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In recent years, Nearfield Acoustical Holography (NAH) has been used to identify stationary vehicle exterior noise sources. However that application has usually been limited to individual components. Since powertrain noise sources are hidden within the engine compartment, it is difficult to use NAH to identify those sources and the associated partial field that combine to create the complete exterior noise field of a motor vehicle. Integrated Nearfield Acoustical Holography (INAH) has been developed to address these concerns: it is described here. The procedure entails sensing the sources inside the engine compartment by using an array of reference microphones, and then calculating the associated partial radiation fields by using NAH. In the second part of this paper, the use of farfield arrays is considered. Several array techniques have previously been applied to identify noise sources on moving vehicles.

Previous research has shown that the homogeneous charge compression ignition (HCCI) combustion concept holds promise for reducing pollutants (i.e. NOx, soot) while maintaining high thermal efficiency. However, it can be difficult to control the operation of the HCCI engines even under steady state running conditions. Power density may also be limited if high inlet air temperatures are used for achieving ignition. A methodology using a small pilot quantity of diesel fuel injected during the compression stroke to improve the power density and operation control is considered in this paper. Multidimensional computations were carried out for an HCCI engine based on a CAT3401 engine. The computations show that the required initial temperature for ignition is reduced by about 70 K for the cases of the diesel pilot charge and a 25∼35% percent increase in power density was found for those cases without adversely impacting the NOx emissions.

Clutches are commonly utilised in passenger type and off-road heavy-duty vehicles to disconnect the engine from the driveline and other parasitic loads. In off-road heavy-duty vehicles, along with fuel efficiency start-up functionality at extended ambient conditions, such as low temperature and intake absolute pressure are crucial. Off-road vehicle manufacturers can overcome the parasitic loads in these conditions by oversizing the engine. Caterpillar Inc. as the pioneer in off-road technology has developed a novel clutch design to allow for engine downsizing while vehicle’s performance is not affected. The tribological behaviour of the clutch will be crucial to start engagement promptly and reach the maximum clutch capacity in the shortest possible time and smoothest way in terms of dynamics. A multi-body dynamics model of the clutch system is developed in MSC ADAMS. The flywheel is introducing the same speed and torque as the engine (represents the engine input to the clutch).

Although soot-formation processes in diesel engines have been well characterized during the mixing-controlled burn, little is known about the distribution of soot throughout the combustion chamber after the end of appreciable heat release during the expansion and exhaust strokes. Hence, the laser-induced incandescence (LII) diagnostic was developed to visualize the distribution of soot within an optically accessible single-cylinder direct-injection diesel engine during this period. The developed LII diagnostic is semi-quantitative; i.e., if certain conditions (listed in the Appendix) are true, it accurately captures spatial and temporal trends in the in-cylinder soot field. The diagnostic features a vertically oriented and vertically propagating laser sheet that can be translated across the combustion chamber, where “vertical” refers to a direction parallel to the axis of the cylinder bore.

Nitrites have long been added to heavy-duty coolant to inhibit iron cylinder liner corrosion initiated by cavitation. However, in heavy-duty use, nitrites deplete from the coolant, which then must be refortified using supplemental coolant additives (SCA's). Recently, carboxylates have also been found to provide excellent cylinder liner protection in heavy-duty application. Unlike nitrites, carboxylate inhibitors deplete slowly and thus do not require continual refortification with SCA's. In the present paper laboratory aging experiments shed light on the mechanism of cylinder liner protection by these inhibitors. The performance of carboxylates, nitrites and mixtures of the two inhibitors are compared. Results correlate well with previously published fleet data. Specifically, rapid nitrite and slow carboxylate depletion are observed. More importantly, when nitrite and carboxylates are used in combination, nitrite depletion is repressed while carboxylates deplete at a very slow rate.

Homogeneous Charge Compression Ignition (HCCI) has been proposed for natural gas engines in heavy duty stationary power generation applications. A number of researchers have demonstrated, through simulation and experiment, the feasibility of obtaining high gross indicated thermal efficiencies and very low NOx emissions at reasonable load levels. With a goal of eventual commercialization of these engines, this paper sets forth some of the primary challenges in obtaining high brake thermal efficiency from production feasible engines. Experimental results, in conjunction with simulation and analysis, are used to compare HCCI operation with traditional lean burn spark ignition performance. Current HCCI technology is characterized by low power density, very dilute mixtures, and low combustion efficiency. The quantitative adverse effect of each of these traits is demonstrated with respect to the brake thermal efficiency that can be expected in real world applications.

