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The performance of an extended stroke spark ignition engine has been assessed by cycle simulation. The base engine is a modern turbo-charged 4-stroke passenger car spark-ignition engine with 10:1 compression ratio. A complex crank mechanism is used so that the intake stroke remains the same while the expansion-to-intake stroke ratio (SR) is varied by changing the crank geometry. The study is limited to the thermodynamic aspect of the extended stroke; the changes in friction, combustion characteristic, and other factors are not included. When the combustion is not knock limited, an efficiency gain of more than 10 percent is obtained for SR = 1.5. At low load, however, there is an efficiency lost due to over-expansion. At the same NIMEP, the extended stroke renders the engine more resistant to knock. At SR of 1.8, the engine is free from knock up to 14 bar NIMEP at 2000 rpm. Under knocking condition, the required spark retard to prevent knocking is less with the extended stroke.

The spark ignition engine particulate number (PN) emissions have been correlated to a particulate matter index (PMI) in the literature. The PMI value addresses the fuel effect on PN emission through the individual fuel species reactivity and vapor pressure. The latter quantity is used to account for the propensity of the non-volatile fuel components to survive to the later part of the combustion event as wall liquid films, which serve as sources for particulate emission. The PMI, however, does not encompass the suppression of vaporization by the evaporative cooling of fuel components, such as ethanol, that have high latent heat of vaporization. This paper assesses this evaporative cooling effect on PN emissions by measurements in a GDI engine operating with a base gasoline which does not contain oxygenate, with a blend of the gasoline and ethanol, and with a blend of the gasoline, ethanol, and a hydrocarbon additive so that the blend has the same PMI as the original gasoline.

The gasoline direct injection (GDI) engine particulate emission sources are assessed under cold start conditions: the fast idle and speed/load combinations representative of the 1st acceleration in the US FTP. The focus is on the accumulation mode particle number (PN) emission. The sources are non-fuel, combustion of the premixed charge, and liquid fuel film. The non-fuel emissions are measured by operating the engine with premixed methane/air or hydrogen/air. Then the PN level is substantially lower than what is obtained with normal GDI operation; thus non-fuel contribution to PN is small. When operating with stoichiometric premixed gasoline/air, the PN level is comparable to the non-fuel level; thus premixed-stoichiometric mixture combustion does not significantly generate particulates. For fuel rich premixed gasoline/air, PN increases dramatically when lambda is less than 0.7 to 0.8.

An ignition delay correlation encompassing the effects of temperature, pressure, residual gas, EGR, and lambda (on both the rich and lean sides) has been developed. The procedure uses the individual knocking cycle data from a boosted direct injection SI engine (GM LNF) operating at 1250 to 2000 rpm, 8-14 bar GIMEP, EGR of 0 to 12.5%, and lambda of 0.8 to 1.3 with a certification fuel (Haltermann 437, with RON=96.6 and MON=88.5). An algorithm has been devised to identify the knock point on individual pressure traces so that the large data set (of some thirty three thousand cycles) could be processed automatically. For lean and for rich operations, the role of the excess fuel, air, and recycled gas (which has excess air in the lean case, and hydrogen and carbon monoxide in the rich case) may be treated effectively as diluents in the ignition delay expression.

The effects of piston top-land crevice size on the indicated net fuel conversion efficiency are assessed in a single cylinder SI engine with 465 cc displacement and 11.2 compression ratio. The operating conditions are at 3.6 and 5.6 bar net indicated mean effective pressure (NIMEP), and at 1500 and 2000 rpm speeds. The cold crevice volume is varied from 524 mm3 to 1331 mm3 by changing the top land height from 3 to 7 mm, and by changing the top-land clearance from 0.247 to 0.586 mm. For a 100 mm3 increase in the top land crevice volume (estimated hot value), the indicated net fuel conversion efficiency decreases by 0.1 percentage point at 1500 rpm, and by 0.13 percentage points at 2000 rpm. The results are not sensitive to the two NIMEP values tested. These values are consistent with a simple crevice filling and discharge/oxidation model.

The engine and its exhaust flow behaviors are investigated in a turbo-charged gasoline direct injection engine under simulated cold-fast-idle condition. The metrics of interest are the exhaust sensible and chemical enthalpy flows, and the exhaust temperature, all of which affect catalyst light off time. The exhaust sensible enthalpy flow is mainly a function of combustion phasing; the exhaust chemical enthalpy flow is mainly a function of equivalence ratio. High sensible and chemical enthalpy flow with acceptable engine stability could be obtained with retarded combustion and enrichment. When split injection is employed with one early and one later and smaller fuel pulse, combustion retards with early secondary injection in the compression stroke but advances with late secondary injection. Comparing gasoline to E85, the latter produces a lower exhaust temperature because of charge cooling effect and because of a faster combustion.

