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The investigation of vehicle performances under on-road conditions has been required for emission reduction and energy saving in the real world. In this study, Real Car Simulation Bench (RC-S) was developed as an instrument for actual vehicle bench tests under on-road driving conditions, which could not be performed by using conventional chassis dynamometer (CH-DY). The experimental results obtained by RC-S were compared with the on-road driving data on the same car as used in RC-S tests. As a result, it was confirmed that RC-S could accurately reproduce the behavior of fuel consumption and exhaust emissions under on-road driving conditions.

Hydrogen engines are required to provide high thermal efficiency and low nitrogen oxide (NOx) emissions. There are many possible combinations of injection pressure, injection timing, ignition timing, lambda and EGR rate that can be used in a direct-injection system for achieving such performance. In this study, several different combinations of injection and ignition timings were classified as possible combustion regimes, and experiments were conducted to make clear the differences in combustion conditions attributable to these timings. Lambda and the EGR rate were also evaluated for achieving the desired performance, and indicated thermal efficiency of over 45% was obtained at IMEP of 0.95 MPa. It was found that a hydrogen engine with a high-pressure direct-injection system has a high potential for improving thermal efficiency and reducing NOx emissions.

A simultaneous multi-composition analyzing (SMCA) resonance enhanced multi-photon ionization (REMPI) system was used to investigate gasoline engine exhaust. Observed peaks for exhaust were smaller mass numbers than those from diesel exhaust. However, large species up to three ring aromatics were observed suggesting that soot precursor forms even in the gasoline engine. At low catalyst temperature condition, the reduction efficiencies of a three-way catalyst were higher for higher mass numbers. This result indicates that the larger species accumulate in the catalyst or elsewhere due to their lower vapor pressures. To evaluate the emission of low volatility species, the accumulation should be taken into account. In the hot mode, reduction efficiencies for aromatic species of three-way catalyst were almost 99.5% however, they fall to 70% in the cold start condition.

Particulate matter (PM) trapping and oxidation in regeneration on the surface of a diesel particulate catalyst-membrane filter (DPMFs) were investigated in detail using an all-in-focus optical microscope. The DPMF consists of two-layer sintered filters, where a SiC-nanoparticle membrane (made from a mixture of 80 nm and 500 nm powders) covers the surface of a conventional SiC filter. Using a visualization experiment, it was shown that PMs were trapped homogeneously along fine surface pores of the membrane's top surface, whereas in the regeneration process, the particulates in contact with the membrane may have been oxidized with some catalytic effect of the SiC nanoparticles. A soot cake was reacted continuously on the nanoparticles since pushed by a gas flow. The oxidation temperature of particulate trapped on the SiC-nanoparticle membrane was about 75 degrees lower than that on the conventional diesel particulate filters (DPF) without a catalyst.

Compression ignition engines provide superior thermal efficiency over other internal combustion engines. Unfortunately the combustion process is diffusive combustion, meaning a lot of fuel is impinged the on the piston and cylinder wall. This creates cooling loss coupled with smoke, CO and THC. Minimization of the nozzle orifice diameter is a simple method widely used to shorten spray penetration. However, decreasing the nozzle orifice diameter also decreases fuel flow rate resulting in a prolonged injection and combustion process and reducing thermal efficiency. An offset orifice nozzle causes less fuel impingement by shorter fuel spray penetration without significant reduction of fuel flow rate. The offset orifice nozzle was made by shifting its alignment from the center of the sac to the edge of the sac following the swirl direction. A counterbore design was applied to maintain constant orifice length.

The diesel particulate membrane filter (DPMF) is a good solution to the problem of high pressure drop that exists across diesel particulate filters (DPFs) as a result of the soot trapping process. Moreover, DPMFs that have a membrane layer composed of SiC nanoparticles can reduce the oxidation temperature of soot and the apparent activation energy. The SiC nanoparticles have an oxide layer on their surface, with a thickness less than 10 nm. From the visualization of soot oxidation on the surface of SiC nanoparticles by an environmental transmission electron microscope (ETEM), soot oxidation is seen to occur at the interface between the soot and oxide layers. The soot oxidation temperature dependency of the contact area between soot and SiC nanoparticles was evaluated using a temperature programmed reactor (TPR). The contact area between soot and SiC nanoparticles was varied by changing the ratio of SiC nanoparticles and carbon black (CB), which was used as an alternative to soot.