A slipstream of exhaust from a Caterpillar 3126B engine was diverted into a plasma-catalytic NOx control system in the space velocity range of 7,000 to 100,000 hr-1. The stream was first fed through a non-thermal plasma that was formed in a coaxial cylinder dielectric barrier discharge reactor. Plasma treated gas was then passed over a catalyst bed held at constant temperature in the range of 573 to 773 K. Catalysts examined consisted of γ-alumina, indium-doped γ-alumina, and silver-doped γ-alumina. Road and rated load conditions resulted in engine out NOx levels of 250 - 600 ppm. The effects of hydrocarbon level, catalyst temperature, and space velocity are discussed where propene and in one case ultra-low sulfur diesel fuel (late cycle injection) were the reducing agents used for NOx reduction. Results showed NOx reduction in the range of 25 - 97% depending on engine operating conditions and management of the catalyst and slipstream conditions.

This paper describes two independent studies on γ-alumina as a plasma-activated catalyst. γ-alumina (2.5 - 4.3 wt%) was coated onto the surface of mesoporous silica to determine the importance of aluminum surface coordination on NOx conversion in conjunction with nonthermal plasma. Results indicate that the presence of 5- and 6- fold aluminum coordination sites in γ-alumina could be a significant factor in the NOx reduction process. A second study examined the effect of changing the reducing agent on NOx conversion. Several hydrocarbons were examined including propene, propane, isooctane, methanol, and acetaldehyde. It is demonstrated that methanol was the most effective reducing agent of those tested for a plasma-facilitated reaction over γ-alumina.

Coolant formulations based on organic acid corrosion inhibitor technology have been tested in over 180 heavy duty engines for a total of more than 50 million kilometers. This testing has been used to document long life coolant performance in various engine types from four major engine manufacturers. Inspections of engines using organic acid based coolant (with no supplemental coolant additive) for up to 610,000 kilometers showed excellent protection of metal engine components. Improved protection was observed against cylinder liner, water pump, and aluminum spacer deck corrosion. In addition, data accumulated from this testing were used to develop depletion rate curves for long life coolant corrosion inhibitors, including tolyltriazole and nitrite. Nitrite was observed to deplete less rapidly in long life coolants than in conventional formulations.

Studies of transient diesel spray characteristics at high injection pressures were conducted in a constant volume chamber by utilizing a high speed photography and light extinction optical diagnostic technique. Two different types of nozzle hole entrances were investigated: a sharp-edged and a round-edged nozzle. The experimental results show that for the same injection delivery, the sharp-edged inlet injector needed a higher injection pressure to overcome the higher friction loss, but it produced longer spray tip penetration length, larger spray angle, smaller droplet sizes, and also lower particulate emission from a parallel engine test. For the round-edged and smooth edged tips at the same injection pressure, the sharp-edged inlet tip took a longer injection duration to deliver a fixed mass of fuel and produced larger overall average Sauter Mean Diameter (SMD) droplets.

A nonlinear, three-dimensional finite element analysis of the cylinder head gasket joint has been developed to allow accurate prediction of global and local joint behavior during engine operation. Nonlinear material properties and load cases that simulate full cycle engine operation are the analysis foundation. The three-dimensional, nonlinear, full-cycle simulation accurately predicts cylinder head gasket joint response to assembly, thermal, and cylinder pressure loading. Predictions correlate well with measured engine test data. Analysis results include local pressure distribution and global load splits. Insight into joint loading and an improved understanding of overall joint behavior provide the basis for informed design and development decisions.

An improved method for studying mixing-controlled compression ignition (MCCI) flame interactions with an engine combustion chamber has been developed. It is implemented in a constant pressure vessel, which contains a portion of a piston and a portion of a cylinder head, where the cylinder head is emulated by a transparent fused silica window. This method allows for vaporizing or combusting fuel jets to be imaged from two orthogonal directions. The piston and cylinder head can be adjusted to emulate in-engine piston positions from top dead center (TDC) to approximately 15 mm away from TDC. The design allows for pistons from engine bore sizes up to approximately 175 mm to be studied, including the ability to simulate injector spray included angles from 120°-180°. In this study, the piston was made as an extruded piston bowl profile, where the length of the extrusion approximated the arc length between two neighboring jets from a 6-hole injector.

It is estimated that operating continuously on a B20 fuel containing the current allowable ASTM specification limits for metal impurities in biodiesel could result in a doubling of ash exposure relative to lube-oil-derived ash. The purpose of this study was to determine if a fuel containing metals at the ASTM limits could cause adverse impacts on the performance and durability of diesel emission control systems. An accelerated durability test method was developed to determine the potential impact of these biodiesel impurities. The test program included engine testing with multiple DPF substrate types as well as DOC and SCR catalysts. The results showed no significant degradation in the thermo-mechanical properties of cordierite, aluminum titanate, or silicon carbide DPFs after exposure to 150,000 mile equivalent biodiesel ash and thermal aging. However, exposure of a cordierite DPF to 435,000 mile equivalent aging resulted in a 69% decrease in the thermal shock resistance parameter.

