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We have achieved injection quantity range enhancement by using the current waveform control technique for direct injection (DI) gasoline injectors. In this study, we developed an injection quantity simulator to find out the mechanism of non-linear characteristics. We clarified the non-linear production mechanism by using the simulator. This simulator is a one-dimensional simulator that incorporates calculation results from both unsteady electromagnetic field analysis and hydraulic flow analysis into the motion equation of this simulation code. We investigated the relation between armature and the injection quantity by using the simulator. As a result, we clarified that the non-linearity was produced by the bounce of the armature in the opening action. Thus, we found that it is effective to reduce the armature bounce to improve the linearity of the injection quantity characteristics.

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.

This paper presents a new substrate for Lean NOx Traps (LNT) which enables high NOx conversion efficiency, even after long-term aging, when using alkali metals as the NOx adsorber. When a conventional metal honeycomb is used as the LNT substrate, the chromium in the metal substrate migrates into the washcoat and reacts with the alkali metals after thermal aging. In order to help prevent this migration, we have developed a new substrate where a fine -alumina barrier is precipitated to the surface of the metal substrate. The new substrate is highly capable of preventing migration of chromium into the washcoat and greatly enhances the NOx conversion. The durability of the new substrate and emission test using a test vehicle are also examined.

Chassis back and forth oscillation caused by sudden engine torque increase tends to occur, according to the characteristic of vehicle dynamics. This oscillation is called an acceleration surge and gives a vehicle driver a feeling of discomfort. This paper provides two control methods which can change the characteristic of vehicle acceleration response in order to suppress acceleration surge and to macth with driver's preference. The first control method is an acceleration servo method which is composed of control reference model and ignition timing control. The second control method is a variable response characteristic control algorithm. We treat the controlled object as the second order model with time delay, and assign the characteristic roots of transfer function in order to obtain the desired response.

The increasing number of controllable parameters in modern engine systems has led to increasingly complicated and enlarged engine control software. This in turn has created dramatic increases in software development time and cost. Model-based control design seems to be an effective way to reduce development time and costs and also to enable engineers to understand the complex relationship between the many controllable parameters and engine performance. In the present study, we have developed model-based methodologies for the engine calibration process, employing engine cycle simulation and regression analysis. The reliability of the proposed method was investigated by validating the regression model predictions with measured data.

Meeting the future exhaust emission and fuel consumption standards for passenger cars will require refinements in how the combustion process is carried out in spark ignition engines. A direct injection system decrease fuel consumption under road load cruising conditions, and stratified charge of the fuel mixture is particularly effective for ultra lean combustion. On the other hands, there are requirements for higher output power of gasoline engines. A direct injection system for a spark ignition engine is seen as a promising technique to meet these requirements. To get higher output power at wide open throttle conditions, spray characteristics and in-cylinder air flow must be optimized. In this paper, the engine system, which has a side injection type engine and flat piston, was investigated. We tried some injectors, which have different spray characteristics, and examined effects of spray characteristics on combustion of the direct injection gasoline engine.

Mixture formation and the ignition process in 4 cycle 4 cylinder spark ignition engines were investigated, using an optical combustion sensor that combines fiber optics with a conventional spark plug. The sensor consists of a 1-mm diameter quartz glass optical fiber cable inserted through the center of a spark plug. The tip of the fiber is machined into a convex shape to provide a 120-degree view of the combustion chamber interior. Light emitted by the spark discharge between spark electrodes and the combustion flames in the cylinder is transmitted by the optical cable to an opto-electric transducer. As a result, the ignition and combustion process which depends on the mixture formation can be easily monitored without installing transparent pistons and cylinders. This sensor can give more accurate information on mixture formation in the cylinders.

This paper proposes a new development method for highly reliable real-time embedded control systems using a CPU model-based hardware/software co-simulation. We take an approach that allows the full simulation of the virtual mechanical control system including CPU and object code level software. In this paper, Renesas SH-2A microcontroller model was developed on CoMET™ platform from VaST Systems Technology. A ETC (Electronic Throttle Control) system and engine control system were chosen to prove this concept. The ETB (Electronic Throttle Body) model on Saber® simulator from Synopsys® or engine model on MATLAB®/Simulink® simulator from MathWorks can be simulated with the SH-2A model. To help the system design, debug and evaluation, we developed an integrated behavior analyzer, which can display CPU behavior graphically during the simulation without affecting the simulation result, such as task level CPU load, interrupt statistics, software variable transition chart, and so on.

