Exhaust Emission Characteristics of Excavator With 6.0 Liter Diesel Engine in Real Work Conditions

The purpose of this study is evaluate emission characteristics, such as nitrogen oxides (NOx), hydrocarbon, carbon monoxide, and particulate matter (PM), of excavator with Tier-4f level diesel engine in the real work conditions. The test excavator has an engine power of 124 kW at an engine speed of 1800rpm, and it has various after-treatment devices, such as exhaust gas recirculation (EGR), selective catalytic reduction (SCR), and diesel oxidation catalyst (DOC), to reduce the engine-out emissions. The emissions including carbon monoxide (CO), carbon dioxides (CO2), and NOx, were measured by portable emission measurement system (PEMS). The PEMS device conducted a correlation analysis with the emission bench on the engine dynamometer before being used to measure the real-work to confirm the reliability of the equipment. The tests were carried out in four categories: idling, driving, excavations and flattening. It revealed that the average power output for each operation mode was higher in the order of flattening, excavation, and drive. On average, those are higher than that for the non-road transient cycle (NRTC) certification mode as 1.5 to 1.9 times. It may be determined that the power output is higher in conditions where there are more boom and bucket movements than the movement of the vehicle itself. In emission analysis, NOx and HC emission in driving mode are higher than other two modes: excavation and flattening. The real time NOx have been low in most test conditions, but large quantities of NOx have been released due to the deactivation of the SCR catalyst during cold start period or immediately after the non-working.

Predicting Cycle-to-Cycle Variation With Concurrent Cycles in a Gasoline Direct Injected Engine With Large Eddy Simulations

High cycle-to-cycle variation (CCV) is detrimental to engine performance, as it leads to poor combustion and high noise and vibration. In this work, CCV in a gasoline engine is studied using large eddy simulation (LES). The engine chosen as the basis of this work is a single-cylinder gasoline direct injection (GDI) research engine. Two stoichiometric part-load engine operating points (6 BMEP, 2000 RPM) were evaluated: a non-dilute (0% EGR) case and a dilute (18% EGR) case. The experimental data for both operating conditions had 500 cycles. The measured CCV in IMEP was 1.40% for the non-dilute case and 7.78% for the dilute case. To estimate CCV from simulation, perturbed concurrent cycles of engine simulations were compared to consecutively obtained engine cycles. The motivation behind this is that running consecutive cycles to estimate CCV is quite time-consuming. For example, running 100 consecutive cycles requires 2–3 months (on a typical cluster), however, by running concurrently one can potentially run all 100 cycles at the same time and reduce the overall turnaround time for 100 cycles to the time taken for a single cycle (2 days). The goal of this paper is to statistically determine if concurrent cycles, with a perturbation applied to each individual cycle at the start, can be representative of consecutively obtained cycles and accurately estimate CCV. 100 cycles were run for each case to obtain statistically valid results. The concurrent cycles began at different timings before the combustion event, with the motivation to identify the closest time before spark to minimize the run time. Only a single combustion cycle was run for each concurrent case. The calculated standard deviation of peak pressure and coefficient of variance (COV) of indicated mean effective pressure (IMEP) were compared between the consecutive and concurrent methods to quantify CCV. It was found that the concurrent method could be used to predict CCV with either a velocity or numerical perturbation. A large and small velocity perturbation were compared and both produced correct predictions, implying that the type of perturbation is not important to yield a valid realization. Starting the simulation too close to the combustion event, at intake valve close (IVC) or at spark timing, under-predicted the CCV. When concurrent simulations were initiated during or before the intake even, at start of injection (SOI) or earlier, distinct and valid realizations were obtained to accurately predict CCV for both operating points. By simulating CCV with concurrent cycles, the required wall clock time can be reduced from 2–3 months to 1–2 days. Additionally, the required core-hours can be reduced up to 41%, since only a portion of each cycle needs to be simulated.

