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For modern, light-duty engine applications, the development of improved operating strategies to expedite catalyst heating during cold-start operation is essential for further reduction of emissions and meeting of future regulations. The development of such strategies would benefit from numerical modeling tools capable of accurate prediction of charge preparation, combustion, and emissions formation at cold-start conditions. Traditional development of simulation tools has primarily focused on standard engine operating conditions, and, as a result, these tools have difficulty accurately capturing extreme behavior during cold-start operation such as extensive wall wetting due to fuel-spray impingement on cold cylinder surfaces, late combustion phasing to increase exhaust enthalpy, and continued oxidation of reactants in the exhaust system. A major objective of the multi-national-laboratory Partnership to Advance Combustion Engines (PACE) consortium is the development and evaluation of new modeling approaches for cold-start operation. In this paper, we present recent progress in simulating charge preparation in a light-duty, multi-cylinder, gasoline engine during cold-start relevant conditions as defined by the U.S. DRIVE Advanced Combustion and Emission Control (ACEC) Tech Team cold-start protocols for catalyst heating. We focus study on fuel spray and spray-wall interactions resulting in extensive film formation due to cold cylinder walls. Simulation results are evaluated at steady-state, cold-start relevant operating conditions. Predictions for film formation and composition with conventional (baseline) models are compared to results with new simulation tools and approaches developed under PACE including the Corrective Distortion Spray Model developed by Sandia National Laboratories, which accounts for non-spherical droplet shapes, and a new spray-wall interaction model developed by Argonne National Laboratory, which accounts for multi-droplet, non-uniform impingement. The current study expands on past studies validating these new submodels with spray-chamber experimental measurements to examine the impact they have on full engine CFD simulations.

In support of the Daimler SuperTruck I team’s 55% brake thermal efficiency (BTE) pathway goal, researchers at Oak Ridge National Laboratory performed an experimental investigation of the potential efficiency and emissions benefits of dual-fuel advanced combustion approaches on a modified heavy-duty 15-L Detroit™ DD15 engine. For this work, a natural gas port fuel injection system with an independent injection control for each cylinder was added to the DD15 engine. For the dual-fuel strategies investigated, 65%–90% of the total fuel energy was supplied through the added port fuel injection natural gas (NG) fueling system. The remaining fuel energy was supplied by one or more direct injections of diesel fuel using the production high pressure diesel fueling system. The production DD15 air handling system and combustion geometry were unmodified for this study. Efficiency and emissions with dual-fuel strategies including both low temperature combustion (LTC) and non-LTC approaches such as dual fuel direct-injection were investigated along with control authority over combustion phasing. Parametric studies of dual-fuel NG/diesel advanced combustion were conducted in order to experimentally investigate the potential of high-efficiency, dual-fuel combustion strategies to improve BTE in a multi-cylinder engine, understand the potential reductions in engine-out emissions, and characterize the range of combustion phasing controllability. Characterization of mode transitions from mixing-controlled diesel pilot ignition to kinetically controlled ignition is presented. Key findings from this study included a reproducible demonstration of BTE approaching 48% at up to a 13-bar brake mean effective pressure with significant reductions in engine-out NOx and soot emissions. Additional results from investigating load transients in dual-fuel mode and initial characterization of particle size distribution during dual-fuel operation are presented.

This work describes the development of a transported Livengood–Wu (L–W) integral model for computational fluid dynamics (CFD) simulation to predict autoignition and engine knock tendency. The currently employed L–W integral model considers both single-stage and two-stage ignition processes, thus can be generally applied to different fuels such as paraffin, olefin, aromatics, and alcohol. The model implementation is first validated in simulations of homogeneous charge compression ignition (HCCI) combustion for three different fuels, showing good accuracy in prediction of autoignition timing for fuels with either single-stage or two-stage ignition characteristics. Then, the L–W integral model is coupled with G-equation model to indicate end-gas autoignition and knock tendency in CFD simulations of a direct-injection spark-ignition engine. This modeling approach is about 10 times more efficient than the ones that based on detailed chemistry calculation and pressure oscillation analysis. Two fuels with same Research Octane Number (RON) but different octane sensitivity are studied, namely, Co-Optima alkylate and Co-Optima E30. Feed-forward neural network model in conjunction with multivariable minimization technique is used to generate fuel surrogates with targets of matched RON, octane sensitivity, and ethanol content. The CFD model is validated against experimental data in terms of pressure traces and heat release rate for both fuels under a wide range of operating conditions. The knock tendency—indicated by the fuel energy contained in the autoignited region—of the two fuels at different load conditions correlates well with the experimental results and the fuel octane sensitivity, implying the current knock modeling approach can capture the octane sensitivity effect and can be applied to further investigation on composition of octane sensitivity.

