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This paper describes the Lean Boost System, a gasoline engine concept for improved fuel economy. The system combines direct injection, lean operation and pressure charging, and allows significant reduction in swept volume, or ‘downsizing’. Engine tests have been undertaken which demonstrate the validity of the combustion concept. The strategy a typical manufacturer might adopt in order to meet future European requirements for CO2 emissions is proposed. Vehicle simulation results for typical North American and European vehicles are presented. Using the exhaust gas emission levels from engine tests and drive cycle simulation, aftertreatment requirements and configurations are considered.

The need to reduce fuel consumption and CO2 emissions while meeting future emission legislation has lead to the investigation of alternative engines, transmissions, aftertreatment and control strategies. The evaluation of alternative configurations at the concept stage requires vehicle drive cycle simulation tools, which include the following features: Fast run-time Alternative transmission models Cold start effects on fuel consumption and emissions modeled After-treatment models. This paper describes the development of a MATLAB/SIMULINKTM - based drive cycle simulation model meeting these requirements. The paper includes validation data comparing fuel consumption, engine-out and tailpipe emissions for a direct injection gasoline vehicle with a stoichiometric/lean switching strategy and lean NOx catalyst.

The methods of operation of four of the leading combustion system designs for fuel only gasoline direct injection (G-DI) engines have been compared by applying a classical analysis procedure for defining fuel transport. The fuel spray requirements for the different systems are discussed in relation to results obtained from a Phase Doppler Anemometry (PDA) rig for different injectors. The combustion systems have then been considered regarding the functional requirements of future G-DI engines. These include power potential, stratified and homogeneous performance, variable air motion requirements, OEID component function monitoring, packaging and manufacturing issues and calibration effort. The paper concludes that there are at least four main approaches capable of producing acceptable combustion and that the choice of system will depend on packaging, cost and manufacturing constraints.

A system for stratifying recycled exhaust gas (EGR) to substantially increase dilution tolerance has been applied to a multi-cylinder port injected four-valve gasoline engine. This system, dubbed Combustion Control through Vortex Stratification (CCVS), has shown greatly improved fuel consumption at stoichiometric conditions whilst retaining ULEV compatible engine-out NOx and HC emission levels. A production feasible variable air motion system has also been assessed which enables stratification at part load with no loss of performance or refinement at full load.

The gasoline-fuelled direct injection poppet-valved two-stroke engine described in (1) has been built in single cylinder form and tested to evaluate the potential of this concept as a passenger car powerplant. Development of the combustion and scavenge system is described. Following development, the engine produced a specific power output of 90 kW/litre at 5000 rev/min, with a peak torque of 200 Nm/litre at 2000-2500 rev/min. HC emissions were maintained in the range 3-15 g/kWh over the majority of the engine operating range and NOx emissions in the load range used in the FTP drive cycle were less than 3 g/kWh. Part load fuel consumption under steady state conditions was 8% lower than for a stoichiometric four-stroke engine sized for equal power output.

The pursuit of flexibility is a recurring theme in engine design and development. Engines that are able to switch between the two-stroke operating cycle and four-stroke operation promise a great leap in flexibility. Such 2S-4S engines could then continuously select the optimum operating mode - including HCCI/CAI combustion - for fuel efficiency, emissions or specific output. With recent developments in valvetrain technology, advanced boosting devices, direct fuel injection and engine control, the 2S-4S engine is an increasingly real prospect. The authors have undertaken a comprehensive feasibility study for 2S-4S gasoline engines. This study has encompassed concept and detailed design, design analysis, one-dimensional gas dynamics simulation, three-dimensional computational fluid dynamics, and vehicle simulation. The resulting 2/4SIGHT concept engine is a 1.04 l in-line three-cylinder engine producing 230 Nm and 85 kW.

This paper describes a two-year programme of research conducted by the authors investigating HCCI in direct injection gasoline engines. Poppet-valved two-stroke cycle operation has been investigated experimentally, using conventional gasoline compression ratios and fuel, and ambient temperature intake air. Extensive combustion and emissions data was gathered from the experimental engine. Computational Fluid Dynamics (CFD) has been used to model HCCI combustion, and the CFD tool validated using experimental data. Based on experience with the two-stroke engine and modelling techniques, a four-stroke engine has been designed and tested. Using this range of tools, practical options for gasoline HCCI engines are evaluated, and a scenario for the market introduction of HCCI is presented.

A system for stratifying recycled exhaust gas (EGR) in order to substantially increase dilution tolerance has been applied to a single cylinder manifold injected pent-roof four-valve gasoline engine. This system has been given the generic name Combustion Control by Vortex Stratification (CCVS). Preliminary research has shown that greatly improved fuel consumption is achievable at stoichiometric conditions compared to a conventional version of the same engine whilst retaining ULEV NOx levels. Simultaneously the combustion system has shown inherently low HC emissions compared to homogeneous EGR engines. A production viable variable air motion system has also been assessed which increases the effectiveness of the stratification whilst allowing full load refinement and retaining high performance.

An investigation into the application of electronically controlled solenoid activated high pressure in-cylinder gasoline injection systems has been carried out in both conventional and novel four-valve four-stroke pent-roof chamber single-cylinder engines. Air motion requirements were studied and their effects on port design and layout were assessed. Alternative injector types, locations and spray characteristics were investigated. Transient and steady-state comparisons of the engines were made under both normal and cold running conditions. The outlook for the use of in-cylinder injection technology compatible with ULEV emissions requirements is discussed in the light of the results obtained.

This paper describes an experimental investigation to explore and optimise the performance, economy and emissions of a direct injection gasoline engine. Building on previous experimental direct injection investigations at Ricardo, a single cylinder engine has been designed to accommodate common rail electronically controlled fuel injection equipment together with appropriate port configuration and combustion chamber geometry. Experimental data is presented on the effects of chamber geometry, charge motion and fuel injection characteristics on octane requirement, lean limit, fuel consumption and exhaust emissions at typical automotive engine operating conditions. The configuration is shown to achieve stable combustion at air/fuel ratios in excess of 50:1 enabling unthrottled operation over a wide operating range. Strategies are demonstrated to control engine out emissions to levels approaching conventional port injected gasoline engines.

The development of technology suitable for meeting the CARB Ultra-low- emission-vehicle (ULEV) legislation has now become a main focus for vehicle manufacturers worldwide. This proliferation of interest is mainly a result of the increasing number of eastern US-states currently considering the adoption of CARB legislation and the indication that emission legislation in Europe and Japan for the turn of the century is likely to be of the same severity as CARB ULEV legislation. Current three way catalyst (TWC) emissions control technology suffers from low catalytic conversion efficiency of HC, CO and NOx pollutants during cold operation i.e. before catalyst light off. Cold start emissions generally contribute up to 70% of HC and CO tailpipe emissions during an FTP test. However, in some cases even early light-off of the catalyst, similar to hot operation is not sufficient to achieve catalytic conversion over a test cycle to reach ULEV emissions levels.

A system for stratifying recycled exhaust gas (EGR) to substantially increase dilution tolerance has been applied to a port injected four-valve gasoline engine. This system, known as Combustion Control through Vortex Stratification (CCVS), has shown greatly improved fuel consumption at a stoichiometric air/fuel ratio. Both burnrate (10-90% burn angle) and HC emissions are almost completely insensitive to EGR up to best economy EGR rate. Cycle to cycle combustion variation is also excellent with a coefficient of variation of IMEP of less than 2% at best economy EGR rate. This paper describes a research programme aimed at gaining a better understanding of the in-cylinder processes in this combustion system.