A new urea-dosing device with an active-ammonia production function was developed. This function is achieved by an electrically heated bypass passage with a hydrolysis catalyst for urea-to-ammonia conversion. The new device also has the function of mixing ammonia and exhaust gas. It is compact and has low-pressure loss by using the vortex occurring at the back of a static vane. We built a trial device for a small diesel engine and obtained steady state and transient data. The heated-bypass concept can be used in the aftertreatment system of passenger cars. Although active-ammonia production consumes electric power, a predictive calculation of power consumption (based on experimental results) shows that the developed bypass heater can suppress the energy consumption enough not to harm the high-energy efficiency of diesel engines.

Emission regulations continue to be strengthened, and it is important to decrease cold start hydrocarbon concentrations in order to meet them, now and in the future. The HC concentration in engine exhaust gas can be reduced by optimizing the air-fuel ratio. However, a conventional air-fuel ratio feedback control does not operate for the first ten seconds after the engine has started because the air-fuel ratio sensor has not yet been activated. In this paper, we report on a study to optimize the air-fuel ratio using a crank angle sensor until the air-fuel ratio sensor has been activated. A difference in fuel properties was used as a typical disturbance factor. The control was applied to both a direct-injection engine (DI) and a port-injection engine (MPI). It was evaluated for two fuel types: one which evaporates easily and one which does not. The experimental results show the air-fuel ratio is optimized for both types of fuel.

Emission regulations continue to be strengthened, and it is important to decrease cold start hydrocarbon concentrations in order to meet them, now and in the future. The HC concentration in engine exhaust gas is reduced by controlling the air-fuel ratio to the low HC range and retarding the ignition timing as much as possible until the engine stability reaches a certain deterioration level. Conventionally however, the target air-fuel ratio has been set at a richer range than the low HC range and the target ignition timing has been more advanced than the engine stability limit, in order to stabilize the engine for various disturbances. As a result, the HC concentration has not been minimized. To solve this problem, a new engine control has been developed. This control uses a crank angle sensor to simultaneously control the air-fuel ratio and the ignition timing so that the HC concentration can be minimized.

Model-based methodologies for the engine calibration process, employing engine cycle simulation and polynomial regression analysis, have been developed and the reliability of the proposed method was confirmed by validating the model predictions with dynamometer test data. From the results, it was clear that the predictions by the engine cycle simulation with a knock model, which considers the two-stage hydrocarbon ignition characteristics of gasoline, were in good agreement with the dynamometer test data if the model tuning parameters were strictly adjusted. Physical model tuning and validation were done, followed by the creation of a dataset for the regression analysis of charging efficiency, EGR mass, and MBT using a 4th order polynomial equation. The stepwise method was demonstrated to yield a logarithm likelihood ratio and its false probability at each term in the polynomial equation.

Hydrogen produced from regenerative sources has the potential to be a sustainable substitute for fossil fuels. A hydrogen internal combustion engine has good combustion characteristics, such as higher flame propagation velocity, shorter quenching distance, and higher thermal conductivity compared with hydrocarbon fuel. However, storing hydrogen is problematic since the energy density is low. Hydrogen can be chemically stored as a hydrocarbon fuel. In particular, an organic hydride can easily generate hydrogen through use of a catalyst. Additionally, it has an advantage in hydrogen transportation due to its liquid form at room temperature and pressure. We examined the application of an organic hydride in a spark ignition (SI) engine. We used methylcyclohexane (MCH) as an organic hydride from which hydrogen and toluene (TOL) can be reformed. First, the theoretical thermal efficiency was examined when hydrogen and TOL were supplied to an SI engine.

Time-resolved continuous images of wrinkling flame front cross-sections were acquired by a laser-light sheet technique in an optically accessible spark ignition engine. The test engine was operated at various engine speeds and compression ratios. The fractal dimension of the curve, D2, was measured in a time series for each cycle. Analysis of the data shows that as the flame propagates the fractal dimension, D2, is close to unity a short time after spark ignition and then increases. Examination of the relationship between the growth rate of the fractal dimension, ΔD2/Δt, and D2 reveals that the higher D2 is, the lower ΔD2/Δt becomes. An Empirical equation for ΔD2/Δt was derived as a function of the ratio of the turbulence intensity to the laminar burning velocity and pressure. This model was tested in an SI engine combustion simulation, and results compared favorably with experimental data.