This work describes the development of a transported Livengood-Wu (L-W) integral model for computational fluid dynamics (CFD) simulation to predict auto-ignition and engine knock tendency. The currently employed L-W integral model considers both single-stage and two-stage ignition processes, thus can be generally applied to different fuels such as paraffin, olefin, aromatics and alcohol. The model implementation is first validated in simulations of homogeneous charge compression ignition combustion for three different fuels, showing good accuracy in prediction of auto-ignition timing for fuels with either single-stage or two-stage ignition characteristics. Then, the L-W integral model is coupled with G-equation model to indicate end-gas auto-ignition and knock tendency in CFD simulations of a direct-injection spark-ignition engine. This modeling approach is about 10 times more efficient than the ones that based on detailed chemistry calculation and pressure oscillation analysis. Two fuels with same Research Octane Number (RON) but different octane sensitivity are studied, namely Co-Optima Alkylate and Co-Optima E30. Feed-forward neural network model in conjunction with multi-variable minimization technique is used to generate fuel surrogates with targets of matched RON, octane sensitivity and ethanol content. The CFD model is validated against experimental data in terms of pressure traces and heat release rate for both fuels under a wide range of operating conditions. The knock tendency — indicated by the fuel energy contained in the auto-ignited region — of the two fuels at different load conditions correlates well with the experimental results and the fuel octane sensitivity, implying the current knock modeling approach can capture the octane sensitivity effect and can be applied to further investigation on composition of octane sensitivity.

With the effort to use alternative refrigerants with lower global warming potential (GWP), the majority of these alternative refrigerants are classified as slightly flammable. In this paper we report on the numerical evaluation of a catastrophic leak scenario of R-32 refrigerant from a 3-ton roof top air conditioning unit (RTU) which serves a 12.2 × 9.14 × 2.4 m room. A full rupture of a 6.35 mm (¼ inch) pipe downstream of the evaporator coil is simulated. Two separate cases with refrigerant releases of 1.81 kg and 3.62 kg charge have been studied. The two charges are released in 10.2 and 20.4 s, respectively, just after the end of a unit cooling cycle. The flammable volume inside the room existed only for about 40 s with a maximum flammable volume inside the room of 1.12% of the total room volume for the 3.62 kg charge case.

Engine knock remains one of the major barriers to further improve the thermal efficiency of spark-ignition (SI) engines. SI engine is usually operated at knock-limited spark advance (KLSA) to achieve possibly maximum efficiency with given engine hardware and fuel properties. Co-optimization of fuels and engines is promising to improve engine efficiency, and predictive computational fluid dynamics (CFD) models can be used to facilitate this process. However, cyclic variability of SI engine demands that multicycle results are required to capture the extreme conditions. In addition, Mach Courant–Friedrichs–Lewy (CFL) number of 1 is desired to accurately predict the knock intensity (KI), resulting in unaffordable computational cost. In this study, a new approach to numerically predict KLSA using large Mach CFL of 50 with ten consecutive cycle simulation is proposed. This approach is validated against the experimental data for a boosted SI engine at multiple loads and spark timings with good agreements in terms of cylinder pressure, combustion phasing, and cyclic variation. Engine knock is predicted with early spark timing, indicated by significant pressure oscillation and end-gas heat release. Maximum amplitude of pressure oscillation analysis is performed to quantify the KI, and the slope change point in KI extrema is used to indicate the KLSA accurately. Using a smaller Mach CFL number of 5 also results in the same conclusions, thus demonstrating that this approach is insensitive to the Mach CFL number. The use of large Mach CFL number allows us to achieve fast turn-around time for multicycle engine CFD simulations.

To meet the demand for greater fuel efficiency in passenger vehicles, various strategies are employed to increase the power density of light-duty SI engines, with attendant thermal or system efficiency increases. One approach is to incorporate higher-performance alloys for critical engine components. These alloys can have advantageous thermal or mechanical properties at higher temperatures, allowing for components constructed from these materials to meet more severe pressure and temperature demands, while maintaining durability. Advanced alloys could reduce the need for charge enrichment to protect certain gas-path components at high speed and load conditions, permit more selective cooling to reduce heat-transfer losses, and allow engine downsizing, while maintaining performance, by achieving higher cylinder temperatures and pressures. As a first step in investigating downsizing strategies made possible through high-performance alloys, a GT-Power model of a 4-cylinder 1.6L turbocharged direct-injection SI engine was developed. The model was tuned and validated against experimental dynamometer data collected from a corresponding engine. The model was then used to investigate various operating strategies for increasing power density. Results from these investigations will provide valuable insight into how new materials might be utilized to meet the needs of future light-duty engines and will serve as the basis for a more comprehensive investigation using more-detailed thermo-mechanical modeling.

Engine knock remains one of the major barriers to further improve thermal efficiency of Spark Ignition (SI) engines. Knock can be suppressed by lowering the compression ratio, or retarding the spark ignition timing, however, at an expense of efficiency penalty. SI engine is usually operated at knock-limited spark advance (KLSA) to achieve possibly maximum efficiency with given engine hardware and fuel properties, such as Research Octane Number (RON), Motor Octane Number (MON), and heat of vaporization, etc. Co-optimization of engine design and fuel properties is promising to improve the engine efficiency and predictive CFD models can be used to facilitate this optimization process. However, difficulties exist in predicting KLSA in CFD simulations. First, cyclic variability of SI engine demands that multi-cycle results are required to capture the extreme conditions. Secondly, Mach Courant-Friedrichs-Lewy (CFL) number of 1 is desired to accurately predict the knock intensity (KI), resulting in unaffordable computational cost, especially for multi-cycle simulations. In this study, a new approach to numerically predict KLSA using large Mach CFL number of 50 is proposed. This approach is validated against experimental data for a boosted Direct Injection Spark Ignition (DISI) engine at multiple loads and spark timings. G-equation combustion model coupled with well-mixed chemical kinetic model are used to predict the turbulent flame propagation and end-gas auto-ignition, respectively. Simulations run for 10 consecutive engine cycles at each condition. The results show good agreement between model predictions and experiments in terms of cylinder pressure, combustion phasing and cyclic variation. Engine knock is predicted with early spark ignition timing, indicated by significant pressure wave oscillation and end-gas heat release. Maximum Amplitude of Pressure Oscillation (MAPO) analysis is performed to quantify the KI, and the slope change point in KI extrema is used to indicate the KLSA accurately. Using a smaller Mach CFL number of 5 also results in the same conclusions thus demonstrating that this approach is insensitive to the Mach CFL number. The use of large Mach CFL number allows us to achieve fast turn-around time for multi-cycle engine CFD simulations.

