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The reduction of both harmful emissions (CO, HC, NOx, etc.) and gases responsible for greenhouse effects (especially CO2) are mandatory aspects to be considered in the development process of any kind of propulsion concept. Focusing on ICEs, the main development topics are today not only the reduction of harmful emissions, increase of thermodynamic efficiency, etc. but also the decarbonization of fuels which offers the highest potential for the reduction of CO2 emissions. Accordingly, the development of future ICEs will be closely linked to the development of CO2 neutral fuels (e.g. biofuels and e-fuels) as they will be part of a common development process. This implies an increase in development complexity, which needs the support of engine simulations. In this work, the virtual modeling of real fuel behavior is addressed to improve current simulation capabilities in studying how a specific composition can affect the engine performance.

This SAE Technical Paper gives a summary of the essential findings in the development and operation of a test engine dedicated to the measuring of the friction between the piston group and the liner. Firstly the fundamental demands on the high-precision and close to real engine operation friction measuring are laid out. Subsequently the basic engine, the measuring system based on the floating liner method including a gas balance device, as well as the implemented measuring technique are specified. Major influencing variables on the friction of the piston assembly and its interference variables are also summarized. Extensive information about the systematic and strategies for the test engine's operation startup are given in acknowledgement of influencing and interference variables. This strategy reduces the developmental and startup process of an engine dedicated to the measuring of piston group friction.

The paper presents a study on the influence of increased rail pressure on the flow field of an injector nozzle at pressures of up to 3200 bar. Additionally the influence of nozzle conicity, HE-Rounding and nozzle-hole-diameter on the injector flow was investigated with CFD calculations. In these calculations the real behaviour of the nozzle movement was considered. The nozzles were tested on a special single cylinder research engine. The results showed high potential to fulfill EURO VI emission standards by raising the injection pressure and by optimizing the nozzle geometry, without exhaust aftertreatment measures.

Aging effects such as coking or erosive damage that occur in fuel injection nozzles are known to deteriorate the engine performance. This article proposes an optimization method to compensate for injector aging and to control the combustion behavior over engine lifetime by adapting the injection strategy. First, a control-oriented combustion model is presented, which takes the condition of the injection nozzle into account. In combination with a simulation model of the entire fuel injection system from a previous study, the model is capable of predicting the heat release rate (HRR) at different working conditions. Measurements with a single-cylinder diesel engine were performed, using injectors with modified and aged nozzles, to validate the proposed combustion model and particularly to analyze the influence of injector aging. Using the simulation model, optimal injection strategies were obtained by applying a line search optimization scheme to recover a reference HRR trajectory.

To cope with increasing, challenging requirements and shorter development cycles, more complex, often nonlinear, systems with high interactions have to be optimized in many fields of research, such as the energy sector. As this often goes beyond the classical parameter studies-based approach, systematic optimization approaches offer a key solution. In the context of the development of energy converters, like engines, such techniques are applied to enhance efficiency and enable optimal use of energy. This review provides a comprehensive overview of the field of optimization approaches, more precisely referred to as Metamodel-Based Design Optimization (MBDO). The MBDO approaches essentially comprise three main modules: the Design of Experiment (DoE), the Response Surface Modeling (RSM), and the Multiobjective Optimization (MoO), in varying compositions.

Measuring and simulating the contact between piston pin and connecting rod (conrod) is very complex. The pin can rotate freely in the conrod as well as in the piston. Further, there is no defined oil supply with a constant pressure as it is for example in main bearings. A tribometer test bench was adapted to measure friction between pin and conrod. The system is loaded with a constant force and oil supply is realized as defined deficient lubrication. During one part of the schedule, the rotational speed is defined as ramp to measure friction coefficient over speed, in another part the speed was pivoted from positive to negative speed within less than 500 milliseconds. With this measurement method, the different friction coefficients between radial slider and pivot bearings could be quantified. The measurements were conducted for four different pin-coatings.