To detect an air-fuel ratio in wide range is very important to control the automotive engines with low fuel consumption and low exhaust emissions. Although the application of zirconia electrolyte for this purpose has been proposed by the authors several years ago, there remained several problems due to the contamination of gas diffusion apertures which are exposed to the exhaust gas environment. Here the behavior of ions transported in zirconia electrolyte have been analyzed to optimize the structure and characteristics, and to guarantee the long life operation of sensor. Gas contents and their reactions in combustion process under the wide range air-fuel ratio have been analyzed, and these results were reflected to the analysis of ion transportation in zirconia electrolyte. Experimental results supported the analytical results, and they showed the possibilities of long life operation of zirconia air-fuel ratio sensor utilizing ion transportation phenomena.

Plastic optical fiber has been widely used in the field of short distance optical transmission. However heat resistance of commercial plastic fiber is so low that its applications are limited. Then, a plastic fiber of thermosetting acrylate resin core has been developed. This fiber shows 80%/m retention of light transmittance at 1m after 1,000 hours at 150°C. It resists heat deformation and withstands up to 200 °C for a short time period. Tests show this fiber has desirable mechanical characteristics, along with good environmental resistance. In addition, a fiber which has a silicon resin as a core material was developed which has even better heat resistance.

High engine load and over-heated engine cylinder are the main causes of engine knock. When knock occurs in an engine, vibrations composed of several specific resonant frequencies occur. Some of these resonant frequencies are missed stochastically because specific resonant frequencies are caused by different resonant vibration modes in an engine cylinder. However, a conventional knock detector can only measure a fixed resonant frequency using a band-pass filter. This paper presents a multi-spectrum method which greatly improves knock detection accuracy by detecting the knock resonance frequencies from several specific vibration frequencies. Through overcoming the random occurrences of knock resonant frequencies by selecting specific frequencies, knock detection accuracy can be greatly improved. We studied a high precision knock detection method using real-time frequency analysis and a piezoelectric accelerometer on a V-6 engine.

An automatic matching method for engine control parameters is described which can aid efficient development of new engine control systems. In a spark-ignition engine, fuel is fed to a cylinder in proportion to the air mass induced in the cylinder. Air flow meter characteristics and fuel injector characteristics govern fuel control. The control parameters in the electronic controller should be tuned to the physical characteristics of the air flow meter and the fuel injectors during driving. Conventional development of the engine control system requires a lot of experiments for control parameter matching. The new matching method utilizes the deviation of feedback coefficients for stoichiometric combustion. The feedback coefficient reflects errors in control parameters of the air flow meter and fuel injectors. The relationship between the feedback coefficients and control parameters has been derived to provide a way to tune control parameters to their physical characteristics.

A fuel injection control method is developed in which the transient air-fuel ratio is accurately controlled by an internal state estimation method with dynamic characteristics. With conventional methods the air-fuel ratio control precision is limited, because the air measurement system, the air and the fuel dynamic characteristics lack precision. In this development, the factors disturbing the air-fuel ratio under transient conditions are determined by analysis of the control mechanisms. The disturbance factors are found to be (1) the hot wire sensor has a delay time, (2) manifold air charging causes an overshoot phenomenon, (3) there is a dead time between sensing and fuel flow into the cylinder and (4) there is a delay of fuel flow into the cylinder caused by the fuel film. Compensation schemes are constructed for each of these technical problems.

We developed the numerical simulation tool by using OpenFOAM® and in-house simulation codes for Gasoline Direct Injection (GDI) engine in order to carry out the precise investigation of the throughout process from the internal nozzle flow to the fuel/air mixture in engines. For the piston/valve motions, a mapping approach is employed and implemented in this study. In the meantime, the spray atomization including the liquid-columnbreakup region and the secondary-breakup region are simulated by combining the different numerical approaches applied to each region. By connecting the result of liquid-column-breakup simulation to the secondary-breakup simulation, the regions which have different physical phenomena with different length scales are seamlessly jointed; i.e., the velocity and position of droplets predicted by the liquid-column-breakup simulation is used in the secondary breakup simulation so that the initial velocity and position of droplets are transferred.