Pinnacle is developing a multicylinder 1.2 L gasoline engine for automotive applications using high-performance computing (HPC) and analysis methods. Pinnacle and Oak Ridge National Laboratory executed large-scale multidimensional combustion analyses at the Oak Ridge Leadership Computing Facility to thoroughly explore the design space. These HPC-led investigations show high fuel efficiency (∼46% gross indicated efficiency) may be achieved by operating with extremely high charge dilution levels of exhaust gas recirculation (EGR) at a light load key drive cycle condition (2000 RPM, 3 bar brake mean effective pressure (BMEP)), while simultaneously attaining high levels of fuel conversion efficiency and low NOx emissions. In this extremely dilute environment, the flame propagation event is supported by turbulence and bulk in-cylinder charge motion brought about by modulation of inlet port flow. This arrangement produces a load and speed adjustable amalgamation of swirl and counter-rotating tumble which provides the turbulence required to support stable low-temperature combustion. At higher load conditions, the engine may operate at more traditional combustion modes to generate competitive power. In this paper, the numerical results from these HPC simulations are presented. Further HPC simulations and test validations are underway and will be reported in future publications.

The prospect of analysis-driven precalibration of a modern diesel engine is extremely valuable in order to significantly reduce hardware investments and accelerate engine designs compliant with stricter fuel economy regulations. Advanced modeling tools, such as CFD, are often used with the goal of streamlining significant portions of the calibration process. The success of the methodology largely relies on the accuracy of analytical predictions, especially engine-out emissions. However, the effectiveness of CFD simulation tools for in-cylinder engine combustion is often compromised by the complexity, accuracy, and computational overhead of detailed chemical kinetics necessary for combustion calculations. The standard approach has been to use skeletal kinetic mechanisms (∼50 species), which consume acceptable computational time but with degraded accuracy. In this work, a comprehensive demonstration and validation of the analytical precalibration process is presented for a passenger car diesel engine using CFD simulations and a graphical processing unit (GPU)-based chemical kinetics solver (Zero-RK, developed at Lawrence Livermore National Laboratory, Livermore, CA) on high performance computing resources to enable the use of detailed kinetic mechanisms. Diesel engine combustion computations have been conducted over 600 operating points spanning in-vehicle speed-load map, using massively parallel ensemble simulation sets on the Titan supercomputer located at the Oak Ridge Leadership Computing Facility. The results with different mesh resolutions have been analyzed to compare differences in combustion and emissions (NOx, carbon monoxide CO, unburned hydrocarbons (UHC), and smoke) with actual engine measurements. The results show improved agreement in combustion and NOx predictions with a large n-heptane mechanism consisting of 144 species and 900 reactions with refined mesh resolution; however, agreement in CO, UHC, and smoke remains a challenge.

We present fuel savings estimates resulting from the combined implementation of multiple advanced energy management technologies in both conventional and parallel hybrid Class 8 diesel trucks. The energy management technologies considered here have been specifically targeted by the 21st Century Truck Partnership (21 CTP) between the U.S. Department of Energy and U.S. industry and include advanced combustion engines, waste heat recovery, and reductions in auxiliary loads, rolling resistance, aerodynamic drag, and gross vehicle weight. We estimate that combined use of all these technologies in hybrid trucks has the potential to improve fuel economy by more than 60% compared to current conventional trucks, but this requires careful system integration to avoid non-optimal interactions. Major factors to be considered in system integration are discussed.

Results from computational simulations of fuel economy and engine-out emissions are presented for light-duty conventional and hybrid vehicles powered by conventional and high-efficiency combustion engines, including use of port fuel-injected, lean gasoline direct injection, reactivity controlled compression ignition, and conventional diesel combustion. The results indicate that multimode operation with conventional diesel combustion plus reactivity controlled compression ignition, conventional diesel combustion only, and lean gasoline direct injection has the potential to significantly exceed port fuel-injected fuel economy. In all cases, hybridization is predicted to significantly improve fuel economy by permitting the maximum exploitation of high efficiency engine combustion states. Predicted engine-out emissions vary considerably with combustion mode, with reactivity controlled compression ignition generating the highest carbon monoxide and hydrocarbon emissions. On the other hand, reactivity controlled compression ignition is predicted to generate the lowest emissions of nitrogen oxides. Importantly, lean gasoline direct injection and reactivity controlled compression ignition combustion modes are expected to dramatically decrease exhaust temperatures, especially for reactivity controlled compression ignition, which can potentially limit aftertreatment performance. While all results presented are from simulations, the results provide prediction of important details and trends for advanced vehicles that are currently extremely difficult to experimentally study.

