Advanced direct injection combustion engine technologies and development: Volume 2: Diesel engines

753 Pages·2009·31.99 MB·English

by  Hua Zhao

i
Advanced direct injection combustion engine technologies
and development
ii
Related titles:
The science and technology of materials in automotive engines
(ISBN 978-1-85573-742-6)
This authoritative book provides an introductory text on the science and technology of
materials used in automotive engines. It focuses on reciprocating engines, both four- and
two-stroke, with particular emphasis on their characteristics and the types of materials
used in their construction. The book considers the engine in terms of each specific part:
the cylinder, piston, camshaft, valves, crankshaft, connecting rod and catalytic converter.
The materials used in automotive engines are required to fulfil a multitude of functions.
It is a subtle balance between material properties, essential design and high performance
characteristics. The intention here is to describe the metallurgy, surface modification, wear
resistance, and chemical composition of these materials. It also includes supplementary
notes that support the core text.
HCCI and CAI engines for the automotive industry
(ISBN 978-1-84569-128-8)
HCCI/CAI has emerged as one of the most promising engine technologies with the
potential to combine fuel efficiency and improved emissions performance. Despite
the considerable advantages, its operational range is rather limited and controlling the
combustion (timing of ignition and rate of energy release) is still an area of ongoing
research. However, commercial applications are close to reality. This book reviews the key
international research on optimising its use, including gasoline HCCI/CAI engines; diesel
HCCI engines; HCCI/CAI engines with alternative fuels; and advanced modelling and
experimental techniques.
Tribology and dynamics of engine and powertrain: Fundamentals, applications and future
trends
(ISBN 978-1-84569-361-9)
Tribology is one element of many interacting within a vehicle engine and powertrain. In
adopting a detailed, theoretical, component approach to solving tribological problems,
the minutiae can be overwhelmingly complex, and practical solutions become elusive and
uneconomic. The system perspective generally adopted in industry, however, can lead
to shortcuts and oversimplifications, industrial projects are subject to ad hoc trial and
error, and subsequent ‘fire-fighting’ activity is required. This book seeks to bridge this
divide, using a multi-physics approach to provide sufficient fundamental grounding and
understanding of both detailed and approximate analyses – thereby making ‘first time
right’ design solutions possible. Tribological issues and solutions in piston systems, valve
train systems, engine bearings and drivetrain systems are addressed. New developments in
materials, micro-engineering, nano-technology and MEMS are also included.
Details of these and other Woodhead Publishing books can be obtained by:
∑ visiting our web site at www.woodheadpublishing.com
∑ contacting Customer Services (e-mail: [email protected]; fax: +44 (0)
1223 893694; tel.: [phone] ext. 130; address: Woodhead Publishing
Limited, Abington Hall, Granta Park, Great Abington, Cambridge CB21 6AH, UK)
If you would like to receive information on forthcoming titles, please send your address details
to: Francis Dodds (address, tel. and fax as above; e-mail: francis.dodds@woodheadpublishing.
com). Please confirm which subject areas you are interested in.
iii
Advanced direct
injection
combustion engine
technologies and
development
Volume 2: Diesel engines
SUPERIOR DOWNSIZING
OUR COMPETENCE FOR YOUR SUCCESS
Edited by
Hua Zhao
Turbocharged engines, in conjunction with innovative technolo-
gies, provide the optimum solution for improved fuel economy
and lower emissions. Our downsizing engine with a displace-
ment of 1.2 liters, which we developed as a technology dem-
onstrator, offers the performance of a conventional engine twice
the size. More importantly, it reduces fuel consumption, and
consequently CO2 emissions by up to 30 percent. Our numer-
ous high-performance projects and systems contribute to this
achievement. As a result of this extensive systems expertise,
MAHLE is the leading development partner for the international
automotive and engine industry. www.mahle-powertrain.com
Unbenannt-2 1 13.05.2009 10:46:20
CRC Press
Boca Raton Boston New York Washington, DC
Woodhead publishing limited
Oxford Cambridge New Delhi
iv
Published by Woodhead Publishing Limited, Abington Hall, Granta Park,
Great Abington, Cambridge CB21 6AH, UK
www.woodheadpublishing.com
Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28 Ansari Road, Daryaganj,
New Delhi – 110002, India
www.woodheadpublishingindia.com
Published in North America by CRC Press LLC, 6000 Broken Sound Parkway, NW,
Suite 300, Boca Raton, FL 33487, USA
First published 2010, Woodhead Publishing Limited and CRC Press LLC