Particulate emissions from a production gasoline direct injection spark ignition engine were studied under a typical cold-fast-idle condition (1200 rpm, 2 bar NIMEP). The particle number (PN) density in the 22 to 365 nm range was measured as a function of the injection timing with single pulse injection and with split injection. Very low PN emissions were observed when injection took place in the mid intake stroke because of the fast fuel evaporation and mixing processes which were facilitated by the high turbulent kinetic energy created by the intake charge motion. Under these conditions, substantial liquid fuel film formation on the combustion chamber surfaces was avoided. PN emissions increased when injection took place in the compression stroke, and increased substantially when the fuel spray hit the piston.

This work examines the effects of valve timing and back pressure on the engine out enthalpy flow which is critical to the light off of the catalyst. The engine behavior is observed under fast-idle condition using a turbocharged production direct injection spark ignition engine with variable cam phasing that could shift both the intake and exhaust valve timing by 50 deg. crank angle. The back pressure is adjusted by throttling the exhaust. The engine operates at a constant net indicated mean effective pressure of 2 bar. The valve timing effect is largely governed by the residual gas trapped. With increasing valve overlap, the exhaust enthalpy flow increases because of the increase in exhaust temperature due to a slower combustion, and of the increase in air and fuel flow to compensate for the lower efficiency due to the slower combustion. When the back pressure is increased, the engine through flow has to increase to compensate for the larger pumping loss.

The effects of cooled exhaust gas recirculation (EGR) on a boosted direct-injection (DI) spark ignition (SI) engine operating at stoichiometric equivalence ratio, gross indicated mean effective pressure of 14-18 bar, and speed of 1500-2500 rpm, are studied under constant fuel condition at each operating point. In the presence of EGR, burn durations are longer and combustion is more retard. At the same combustion phasing, the indicated specific fuel consumption improves because of a decrease in heat loss and an increase in the specific heat ratio. The knock limited spark advance increases substantially with EGR. This increase is due partly to a slower combustion which is equivalent to a spark retard, as manifested by a retarded value of the 50% burn point (CA50), and due partly to a slower ignition chemistry of the diluted charge, as manifested by the knock limited spark advance to beyond the value offered by the retarded CA50.

The fuel effects on HCCI operation in a spark assisted direct injection gasoline engine are assessed. The low load limit has been extended with a pilot fuel injection during the negative valve overlap (NVO) period. The fuel matrix consists of hydrocarbon fuels and various ethanol blends and a butanol blend, plus fuels with added ignition improvers. The hydrocarbon fuels and the butanol blend do not significantly alter the high or the low limits of operation. The HCCI operation appears to be controlled more by the thermal environment than by the fuel properties. For E85, the engine behavior depends on the extent that the heat release from the pilot injected fuel in the NVO period compensates for the evaporative cooling of the fuel.

The effects of charge motion and laminar flame speeds on combustion and exhaust temperature have been studied by using an air jet in the intake flow to produce an adjustable swirl or tumble motion, and by replacing the nitrogen in the intake air by argon or CO₂, thereby increasing or decreasing the laminar flame speed. The objective is to examine the "Late Robust Combustion" concept: whether there are opportunities for producing a high exhaust temperature using retarded combustion to facilitate catalyst warm-up, while at the same time, keeping an acceptable cycle-to-cycle torque variation as measured by the coefficient of variation (COV) of the net indicated mean effective pressure (NIMEP). The operating condition of interest is at the fast idle period of a cold start with engine speed at 1400 RPM and NIMEP at 2.6 bar. A fast burn could be produced by appropriate charge motion. The combustion phasing is primarily a function of the spark timing.

The use of hydrogen as a fuel supplement for lean-burn engines at higher compression ratios has been studied extensively in recent years, with good promise of performance and efficiency gains. With the advances in reformer technology, the use of a gaseous fuel stock, comprising of substantially higher fractions of hydrogen and other flammable reformate species, could provide additional improvements. This paper presents the performance and emission characteristics of a gas mixture of equal volumes of hydrogen, CO, and methane. It has recently been reported that this gas mixture can be produced by reforming of ethanol at comparatively low temperature, around 300C. Experiments were performed on a 1.8-liter passenger-car Nissan engine modified for single-cylinder operation. Special pistons were made so that compression ratios ranging from CR= 9.5 to 17 could be used. The lean limit was extended beyond twice stoichiometric (up to lambda=2.2).

The windage tray effect on aeration in the engine sump was assessed by replacing much of the windage tray materials with wire meshes of various blockages. The mesh was to prevent direct impact of the oil drops spinning off the crank shaft onto the sump oil, and simultaneously, to provide sufficient drainage so that there was no significant build up of windage tray oil film that would interact with these droplets. Aeration at the oil pump inlet was measured by X-ray absorption in a production V-6 SI engine motoring at 2000 to 6000 rpm. Within experimental uncertainty, these windage tray changes had no effect on aeration. Thus activities in the sump such as the interaction of the oil drops spun from the crank shaft with the sump oil or with the windage tray, and the agitation of the sump oil by the crank case gas, were not major contributors to aeration at the pump inlet.

