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A 2007 Cummins ISL 8.9L direct-injection common rail diesel engine rated at 272 kW (365 hp) was used to load the filter to 2.2 g/L and passively oxidize particulate matter (PM) within a 2007 OEM aftertreatment system consisting of a diesel oxidation catalyst (DOC) and catalyzed particulate filter (CPF). Having a better understanding of the passive NO₂ oxidation kinetics of PM within the CPF allows for reducing the frequency of active regenerations (hydrocarbon injection) and the associated fuel penalties. Being able to model the passive oxidation of accumulated PM in the CPF is critical to creating accurate state estimation strategies. The MTU 1-D CPF model will be used to simulate data collected from this study to examine differences in the PM oxidation kinetics when soy methyl ester (SME) biodiesel is used as the source of fuel for the engine.

The effect of the use of a manganese-copper fuel additive with a Corning EX-47 particulate trap on heavy-duty diesel emissions has been investigated; reductions in total particulate matter (70%), sulfates (65%), and the soluble organic fraction (SOF) (62%) were measured in the diluted (15:1) exhaust and solids were reduced by 94% as measured in the raw exhaust. The use of the additive plus the trap had the same effect on gaseous emissions (hydrocarbons and oxides of nitrogen) as did the trap alone. The use of the additive without the trap had no effect on measured gaseous emissions, although sulfate increased by 20%. Approximately 50% of the metals added to the fuel were calculated to be retained in the engine system. The metals emitted by the engine were collected very efficiently (>97%) by the trap even during regeneration, which occured 180°C lower when the additive was used.

Protocols for sampling and analysis of particulate and gaseous-phase diesel emissions were developed to characterize the chemical and biological effects of using ceramic traps as particulate control devices. A stainless-steel sampler was designed, constructed, and tested with XAD-2 sorbent for the collection of volatile organic compounds (VOC). Raw exhaust levels of TPM and SOF and mutagenicity of the SOF and VOC were all reduced when the traps were used. Hydrocarbon mass balances indicated that some hydrocarbons were not collected by the sampling system and that the proportions of collected SOF and VOC were altered by the use of the traps. SOF hydrocarbons appeared to be derived mainly from engine lubricating oil; VOC hydrocarbons were apparently fuel-derived. There was no apparent effect on SOF mutagenicity due to either sampling time or reexposure of particulate to exhaust gases.

A Coordinating Research Council cooperative program was conducted to evaluate the measurement methods used to analyze nitric oxide and carbon monoxide in diesel exhaust. Initially, a single-cylinder test engine was circulated among participants with poor results. Tests were then conducted at one site using a multicylinder diesel engine. Six organizations participated in the program. Exhaust analyses were conducted at steady-state engine conditions and on a 3 min cycle test. Span gases of unknown concentration were also analyzed. The participants results varied but averaged less than ±5% standard deviation both within (repeatability) and among (reproducibility) the instruments. The short cycle test was in good agreement with the steady-state measurements. No significant difference in the use of Drierite, nonindicating Drierite, or Aquasorb desiccants was evident in sampling system tests.

A microprocessor controlled lubricating oil cooling system of truck diesel engine was designed to minimize the sump oil temperature fluctuation during start-up and nonsteady engine operations. Model reference adaptive control method is utilized in the control system design. The analysis involved in the design of the microprocessor controlled oil cooling system, and the applications of a special vehicle-engine-cooling system (VEC) computer simulation code in the implementation and testing of the model reference adaptive control strategy are described. Using the VEC simulation code, the performance of the microprocessor controlled oil cooling system and the conventionally controlled oil cooling systems were compared for the ATB, temperature disturbances, and cold weather transient tests. An explanation of each test, as well as a review of the results of comparison tests are presented.

A thermal management system for heavy duty diesel engines is presented for maintaining acceptable and constant engine temperatures over a wide range of operational conditions. It consists of a computer controlled variable speed coolant pump, a position controlled thermostat, and a model-based control strategy. An experimentally validated, diesel engine cooling system simulation was used to demonstrate the thermal management system's capability to reduce power consumption. The controller was evaluated using a variety of operating scenarios across a wide range of loads, vehicle speeds, and ambient temperatures. Three metrics were used to assess the effects of the computer controlled system: engine temperature, energy savings, and cab temperature. The proposed control system provided very good control over the engine coolant temperatures while maintaining engine metal temperatures within a desired range.

A computer simulation program was developed to simulate the thermal responses of an on-highway, heavy duty diesel powered truck in transient operation for evaluation of cooling system performance. Mathematical models of the engine, heat exchangers, lubricating oil system, thermal control sensors (thermostat and shutterstat), auxiliary components, and the cab were formulated and calibrated to laboratory experimental data. The component models were assembled into the vehicle engine cooling system model and used to predict air-to-boil temperatures. The model has the capability to predict real time coolant, oil and cab temperatures using vehicle simulation input data over various routes.