We review developments in the understanding of cycle–to–cycle variability in internal combustion engines, with a focus on spark-ignited and premixed combustion conditions. Much of the research on cyclic variability has focused on stochastic aspects, that is, features that can be modeled as inherently random with no short–term predictability. In some cases, models of this type appear to work very well at describing experimental observations, but the lack of predictability limits control options. Also, even when the statistical properties of the stochastic variations are known, it can be very difficult to discern their underlying physical causes and thus mitigate them. Some recent studies have demonstrated that under some conditions, cyclic combustion variations can have a relatively high degree of low–dimensional deterministic structure, which implies some degree of predictability and potential for real–time control. These deterministic effects are typically more pronounced near critical stability limits (e.g. near tipping points associated with ignition or flame propagation) such during highly dilute fueling or near the onset of homogeneous charge compression ignition. We review recent progress in experimental and analytical characterization of cyclic variability where low–dimensional, deterministic effects have been observed. We describe some theories about the sources of these dynamical features and discuss prospects for interactive control and improved engine designs. Taken as a whole, the research summarized here implies that the deterministic component of cyclic variability will become a pivotal issue (and potential opportunity) as engine manufacturers strive to meet aggressive emissions and fuel economy regulations in the coming decades.

This work presents a modeling approach for multidimensional combustion simulations of a highly dilute opposed-piston spark-ignited gasoline engine. Detailed chemical kinetics is used to model combustion with no sub-grid correction for reaction rates based on the turbulent fluctuations of temperature and species mass fractions. Turbulence is modeled using RNG k-ε model and the RANS-length scales resolution is done efficiently by the use of automatic mesh refinement when and where the flow parameter curvature (2nd derivative) is large. The laminar flame is thickened by the RANS viscosity and a constant turbulent Schmidt (Sc) number and a refined mesh (sufficient to resolve the thickened turbulent flame) is used to get accurate predictions of turbulent flame speeds. An accurate chemical kinetics mechanism is required to model flame kinetics and fuel burn rates under the conditions of interest. For practical computational fluid dynamics applications, use of large detailed chemistry mechanisms with 1000s of species is both costly as well as memory intensive. For this reason, skeletal mechanisms with a lower number of species (typically ∼100) reduced under specific operating conditions are often used. In this work, a new primary reference fuel chemical mechanism is developed to better correlate with the laminar flame speed data, relevant for highly dilute engine conditions. Simulations are carried out in a dilute gasoline engine with opposed piston architecture, and results are presented here across various dilution conditions.

Pinnacle is developing multi-cylinder 1.2 L gasoline engine for automotive applications using high performance computing (HPC) and analysis methods. Pinnacle and Oak Ridge National Laboratory executed large-scale multi-dimensional combustion analyses at the Oak Ridge Leadership Computing Facility to thoroughly explore the design space. These HPC-led investigations show high fuel efficiency (∼46% gross indicated efficiency) may be achieved by operating with extremely high charge dilution levels of exhaust gas recirculation (EGR) at a light load key drive cycle condition (2000 RPM, 3 bar BMEP), while simultaneously attaining high levels of fuel conversion efficiency and low NOx emissions. In this extremely dilute environment, the flame propagation event is supported by turbulence and bulk in-cylinder charge motion brought about by modulation of inlet port flow. This arrangement produces a load and speed adjustable amalgamation of swirl and counter-rotating tumble which provides the turbulence required to support stable low-temperature combustion (LTC). At higher load conditions, the engine may operate at more traditional combustion modes to generate competitive power. In this paper, the numerical results from these HPC simulations are presented. Further HPC simulations and test validations are underway and will be reported in future publications.

The prospect of analysis-driven pre-calibration of a modern diesel engine is extremely valuable in order to significantly reduce hardware investments and accelerate engine designs compliant with stricter EPA fuel economy regulations. Advanced modeling tools, such as CFD, are often used with the goal of streamlining significant portions of the calibration process. The success of the methodology largely relies on the accuracy of analytical predictions, especially engine-out emissions. However, the effectiveness of CFD simulation tools for in-cylinder engine combustion is often compromised by the complexity, accuracy, and computational overhead of detailed chemical kinetics necessary for combustion calculations. The standard approach has been to use skeletal kinetic mechanisms (∼50 species) which consume acceptable computational time but with degraded accuracy. In this work, a comprehensive demonstration and validation of the analytical pre-calibration process is presented for a passenger car diesel engine using CFD simulations with CONVERGE™ and a GPU-based chemical kinetics solver (Zero-RK, developed at Lawrence Livermore National Laboratory) on high performance computing resources to enable the use of detailed kinetic mechanisms. Diesel engine combustion computations have been conducted over 600 operating points spanning in-vehicle speed-load map, using massively parallel ensemble simulation sets on the Titan supercomputer located at the Oak Ridge Leadership Computing Facility. The results with different mesh resolutions have been analyzed to compare differences in combustion and emissions (NOx, Carbon Monoxide CO, Unburned Hydrocarbons UHC, and Smoke) with actual engine measurements. The results show improved agreement in combustion and NOx predictions with a large n-heptane mechanism consisting of 144 species and 900 reactions with refined mesh resolution; however; agreement in CO, UHC and Smoke remain a challenge.

