Stefania Zanforlin

Two-Step Concept for Low-Pressure Direct Hydrogen Injection

In this paper, a low-pressure hydrogen direct-injection solution is presented that entails low storage residual pressure (∼12 bar). The injection is realised in two steps. First, hydrogen is simply metered by an electro-injector (a conventional one for Compressed Natural Gas - CNG application) that feeds a small intermediate chamber. Next, hydrogen enters the cylinder by means of a mechanically-actuated valve which allows higher flow than any electro-injector. Injection must end early enough to allow good charge homogeneity and, in any case, before in-cylinder pressure rise constraints hydrogen admission. Backfire is avoided by starting injection at intake valve closing. A prototype has been realised modifying a single-cylinder 650 cc production engine with three intake valves. The central one has been modified and properly timed to in-cylinder inject hydrogen from the intermediate chamber. Hydrogen injection through different-shape poppet valves in a quiescent, constant volume has been simulated in order to investigate the effects of valve and seat-valve geometries in controlling fuel-air mixing in the cylinder. Additional predictions for the actual engine configuration indicate that an acceptable fuel distribution can be obtained in the combustion chamber at the spark timing, with equivalence ratios in the ignition region that are inside the flammability range of the mixture for all the operating conditions (loads and speeds) that have been considered.© 2009 ASME

Direct Injection and Charge Stratification in a 50 cc Two-Stroke Engine: CFD Studies and Test Bench Results

Direct fuel injection has become necessary in two-stroke S.I. engines, since it prevents one of the major problems of these engines, that is fuel loss from the exhaust port. Another important problem is combustion irregularity at light loads, due to excessive residual gas in the charge, and can be solved by charge stratification. High-pressure liquid fuel injection is able to control the mixing process inside the cylinder for getting either stratified charge at partial loads or quasi-stoichiometric conditions, as it is required at full load. The feasibility of this solution for a small engine for light motorcycles has been studied using CFD tools. An exhaustive investigation carried out by the KIVA3v code allowed to design a 50 cm3 engine prototype with a satisfactory behaviour even at light loads in unthrottled condition, as proved by good fuel economy and engine stability in dynamometric bench tests. Exhaust gas analysis and indicated pressure behaviour confirm stratification and combustion correctness. For the final part of the research the adoption of the AVL-Fire code has been considered: the possibility to take into account any combustion chamber and transfer duct geometric details and the accuracy of spray breakup and wall film models allow to better understand the engine behaviour throughout the operating range, obtaining useful information in order to efficiently shorten the experimental time required for the EU map-setting.© 2006 ASME

Four Stroke Engine Geometry for Stratified Charge Combustion

In four-stroke engines direct injection increases power and fuel economy, which is further improved by charge stratification, due to pumping loss reduction and better combustion efficiency at partial loads. Charge stratification can be obtained by different techniques and injector designs. In every case late injection is necessary for stratification, which however is impaired by fuel dilution and spreading in consequence of burnt gas expansion, leading to incomplete combustion at very light loads. A numerical study has been carried out modifying KIVA code to handle new piston shapes. An innovative combustion chamber that is split in two volumes and allows fuel confinement during combustion has been conceived. CFD comparison has been made between a conventional combustion chamber and the proposed new one in term of combustion efficiency. Combustion is enhanced by the new design and unburnt emissions are reduced.Copyright

Stable Fuel Confinement in Stratified Charge GDI Engines

Direct fuel injection combined with charge stratification represents a must for two-stroke S.I. engines, since it prevents fuel loss from the exhaust port and incomplete combustion or misfire at light loads. The most difficult aims are keeping stable stratification when engine operating conditions change and, at very light loads, avoiding excessive dilution and spreading of fuel vapour in consequence of burned gas expansion. Two new-concept engine designs are proposed in this paper. In both cases shapes of piston and head, together with scavenging-duct orientation have been optimised to obtain stable in-cylinder flow field features (independently of engine speed) and proper fuel distribution at ignition time. Computational Fluid Dynamics (CFD) predictions at different loads and speeds are reported and discussed.© 2004 ASME

Flow Dynamics of Charge Stratification in Small GDI Two-Stroke Engines

Direct high-pressure liquid fuel injection is able to control the mixing process inside the cylinder for getting either stratified charge at partial loads or quasi-homogeneous conditions, as it is required at full load. This paper shows the development of this solution for small two-stoke engines, using multidimensional modelling. The aim is investigating how the design of scavenging ducts and combustion chamber influences charge stratification behaviour, taking into account fuel distribution and stratification stability varying engine load and speed.Copyright

Implementation of a novel hydrogen direct-injection concept in single and multi-cylinder engines: CFD, experimental and engine powertrain design studies

A novel low-pressure hydrogen direct-injection system, characterised by low storage residual pressure and simple mechanical solutions, has been implemented in single and multi-cylinder engines. Based on two-step operation, this system keeps hydrogen metering apart from injection. The first step relates to the system with constant H2 flow rate and variable opening duration. The second step is characterised by variable H2 flow rate and constant angular duration. A prototype has been realised modifying a single-cylinder production engine, following the results of a wide CFD activity during which in-cylinder hydrogen injection and mixing phases have been simulated to investigate how valve and seat-valve geometries affect mixing characteristics. The prototype engine ran properly at full load, without pre-ignition, knocking or roughness even with stoichiometric or slightly rich mixtures, providing higher maximum power than with gasoline. At part load the engine worked correctly even with very lean mixtures. Current research is directed to explore the feasibility of applying the two-step injection concept in a multi-cylinder engine. The CFD analysis together with the design study aimed to integrate the injection system in the engine powertrain are shown and discussed.

Numerical and Experimental Analysis on a Small GDI, Stratified Charge, Motorcycle Engine

In the field of engines for light motorcycles, two-stroke cycle survival is submitted to the application of direct fuel injection and charge stratification, even in the case of low-cost small engines. However, charge stratification is a difficult target in two-stroke engines, chiefly because timings of late injection (necessary for charge stratification) and of early injection (necessary for homogeneous charge) are much closer than in four-stroke engines. The compatibility between stratified and homogeneous charge operations needs a thorough CFD study of injection and mixing processes, with the support of techniques of spray visualization. Results strongly depend on the possibility of optimising the interaction between in-cylinder gas-dynamic field and spray; experimental activity is necessary as data source and verification of computational prediction. This paper shows the latest CFD investigation, experimental tests and results concerning a 50 cm3 engine for light motorcycles. The injection is of the liquid type with wall-and-air guided spray produced by a swirl injector. The research has been focused on the attainment of charge stratification at every engine speed. Spray actual characteristics have been investigated, attesting suitable repeatability and proper variation versus backpressure. Engine satisfactory behaviour even at light loads in unthrottled condition is proved by good fuel economy and engine stability in dynamometric bench tests. Exhaust gas analysis and indicated pressure behaviour confirm stratification and combustion correctness.Copyright