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Liquid fuel attached to the wall surface of the intake port, the piston and the combustion chamber is one of the main causes of the unburned hydrocarbon emissions from a port fueled SI engine, especially during transient operations. To investigate the liquid fuel film formation process and fuel film behavior during transient operation is essential to reduce exhaust emissions in real driving operations, including cold start operations. Optical techniques have been often applied to measure the fuel film in conventional reports, however, it is difficult to apply those previous techniques to actual engines during transient operations. In this study, using MEMS technique, a novel capacitance sensor has been developed to detect liquid fuel film formation and evaporation processes in actual engines. A resistance temperature detector (RTD) was also constructed on the MEMS sensor with the capacitance sensor to measure the sensor surface temperature.

In internal combustion engine development, the ongoing research can be mainly classified into two categories based on the purpose: limiting exhaust emissions and searching for alternative fuels. One of the effective approaches reduce emissions is the improvement of thermal efficiency. Certain types of alternative fuels derived from renewable resources were estimated to confirm the thermal efficiency. This study uses a single-cylinder engine added with olefin and oxygenated additive fuel, such as 1-hexene, ethanol, and ETBE, to evaluate the parameters that affect thermal efficiency. Furthermore, the effects of various additive fuels are summarized and essential information is provided for determining next- generation fuel composition.

Lean combustion has been well known to be an effective method to improve the thermal efficiency. However, leaner mixture is prone to cause the unstable combustion and poorer unburned hydrocarbon (UTHC) emissions. Pre-chamber turbulent jet combustion has been proved to enhance the combustion stability under ultra-lean conditions. However, more NOx is formed during the combustion, resulting in the fact that the tailpipe NOx emission is too high to be still not available for the real application. In this report, in order to achieve a higher air excess ratio while keeping lower UTHC emissions, and especially NOx emission, a new combustion technique which combined pre-chamber jet combustion with fuel reforming was proposed and experimentally demonstrated on a pre-chamber engine.

There is a growing need for low-emissions concepts due to stricter emission regulations, more stringent homologation cycles, and the possibility of a ban on new engines by 2035. Of particular concern are the conditions during a cold start, when the Three-Way Catalyst is not yet heated to its light-off temperature. During this period, the catalyst remains inactive, thereby failing to convert pollutants. Reducing the time needed to reach this temperature is crucial to comply with the more stringent emissions standards. The post oxidation by means of secondary air injection, illustrated in this work, is a possible solution to reduce the time needed to reach the above-mentioned temperature. The strategy consists of injecting air into the exhaust manifold via secondary air injectors to oxidize unburned fuel that comes from a rich combustion within the cylinder.

Some SI (spark-ignition) engines fueled with gasoline for industrial machineries are designed based on the conventional diesel engine in consideration of the compatibility with installation. Such diesel engine-based SI engines secure a combustion chamber by a piston bowl instead of a pent-roof combustion chamber widely applied for SI engines for automobiles. In the development of SI engines, because knocking deteriorates the power output and the thermal efficiency, it is essential to clarify causes of knocking and predict knocking events. However, there has been little research on knocking in diesel engine-based SI engines. The purpose of this study is to elucidate knocking phenomena in a gasoline engine with a re-entrant piston bowl and swirl flow numerically and experimentally. In-cylinder visualization and pressure analysis of knock onset cycles have been experimentally performed. Locations of autoignition have been predicted by 3D-CFD analysis with detailed chemical reactions.

In recent years, the improvement in the fuel efficiency and reduction in CO2 emission from internal combustion engines has been an urgent issue. The lean burn technology is one of the key technologies to improve thermal efficiency of SI engines. However, combustion stability deteriorates at lean burn operations. The reduction in cycle-to-cycle and cylinder-to-cylinder variations is one of the major issues to adapt the lean burn technique for production engines. However, the details of the causes and mechanisms for the combustion variations under the lean burn operations have not been cleared yet. The purpose of this study is to control cylinder to cylinder combustion variation. A conventional turbocharged direct injection SI engine was used as the test engine to investigate the effect of engine control parameters on the cylinder to cylinder variations. The engine speed is set at 2200 rpm and the intake pressure is set at 58, 78, 98 kPa respectively.

The introduction of real driving emissions cycles and increasingly restrictive emissions regulations force the automotive industry to develop new and more efficient solutions for emission reductions. In particular, the cold start and catalyst heating conditions are crucial for modern cars because is when most of the emissions are produced. One interesting strategy to reduce the time required for catalyst heating is post-oxidation. It consists in operating the engine with a rich in-cylinder mixture and completing the oxidation of fuel inside the exhaust manifold. The result is an increase in temperature and enthalpy of the gases in the exhaust, therefore heating the three-way-catalyst. The following investigation focuses on the implementation of post-oxidation by means of scavenging in a four-cylinder, turbocharged, direct injection spark ignition engine. The investigation is based on detailed measurements that are carried out at the test-bench.

