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The acceleration response of a supercharged diesel engine passenger car, equipped with a particulate trap, is studied using a simulation program. The superchargers evaluated are the Comprex(R) pressure-wave supercharger as well as turbochargers with fixed and variable-geometry. The particulate trap is placed before the supercharger to promote the trap regeneration and to reduce the pumping gas-exchange work. Particulate traps currently used are such a large thermal sink that the acceleration response is unacceptable. There are promising innovations in progress to develop a particulate trap with less than a quarter of the present mass. The computations demonstrate that the acceleration response should then be acceptable.

The Comprex(R) is a pressure-wave supercharger (PWS) for passenger car diesel engines. It has many features which ideally suit it for the continually increasing demands on driveability, fuel economy and reduction of exhaust pollutants. To counter the disadvantages of the previously required belt drive, a free-running machine was developed. It is self driven by the kinetic energy of the exhaust gas; made possible by employing a rotor having reduced inertia. In addition to the well known Comprex features, this advanced development offers advantages such as rapid response, high efficiency, compactness and freedom in placement. The paper discusses the design of the free-running PWS, its construction, supercharging characteristics and preliminary experience.

1 A methodology for correctly matching trap systems to the vehicle types was developed within the scope of a feasibility study to retrofit the entire Swiss fleet of on-road HDV. Representative test vehicles from 11 vehicle categories were equipped with high capacity data loggers during a period of 4-6 weeks. Statistical evaluation of exhaust temperatures indicate that data on averages, peaks and frequency distributions alone can be misleading, because these tend to over-estimate the available exhaust enthalpy. Analysis of dwell time intervals, at certain temperature levels, is a better method to assess the energy available for the regeneration. Such verification of duty cycles is indispensable before retrofitting traps and choosing either active or passive regeneration systems.

Primary measures, to reduce the NOx emissions from diesel engines, penalize the fuel consumption and aggravate the CO2 problem. Instead, an after-treatment system is proposed that permits optimum combustion and yet reduces the NOx by more than 95%. Such installations are in operation for more than five years. Successful deployment on a short-haul ferry, subject to highly cyclic operation, began in Spring 1992. The chief features are high space-velocity (25,000 1/h), urea as non-toxic reactant and rapid transient response. The attained results counter the misgivings about the SCR catalysis. Development aims at further halving the size thus facilitating service in off-highway vehicles such as locomotives and earth-movers. The integration of particulate traps using knitted micro-fibers is under development.

Vegetable oils blended to Diesel fuel are becoming popular. Economic, ecological and even political reasons are cited to decrease dependence on mineral oil and improve CO2 balance. The chemical composition of these bio fuels is different from mineral fuel, having less carbon and much more oxygen. Hence, internal combustion of Diesel + RME (Rapeseed Methyl Ester) blends was tested with particular focus on nanoparticle emissions, particle filtration characteristics and PAH-emissions. Fuel economy and emissions of bus engines were investigated in traffic, on a test-rig during standardized cycles, and on the chassis dynamometer. Fuel compositions were varied from standard EN 590 Diesel with <50 ppm sulfur to RME blends of 15, 30, and 50%. Also 100 % RME was tested on the test-rig. Emissions were compared with and without CRT traps. The PAH profiles of PM were determined. Particles were counted and analyzed for size, surface, and composition, using SMPS, PAS, DC and Coulometry.

Based on the emission inventory Fig. 1, the Swiss 1998 Ordinance on Air Pollution Control (OAPC) mandates curtailment of carcinogenic diesel particle emissions at type B construction sites [1]. Moreover, particle traps are compulsory at underground workplaces [2]. In compliance, more than 6,000 Diesel engines were retrofitted with various particle trap systems. Many traps surpassed 99% filtration efficiency and secondary emissions were mostly prevented. However, trap failure due to mechanical and thermal damage was initially rather high at about 10%. By the year 2000 the failure rate was halved to about 6%. Thanks to focussed improvements, the year 2003 statistics show yearly failures of “only” about 2%. The Swiss target is to retrofit 15,000 construction machines with traps, fully compliant with environmental directives, having 5,000 operating hours durability and failure rates below 1%. Traps must pass the VERT suitability test before deployment.

Close collaboration between ABB and NGK enabled the development of the rotor for the Comprex(R) pressure-wave supercharger (PWS) as an extruded component in pressureless sintered silicon nitride. The ceramic rotor is lighter than the steel rotor, permitting a free-running PWS. And, the lower thermal expansion of ceramic improves the supercharging efficiency. Prototypes have been road tested since 1984 and fulfil the major engineering requirements: burst speed thrice nominal, probability of fracture ≤ 10-5, maximum temperature well above operating and low risk of damage from foreign objects. When the ceramic rotor becomes cost competitive and can be mass produced, it will considerably expand the range of applications of the PWS.

THE COMPREX PRESSURE WAVE SUPERCHARGER (PWS), developed for passenger car diesel engines, is now in production. Those of its properties which influence road performance, fuel consumption, and emission behavior of the PWS charged engine are described on the basis of the maps of the production models. The design for high volume production is presented and substantiated by test results. 6 types are available, covering an engine range from one to three litr swept volume with and without charge air cooling and optional waste gate. Instant response and high efficiency allow downsizing and downspeeding and lead to improved fuel economy, low emission and low noise level.

The Comprex pressure-wave machine is well qualified for supercharging automotive Diesel engines, demonstrating as it does, improvements in power output, fuel consumption and emissions. The special form of the charging characteristics is established from theoretical considerations of the pressure wave compression process. Data from the currently available production machines show, with the aid of supercharging parameters, such a pressure ratio, density ratio and adiabatic compression efficiency, the operating limits of the machine with respect to cell filling and pressure-wave tuning. A computer program, interpolating from measured data and using a simplified model of the engine, allows optimisation of an installation considering Comprex type, shaft drive ratio, charge air cooling and control system functions. The correlation of the program with measured values is adequate for the purpose of engine-to-Comprex matching.

1 Small off-road 4-stroke SI-engines have extraordinarily high pollutant emissions. These must be curtailed to comply with the new Swiss clean air act LRV 98. The Swiss environmental protection agency (BUWAL) investigated the state of the technology. The aim was a cleaner agricultural walk behind mower with a 10kW 4-stroke SI-engine. Two engine designs were compared: side-valve and OHV. A commercially available 3-way catalytic converter system substantially curtailed emissions: In the ISO 8178 G test-cycle-average, HC was minimized to 8% and CO to 5% of raw emissions. At part load points, the residual emission was < 1%. Simultaneously, fuel consumption improved 10%. Using a special gasoline (Swiss standard SN 181 163), the aromatic hydrocarbons were curtailed, e.g. Benzene < 1%, and fuel consumption further improved. Those results were confirmed in field tests. The engine is approved for retrofitting.