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The paper compares two different design concepts for a range extender engine rated at 30 kW at 4500 rpm. The first project is a conventional 4-Stroke SI engine, 2-cylinder, 2-valve, equipped with port fuel injection. The second is a new type of 2-Stroke loop scavenged SI engine, featuring a direct gasoline injection and a patented rotary valve for enhancing the induction and scavenging processes. Both power units have been virtually designed with the help of CFD simulation. Moreover, for the 2-Stroke engine, a prototype has been also built and tested at the dynamometer bench, allowing the authors to make a reliable theoretical comparison with the well assessed 4-Stroke unit.

This work reports a CFD study on a 2-stroke (2-S) opposed piston high speed direct injection (HSDI) Diesel engine. The engine main features (bore, stroke, port timings, et cetera) are defined in a previous stage of the project, while the current analysis is focused on the assembly made up of scavenge ports, manifold and cylinder. The first step of the study consists in the construction of a parametric mesh on a simplified geometry. Two geometric parameters and three different operating conditions are considered. A CFD-3D simulation by using a customized version of the KIVA-4 code is performed on a set of 243 different cases, sweeping all the most interesting combinations of geometric parameters and operating conditions. The post-processing of this huge amount of data allow us to define the most effective geometric configuration, named baseline.

Interest in 2-stroke engines has been recently renewed by several prototypes, developed for the automotive and/or the aircraft field. Loop scavenging, with piston controlled ports is particularly attractive, but the configurations successfully developed in the past for motorbike racing (in particular, the 125cc unit displacement, crankcase pump engines), are not suitable for automotive applications. Therefore, new criteria are necessary to address the scavenging system design of the new generation of 2-stroke automobile/aircraft engines. The paper reviews the transfer ports optimization of a loop scavenged 2-stroke cylinder, whose main parameters were defined in a previous study. The optimization has been carried by means of a parametric grid, considering 3 parameters (2 tilt angles, and the focus distance), and 3 different engine speeds (2000-3000-4000 rpm, assuming a Diesel engine). A set of scavenging CFD-3d simulations have been performed by using a customized version of KIVA-3V.

The paper presents a numerical investigation, aimed to explore the potential of 2-stroke Diesel engines, able to meet Euro VI requirements, for application to medium size commercial vehicles (power rate: 80 kW at 2600 rpm, max. torque 420 Nm from 1200 to 1400 rpm). The study is based on experimental performance of a highly developed 4-stroke engine. Two different designs are considered: Loop and Uniflow scavenging, the latter obtained through an opposed piston configuration. In both cases, no poppet valves are used, and the lubrication is provided by a 4-stroke-like oil sump. The study started with the development of a 4-stroke EURO VI engine, on the basis of a previous EURO IV version. A prototype of the new engine (named 430) was built and tested.

The basic requirements for range extender engines are low cost, compact dimensions, high specific power, good efficiency, low pollutant emission levels, excellent NVH behavior. For a power rate lower than 30 kW, it is very difficult to find an off-the-shelf engine meeting all the requirements listed above, so that a new generation of dedicated engines is under development. Following a preliminary theoretical work presented in 2012 [1], the current paper reviews the design process and the first experimental tests carried out on a novel 2-stroke GDI single-cylinder engine, rated at 30 kW at 4500 rpm, featuring a patented induction valve and a piston pump for scavenging. A prototype has been designed with the support of CFD simulations, then built and tested at the BRC laboratories, in Cherasco (Italy).

The paper presents a preliminary study on a virtual 2-stroke 3-cylinder 0.9 L DI SI supercharged engine running on Hydrogen (H2), able to meet both high performance targets and ultra-low emissions limits (NOx<20 ppm). Combustion is similar to a conventional 4-stroke H2 DI engine, while the design of the cylinder and the actuation law of both intake and exhaust valves are specifically optimized for the 2-stroke cycle. In comparison to a more conventional 2-stroke loop scavenged engine, with piston-controlled ports, the use of poppet valves enables a more flexible control of the gas exchange process and to maintain the same design of a 4-stroke engine for pistons, cylinders block, crankcase and lubrication system. On the other hand, it is more difficult to avoid the short-circuit of the fresh charge, while permeability of the valves becomes quite critical at high engine speed.

The paper describes a numerical study, supported by experiments, on light aircraft 2-Stroke Direct Injected Diesel engines, typically rated up to 110 kW (corresponding to about 150 imperial HP). The engines must be as light as possible and they are to be directly coupled to the propeller, without reduction drive. The ensuing main design constraints are: i) in-cylinder peak pressure as low as possible (typically, no more than 120 bar); ii) maximum rotational speed limited to 2600 rpm. As far as exhaust emissions are concerned, piston aircraft engines remain unregulated but lack of visible smoke is a customer requirement, so that a value of 1 is assumed as maximum Smoke number. For the reasons clarified in the paper, only three cylinder in line engines are investigated. Reference is made to two types of scavenging and combustion systems, designed by the authors with the assistance of state-of-the-art CFD tools and described in detail in a parallel paper.