Numerical Investigation on the Effect of Advanced Breakup Model on Spray Simulation of a Multi-Hole Injector

Computational fluid dynamics (CFD) plays a tremendous role in evaluating and visualizing the spray breakup, atomization and vaporization process. In this study, ANSYS Forte CFD tool was used to simulate the spray penetration length and spray morphology in a constant volume chamber at different grid size of a multi-hole injector. An unsteady gas jet model was coupled with Kelvin-Helmholtz (KH) and Rayleigh-Taylor (RT) model for multi-hole spray simulation. The effect of CFD cell size and ambient gas pressure on spray penetration length and spray morphology of fuel vapor mass fraction were investigated for both KH-RT and KH-RT with the unsteady gas jet model. It is found that KH-RT with the unsteady gas jet model shows mesh independent spray penetration length and spray morphology of fuel vapor mass fraction as compared to KH-RT model. This can be explained by the Lagrangian-Eulerian coupling of axial droplet-gas relative velocity is modeled on the principle of unsteady gas jet theory instead of discretizing very fine grid to the computational domain. This reduces the requirement of fine mesh near the nozzle and allows larger time step during spray injection. It is also observed that at higher ambient gas pressure, an aerodynamic force between the droplet and gas intensifies which reduces the overall spray penetration length and fuel vapor mass. The distorted spray morphology of fuel vapor mass fraction was accurately predicted at high ambient gas pressure using the KH-RT with an unsteady gas jet model which results in mesh independent drag predictions. The use of advanced spray model results in the mesh size dependency reduction and accurate drag prediction with less computational time and faster accurate solutions over all conventional spray breakup models.

Numerical Simulation of Ignition Mechanism in the Main Chamber of Turbulent Jet Ignition System

The ignition mechanism of a lean premixed CHVair mixture by a hot turbulent jet issued from the pre-chamber combustion is investigated using 3D combustion CFD. The turbulent jet ignition experiments conducted in the rapid compression machine (RCM) at Michigan State University (MSU) were simulated. A full simulation was carried out first using RANS model for validation, the results of which were then taken as the boundary condition for the detailed simulations using both RANS and LES. To isolate the thermal and chemical kinetic effects from the hot jet, two different inlet conditions of the chamber were considered: inert case (including thermal effects only) and reactive case (accounting for both thermal and chemical kinetic effects). It is found that the chemical kinetic effects are important for the ignition in the main chamber. Comparison of OH and HRR (heat release rate) computed by RANS and LES shows that RANS predicts slightly faster combustion, which implies higher predicted turbulent flame speed. Correlations between vorticity, mixing field, and temperature field are observed, which indicate that the flow dynamics strongly influence the mixing process near the flame front, and consequently affect flame propagation.

A Signal Processing of In-Cylinder Pressure for the Resonant Frequency Prediction of Combustion Process in Diesel Engines

The combustion resonance is a focal point of the analysis of combustion and thermodynamic processes in diesel engines, such as detecting ‘knock’ and predicting combustion noise. Combustion resonant frequency is also significant for the estimation of in-cylinder bulk gas temperature and trapped mass. Normally, the resonant frequency information is contained in in-cylinder pressure signals. Therefore, the in-cylinder pressure signal processing is used for resonant frequency calculation. Conventional spectral analyses, such as FFT (Fast Fourier transform), are unsuitable for processing in-cylinder pressure signals because of its non-stationary characteristic. Other approaches to deal with non-stationary signals are Short-Time Fourier Transform (STFT) and Continue Wavelet Transform (CWT). However, the choice of size and shape of window for STFT and the selection of wavelet basis for CWT are totally empirical, which is the limit for precisely calculating the resonant frequency. In this study, an approach based on Empirical Wavelet Transform (EWT) and Hilbert Transform (HT) is proposed to process in-cylinder pressure signals and extract resonant frequencies. In order to decompose in-cylinder pressure spectrum precisely, the EWT are applied for separating the frequency band corresponding combustion resonance mode from other irrelevant modes adaptively. The signals containing combustion resonant mode is processed by HT, so that the instantaneous resonant frequency and amplitude can be extracted. Validation is performed by four in-cylinder pressure signals with different injection timing. And the effects of injection timing on resonant frequency are discussed.

