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Increasingly stringent tailpipe emissions regulations have prompted renewed interest in catalyst heating technology – where an integrated device supplies supplemental heat to accelerate catalyst ‘light-off’. Bosch and Boysen, following a collaborative multi-year effort, have developed a Rapid Catalyst Heating System (RCH) for gasoline-fueled applications. The RCH system provides upwards of 25 kW of thermal power, greatly enhancing catalyst performance and robustness. Additional benefits include reduction of precious metal loading (versus a ‘PGM-only’ approach) and avoidance of near-engine catalyst placement (limiting the need for enrichment strategies). The following paper provides a technical overview of the Bosch/Boysen (BOB) Rapid Catalyst Heating system – including a detailed review of the system’s architecture, key performance characteristics, and the associated impact on vehicle-level emissions.

This study focuses on evaluation of various fuels within a conventional gasoline internal combustion engine (ICE) vehicle and the implementation of advanced emissions reduction technology. It shows the robustness of the implemented technology packages for achieving ultra-low tailpipe emissions to different market fuels and demonstrates the potential of future GHG neutral powertrains enabled by drop-in lower carbon fuels (LCF). An ultra-low emission (ULE) sedan vehicle was set up using state-of-the-art engine technology, with advanced vehicle control and exhaust gas aftertreatment system including a prototype rapid catalyst heating (RCH) unit. Currently regulated criteria pollutant emission species were measured at both engine-out and tailpipe locations. Vehicle was run on three different drive cycles at the chassis dynamometer: two standard cycles (WLTC and TfL) at 20°C, and a real driving emission (RDE) cycle at -7°C.

Particulate matter emissions from internal combustion engines have become an increasingly important area of focus for development teams in recent years. This is due to greater regulatory scrutiny on vehicles globally, and especially on particulate emissions. The chemical composition and bulk physical properties of the fuel have been shown to influence the particulate number emissions characteristics. Although some predictive models have been proposed, the causality of specific properties or constituents has not been demonstrated due to the co-linearity of the variables considered in previous studies. In this work, fuels were formulated to capture the expected variation in three key properties of United States (US) market gasoline fuels. Specifically, total aromatics, volatility, and particulate matter index (PMI) were varied across market extremes within regulatory limits--while holding other properties constant.

Studies have shown that fuel quality plays an important role in engine-out emissions. The wide variation in composition and properties of gasoline fuels available in the market can lead to discrepancies between the expected emission levels as per set regulations and actual on-road measurements. This study compares engine-out gaseous and particulate emission results between 5 US market fuels, 5 certification fuels and one street-legal race fuel. The market fuels were acquired from different terminals in Michigan. Tests were performed on a 4-cylinder 2.3 L turbocharged direct injection spark-ignited engine. The tests covered a wide range of steady-state operating conditions including load, injection timing and engine speed sweeps. Transient load steps were also performed under warm and cold engine conditions.

This paper presents an experimental investigation of the impact of EGR dilution on the tradeoff between flame and end-gas autoignition heat release in a Spark-Assisted Compression Ignition (SACI) combustion engine. The mixture was maintained stoichiometric and fuel-to-charge equivalence ratio (ϕ′) was controlled by varying the EGR dilution level at constant engine speed. Under all conditions investigated, end-gas autoignition timing was maintained constant by modulating the mixture temperature and spark timing. Experiments at constant intake pressure and constant spark timing showed that as ϕ′ is increased, lower mixture temperatures are required to match end-gas autoignition timing. Higher ϕ′ mixtures exhibited faster initial flame burn rates, which were attributed to the higher laminar flame speeds immediately after spark timing and their effect on the overall turbulent burning velocity.

Gasoline Direct Injection (GDI) has become the preferred technology for spark-ignition engines resulting in greater specific power output and lower fuel consumption, and consequently reduction in CO2 emission. However, GDI engines face a substantial challenge in meeting new and future emission limits, especially the stringent particle number (PN) emissions recently introduced in Europe and China. Studies have shown that the fuel used by a vehicle has a significant impact on engine out emissions. In this study, nine fuels with varying chemical composition and physical properties were tested on a modern turbo-charged side-mounted GDI engine with design changes to reduce particulate emissions. The fuels tested included four fuels meeting US certification requirements; two fuels meeting European certification requirements; and one fuel meeting China 6 certification requirements being proposed at the time of this work.

High-pressure gasoline fuel injection is a means to improve combustion efficiency and lower engine-out emissions. The objective of this study was to quantify the effects of fuel injection pressure on transient gasoline fuel spray development for a wide range of injection pressures, including over 1000 bar, using a constant volume chamber and high-speed imaging. Reference grade gasoline was injected at fuel pressures of 300, 600, 900, 1200, and 1500 bar into the chamber, which was pressurized with nitrogen at 1, 5, 10, and 20 bar at room temperature (298 K). Bulk spray imaging data were used to quantify spray tip penetration distance, rate of spray tip penetration and spray cone angle. Near-nozzle data were used to evaluate the early spray development.