A simple method is frequently used to calculate a reciprocating engine’s bearing load from the measured cylinder pressure. However, it has become apparent that engine downsizing and weight reduction cannot be achieved easily if an engine is designed based on the simple method. Because of this, an actual load on a bearing was measured, and the measured load values were compared with a bearing load distribution calculated from cylinder pressure. As a result, it was found that some of actual loads were about half of the calculated ones at certain crank angles. The connecting rod’s elastic deformation was focused on as a factor behind such differences, and the rod’s deformation due to the engine’s explosion load was studied. As a result, it was found that the rod part of the engine’s connecting rod was bent by 0.2 mm and became doglegged. Additional investigation regarding these findings would allow further engine downsizing.

Fuel consumption and exhaust gas emission regulations are being tightened around the world year by year. Electric vehicles are needed to reduce carbon dioxide emissions. Especially, Plug-in hybrid heavy-duty vehicles (PHEVs) are expected to become widespread. PHEVs enable all-electric modes, as well as hybrid modes, using both engines and electric motors, but the control system significantly affects the characteristics of fuel consumption and gas emission. In this study, we used new testing machine (we call extended HILS) to analyze the fuel consumption and gas emission for different plug-in hybrid control systems and investigated the optimal control method for PHEVs.

Trapping and regeneration processes in a SiC wall-flow diesel particulate filter (DPF) without a catalyst were investigated in detail through microscopic visualization. By microscopic observation of the cross section and surface, the transition from depth filtration to surface filtration could be observed clearly. The open pores on the wall surface were strongly related to the filtration depth of diesel particulate matter (PM). During the regeneration process, after the soot cake was burnt out, the particulates trapped inside the surface pores were oxidized. As a result, the particulate trapping and oxidation behaviors were strongly dependent on the microstructural surface pores.

Repeatabilities of PM measurements on a heavy-duty diesel engine equipped with a diesel particulate filter (DPF) using a filter weighing method and a number counting method with a full flow dilution system and a partial flow system were evaluated. The filter method with partial flow exhibited the best repeatability. However, a good correlation between the full flow and the partial flow number counting results suggests that the fluctuations observed using the number counting method were caused by changes in the engine exhaust. Applying a strict preconditioning procedure should improve the repeatability of the number counting method because this method is more sensitive than the filter weighing method. In addition, the effects of the specifications for the number counting method were evaluated. The results indicate that the hose length from the tip of the sampling probe to the inlet of the number counting system had a negligible effect.

Through microscopic visualization experiments, a process generally known as depth filtration was shown to be caused by surface pores. Moreover, the existence of a soot cake layer was an important advantage for filtration performance because it could trap most of the particulates. We proposed an ideal diesel particulate filter (DPF), in which a silicon carbide (SiC) nanoparticle membrane (made from a mixture of 80 nm and 500 nm powders) instead of a soot cake was sintered on the DPF wall surface; this improved the filtration performance at the beginning of the trapping process and reduced energy consumption during the regeneration process. The proposed filter was called a diesel particulate membrane filter (DPMF). A diesel fuel lamp was used in the trapping process to verify the trapping and oxidation mechanisms of ultrafine particulate matter. Thus, the filtration performance of the membrane filters was shown to be better than that of conventional DPFs.

A prototype CNG engine for heavy-duty trucks has been developed. The engine had sufficient output in practical use, and the green-house gas emission rate was below that of the base diesel engine. Furthermore, the NOx emission rate was reduced to 0.16 g/kWh in the JE05 mode as results of having fully adjusted air fuel ratio control. The measured emission characteristics of particles from the prototype CNG engine demonstrated that oil consumption was related to the number of particles. Moreover, when oil consumption is at an appropriate level, the accumulation mode particles are significantly reduced, and the nuclei mode particles are fewer than those of diesel-fueled engines.

Reducing friction in the crankshaft main bearings is an effective means of improving the fuel efficiency of reciprocating internal combustion engines. To realize these improvements, it is necessary to understand the lubricating conditions, in particular the oil film pressure distributions between crankshaft and bearings. In this study, we developed a thin-film pressure sensor and applied it to the measurement of engine main bearing oil film pressure in a 4-cylinder, 2.5 L gasoline engine. This thin-film sensor is applied directly to the bearing surface by sputtering, allowing for measurement of oil film pressure without changing the shape and rigidity of the bearing. Moreover, the sensor material and shape were optimized to minimize influence from strain and temperature on the oil film pressure measurement. Measurements were performed at the No. 2 and 5 main bearings.

Time-lapse images of particulate matter (PM) deposition on diesel particulate filters (DPFs) at the PM-particle scale were obtained via field-emission scanning electron microscopy (FE-SEM). This particle scale time-series visualization showed the detailed processes of PM accumulation inside the DPF. First, PM introduced into a micro-pore of the DPF wall was deposited onto the surface of SiC grains composing the DPF, where it formed dendritic structures. The dendrite structures were locally grown at the contracted flow area between the SiC grains by accumulation of PM, ultimately constructing a bridge and closing the porous channel. To investigate the dominant parameters governing bridge formation, the filtration efficiency by Brownian diffusion and by interception obtained using theoretical filtration efficiency analysis of a spherical collector model were compared with the visualization results.