We compare simulated fuel economy and emissions for both conventional and hybrid class 8 heavy-duty diesel trucks operating over multiple urban and highway driving cycles. Both light and heavy freight loads were considered, and all simulations included full aftertreatment for NOx and particulate emissions controls. The aftertreatment components included a diesel oxidation catalyst (DOC), urea-selective catalytic NOx reduction (SCR), and a catalyzed diesel particulate filter (DPF). Our simulated hybrid powertrain was configured with a pre-transmission parallel drive, with a single electric motor between the clutch and gearbox. A conventional HD truck with equivalent diesel engine and aftertreatment was also simulated for comparison. Our results indicate that hybridization can significantly increase HD fuel economy and improve emissions control in city driving. However, there is less potential hybridization benefit for HD highway driving. A major factor behind the reduced hybridization benefit for highway driving is that there are fewer opportunities to utilize regenerative breaking. Our aftertreatment simulations indicate that opportunities for passive DPF regeneration are much greater for both hybrid and conventional trucks during highway driving due to higher sustained exhaust temperatures. When passive DPF regeneration is extensively utilized, the fuel penalty for particulate control is virtually eliminated, except for the 0.4%-0.9%more » fuel penalty associated with the slightly higher exhaust backpressure.« less

We report results from urban drive cycle simulations of a light-duty conventional vehicle and a similar hybrid electric vehicle, both of which are equipped with diesel engines capable of operating in either conventional diesel combustion mode or in premixed charge compression ignition mode. Both simulated vehicles include lean exhaust after-treatment trains for controlling hydrocarbon, carbon monoxide, nitrogen oxide, and particulate matter emissions. Our results indicate that, in the simulated conventional vehicle, premixed charge compression ignition can significantly reduce fuel consumption and emissions by reducing the need for lean nitrogen oxide traps and diesel particulate filter regeneration. However, the opportunity for utilizing premixed charge compression ignition in the simulated hybrid electric vehicle is limited because the engine typically experiences higher loads and multiple stop–start transients that are outside the allowable premixed charge compression ignition operating range. This suggests that developing ways of extending the premixed charge compression ignition operating range combined with improved control strategies for engine and emissions control management will be especially important for realizing the potential benefits of premixed charge compression ignition in hybrid electric vehicles.

A heuristic algorithm based on a double Wiebe function is proposed for estimating the relative importance of distinct combustion modes (propagating flame and compression ignition) occurring within individual combustion cycles as an engine is transitioned from conventional spark-ignited (SI) combustion to homogeneous charge compression ignition (HCCI). The proposed algorithm automates the analysis and categorization of pressure measurements from large numbers of individual cycles, providing new insight into the unstable combustion processes occurring during mode transition. Similar techniques could potentially be utilized for on-line diagnostics and control of the balance between SI and HCCI combustion in spark-assisted HCCI.

We describe experimental observations of the gradual transition between conventional spark-ignited (SI) propagating flame combustion and homogeneous charge compression ignition (HCCI) in a singlecylinder, stoichiometrically fueled gasoline engine. Our objective is to better understand the transition process in terms of characteristic changes to the combustion stability as indicated by patterns of cyclic variations. The transition was experimentally achieved by incrementally adjusting the level of internal exhaust gas recirculation (EGR) using variable exhaust valve actuation. Throttle adjustments were also made to maintain a constant fueling rate. For low levels of EGR, conventional spark ignition was stable, while at the highest EGR levels, HCCI was stable. The spark was used to ignite conventional combustion and was optionally available during HCCI. The character of the cyclic combustion oscillations that occurred between the conventional and HCCI limits suggests that it can be described as a sequence of bifurcations in a low-dimensional dynamic map. Comparisons with previous studies of lean-limit cyclic variations suggest that nonlinear EGR feedback is probably a major factor in these dynamics. Published by Elsevier Inc. on behalf of The Combustion Institute.

Combustion instabilities in dilute internal combustion engines are manifest in cyclic variability (CV) in engine performance measures such as integrated heat release or shaft work. Understanding the factors leading to CV is important in model-based control, especially with high dilution where experimental studies have demonstrated that deterministic effects can become more prominent. Observation of enough consecutive engine cycles for significant statistical analysis is standard in experimental studies but is largely wanting in numerical simulations because of the computational time required to compute hundreds or thousands of consecutive cycles. We have proposed and begun implementation of an alternative approach to allow rapid simulation of long series of engine dynamics based on a low-dimensional mapping of ensembles of single-cycle simulations which map input parameters to output engine performance. This paper details the use Titan at the Oak Ridge Leadership Computing Facility to investigate CV in a gasoline direct-injected spark-ignited engine with a moderately high rate of dilution achieved through external exhaust gas recirculation. The CONVERGE™ CFD software was used to perform single-cycle simulations with imposed variations of operating parameters and boundary conditions selected according to a sparse grid sampling of the parameter space. Using an uncertainty quantification technique, the sampling scheme is chosen similar to a design of experiments grid but uses algorithms designed to minimize the number of samples required to achieve a desired degree of accuracy. The simulations map input parameters to output metrics of engine performance for a single cycle, and by mapping over a large parameter space, results can be interpolated from within that space. This interpolation scheme forms the basis for a low-dimensional ‘metamodel’ (or model of a model) which can be used to mimic the dynamical behavior of corresponding high-dimensional simulations. Simulations of high-EGR spark-ignition combustion cycles within a parametric sampling grid were performed and analyzed statistically, and sensitivities of the physical factors leading to high CV are presented. With these results, the prospect of producing low-dimensional metamodels to describe engine dynamics at any point in the parameter space will be discussed. Additionally, modifications to the methodology to account for nondeterministic effects in the numerical solution environment are proposed.

