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The formation of combustion chamber deposits in modern SI engines is predominantly derived from hydrocarbon fuels and occurs as a consequence of the quenching action of the combustion chamber walls on the flame. A laboratory experiment has been designed which enables rapid generation of deposit material in the form of viscous brown liquids. Heating these deposits produces material that is consistent in composition and physical appearance with mature engine deposits. The deposit-forming tendency of a number of individual hydrocarbon species has been determined. The amount of deposit increases with i) the amount of unsaturation present in the molecular structure and ii) the boiling point of the hydrocarbon fuel being burned. A structurally derived parameter for each hydrocarbon molecule is found to correlate well with deposition rate, allowing a unified treatment of the different generic forms of hydrocarbons in which deposit-forming tendency is linked to molecular structure.

A 1.8 litre four-cylinder engine with a slice between the head and the block carrying instrumented plugs has been used to study the growth of combustion chamber deposits and some of their effects on engine operation. Different techniques for measuring deposit thickness, knock onset and deposit effects on the thermal characteristics of the cylinder have been developed. Deposit growth as measured by deposit weight on the plugs is reasonably repeatable from run to run and cylinder to cylinder. The presence of deposits already in the cylinder does not affect deposit growth on clean plugs introduced into the combustion chamber. Deposit thickness and morphology vary substantially at different locations, the thickness being greatest at the coolest surfaces. Deposits increase the flame speed and reduce the metal temperatures just below the surface. They also reduce the mean heat flux away from the cylinder.

Vehicle driveability is a function of gasoline volatility, ambient conditions and engine design. The ability to predict driveability performance from a knowledge of fuel/air mixture temperatures and gasoline properties would greatly assist both fuel and engine development. Accordingly, a model to predict engine hesitation under full-throttle accelerations (a major driveabilty malfunction) has been developed. Hesitation occurs when the fuel/air mixture reaching the combustion chambers is too lean to burn. Thus the model is based on the calculation of heat flow and air/fuel vapour ratios in the engine inlet manifold. Chassis dynamometer tests for two different cars using a range of fuels and a range of test temperatures have shown that the model gives an accurate prediction of mixture temperatures and engine hesitation under full-throttle conditions.

Departures from optimum stoichiometry during transients (acceleration and deceleration) and cold start can lead to significant degradation in driveability and emissions control. Such departures occur as a result of a complex interplay between fuel transport mechanisms and the fuelling strategy. The relative contributions of several of these mechanisms are affected by fuel composition. To help understand these effects an open-path differential infra-red absorption technique has been used to monitor the transient evolution of the fuel vapour phase directly within the combustion chamber. The sensor projected a narrow infra-red beam which traversed the cylinder of an optical access engine along an open path under the head, and measured the path-integrated attenuation caused by absorption of the infra-red radiation by the fuel vapour. It operated in the near infrared (NIR) spectral region around 2.3 μm, an absorption band in hydrocarbon species containing methyl groups.

An experimental programme has been carried out to quantify the influence of Combustion Chamber Deposit (CCD) removal on vehicle acceleration performance, fuel consumption and tailpipe emissions in several modern European car models. Vehicles were performance and emissions tested dirty', following accumulation of 16,000 kilometres (10,000 miles) with a light duty cycle, then ‘clean’, following removal of CCDs. This scheme was repeated for one model using a heavy duty driving cycle. Additional tests were carried out on three vehicle models equipped with knock-sensors for which ignition timing was monitored. CCDs reduced fuel consumption relative to the clean engine, in amounts dependent on vehicle model. CCDs had only small, detrimental effects on acceleration performance and power. They generally (but not always) increased NOx emissions and had variable and usually small effects on HC and CO emissions.

Investigations into fuel compositional effects on emissions using model and full range fuels suggest aromatic components promote NOx conversion over the catalyst Steady state results derived from a single engine (Ricardo Gasoline Fuels Consortium data) show that at a typical part load condition, the catalyst removes NOx less effectively with lower aromatic fuels. Neither CO nor H2 contribute significantly to catalyst performance. Two vehicles were tested over a European cycle. Toluene formed more combustion chamber NOx, offset by increased catalyst conversion efficiency giving lower tailpipe NOx than isooctane in the vehicle with the better catalyst light-off and AFR control.

Combustion chamber deposit (CCD) formation in SI engines is a complex phenomenon which is dependent on a number of fuel and engine parameters. A mathematical model has been developed, based upon a previously proposed mechanism of CCD formation, which describes the physical and chemical processes controlling the growth of deposits in SI combustion chambers. The model allows deposit thickness to be predicted as a function of time, taking into account gasoline composition and factors influenced by engine operating conditions. Piston top deposit thicknesses predicted by the model for 38 unadditivated fuels show a strong correlation with data from three different bench engine tests. The model offers the possibility of predicting the amount of CCD produced by unadditivated gasolines for a range of engine designs, operating conditions and test durations.

The transport of fuel droplets into the combustion chamber of an SI engine and their subsequent evaporation has been studied, using a new optical diagnostic technique, Interferometric Laser Imaging for Droplet Sizing (ILIDS), which allows temporally and spatially resolved measurements of droplet size distributions. The measurement technique and its application to in-cylinder engine measurements are described. Measurements were made under warmed-up conditions, with open valve injection timing, in a Ricardo Hydra single cylinder engine. The results showed differences in the evolution of the droplet size distribution in cylinder with variations in load and speed. At 1200 rpm under full load, droplets arrived quickly into the cylinder, and were small, the Sauter Mean Diameter (SMD) being in the region 10-12 μm on arrival, so that mixture preparation was good.

A piston ring-pack lubrication model has been developed which takes into account both lubricant viscosity/temperature and viscosity/shear rate variations. In addition, lubricant starvation of the upper piston rings, due to restriction of the oil supply by the lower rings, has been included. Inputs to the model include piston ring profiles (measured using Talysurf profilometry) and gas pressure distributions throughout the ring-pack. The latter were calculated using the (known) combustion chamber pressure diagram at the relevant engine operating conditions. The model was validated by comparing predicted oil film thicknesses with those measured using a laser-induced fluorescence technique on a Caterpillar-1Y73 single-cylinder diesel engine. The engine was run at a range of speeds with two different, fully formulated, multigrade lubricants, and the oil film thickness under each of the piston rings was measured.

Vehicle-based studies have shown that a reduction in the aromatic content of gasoline fuels can result in increased NOx emissions from catalyst-equipped vehicles. A study with simulated exhaust gas has shown that light paraffins, especially methane, are unreactive and cause substantial breakthrough of unreacted NO over the catalyst. However, unsaturated exhaust components including aromatics are effective reactants and play a large part in converting NO over the catalyst. Engine tests have shown that methane is predominantly produced by fuel paraffins and olefins, but hardly at all by aromatics. Thus it appears that methane generated during combustion of low aromatics fuels may be the cause, wholly or in part, of the poor NO conversion efficiency observed when catalyst-equipped cars are operated on such fuels. However, it cannot be excluded that low aromatics fuels are associated with increased air-to-fuel ratio which will also contribute to poor NO performance.