To increase thermal efficiency of internal combustion engines, dilution combustion systems, such as lean burn and exhaust gas recirculation systems, have been developed. These systems require spark-ignition coils generating large discharge current and discharge energy to achieve stable ignition under diluted mixture conditions. Several studies have clarified that larger discharge current increases spark-channel stretch and decreases the possibility of spark channel blow-off and misfire. However, these investigations do not mention the effect of larger discharge current and energy on the initial combustion period. The purpose of this study was to investigate the relation among dilution ratio, initial-combustion period, and coil specifications to clarify the control factor of the dilution limit.

Porous materials, which have large surface areas, have been used for heat storage. However, porous Si-SiC material, as heat storage medium to be applied to a turbocharged gasoline engine has not been investigated extensively. In this study, porous Si-SiC material was used in the upstream of the turbine as heat storage medium and a model was thereby developed for further study. Substrate surface area and substrate volume of Si-SiC were calculated for structure model calibration. Following these calculations and test results, the pressure loss and thermal model were validated. Results show that the weaken exhaust gas pulsation amplitude by porous Si-SiC leads to better turbine performance and BSFC in steady engine condition for a turbocharged gasoline engine. In addition, its transient operation response needs to be improved under transient engine conditions. Hence the possibility of improving the transient response is investigated with characteristics of porous Si-SiC material.

Effects of measurement method, coolant temperature and fuel composition on soot emissions were examined by engine experiments. By reducing the pressure fluctuation in the sampling line, the measured soot emissions with better stability and reproducibility could be obtained. With lower coolant temperatures, larger soot emissions were yielded at much advanced fuel injection timings. Compared to gasoline, soot emissions with a blend fuel of normal heptane, isooctane and toluene were significantly decreased, suggesting the amounts of aromatic components (toluene or others) should be increased to obtain a representative fuel for the predictive model of particulate matter in SIDI engines.

Resistive particulate matter sensor (PMS) is a promising solution for the diagnosis of diesel/gasoline particulate filter (DPF/GPF) functionality. Frequently triggered regeneration of their sensing element, for cleaning the soot dendrites deposited on the surface, leads to experience high temperature and thermal stress and pose high risk of developing cracks in the electrodes or sensing substrate. A semiconductor with a dopant concentration of 100 ppm~10000 ppm is applied as a sensing element for PMS self-diagnosis. Upon cooling at air, the polarization doped-insulating layer in a resistive PMS starts to resume the electrical conductivity in the wake of experiencing high regeneration temperature, through the electron and hole directional mobility.

NOx emissions from diesel passenger vehicles affect the atmospheric environment. It is difficult to evaluate the NOx emissions influenced by environmental conditions such as humidity and temperature, traffic conditions, driving patterns, etc. In the authors’ previous study, real-driving experiments were performed on city and highway routes using a diesel passenger car with only an exhaust gas recirculation system. A statistical prediction model of NOx emissions was considered for simple estimations in the real world using instantaneous vehicle data measured by the portable emissions measurement system and global positioning system. The prediction model consisted of explanatory variables, such as velocity, acceleration, road gradient, and position of transmission gear. Using the explanatory variables, NOx emissions on the city and highway routes was well predicted using a diesel vehicle without NOx reduction devices.

To drastically improve thermal efficiency of a gasoline spark-ignited engine, super-lean burn is a promising solution. Although, studies of lean burn have been made by so many researchers, the realization is blocked by a cycle-to-cycle combustion variation. In this study, based on the causes of cycle-to-cycle variation clarified by the authors’ previous study, a unique method to reduce the cycle-to-cycle variation is proposed and evaluated. That is, a bulk quench at early expansion stroke could be reduced by making slight fuel stratification inside the cylinder using the twin-tumble of intake flows. As a result, the lean limit was extended with keeping low NOx and moderate THC emissions, leading to higher thermal efficiency.

An optimization of thermal management system in a gasoline engine is considered to improve thermal efficiency by minimizing the cost increase without largely changing the configuration of engine system. In this study, the influence of water temperature and intake air temperature on thermal efficiency were investigated using an inline four-cylinder 1.2L gasoline engine. In addition, one-dimensional engine simulations were conducted by using a software of GT-SUITE. Brake thermal efficiency for different engine speeds and loads could be quantitatively predicted with changing the cooling water temperature in the cylinder head. Then, in order to predict the improvement of the fuel consumption in actual use, vehicle mode running simulation and general-purpose engine transient mode simulation were carried out by GT-SUITE. As a result, it was found that by controlling the temperatures of the cooling water and intake gas, thermal efficiency can be improved by several percent.