In collaboration with a major automotive manufacturer, we are using computational simulations of in-cylinder combustion to understand the multi-scale nonlinear physics of the dilute stability limit. Because some key features of dilute combustion can take thousands of successive cycles to develop, the computation time involved in using complex models to simulate these effects has limited industrys ability to exploit simulations in optimizing advanced engines. We describe a novel approach for utilizing parallel computations to reveal long-timescale features of dilute combustion without the need to simulate many successive engine cycles in series. Our approach relies on carefully guided, concurrent, single-cycle simulations to create metamodels that preserve the long-timescale features of interest. We use a simplified combustion model to develop and demonstrate our strategy for adaptively guiding the concurrent simulations to generate metamodels. We next will implement this strategy with higher-fidelity, multi-scale combustion models on large computing facilities to generate more refined metamodels. The refined metamodels can then be used to accelerate engine development because of their efficiency. Similar approaches might also be used for rapidly exploring the dynamics of other complex multi-scale systems that evolve with serial dependency on time.

Lean Gasoline Direct Injection (LGDI) combustion is a promising technical path for achieving significant improvements in fuel efficiency while meeting future emissions requirements. Though Stoichiometric Gasoline Direct Injection (SGDI) technology is commercially available in a few vehicles on the American market, LGDI vehicles are not, but can be found in Europe. Oak Ridge National Laboratory (ORNL) obtained a European BMW 1-series fitted with a 2.0l LGDI engine. The vehicle was instrumented and commissioned on a chassis dynamometer. The engine and after-treatment performance and emissions were characterized over US drive cycles (Federal Test Procedure (FTP), the Highway Fuel Economy Test (HFET), and US06 Supplemental Federal Test Procedure (US06)) and steady state mappings. The vehicle micro hybrid features (engine stop-start and intelligent alternator) were benchmarked as well during the course of that study. The data was analyzed to quantify the benefits and drawbacks of the lean gasoline direct injection and micro hybrid technologies from a fuel economy and emissions perspectives with respect to the US market. Additionally that data will be formatted to develop, substantiate, and exercise vehicle simulations with conventional and advanced powertrains.

Modern diesel engines used in light-duty transportation applications have peak brake thermal efficiencies in the range of 40-42% for high-load operation with substantially lower efficiencies at realistic road-load conditions. Thermodynamic energy and exergy analysis reveals that the largest losses from these engines are due to combustion irreversibility and heat loss to the coolant, through the exhaust, and by direct convection and radiation to the environment. Substantial improvement in overall engine efficiency requires reducing or recovering these losses. Unfortunately, much of the heat transfer either occurs at relatively low temperatures resulting in large entropy generation (such as in the air-charge cooler), is transferred to low-exergy flow streams (such as the oil and engine coolant), or is radiated or convected directly to the environment. While there are significant opportunities for recovery from the exhaust and EGR cooler for heavy-duty applications, achieving similar benefits for light-duty applications is complicated by transient, low-load operation at typical driving conditions and competition with the turbocharger and aftertreatment system for the limited thermal resources. We have developed an organic Rankine cycle model using GT-Suite to investigate the potential for efficiency improvement through waste-heat recovery from the exhaust and EGR cooler of a light-duty diesel engine. The modelmore » is used to examine the effects of efficiency-improvement strategies such as cylinder deactivation, use of advanced materials and improved insulation to limit ambient heat loss, and turbo-compounding on the steady-state performance of the ORC system and the availability of thermal energy for downstream aftertreatment systems. Results from transient drive-cycle simulations are also presented, and we discuss strategies to address operational difficulties associated with transient drive cycles and balancing the thermal requirements of waste-heat recovery, turbocharging or turbo-compounding, and exhaust aftertreatment.« less

In order to achieve proposed fuel economy requirements, engines must make better use of the available fuel energy. Regardless of how efficient the engine is, there will still be a significant fraction of the fuel energy that is rejected in the exhaust and coolant streams. One viable technology for recovering this waste heat is an Organic Rankine Cycle. This cycle heats a working fluid using these heat streams and expands the fluid through a turbine to produce shaft power. The present work was the development of such a system applied to a light duty diesel engine. This lab demonstration was designed to maximize the peak brake thermal efficiency of the engine, and the combined system achieved an efficiency of 44.4%. The design of the system is discussed, as are the experimental performance results. The system potential at typical operating conditions was evaluated to determine the practicality of installing such a system in a vehicle.

We describe a CHEMKIN-based multi-zone model that simulates the expected combustion variations in a single-cylinder engine fueled with iso-octane as the engine transitions from spark-ignited (SI) combustion to homogenous charge compression ignition (HCCI) combustion. The model includes a 63-species reaction mechanism and mass and energy balances for the cylinder and the exhaust flow. For this study we assumed that the SI-to-HCCI transition is implemented by means of increasing the internal exhaust gas recirculation (EGR) at constant engine speed. This transition scenario is consistent with that implemented in previously reported experimental measurements on an experimental engine equipped with variable valve actuation. We find that the model captures many of the important experimental trends, including stable SI combustion at low EGR (-0.10), a transition to highly unstable combustion at intermediate EGR, and finally stable HCCI combustion at very high EGR (-0.75). Remaining differences between the predicted and experimental instability patterns indicate that there is further room for model improvement.