Low-pressure cooled EGR (LP-cEGR) systems can provide significant improvements in spark-ignition engine efficiency and knock resistance. However, open-loop control of these systems is challenging due to low pressure differentials and the presence of pulsating flow at the EGR valve. This research describes a control structure for Low-pressure cooled EGR systems using closed loop feedback control along with internal model control. A Smith Predictor based PID controller is utilized in combination with an intake oxygen sensor for feedback control of EGR fraction. Gas transport delays are considered as dead-time delays and a Smith Predictor is one of the conventional methods to address stability concerns of such systems. However, this approach requires a plant model of the air-path from the EGR valve to the sensor.

Low pressure (LP) and cooled EGR systems are capable of increasing fuel efficiency of turbocharged gasoline engines, however they introduce control challenges. Accurate exhaust pressure modeling is of particular importance for real-time feedforward control of these EGR systems since they operate under low pressure differentials. To provide a solution that does not depend on physical sensors in the exhaust and also does not require extensive calibration, a coupled temperature and pressure physics-based model is proposed. The exhaust pipe is split into two different lumped sections based on flow conditions in order to calculate turbine-outlet pressure, which is the driving force for LP-EGR. The temperature model uses the turbine-outlet temperature as an input, which is known through existing engine control models, to determine heat transfer losses through the exhaust.

The use of Low Pressure - Exhaust Gas Recirculation (EGR) is intended to allow displacement reduction in turbocharged gasoline engines and improve fuel economy. Low Pressure EGR designs have an advantage over High Pressure configurations since they interfere less with turbocharger efficiency and improve the uniformity of air-EGR mixing in the engine. In this research, Low Pressure (LP) cooled EGR is evaluated on a turbocharged direct injection gasoline engine with variable valve timing using both simulation and experimental results. First, a model-based calibration study is conducted using simulation tools to identify fuel efficiency gains of LP EGR over the base calibration. The main sources of the efficiency improvement are then quantified individually, focusing on part-load de-throttling of the engine, heat loss reduction, knock mitigation as well as decreased high-load fuel enrichment through exhaust temperature reduction.

HCCI (Homogeneous Charge Compression Ignition) has the potential for significant fuel efficiency improvements and low engine-out emissions but a major limitation is its relatively small operating range, limited by pressure rise rate at high loads and cyclic variability and incomplete combustion at low loads. Spark Assisted Compression Ignition (SACI) can extend the operating range of HCCI, but since SACI includes both flame propagation and auto-ignition, it experiences higher cyclic variance than HCCI combustion and phasing control can be challenging. This paper investigates the effects of environmental conditions on SACI combustion. The first part of the paper investigates whether CA50 (the location of 50% heat release and the most commonly used combustion parameter for describing combustion phasing) is the best metric to describe combustion phasing and facilitate its control. CA50 and four other combustion phasing metrics are evaluated and compared in this study.

This study reanalyzes the data from a recent experimental report from the University of Utah investigating the effect on driving performance of auditory-vocal secondary tasks (such as cell phone and passenger conversations, speech-to-text, and a complex artificial cognitive task). The current objective is to estimate the relative risk of crashes associated with such auditory-vocal tasks. Contrary to the Utah study's assumption of an increase in crash risk from the attentional effects of cognitive load, a deeper analysis of the Utah data shows that driver self-regulation provides an effective countermeasure that offsets possible increases in crash risk. For example, drivers self-regulated their following distances to compensate for the slight increases in brake response time while performing auditory-vocal tasks. This new finding is supported by naturalistic driving data showing that cell phone conversation does not increase crash risk above that of normal baseline driving.

A key aim of research into cell phone tasks is to obtain an unbiased estimate of their relative risk (RR) for crashes. This paper re-examines five RR estimates of cell phone conversation in automobiles. The Toronto and Australian studies estimated an RR near 4, but used subjective estimates of driving and crash times. The OnStar, 100-Car, and a recent naturalistic study used objective measures of driving and crash times and estimated an RR near 1, not 4 - a major discrepancy. Analysis of data from GPS trip studies shows that people were in the car only 20% of the time on any given prior day at the same clock time they were in the car on a later day. Hence, the Toronto estimate of driving time during control windows must be reduced from 10 to 2 min.