Aging effects such as coking or cavitation in the nozzle of common rail (CR) diesel injectors deteriorate combustion performance. This is of particular relevance when it comes to complying with emission legislation and demonstrates the need for detecting and compensating aging effects during operation. The first objective of this paper is to analyze the influence of worn nozzles on the injection rate. Therefore, measurements of commercial solenoid common rail diesel injectors with different nozzles are carried out using an injection rate analyzer of the Bosch type. Furthermore, a fault model for typical aging effects in the nozzle of the injector is presented together with two methods to detect and identify these effects. Both methods are based on a multi-domain simulation model of the injector. The needle lift, the control piston lift and the pressure in the lower feed line are used for the fault diagnosis.

Polyoxymethylene dimethyl ethers (OME) are synthetic fuels, which offer the property of sustainability because the reactants of production base on hydrogen and carbon dioxide on the one hand, and the air pollution control in consequence of a soot-free combustion in a diesel engine on the other hand. High exhaust gas recirculation (EGR) rates are a promising measure for nitrogen oxide (NOx) reduction without increasing particle emissions because of the resolved soot-NOx trade-off. However, EGR rates towards stoichiometric combustion in OME operation reveals other trade-offs such as methane and formaldehyde emissions. To avoid these, a lean mixture with a combination of EGR and exhaust after-treatment with selective catalytic reduction (SCR) is useful. The limitation of urea dosing due to the light-off temperature of SCR systems requires heating measures.

In order to fulfill future exhaust emission regulations, the variety of subsystems of internal combustion engines is progressively investigated and optimized in detail. The present article mainly focuses on studies of the flow field and the resulting discharge coefficients of the intake and exhaust valves and ports. In particular, the valves and ports influence the required work for the gas exchange process, as well as the cylinder charge and consequently highly impact the engine’s performance. For the evaluation of discharge coefficients of a modern combustion engine, a stationary flow test bench has been set up at the Chair of Internal Combustion Engines (LVK) of the Technical University of Munich (TUM). The setup is connected to the test bench’s charge air system, allowing the adjustment and control of the system pressure, as well as the pressure difference across the particular gas exchange valve.

The development of today's powertrains focuses on the reduction of CO₂ emissions. Therefore several new technologies for internal combustion engines have been established. A further tendency is the successive electrification of powertrains in hybrid vehicles. However, these trends lead to increasing system costs which are a very important aspect at the market segment of compact cars. At the Institute of Internal Combustion Engines of the Technical University of Munich a drivetrain concept for urban and commuter traffic is under development. It is based on a lean-burn air-cooled two-cylinder natural gas engine which is combined with a hydraulic hybrid system. The paper contains detailed information about the engine as well as the hybrid vehicle powertrain in parallel structure. Particular characteristics and innovations of the hydraulic hybrid system compared to systems known so far are shown.

In this project funded by the Bayerische Forschungsstiftung two fundamental investigations had been carried out: first a new N-rich liquid ammonia precursor solution based on guanidine salts had been completely characterized and secondly a new type of side-flow reactor for the controlled catalytic decomposition of aqueous NH₃ precursor to ammonia gas has been designed, applied and tested in a 3-liter passenger car diesel engine. Guanidine salts came into the focus due to the fact of a high nitrogen-content derivate of urea. Specially guanidinium formate has shown extraordinary solubility in water (more than 6 kg per 1 liter water at room temperature) and therefore a possible high ammonia potential per liter solution compared to the classical 32.5% aqueous urea solution (AUS32) standardized in ISO 22241 and known as DEF (diesel emission fluid), ARLA32 or AdBlue® .

For the next stage of Homogeneous Charge Compression Ignition (HCCI) engine researches, the development of an engine controller, taking account of dynamics is required. The objective of this paper is to develop dynamic multi input and multi output HCCI engine models and a controller to deal with variable valve lift, variable valve phase, and fuel injection. First, a physical continuous model has been developed. This model mainly consists of air flow models, an ignition model, and a combustion and mechanical model of the engine. The flow models use a receiver model on volumetric elements such as an intake manifold and a valve flow model on throttling elements such as intake valves. Livengood-wu integration of Arrhenius function is used to predict ignition timing. The combustion duration is expressed as a function of ignition timings.