A novel engine management strategy for achieving fast catalyst light-off without the use of an exhaust air pump in a port-fuel-injected, spark ignition engine was developed. A conventional 4-cylinder engine was operated with three cylinders running rich and the fourth one as an air pump to supply air to the exhaust manifold. Under steady-state cold coolant conditions, this strategy achieved near total oxidation of CO and HC with sufficiently retarded spark timing, resulting in a 400% increase in feedgas enthalpy flow and a 90% reduction in feedgas HC emissions compared to conventional operation. The strategy was also evaluated for crank starts. Using the existing engine hardware, implementing the strategy resulted in a reduction in catalyst light-off time from 28.0 seconds under conventional operation to 9.1 seconds.

Gasoline HCCI engine has the potential of providing better fuel economy and emissions characteristics than the current SI engines. However, management of HCCI operation for a vehicle is a challenging task. In this paper, the issues of mode transitions between the Spark Ignition and HCCI regimes, and the dynamic nature of the load trajectory within the HCCI regime are considered. Then the phenomena encountered in these operations are illustrated by the data from a single-cylinder engine with electromagnetic-variable-valve timing control. Mode transitions from the SI to HCCI regime may be categorized as robust and non-robust. In a robust transition, every intended HCCI cycle is successful. In a non-robust transition, one or more intended HCCI cycles misfire, although the cycles progress to a satisfactory HCCI operating point in steady state. (The spark ignition was kept on so that the engine could recover from a misfired cycle.)

Engine Hydrocarbon (HC) emissions behaviors in the shut down and re-start processes were examined in a production 4-cylinder 2.4 L engine. Depending on when the power to the ECU was cut off relative to the engine events, there could be two or three mis-fired cylinders (i.e. cylinders with fuel injected but no ignition). The total HC pumped out by the engine into the catalyst in the stopping process was ∼ 4 mg (approximately equaled to the amount of one injection at idle condition). Because the size of the catalyst was larger than the total exhaust volume in the stopping process, this HC was not observed at the catalyst exit. The catalyst temperature was also not affected. When the engine was purged after shut down (by cranking the engine with the injectors and ignition disconnected), the total exit HC was 33 mg. In a restart 90 minutes after shut down, the integrated amount of HC emissions due to residual fuel from the stopping process was 16 mg.

The mixture preparation and hydrocarbon (HC) emissions behaviors for a single-cylinder port-fuel-injection SI engine were examined in an engine/dynamometer set up that simulated the first cycle of cranking. The engine was motored continuously at a fixed low speed with the ignition on, and fuel was injected every 8 cycles. Unlike the real engine cranking process, the set up provided a well controlled and repeatable environment to study the cranking process. The parameters were the Engine Coolant Temperature (ECT), speed, and the fuel injection pulse width. The in-cylinder and exhaust HC were measured simultaneously with two Fast-response Flame Ionization Detectors. A large amount of injected fuel (an order of magnitude larger than the normal amount that would produce a stoichiometric mixture in a warm-up engine) was required to form a combustible mixture at low temperatures.

The purpose of this work was to develop an understanding of how liquid fuel transported into the cylinder of a port-fuel-injected gasoline-fueled SI engine contributes to hydrocarbon (HC) emissions. To simulate the liquid fuel flow from the valve seat region into the cylinder, a specially designed fuel probe was developed and used to inject controlled amounts of liquid fuel onto the port wall close to the valve seat. By operating the engine on pre-vaporized Indolene, and injecting a small amount of liquid fuel close to the valve seat while the intake valve was open, we examined the effects of liquid fuel entering the cylinder at different circumferential locations around the valve seat. Similar experiments were also carried out with closed valve injection of liquid fuel at the valve seat to assess the effects of residual blowback, and of evaporation from the intake valve and port surfaces.

An adaptive air/fuel ratio controller for SI engine throttle transient was developed. The scheme is based on an event- based, single- parameter fuel dynamics model. A least- square- error algorithm with an active forgetting factor was used for parameter identifications. A one- step- look- ahead controller was designed to maintain the desired air/fuel ratio by canceling the fuel dynamics with the controller setting updated adaptively according to the identified parameters. When implemented on a Ford Ztech engine and tested under a set of throttle- transient operations, the adaptive controller learned quickly and performed well.

This paper describes the development of a spark ignition engine operating in a stratified-EGR mode at part load. The concept is to reduce the pumping loss with high levels of EGR while maintaining stable combustion via charge stratification. Since the engine operates stoichiometrically, the ability to control NOx emissions by the three-way catalyst is retained. The configuration of introducing the stoichiometric fresh mixture to the center portion of the combustion chamber with the EGR gas on the two sides is visualized in a transparent engine using planar laser-induced fluorescence (PLIF) and Mie scattering. Visualization results showed that the stratification between air/fuel mixture and EGR gas was relatively well established during the intake stroke. There was, however, significant mixing in the late part of the compression stroke.