A quasi-steady 1-dimensional computer model of a catalyzed particulate filter (CPF) capable of simulating active regeneration of the CPF via diesel fuel injection upstream of a diesel oxidation catalyst (DOC) or other means to increase the exhaust gas temperature has been developed. This model is capable of predicting gaseous species concentrations (HC's, CO, NO and NO2) and exhaust gas temperatures within and after the CPF, for given input values of gaseous species and PM concentrations before the CPF and other inlet variables such as time-varying temperature of the exhaust gas at the inlet of the CPF and volumetric flow rate of exhaust gas.

Numerical modeling of aftertreatment systems has been proven to reduce development time as well as to facilitate understanding of the internal physical and chemical processes occurring during different operating conditions. Such a numerical model for a catalyzed diesel particulate filter (CPF) was developed in this research work which has been improved from an existing numerical model briefly described in reference. The focus of this CPF model was to predict the effect of the catalyst on the gaseous species concentrations and to develop particulate matter (PM) filtration and oxidation models for the PM cake layer and substrate wall so as to develop an overall model that accurately predicts the pressure drop and PM oxidized during passive oxidation and active regeneration. Descriptions of the governing equations and corresponding numerical methods used with relevant boundary conditions are presented.

The increasing complexity of vehicle engine cooling systems results in additional system interactions. Design and evaluation of such systems and related interactions requires a fully coupled detailed engine and cooling system model. The Vehicle Engine Cooling System Simulation (VECSS) developed at Michigan Technological University was enhanced by linking with GT-POWER for the engine/cycle analysis model. Enhanced VECSS (E-VECSS) predicts the effects of cooling system performance on engine performance including accessory power and fuel conversion efficiency. Along with the engine cycle, modeled components include the engine manifolds, turbocharger, radiator, charge-air-cooler, engine oil circuit, oil cooler, cab heater, coolant pump, thermostat, and fan. This tool was then applied to develop and simulate an actively controlled electric cooling system for a 12.7 liter diesel engine.

Optimizing the performance of the aftertreatment system used on heavy duty diesel engines requires a thorough understanding of the operational characteristics of the individual components. Within this, understanding the performance of the catalyzed particulate filter (CPF), and the development of an accurate CPF model, requires knowledge of the particulate matter (PM) distribution throughout the substrate. Experimental measurements of the PM distribution provide the detailed interactions of PM loading, passive oxidation, and active regeneration. Recently, a terahertz wave scanner has been developed that can non-destructively measure the three dimensional (3D) PM distribution. To enable quantitative comparisons of the PM distributions collected under different operational conditions, it is beneficial if the results can be discussed in terms of the axial, radial, and angular directions.

Flame arrival data, determined by ionization gaps and a radiation detector, are presented for a multi-hole CFR engine equipped with six spark plugs spaced around the periphery of the combustion chamber, using a shrouded intake valve to produce swirl and with a standard valve to eliminate it. For results with the shrouded valve, path equations for the burnt gases are derived for several velocity distributions that satisfy the Navier-Stokes equations of motion for the unburned gas. Previous velocity distribution and observed flame movement data are presented in support of the derived model for the path of the burnt gases.

Active regeneration experiments were performed on a production diesel aftertreatment system containing a diesel oxidation catalyst and catalyzed particulate filter (CPF) using blends of soy-based biodiesel. The effects of biodiesel on particulate matter oxidation rates in the filter were explored. These experiments are a continuation of the work performed by Chilumukuru et al., in SAE Technical Paper No. 2009-01-1474, which studied the active regeneration characteristics of the same aftertreatment system using ultra-low sulfur diesel fuel. Experiments were conducted using a 10.8 L 2002 Cummins ISM heavy-duty diesel engine. Particulate matter loading of the filter was performed at the rated engine speed of 2100 rpm and 20% of the full engine load of 1120 Nm. At this engine speed and load the passive oxidation rate is low. The 17 L CPF was loaded to a particulate matter level of 2.2 g/L.

A wide range of emissions were characterized from a heavy-duty diesel engine operated on conventional low sulfur (∼375 ppm) fuel, equipped with manually controlled EGR and a catalyzed particulate filter (CPF). The effect of the CPF and engine load was studied, along with a comparison of results between the gravimetric and thermal optical methods (TOM) for determining diesel particulate levels. Data were obtained from four of the EPA old 13 mode test cycle steady-state operating conditions, i.e., Modes 11, 10, 9, and 8 using a 1995 Cummins M11-330E engine with a Corning EX-80 cordierite particulate filter, coated with a platinum catalyst (5 g/ft3).

