Roland Paul Stark

Systems Approach to the Improvement of Engine Warm-Up Behaviour

Modifications to the coolant and oil circuits of a modern production 2.4 l diesel engine have been made in an attempt to promote oil warm-up to reduce fuel consumption. The new system used oil to cool exhaust gas recirculation (EGR) gases and incorporates a number of coolant flow control valves to reduce heat loss during warm-up. The engine was run over cold-start New European Drive Cycles with various flow strategies as a screening exercise to understand the behaviour of the system. Fuel consumption benefits of up to 4 per cent were observed, but these were accompanied by 3 per cent increases in nitrogen oxide (NO x ) emissions. Detailed analysis of the coolant flows and temperatures showed that, when throttling the flow, the mass of coolant in the degas bottle and radiator could be isolated from the system during warm-up, essentially reducing the thermal inertia. Heat transfer directly to the oil from the EGR gases rather than via the coolant allowed more heat to be put into the oil, with engine oil supply temperatures up to 6 °C hotter; however, it was not possible to verify that the oil was hotter at the bearings, valve train, and cylinder liner. The engine strategy was seen to react to the faster warm-up and to retard injection timing, reducing NO x but also compromising overall fuel consumption benefits. Further tests were conducted with various injection timings to establish a NO x —fuel consumption trade-off to demonstrate further benefits when the engine strategy is included in the operation of novel thermal management systems.

Vehicle modal emissions measurement: techniques and issues

Abstract The measurement of vehicle modal emissions is technically challenging owing to the major issue of determining exhaust-gas mass flowrate and ensuring that it is synchronous with the corresponding ‘slug’ of gas to be measured. This is also extended to the simultaneous measurement of pre- and post-catalyst emissions to determine small passive NOx conversion efficiencies. Although only really evident for passive NOx conversion efficiencies where the magnitude of catalyst performance is low in comparison to HC and CO, a misalignment between these measuring points of between will cause the resulting NOx conversion efficiency to lie anywhere between 0 per cent and 20 per cent. Further alignment issues arise when the CO2 tracer method is used for determining exhaust-gas volume flowrates. The sensitivity of time-alignment along with techniques and associated issues concerned with modal gas-flow measurement is presented in this paper.

Systems optimisation of an active thermal management system during engine warm-up

Active thermal management systems offer a potential for small improvements in fuel consumption that will contribute to upcoming legislation on carbon dioxide emissions. These systems offer new degrees of freedom for engine calibration; however, their full potential will only be exploited if a systems approach to their calibration is adopted, in conjunction with other engine controls. In this work, a design-of-experiments approach is extended to allow its application to transient drive cycles performed on a dynamic test stand. Experimental precision is of crucial importance in this technique since even small errors would obscure the effects of interest. The dynamic behaviour of the engine was represented mathematically in a manner that enabled conventional steady state modelling approaches to be employed in order to predict the thermal state of critical parts of the engine as a function of the actuator settings. A 17-point test matrix was undertaken, and subsequent modelling and optimisation procedures indicated potential 2–3% fuel consumption benefits under iso-nitrogen oxide conditions. Reductions in the thermal inertia appeared to be the most effective approach for reducing the engine warm-up time, which translated approximately to a 1.3% reduction in the fuel consumption per kilogram of coolant. A novel oil-cooled exhaust gas recirculation system showed the significant benefits of cooling the exhaust gases, thereby reducing the inlet gas temperature by 5 °C and subsequently the nitrogen oxide emissions by 6%, in addition to increasing the warm-up rate of the oil. This suggested that optimising the thermal management system for cooling the gases in the exhaust gas recirculation system can offer significant improvements. For the first time this paper presents a technique that allows simple predictive models of the thermal state of the engine to be integrated into the calibration process in order to deliver the optimum benefit. In particular, it is shown how the effect of the thermal management system on the nitrogen oxides can be traded off, by advancing the injection timing, to give significant improvements in the fuel consumption.