Modern diesel engines used in light-duty transportation applications have peak brake thermal efficiencies in the range of 40–42% for high-load operation with substantially lower efficiencies at realistic road-load conditions. Thermodynamic energy and exergy analysis reveals that the largest losses from these engines are due to heat loss and combustion irreversibility. Substantial improvement in overall engine efficiency requires reducing or recovering these losses. Unfortunately, much of the heat transfer either occurs at relatively low temperatures resulting in large entropy generation (such as in the air-charge cooler), is transferred to low-exergy flow streams (such as the oil and engine coolant), or is radiated or convected directly to the environment. While there are significant opportunities for recovery from the exhaust and EGR cooler for heavy-duty applications, the potential benefits of such a strategy for light-duty diesel applications are unknown due to transient operation, the low thermal quality of exhaust gases at typical driving conditions, and the added mass of the system. Waste-heat recovery efforts will directly compete with NOx aftertreatment systems for the limited thermal energy in the exhaust during low-load operation. We have developed an organic Rankine cycle model using GT-Suite® to investigate the potential for efficiency improvement through waste-heat recovery from the exhaust and EGR cooler of a light-duty diesel engine. Results from steady-state and drive-cycle simulations are presented, and we discuss the operational difficulties associated with transient drive cycles and competition between waste-heat recovery systems, turbochargers, aftertreatment devices, and other systems for the limited thermal resources at typical driving conditions.Copyright © 2010 by ASME

Current political and environmental concerns are driving renewed efforts to develop techniques for improving the efficiency of internal combustion engines. A detailed thermodynamic analysis of an engine and its components from a 1st and 2nd law perspective is necessary to characterize system losses and to identify efficiency opportunities. We have developed a method for performing this analysis using engine-simulation results obtained from WAVE , a commercial engine-modeling software package available from Ricardo, Inc. Results from the engine simulation are post-processed to compute thermodynamic properties such as internal energy, enthalpy, entropy, and availability (or exergy), which are required to perform energy and availability balances of the system. This analysis is performed for all major components (turbocharger, intercooler, EGR cooler, etc.) of the engine as a function of crank angle degree for the entire engine cycle. With this information, we are able to identify potential efficiency opportunities as well as guide engine experiments for exploring new technologies for recovering system losses.

Spark assist appears to offer considerable potential for increasing the speed and load range over which homogeneous charge compression ignition (HCCI) is possible in gasoline engines. Numerous experimental studies of the transition between conventional spark-ignited (SI) propagating-flame combustion and HCCI combustion in gasoline engines with spark assist have demonstrated a high degree of deterministic coupling between successive combustion events. Analysis of this coupling suggests that the transition between SI and HCCI can be described as a sequence of bifurcations in a low-dimensional dynamic map. In this paper, we describe methods for utilizing the deterministic relationship between cycles to extract global kinetic rate parameters that can be used to discriminate multiple distinct combustion states and develop a more quantitative understanding of the SI-HCCI transition. We demonstrate the application of these methods for indolene-containing fuels and point out an apparent HCCI mode switching not previously reported. Our results have specific implications for developing dynamic combustion models and feedback control strategies that utilize spark assist to expand the operating range of HCCI combustion.

We report experimental observations of cyclic combus-tion variability during the transition between propagating flame combustion and homogeneous charge compres-sion ignition (HCCI) in a single-cylinder, stoichiometri-cally fueled, spark-assisted gasoline engine. The level of internal EGR was controlled with variable valve actua-tion (VVA), and HCCI combustion was achieved at high levels of internal EGR using the VVA system. Spark-ignition was used for conventional combustion and was optionally available during HCCI. The transition region between purely propagating combustion and HCCI was mapped at multiple engine speeds and loads by incre-mentally adjusting the internal EGR level and capturing data for 2800 sequential cycles. These measurements revealed a complex sequence of high COV, cyclic com-bustion variations when operating between the propagat-ing flame and HCCI limits. We were able to experimen-tally demonstrate an increase in the zone of acceptable HCCI-like combustion by using the spark assist. A de-tailed analysis of the cyclic variations in the intermediate zone indicates that they are dominated by nonlinear, nonrandom processes. Comparisons with previous studies of lean-limit cyclic variations suggest that nonlin-ear EGR feedback is probably the major source of the observed variations for this engine. The predictable na-ture of this feedback suggests the possibility of develop-ing on-line diagnostics and proactivemore » control algorithms for expanding stable HCCI operation and improving transitions between conventional and HCCI modes.« less

Internal combustion engines are operated under conditions of high exhaust gas recirculation (EGR) to reduce NO x emissions and promote enhanced combustion modes such as HCCI. However, high EGR under certain conditions also promotes nonlinear feedback between cycles, leading to the development of combustion instabilities and cyclic variability. We employ a two-zone phenomenological combustion model to simulate the onset of combustion instabilities under highly dilute conditions and to illustrate the impact of these instabilities on emissions and fuel efficiency. The two-zone in-cylinder combustion model is coupled to a WAVE engine-simulation code through a Simulink interface, allowing rapid simulation of several hundred successive engine cycles with many external engine parametric effects included. We demonstrate how this hybrid model can be used to study strategies for adaptive feedback control to reduce cyclic combustion instabilities and, thus, preserve fuel efficiency and reduce emissions.