Direct Simultaneous Measurement of Particulate Matter and Ammonia Storage on Combined Selective Catalytic Reduction Filter Systems Using Radio Frequency Sensors

Tightening global emissions regulations are motivating interest in the development and implementation of Selective Catalytic Reduction + Filtration (SCRF) systems, which are designed to reduce the concentration of tailpipe particulate matter (PM) and NOx emissions. These systems allow designers to combine the NOx reduction capability of an SCR with the filtration capability of a particulate filter on a single unit. Practical implementation of these systems requires reliable measurement and diagnosis of their state — both with respect to trapped particulate matter as well as adsorbed ammonia. Currently, these systems rely on a variety of gas sensors, mounted upstream or downstream of the system, that only provide an indirect inference of the operation state. In this study, a single radio frequency (RF) sensor was used to perform simultaneous measurements of soot loading and ammonia inventory on an SCRF. Several SCRF core samples were tested at varying soot and ash loads in a catalyst reactor bench. Soot levels were measured by monitoring changes in the bulk dielectric properties within the catalyst using the sensor, while ammonia levels were determined by feeding selected regions of the RF spectrum into a pretrained generalized regression neural network model. Results show the RF sensor is able to directly measure the instantaneous ammonia inventory, while simultaneously providing soot loading measurements within 0.5 g/L. These results confirm that simultaneous measurements of both the PM and ammonia loading state of an SCRF are possible using a single RF sensor via analysis of specific features in the full RF spectrum. The results indicate significant potential to remove the control barriers typically associated with the implementation of advanced SCRF systems.

Heat Release Experimental Analysis for RCCI Combustion Optimization

Over the past years, the increasingly stringent emission regulations for Internal Combustion Engines (ICE) spawned a great amount of research in the field of combustion control optimization. Nowadays, optimal combustion control has become crucial, especially to properly manage innovative Low Temperature Combustion (LTC) strategies, usually characterized by high instability, cycle-to-cycle variability and sensitivity to slight variations of injection parameters and thermal conditions. Many works demonstrate that stability and maximum efficiency of LTC strategies can be guaranteed using closed-loop control strategies that vary the standard injection parameters (mapped during the base calibration activity) to keep engine torque and center of combustion (CA50) approximately equal to their target values. However, the combination of standard base calibration and closed-loop control is usually not sufficient to accurately control Low Temperature Combustions in transient conditions. As a matter of fact, to properly manage LTC strategies in transient conditions it is usually necessary to investigate the combustion methodology of interest and implement specific functions that provide an accurate feed-forward contribution to the closed-loop controller. This work presents the experimental analysis performed running a light-duty compression ignited engine in dual-fuel RCCI mode, the goal being to highlight the way injection parameters and charge temperature affect combustion stability and ignition delay. Finally, the paper describes how the obtained results can be used to define the optimal injections strategy in the analyzed operating points, i.e. the combination of injection parameters to be used as a feed-forward for a closed-loop combustion control strategy.

Powertrain Resilient Mounting Design Analysis

For efficient modeling of engine (or powertrain) supported by non-linear elastic mounts, a special methodology has been elaborated. Based on it, software tool has been developed to analyze the motion of rigid body and elastic mounts, which comprises of three modules: • Non-linear static analysis; • Modal analysis (undamped and damped); • Forced response (in frequency domain). Application example of a large V12 marine engine illustrates the suggested workflow. The results are verified against other software tools and validated by measurements.

Impact of a Holistic Turbocharger Model in the Prediction of Engines Performance in Transient Operation and in Steady State With LP-EGR

Turbocharged engines are the standard powertrain type of internal combustion engines for both spark ignition and compression ignition concepts. Turbochargers modeling traditionally rely in look up tables based on turbocharger manufacturer provided maps. These maps as the only secure source of information. They are used both for the matching between reciprocating engine and the turbocharger and for the further engine optimization and performance analysis. In the last years have become evident that only these maps are not being useful for detailed calculation of variables like after-treatment inlet temperature (turbine outlet), intercooler inlet temperature (compressor outlet) and engine BSFC at low loads. This paper shows a comprehensive study that quantifies the errors of using just look up tables compared with a model that accounts for friction losses, heat transfer and gas-dynamics in a turbocharger and in a conjugated way. The study is based in an Euro 5 engine operating in load transient conditions and using a LP-EGR circuit during steady state operation.

Spray Evaporative Cooling System Design for Automotive Internal Combustion Engines

IC engine spray evaporative cooling system design is discussed starting with a review of existing evaporative cooling systems that automotive applications are required to address. A component-level system design is proposed culminating in a simulation model of a PID strategy used to control transient gasside metal temperatures with varying engine load. The model combines a spray evaporation correlation model with 1D finite-difference equations to model the transient heat transfer through a 7 mm thick metal slab which represents the wall of a cylinderhead. Based on the simulation results, the particular changes required of existing engine cooling jacket designs are discussed.