Modern methods of engine development use complex mathematical models. Adding advanced components such as variable valve trains or direct injection systems to the model increases the degrees of freedom resulting in a high number of measurements for validation. Steadily rising costs for development, time and staff make it crucial for industry to improve the quality of measurements with advanced analysis techniques. Often, such models consider the simulated system as stationary, implying that system variables no longer change with time. This paper presents an internal combustion engine measurement system utilizing algorithms for the real-time evaluation of the state of the engine or its components. Several approaches have been reviewed and tested regarding their applicability. The most straightforward algorithms compare the gradient of a sensor signal to a pre-defined threshold.

The thermal and emission efficiency of diesel engines depends to a large extent on the quality of fuel injection. However, over engine lifetime, injection rate and quality will change due to adverse nozzle aging effects, such as coking or cavitation. In this study, we discuss the influences of these effects on injection and heat release rate. The injection rates of previously unused nozzles and a nozzle that had been operated in a vehicle engine were compared in order to clarify the impact of aging effects. The key to the detection of alterations of injection nozzles is the identification of strongly correlating parameters. As a first step, an instrumented injector was set up to measure fuel pressure inside the feed line of the injector and the lift of the control piston. Different nozzles showed a distinguishable control piston motion depending on their different geometric specifications, which also affect the injection rates.

This SAE Technical Paper contains detailed data which are relevant for the calculation of the friction forces of the piston assembly in internal combustion engines. Useful ways of employing calculations besides measurements are exactly classified for the optimization of the piston assembly system in order to reduce friction losses. In the first step the theoretical basics for the calculation of the tribological system are introduced. Referring to the theory, the paper goes into detail about the basic set-up and the modeling degree of the calculation program. Furthermore, measured and calculated curves of friction forces are compared for different operating points. In addition, analysis of the crank-angle resolved friction force are presented with varying engine speeds, oil temperatures and loads and a detailed interpretation of the results is given.

Presented within the framework of this SAE Technical Paper are the highly accurate results of friction experiments, performed upon a floating-liner, single-cylinder test engine with a capacity 0.5 liters and crank angle resolution during motored and fired operation. This allows for the measurement of mixed friction zones at the dead centers. These mixed friction zones can result in friction losses and lead to wear in the components in-volved. The strength of the friction forces in any given mixed friction zone is largely dependent on the operating point. This is why the influence of each of the most important operating parameters - speed (rpm), load, oil and coolant temperature - is individually analysed, before the interactions, which are depicted in the resultant engine map, are discussed.

In order to meet the severe emission restrictions imposed by SULEV and EURO V standards the catalytic converter must reach light-off temperature during the first 20 seconds after engine cold start. Thermal losses in the exhaust manifold are driven by the heat transfer of the pulsating and turbulent exhaust flow and affect significantly the warm-up time of the catalyst. In the present paper an investigation concerning the gas-side heat transfer in the exhaust system of a spark ignited (SI) combustion engine with retarded ignition timing and secondary air injection into the exhaust port is reported. Based on this analysis, the warm-up simulation of a one-dimensional flow simulation tool is improved for an evaluation of different exhaust system configurations.

This paper presents a phenomenological and semi-empirical simulation model to predict the injection rate of a diesel solenoid valve injector based on a few injection quantity measurements and indications (EMI). The approximate injection rate will be used as the input data for a subsequent model, which simulates the rate of heat release (ROHR). The injection rate model encompasses algebraic relations and differential equations deviating from the equations of motion and conservation, which describes the characteristic processes in the injector by using modular submodules. The process and its assumptions are explained step by step for each submodule. In addition, the injection rate predictions are presented and compared with experimental results arising from the selected reference solenoid valve injector.

The analysis of type and form of the loading in the guidance between the needle and body of a CR-injector, as well as the transformation of friction energy on the contact surfaces which absorbs mechanical and thermal loads with deforming and heating the contact layer is presented. The dominant parameters of friction and wear for the investigated interface (radial force, mode of friction, relation for the nominal and real contact areas etc.) are shown in function of different values of rail pressures, varying from 500 to 3000 bar. A special coefficient of accumulation of energy is defined. With these coefficient the analysis of thermal- and stress-conditions for the precision tribosystem become possible. Furthermore this leads to the calculation of the intensity of wear for the mentioned components of the nozzle.