Influence of time-alignment on the calculation of mass emissions on a chassis rolls dynamometer

Time-alignment sensitivity studies have been carried out to assess the accuracy of instantaneous mass NOx emissions on a chassis rolls dynamometer. The work is part of a larger project aimed at measuring passive NOx catalyst conversion efficiencies. Instantaneous NOx emissions are examined in relation to the NEDC vehicle speed trace at multi-sampling points, and phase and time alignment issues are highlighted and discussed. It has been found that a small mismatch of the vehicle speed trace to the instantaneous mass of emissions of \mP2 seconds can lead to results indicating that the conversion efficiency is anywhere between 0-20%. Finally, examples are presented showing the difficulties of attempting to adjust the time alignment of raw emissions data.

Further Investigations on Time-Alignment

The measurement of vehicle modal emissions is technically challenging due to the major issue of determining exhaust gas mass flow rate and ensuring that it is synchronous with the emission measurement of that corresponding slug” of exhaust gas. This is very evident when attempting to measure small passive NOx catalyst conversion efficiencies. This paper highlights alignment issues with regard to the variation of time delays associated with engine and vehicle events and the CO\d2 tracer method for determining exhaust gas flows.

Investigation into the benefits of reduced oil flows in internal combustion engines

The engine lubrication system is a vital element for engine health but causes a parasitic load on the engine which increases the fuel consumption: this load can be reduced by matching the oil flow to lubricating requirements using a variable displacement oil pump. In a first stage, two variable displacement oil pumps were installed on a 2.4-L diesel engine; experiments over the New European Drive cycle showed reductions in fuel consumption of up to 3.4% and up to 5.8% over the urban phase of the cycle. A variable displacement oil pump was subsequently installed on an instrumented engine capturing over 100 metal and fluid temperatures within the engine structure. This showed that reducing oil flows resulted in lower oil temperature by up to 4 °C during cold-start New European Drive cycle but hotter cylinder liner temperatures by up to 6 °C. The higher cylinder wall temperatures caused an increase of 3% in oxides of nitrogen emissions but a reduction of 3%−5% in carbon monoxide and hydrocarbon emissions. Finally, an energy flow analysis showed that the variable displacement oil pump can reduce oil pump energy consumption by 160 kJ (32%) but that this led to a 400-kJ reduction in friction and accessory work. These findings highlight the need for a system-level rather than a component-level approach to engine lubrication design to capture key thermal interactions.

On-Engine Study of the Thermal and Performance Impacts of a Variable Displacement Oil Pump

Variable displacement lubricant pumps allow oil flow to be matched to engine requirements over the whole operating range, reducing energy losses through excessive pumping work. An experimental investigation has been performed on-engine to understand the effects of such devices. Significant instrumentation was fitted to the production, EURO IV specification, 2.4L Diesel engine to assess the impacts of lubricant flow on thermal state. The reduced oil flow was measured as a reduction in engine oil pressure with the production pump supplying 4–6bar whereas the variable flow device provided pressures as low as 1–2bar.The reduction in oil flow significantly reduced the oil pump energy consumption, measured as a change in indicated work, resulting in a 4% benefit in fuel economy over both hot and cold start NEDC. The reduced oil flow also impacted oil and metal temperatures: during engine warm-up, oil temperatures were approximately 4°C colder with the lower flow as a result of less work input from the oil pump. Conversely, cylinder liner temperatures were 2–6°C hotter both during warm-up and fully warm conditions as a result of reduced piston cooling from piston cooling jets. The changes in thermal state were reflected by changes in emissions with a 3% increase in NOx and a 3–5% reduction in HC and CO.The calibration of the variable flow device follows a fuel consumption/NOx trade-off that is more favourable to fuel economy than conventional control parameters. However, these benefits are strongly linked to engine duty cycle with larger benefits at higher engine speeds.Copyright