This research quantifies the effects of a copper fuel additive on the regulated [oxides of nitrogen (NOx), hydrocarbons (HC) and total particulate matter (TPM)] and unregulated emissions [soluble organic fraction (SOF), vapor phase organics (XOC), polynuclear aromatic hydrocarbons (PAH), nitro-PAH, particle size distributions and mutagenic activity] from a 1988 Cummins LTA10 diesel engine using a low sulfur fuel. The engine was operated at two steady state modes (EPA modes 9 and 11, which are 75 and 25% load at rated speed, respectively) and five additive levels (0, 15, 30, 60 and 100 ppm Cu by mass) with and without a ceramic trap. Measurements of PAH and mutagenic activity were limited to the 0, 30 and 60 ppm Cu levels. Data were also collected to assess the effect of the additive on regeneration temperature and duration. Copper species collected within the trap were identified and exhaust copper concentrations quantified.

In this study, the effects of an oxidation catalytic converter (OCC) on regulated and unregulated emissions from a 1991 prototype Cummins I.10-310 diesel engine fueled with a 0.01 weight percent sulfur fuel were investigated. The OCC's effects were determined by measuring and comparing selected raw exhaust emissions with and without the platinum-based OCC installed in the exhaust system, with the engine operated at three steady-state modes. It was found that the OCC had no significant effect on oxides of nitrogen (NOX) and nitric oxide (NO) at any mode, but reduced hydrocarbon (HC) emmissions by 60 to 70 percent. The OCC reduced total particulate matter (TPM) levels by 27 to 54 percent, primarily resulting from 53 to 71 percent reductions of the soluble organic fraction (SOF). The OCC increased sulfate (SO42-) levels at two of the three modes (modes 9 and 10), but the overall SO42- contribution to TPM was less than 6 percent at all modes due to the low sulfur level of the fuel.

This paper presents an approach to modeling the United States truck and bus population. A detailed model is developed that utilizes domestic factory sales figures combined with a scrappage factor as a building block for the total population. Comparison with historical data for 1958-1970 shows that the model follows trends well for intermediate parameters such as total vehicle miles per year, total fuel consumption, scrappage, etc. Fuel consumption and HC, CO, NO2, CO2 and particulate matter emissions for gasoline and diesel engines are of primary interest. The model details these parameters for the time span 1958-2000 in one-year increments. For HC and CO, truck and bus emissions could equal or exceed automobile emissions in the early 1980s, depending on the degree of control. Three population control strategies are analyzed to determine their effects on reducing fuel consumption or air pollution in later years.

A Cummins ISB 5.9 liter medium-duty engine with cooled EGR has been used to study an early extrusion of an advanced ceramic uncatalyzed diesel particulate filter (DPF). Data for the advanced ceramic material (ACM) and an uncatalyzed cordierite filter of similar dimensions are presented. Pressure drop data as a function of mass loadings (0, 4, and 6 grams of particulate matter (PM) per liter of filter volume) for various flow rate/temperature combinations (0.115 - 0.187 kg/sec and 240 - 375 °C) based upon loads of 15, 25, 40 and 60% of full engine load (684 N-m) at 2300 rpm are presented. The data obtained from these experiments were used to calibrate the MTU 1-D 2-Layer computer model developed previously at MTU. Clean wall permeability determined from the model calibration for the ACM was 5.0e-13 m2 as compared to 3.0e-13 m2 for cordierite.

Steady state loading characterization experiments were conducted at three different engine load conditions and rated speed on the cracked catalyzed particulate filter (CPF). The experiments were performed using a 10.8 L 2002 Cummins ISM-330 heavy duty diesel engine. The CPF underwent a ring off failure, commonly seen in particulate filters, due to high radial and axial temperature gradients. The filters were cracked during baking in an oven which was done to regenerate PM collected after every loading characterization experiment. Two different configurations i.e. with and without a diesel oxidation catalyst (DOC) upstream of the CPF were studied. The data were compared with that on an un-cracked CPF at similar engine conditions and configurations. Pressure drop, transient filtration efficiency by particle size and PM mass and gaseous emissions measurements were made during each experiment.

Steady-state particulate loading experiments were conducted on an advanced production catalyzed particulate filter (CPF), both with and without a diesel oxidation catalyst (DOC). A heavy-duty diesel engine was used for this study with the experiments conducted at 20, 40, 60 and 75 % of full load (1120 Nm) at rated speed (2100 rpm). The data obtained from these experiments were used and are necessary for calibrating the MTU 1-D 2-Layer CPF model. These experimental and modeling results were compared to previous research conducted at MTU that used the same engine but an earlier development version of the combination of DOC and CPF. The motivation for the comparison of the two systems was to determine whether the reformulated production catalysts performed as good or better than the early development catalysts. The results were compared to understand the filtration and oxidation differences between the two DOC+CPF and the CPF-only aftertreatment systems.