Dilute operation of internal combustion engines through lean fueling and/or high levels of exhaust gas recirculation (EGR) is frequently employed to increase fuel efficiency, reduce NOx emissions, and promote enhanced combustion modes such as HCCI. The maximum level of dilution is limited by the development of combustion instabilities that produce unacceptable levels of cycle-to-cycle combustion variability. These combustion instabilities are frequently stimulated by the nonlinear feedback associated with the residual and recirculated exhaust gases exchanged between successive cycles. However, with the application of adaptive control, it is possible to limit the severity of the combustion variability and regain efficiency and emission reduction benefits that would otherwise be lost. In order to better characterize the benefits of adaptive control, we have employed a two-zone phenomenological combustion model to simulate the onset of combustion instabilities under dilute operating conditions and illustrate the impact of these instabilities on emissions and fuel efficiency. The two-zone in-cylinder combustion model is coupled to a WAVE engine-simulation code, allowing rapid simulation of several hundred successive engine cycles with many external engine parametric effects included. By applying adaptive feedback control to the WAVE model, we demonstrate how mitigation of the extreme combustion events can result in improved efficiency and reduced emissions levels. We expect that this approach can be used to estimate the potential benefits of implementing adaptive control strategies on specific engine platforms to achieve further efficiency and emission-reduction gains.Copyright © 2005 by ASME

Predictive feedback control is applied to achieve reduction in cyclic dispersion in an analytical, lean, spark-ignition model and a two-cylinder, four-stroke, natural gas Kohler Command 25 engine operating at lean conditions. Recent observations of the combustion dynamics are used to define a desired target point for control and to predict future combustion events which may stray from the target point. Fueling perturbations are applied to steer the system back toward the desired behavior. Overall control perturbations are constrained to maintain a constant average fuel-to-air ratio. We present two methods for obtaining the prediction of future combustion events. In the first method, the recent history of cycle heat release is used to construct an adaptive, low-order map which relates the current-cycle heat release to the next-cycle heat release. The second method uses symbolic analysis to determine the relative frequency of successive-cycle combustion events and predict the most probable successor to the current cycle. Results are presented which show a moderate reduction in cycle-to-cycle variation near the lean limit in both the model and the engine. Similarities in behavior have been shown to exist-ignition engines suggesting that a similar prediction strategy could be successfully applied to control cyclic dispersion in large-scale reciprocating engines.Copyright © 2004 by ASME

The dynamics of a thermal pulse combustor model are examined. It is found that, as a parameter related to the fuel flow rate is varied, the combustor will undergo a transition from periodic pulsing to chaotic pulsing to a chaotic transient leading to flameout. Results from the numerical model are compared to those obtained from a laboratory-scale thermal pulse combustor. Finally the technique of maintenance (or anticontrol) of chaos is successfully applied to the model, with the result that the operation of the combustor can be continued well into the flameout regime. (c) 1997 American Institute of Physics.

This paper describes the simultaneous reduction of nitrogen oxides (NOx) and particulate matter (PM) in a modern light-duty diesel engine under high exhaust gas recirculation (EGR) levels. Simultaneous reduction of NOx and PM emissions was observed under lean conditions at several low to moderate load conditions using two different approaches. The first approach utilizes a throttle to increase EGR rate beyond the maximum rate possible with sole use of the EGR valve for a particular engine condition. The second approach does not use a throttle, but rather uses a combination of EGR and manipulation of injection parameters. A significant reduction in particulate matter size and concentration was observed corresponding to the reduction in particulate mass. This PM reduction was accompanied by a significant shift in the heat release profile. In addition, there were significant cylinder-to-cylinder variations in particulate matter characteristics, gaseous emissions, and heat release. A fuel penalty is associated with operating in the low NOx and low PM regime when there are no modifications to the injection strategy. Preliminary experiments indicate that the penalty can be eliminated or reduced to a few percent while still maintaining a significant reduction in NOx and PM. An improved understanding of this combustion regime will lead to improved EGR utilization for lowering the performance requirements of post-combustion emissions controls.

As part of a multi-agency study concerning emissions and fuel consumption from heavy-duty diesel truck idling, Oak Ridge National Laboratory personnel measured CO, HC, NOx, CO2, O2, particulate matter (PM), aldehyde and ketone emissions from truck idle exhaust. Two methods of quantifying PM were employed: conventional filters and a Tapered Element Oscillating Microbalance (TEOM). A partial flow micro-dilution tunnel was used to dilute the sampled exhaust to make the PM and aldehyde measurements. The work was performed at the U.S. Army's Aberdeen Test Center's (ATC) climate controlled chamber. ATC performed 37 tests on five class-8 trucks (model years ranging from 1992 to 2001). One was equipped with an 11 hp diesel auxiliary power unit (APU), and another with a diesel direct-fired heater (DFH). The APU powers electrical accessories, heating, and air conditioning, whereas a DFH heats the cab in cold weather. Both devices offer an alternative to extended truck-engine idling. Exhaust emission measurements were also made for the APU and DFH. Trucks were idled at a high and low engine speed in the following environments: 32 °C (90 °F) with cabin air conditioning on, −18 °C (0 °F) with the cabin heater on, and 18 °C (65 °F) with no accessories on. ATC test technicians adjusted the air conditioning or heater to maintain a target cabin temperature of 21 °C (70 °F). Each test was run for approximately three hours. Comparison of the results from the APU to those from the idling trucks implies that use of an APU to replace truck idling gives fuel savings (and CO2 reduction) on the order of 60-85%, 50-97% reductions in NOx, CO and HC, and PM reductions of -20% to 95%. PM emissions from the APU were higher than the “best” idling truck engine cases. The diesel-fired heater had significantly lower emissions and fuel consumption than the APU. The potential for fuel savings and environmental benefits are readily apparent. Results for PM emissions showed a wide range of emissions rates from