Reduction in the cycle-to-cycle variation (CCV) of combustion in internal combustion engines is required to reduce fuel consumption, exhaust emissions, and improve drivability. CCV increases at low load operations and lean/dilute burn conditions. Specifically, the factors that cause CCV of combustion are the cyclic variations of in-cylinder flow, in-cylinder distributions of fuel concentration, temperature and residual gas, and ignition energy. However, it is difficult to measure and analyze these factors in a production engine. This study used an optically accessible single-cylinder engine in which combustion and optical measurements were performed for 45 consecutive cycles. CCVs of the combustion and in-cylinder phenomena were investigated for the same cycle. Using this optically accessible engine, the volume inside the combustion chamber, including the pent-roof region can be observed through a quartz cylinder.

Among the emerging technologies in order to meet ever stringent emission and fuel consumption regulations, Exhaust Gas Recirculation (EGR) system is becoming one of the prerequisites particularly for diesel engines. Although EGR cooler is considered to be an effective measure for further performance enhancement, exhaust gas soot deposition may cause degradation of the cooling. To address this issue, the authors studied the visualization of the soot deposition and removal phenomena to understand its behavior. Based on thermophoresis theory, which indicates that the effect of thermophoresis depends on the temperature difference between the gas and the wall surface exposed to the gas, a visualization method using a heated glass window was developed. By using glass with the transparent conductive oxide: tin-doped indium oxide, temperature of the heated glass surface is raised.

In recent years, improvements in the fuel economy and exhaust emission performance of internal combustion engines have been increasingly required by regulatory agencies. One of the salient concerns regarding general purpose engines is the larger amount of CO emissions with which they are associated, compared with CO emissions from automobile engines. To reduce CO and other exhaust emissions while maintaining high fuel efficiency, the optimization of total engine system, including various design parameters, is essential. In the engine system optimization process, cycle simulation using 0-D and 1-D engine models are highly useful. To define an optimum design, the model used for the cycle simulation must be capable of predicting the effects of various parameters on the engine performance. In this study, a model for predicting the performance of a general purpose SI (Spark Ignited) engine is developed based on the commercially available engine simulation software, GT-POWER.

An improvement of thermal efficiency of internal combustion engines is strongly required. Meanwhile, from the viewpoint of refinery, CO2 emissions and gasoline price decrease when lower octane gasoline can be used for vehicles. If lower octane gasoline is used for current vehicles, fuel consumption rate would increase due to abnormal combustion. However, if a Homogeneous Charge Compression Ignition (HCCI) engine were to be used, the effect of octane number on engine performance would be relatively small and it has been revealed that the thermal efficiency is almost unchanged. In this study, the engine performance estimation of HCCI combustion using lower octane gasoline as a vision of the future engine was achieved. To quantitatively investigate the fuel consumption performance of a gasoline HCCI engine using lower octane fuel, the estimation of fuel consumption under different driving test cycles with different transmissions is carried out using 1D engine simulation code.

In the conventional approval test method of fuel consumption for heavy-duty diesel vehicles currently in use in Japan, the fuel consumption under the transient test cycle is calculated by integrating the instantaneous fuel consumption rate referred from a look-up table of fuel consumptions measured under the steady state conditions of the engine. Therefore, the transient engine performance is not considered in this conventional method. In this study, a highly accurate test method for fuel consumption in which the map-based fuel consumption rate is corrected using the transient characteristics of individual engines was developed. The method and its applicability for a heavy-duty diesel engine that complied with the Japanese 2009 emission regulation were validated.

Degradation of the deNOx performance has been found in in-use heavy-duty vehicles with a urea-SCR system in Japan. The causes of the degradation were studied, and two major reasons are suggested here: HC poisoning and deactivation of pre-oxidation catalysts. Hydrocarbons that accumulated on the catalysts inhibited the catalysis. Although they were easily removed by a simple heat treatment, the treatment could only partially recover the original catalytic performance for the deNOx reaction. The unrecovered catalytic activity was found to result from the decrease in conversion of NO to NO2 on the pre-oxidation catalyst. The pre-oxidation catalyst was thus studied in detail by various techniques to reveal the causes of the degradation: Exhaust emission tests for in-use vehicles, effect of heat treatment on the urea-SCR systems, structural changes and chemical changes in active components during the deactivation were systematically investigated.