H2ICEs) are considered one of the most promising solutions for the future of medium and heavy duty vehicles. However, the combustion of an air-hydrogen mixture presents challenges related to the production of nitrogen oxides (NOx) and high knock tendency, mainly due to the chemical characteristics of the fuel. Although these problems can be mitigated by the use of a lean mixture, which is also useful to increase the combustion efficiency, the presence of excess air reduces exhaust temperatures and, consequently, the enthalpy content in the exhaust would be limited, leading to a reduced boosting capability. Therefore, a proper control of mixture preparation and combustion phasing is mandatory to limit NOx emissions, avoid abnormal combustions, and maximize efficiency without performance limitations. This paper focuses on the design of a dedicated control strategy for H2ICEs. Starting from a previously validated 1-D engine model operated with hydrogen, a 0-D Artificial Neural Network (ANN) - based engine model has been designed and calibrated. By using the obtained fast running ANN-based model, an innovative torquebased engine controller has been developed and both engine and controller models have been tested covering different torque profiles. The results show good accuracy within a range of +/- 5% on producing the requested torque by controlling the centre of combustion

Injection Pattern Investigation for Gasoline Partially Premixed Combustion Analysis

Nowadays, compression-ignited engines are considered the most efficient and reliable technology for automotive applications. However, mainly due to the current emission regulations, that require increasingly stringent reductions of NOx and particulate matter, the use of diesel-like fuels is becoming a critical issue. For this reason, a large amount of research and experimentation is being carried out to investigate innovative combustion techniques suitable to simultaneously mitigate the production of NOx and soot, while improving engine efficiency. In this scenario, the combined use of compression-ignited engines and gasoline-like fuels proved to be very promising, especially in case the fuel is directly-injected in the combustion chamber at high pressure. The presented study analyzes the combustion process produced by the direct injection of small amounts of gasoline in a compression-ignited light-duty engine. The engine under investigation has been modified to guarantee a stable engine operation over its whole operating range, that is achieved controlling boost pressure and temperature, together with the design of the injection pattern. Experimental tests have been performed to highlight the impact of several control variables on the combustion effectiveness, i.e. on combustion efficiency and ignition delay. To identify the main mechanisms which impact the start of the combustion process and the sensitivity to the variation of the main control parameters, several tests have been run, directly-injecting constant amounts of gasoline in a compression ignited engine. These tests have been performed changing intake pressure and temperature (when suitable to maintain combustion stability), fuel pressure and injection timing within the cycle

Investigation of Gasoline Partially Premixed Combustion with External Exhaust Gas Recirculation

The stringent emission regulations for Internal Combustion Engines (ICEs) spawned a great amount of research in the field of innovative combustion approaches characterized by high efficiency and low emissions. Previous research demonstrate that such promising techniques, named Low-Temperature Combustion (LTC), combine the benefits of Compression Ignition (CI) engines, such as high compression ratio and unthrottled lean mixture, with low engine-out emissions using a properly premixed air-fuel mixture. Due to longer ignition delay and high volatility compared to diesel, gasoline-like fuels show good potential for the generation of a highly premixed charge, which is needed to reach LTC characteristics. In this scenario, gasoline Partially Premixed Combustion (PPC), characterized by the high-pressure direct injection of gasoline, showed good potential for the simultaneous reduction of pollutants and emissions in CI engines. However, previous research on gasoline CI highlight that a key factor for the optimization of both efficiency and pollutants is the proper management of Exhaust Gas Recirculation (EGR). This work presents the experimental investigation performed running a light-duty CI engine, operated with gasoline PPC, and varying the mass of recirculated gases trapped in the combustion chamber. To guarantee the stability of gasoline autoignition in all the tested conditions, a specific experimental layout has been developed to accurately quantify the amount of trapped residual gases due to the internal and external EGR. The obtained results clearly highlight the impact of EGR on the combustion process and emissions, demonstrating that optimization of charge dilution with EGR is fundamental to guarantee the optimal compromise between efficiency and emissions over the whole operating range