Emissions of Unburned Hydrocarbons (UHC) from diesel engines are a particular concern during the starting process, when after-treatment devices are typically below optimal operating temperatures. Drivability in the subsequent warm-up phase is also impaired by large cyclic fluctuations in mean effective pressure (MEP). This paper discusses in-cylinder wall temperature influence on unburned hydrocarbon emissions and combustion stability during the starting and warm-up process in an optical engine. A laser-induced phosphorescence technique is used for quantitative measurements of in-cylinder wall temperatures just prior to start of injection (SOI), which are correlated to engine out UHC emission mole fractions and combustion phasing during starting sequences over a range of charge densities, at a fixed fueling rate. Squish zone cylinder wall temperature shows significant influence on engine out UHC emissions during the warm-up process.

On-board fuel identification is important to ensure engine safe operation, similar power output, fuel economy and emissions levels when different fuels are used. Real-time detection of physical and chemical properties of the fuel requires the development of identifying techniques based on a simple, non-intrusive sensor. The measured crankshaft speed signal is already available on series engine and can be utilized to estimate at least one of the essential combustion parameters such as peak pressure and its location, rate of cylinder pressure rise and start of combustion, which are an indicative of the ignition properties of the fuel. Using a dynamic model of the crankshaft numerous methods have been previously developed to identify the fuel type but all with limited applications in terms of number of cylinders and computational resources for real time control.

This paper presents the results of an experimental investigation on a single cylinder engine to validate a two-component JP-8 surrogate. The two-component surrogate was chosen based on a previous investigation where the key properties, such as DCN, volatility, density, and lower heating value, of the surrogate were matched with those of the target JP-8. The matching of the auto-ignition, combustion, and emission characteristics of the surrogate with JP-8 was investigated in an actual diesel engine environment. The engine tests for the validation of the surrogate were conducted at an engine speed of 1500 rpm, a load of 3 bar, and different injection timings. The results for the cylinder gas pressure, ignition delay period, rate of heat release, and the CO, HC, and NOx emissions showed a good match between the surrogate and the target JP-8. However, the engine-out particulate matter for the surrogate was lower than that for the JP-8 at all tested conditions.

A hot and cold water mixing process with a steam condenser and a chilled water heat exchanger is set up for an engine EGR fouling test. The test rig has water recycled in the loop of a pump, heat exchangers, a three-way mixing valve, and a test EGR unit. The target unit temperature is controlled by a heating, cooling and mixing process with individual valves regulating the flow-rate of saturated steam, chilled water and mixing ratio. The challenges in control design are the dead-time, interaction, nonlinearity and multivariable characteristics of heat exchangers, plus the flow recycle in the system. A systems method is applied to extract a simple linear model for control design. The method avoids the nonlinearity and interaction among different temperatures at inlet, outlet and flow-rate. The test data proves the effectiveness of systems analysis and modeling methodology. As a result, the first-order linear model facilitates the controller design.

Natural gas has been considered to be one of the most promising alternative fuels due to its lower NOx and soot emissions, less carbon footprint as well as attractive price. Furthermore, higher octane number makes it suitable for high compression ratio application compared with other gaseous fuels. For better economical and lower emissions, a turbocharged, four strokes, direct injection, high pressure common rail diesel engine has been converted into a diesel/natural gas dual-fuel engine. For dual-fuel engine operation, natural gas as the main fuel is sequentially injected into intake manifold, and a very small amount of diesel is directly injected into cylinder as the ignition source. In this paper, a dual-fuel electronic control unit (ECU) based on the PowerPC 32-bit microprocessor was developed. It cooperates with the original diesel ECU to control the fuel injection of the diesel/natural gas dual-fuel engine.

Spark Assisted Compression Ignition (SACI) aims to increase the load limit of homogeneous charge compression ignition (HCCI) engines, enabling the benefits of dilute combustion over a larger engine operation range. Compared to HCCI, SACI exhibits higher cyclic variation of several combustion features. Due to the necessity of control of the timing of the auto-ignition event during SACI operation, a suitable characterization of the combustion at a given set of actuator inputs is required to enable robust model-based controls of combustion. This paper investigates statistical approaches to analyze in-cylinder pressure data of SACI in order to find a real or reconstructed cycle that will represent the important characteristics of combustion. To determine the representativeness of such a cycle, several combustion characteristics were compared that could serve as operational limits.

This paper focuses on the combustion development portion of the Advanced Combustion Controls Enabling Systems and Solutions (ACCESS) project, a joint research project partially funded by a Department of Energy grant. The main goal of the project is to improve fuel economy in a gasoline fueled light-duty vehicle by 30% while maintaining similar performance and meeting SULEV emission standards for the Federal Test Procedure (FTP) cycle. In this study, several combustion modes Spark Ignited (SI), Homogeneous Charge Compression Ignition (HCCI), Spark- Assisted Compression Ignition (SACI)) were compared under various conditions (naturally aspirated, boosted, lean, and stoichiometric) to compare the methods of controlled auto-ignition on a downsized, boosted multi-cylinder engine with an advanced valvetrain system capable of operating under wide negative valve overlap (NVO) conditions.