Study of DME diesel engines was conducted to improve fuel consumption and emissions of its. Additionally, DME trucks were built for the promotion and the road tests of these trucks were executed on EFV21 project. In this paper, results of diesel engine tests and DME truck driving tests are presented. As for DME diesel engines, the performance of a DME turbocharged diesel engine with LPL-EGR was evaluated and the influence of the compression ratio was also explored. As for DME trucks, a 100,000km road test was conducted on a DME light duty truck. After the road test, the engine was disassembled for investigation. Furthermore, two DME medium duty trucks have been developed and are now the undergoing practical road testing in each area of two transportation companies in Japan.

Application of biodiesel fuel (BDF) to diesel engine is very effective to reduce CO2 emission, because bio-diesel is carbon neutral in principle. However, when biodiesel was applied to conventional diesel engines without modification for biodiesel, NOx emission was increased by the change in fuel characteristics. It is necessary to introduce some strategies into diesel engines fuelled with biodiesel for lower NOx emission than conventional diesel fuel case. The purpose of this study is to reveal that exhaust gas recirculation (EGR) is one of the solutions for the reduction of NOx emission and meeting the future emission regulations when using biodiesel. Neat Rapeseed oil methyl ester (RME) as a biodiesel (B100) was applied to diesel engines equipped with high pressure loop (HPL) EGR system and low pressure loop (LPL) EGR system. Cooled HPL EGR was increased during steady-state operations and JE05 transient mode tests.

In this paper, emissions reduction technologies applied to high-speed direct injection (HSDI) diesel passenger car engines to meet the stricter exhaust emission legislation are described. To reduce smoke, the F.I.E. has been improved by using a radial-piston distributor pump which delivers fuel-injection-pressure up to 120MPa. Cooled exhaust gas re-circulation (EGR) system and increase in volume ratio of the combustion chamber has made it possible to increase EGR ratio and reduced nitrogen oxides (NOx) and smoke simultaneously. Furthermore, improvements in the oxidation catalyst activating temperature reduces PM at lower exhaust gas temperatures. As a result of applying these technologies, a clean and economical HSDI diesel engine for passenger cars, which complies with Japanese '98 exhaust emissions legislation and has better fuel economy than indirect injection (IDI) diesel engines (above 15%), has been developed.

In this study, the combustion characteristics of diesel flame achieved in a rapid compression and expansion machine (RCEM) at various patterns of oxygen distribution in the chamber are investigated in order to clarify the effect of heterogeneity of oxygen distribution in diesel engines induced by EGR on the soot and NOx emissions. To make the heterogeneous distribution of oxygen in a combustion chamber, the mixtures with different oxygen concentrations are injected through the each different port located on the cylinder wall. Results indicate that the amount of oxygen entrained into the spray upstream the luminous flame region affects the NO emission from diesel flame strongly.

A new state of the art DOC (Diesel Oxidation Catalyst) having superior light-off and exothermic activity for forced regeneration compared to conventional Pt base passive DOC, was investigated for LDD application. The DOC uses the latest Pt/Pd technology resulting cost effective DPF system. The newly developed DOC demonstrated improved catalytic activities from Pt only DOC in model gas or engine bench tests. In this study, DOC at early development stage showed excellent light-off activity in model gas and engine bench test compared to conventional Pt only DOC, however, it showed “extinction” phenomenon which is one of the deactivation mode while the post injection and it was observed when post injection operation was done at lower DOC inlet temperatures, e.g. below 250 C. Temperature profiles along diameter and length into DOC bed while active regeneration suggested extinction would be caused by fouling of supplied hydrocarbons derived from diesel fuel.

Application of biodiesel fuel (BDF) to diesel engine is very effective to reduce CO2 emission, because biodiesel is carbon neutral in principle. However, biodiesels yield an increase in NOx emission from conventional diesel engine, compared with diesel fuel case. Therefore, some strategies are needed for meeting the future emission regulations when using biodiesel. In this study, rapeseed oil methyl ester (RME) was applied to diesel engine equipped with exhaust gas recirculation (EGR) system and NOx storage reduction (NSR) catalyst. NOx reduction rate of NSR catalyst was drastically decreased by using RME, even if injection quantity of RME for rich spike was enhanced. However, an increase in EGR rate could reduce NOx emission without the deterioration in smoke and PM emissions.