In recent decades, “physics-based” gas-dynamics simulation tools have been employed to reduce development timescales of IC engines by enabling engineers to carry out parametric examinations and optimisation of alternative engine geometry and operating strategy configurations using desktop PCs. However to date, these models have proved inadequate for optimisation of in-cylinder combustion and emissions characteristics thus extending development timescales through additional experimental development efforts. This research paper describes how a Stochastic Reactor Model (SRM) with reduced chemistry can be employed to successfully determine in-cylinder pressure, heat release and emissions trends from a diesel fuelled engine operated in compression ignition direct injection mode using computations which are completed in 147 seconds per cycle.

This paper features an application study on the impact of different blend levels of commercially-supplied biodiesel on engine and aftertreatment systems' durability and reliability as well as the impact on owning and operating factors: service intervals and fuel economy. The study was conducted on a bus application with a 2007 on highway emissions equipped engine running biodiesel blends of B5, B20, and B99 for a total period approaching 4500 hours. Biodiesel of waste cooking grease feedstock was used for the majority of the testing, including B5 and B20 blends. Biodiesel of soybean feedstock was used for testing on B99 blend. No negative impacts on engine and aftertreatment performance and durability or indication of future potential issues were found when using B5 and B20. For B99 measurable impacts on engine and aftertreatment performance and owning and operating cost were observed.

Natural gas quality, in terms of the volume fraction of higher hydrocarbons, strongly affects the auto-ignition characteristics of the air-fuel mixture, the engine performance and its controllability. The influence of natural gas composition on engine operation has been investigated both experimentally and through chemical kinetic based cycle simulation. A range of two component gas mixtures has been tested with methane as the base fuel. The equivalence ratio (0.3), the compression ratio (19.8), and the engine speed (1000 rpm) were held constant in order to isolate the impact of fuel autoignition chemistry. For each fuel mixture, the start of combustion was phased near top dead center (TDC) and then the inlet mixture temperature was reduced. These experimental results have been utilized as a source of data for the validation of a chemical kinetic based full-cycle simulation.

The effect of piston ring pack crevice flow and lubricant oil vaporization on heavy-duty diesel engine deposits is investigated numerically using a multidimensional CFD code, KIVA3V, coupled with Chemkin II, and computational grids that resolve part of the crevice region appropriately. Improvements have been made to the code to be able to deal with the complex geometry of the ring pack, and sub-models for the crevice flow dynamics, lubricating oil vaporization and combustion, soot formation and deposition were also added to the code. Eight parametric cases were simulated under reacting conditions using detailed chemical kinetics to determine the effects of variations of lube-oil film thickness, distribution of the oil film thickness, number of injection pulses, and the main injection timing on engine soot deposition. The results show that crevice-borne hydrocarbon species play an important role in deposit formation on crevice surfaces.

A study was performed to correlate the Sauter Mean Diameter (SMD), NOx and particulate emissions of a direct injection diesel engine with various injection pressures and different nozzle geometry. The spray experiments and engine emission tests were conducted in parallel using the same fuel injection system and same operating conditions. With high speed photography and digital image analysis, a light extinction technique was used to obtain the spray characteristics which included spray tip penetration length, spray angle, and overall average SMD for the entire spray. The NOx and particulate emissions were acquired by running the tests on a fully instrumented Caterpillar 3406 heavy duty engine. Experimental results showed that for higher injection pressures, a smaller SMD was observed, i.e. a finer spray was obtained. For this case, a higher NOx and lower particulate resulted.

Low-temperature combustion of diesel fuel was studied in a heavy-duty, single-cylinder, optical engine employing a 15-hole, dual-row, narrow-included-angle nozzle (10 holes × 70° and 5 holes × 35°) with 103-μm-diameter orifices. This nozzle configuration provided the spray targeting necessary to contain the direct-injected diesel fuel within the piston bowl for injection timings as early as 70° before top dead center. Spray-visualization movies, acquired using a high-speed camera, show that impingement of liquid fuel on the piston surface can result when the in-cylinder temperature and density at the time of injection are sufficiently low. Seven single- and two-parameter sweeps around a 4.82-bar gross indicated mean effective pressure load point were performed to map the sensitivity of the combustion and emissions to variations in injection timing, injection pressure, equivalence ratio, simulated exhaust-gas recirculation, intake temperature, intake boost pressure, and load.

Ducted fuel injection (DFI) has been shown to be an effective method to significantly reduce soot formation in mixing controlled compression ignition (MCCI) diesel combustion. This reduction has been demonstrated in both combustion vessels and in an optical engine. The mechanisms driving the soot reduction are to date not fully understood. Optimal duct configurations are also not immediately evident. The objective of this study is to show the effects of two geometric variables, namely distance from fuel injector orifice exit to duct inlet (0.1-6 mm) for a 2x14 mm duct, and duct length variation (8-14 mm) at a given stand-off distance of 0.1 mm. A 138 μm on-axis single-orifice injector operated at 100-250 MPa was used in a heated, continuous flow, constant pressure vessel with optical access.