© 2010, Woodhead Publishing Limited; Ch 17 © United States Government
The authors have asserted their moral rights.
This book contains information obtained from authentic and highly regarded sources. Reprinted
material is quoted with permission, and sources are indicated. Reasonable efforts have been
made to publish reliable data and information, but the authors and the publishers cannot assume
responsibility for the validity of all materials. Neither the authors nor the publishers, nor
anyone else associated with this publication, shall be liable for any loss, damage or liability
directly or indirectly caused or alleged to be caused by this book.
Neither this book nor any part may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopying, microfilming and recording, or by
any information storage or retrieval system, without permission in writing from Woodhead
Publishing Limited.
The consent of Woodhead Publishing Limited does not extend to copying for general
distribution, for promotion, for creating new works, or for resale. Specific permission must
be obtained in writing from Woodhead Publishing Limited for such copying.
Trademark notice: Product or corporate names may be trademarks or registered trademarks,
and are used only for identification and explanation, without intent to infringe.
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.
Library of Congress Cataloging in Publication Data
A catalog record for this book is available from the Library of Congress.
Woodhead Publishing ISBN 978-1-84569-744-0 (book)
Woodhead Publishing ISBN 978-1-84569-745-7 (e-book)
CRC Press ISBN 978-1-4398-2475-7
CRC Press order number: N10132
The publishers’ policy is to use permanent paper from mills that operate a sustainable forestry
policy, and which has been manufactured from pulp which is processed using acid-free and
elemental chlorine-free practices. Furthermore, the publishers ensure that the text paper and
cover board used have met acceptable environmental accreditation standards.
Typeset by Replika Press Pvt Ltd, India
Printed by TJ International Limited, Padstow, Cornwall, UK
v
Contents
Contributor contact details xiii
Preface xvii
Part I Light-duty direct injection diesel engines
1 Overview of high-speed direct injection diesel
engines 3
R. W. Horrocks, Ford Motor Company Limited, UK
1.1 Background 3
1.2 Early development of the high-speed direct injection
(HSDI) diesel engine 4
1.3 Recent trends in high-speed direct injection (HSDI)
diesel engine design 10
1.4 A survey of some of today’s engines 31
1.5 Future trends 48
1.6 Sources of further information and advice 55
1.7 References 56
2 Fuel injection systems for high-speed direct
injection diesel engines 61
R. W. Horrocks, R. Lawther and L. Hatfield, Ford Motor
Company Limited, UK
2.1 Introduction 61
2.2 Early high-speed direct injection (HSDI) diesel fuel
systems 63
2.3 Common rail fuel injection systems 66
2.4 Common rail systems 74
2.5 Nozzle technology 86
2.6 High pressure (HP) pump technology 88
2.7 Diesel fuel injection equipment heat rejection 92
2.8 Electronic control of fuel systems 96
vi Contents
2.9 Future trends 102
2.10 References 103
3 Mixture formation, combustion and pollutant
emissions in high-speed direct injection diesel
engines 105
A. Velji, M. Lüft and S. Merkel, Universität Karlsruhe (TH),
Germany
3.1 Mixture preparation 105
3.2 Combustion 120
3.3 Pollutant emissions 132
3.4 Future trends 151
3.5 References and further reading 153
4 Multiple injection diesel combustion process in the
high-speed direct injection diesel engine 155
B. M. Vaglieco, Istituto Motori-CNR, Italy
4.1 Introduction 155
4.2 Double injection or pilot + main 158
4.3 Multiple injection technology 163
4.4 Other diesel combustion technologies 168
4.5 Conclusions 171
4.6 Acknowledgements 172
4.7 References 172
5 Turbocharging and air-path management for
light-duty diesel engines 175
K. Tufail, Ford Motor Company Limited, UK
5.1 Introduction: air-path challenges and acceptance criteria 175
5.2 Air-path technologies, part 1: exhaust gas recirculation
(EGR) 178
5.3 Air-path technologies, part 2: boosting systems 184
5.4 Air-path management 197
5.5 Future trends 206
5.6 Acknowledgements 207
5.7 References 208
5.8 Appendix: Acronyms 213
6 Advanced concepts for future light-duty diesel
engines 215
I. Denbratt, Chalmers University of Technology, Sweden
6.1 Introduction 215
Contents vii
6.2 Legislative exhaust emission standards 216
6.3 Current developments 220
6.4 Low emissions concepts: key aspects 221
6.5 Combustion systems 227
6.6 Fuel injection 230
6.7 Charge induction 233
6.8 Combustion chamber shape 237
6.9 Exhaust gas after-treatment 237
6.10 Heat recovery 241
6.11 Engine control 242
6.12 Future fuels 242
6.13 References and further reading 243
7 Advanced control and engine management for future
light-duty diesel engines 246
L. Guzzella, Swiss Federal Institute of Technology (ETH),
Switzerland
7.1 Main control objectives 246
7.2 Standard control loops 248
7.3 System modelling 252
7.4 Advanced control systems 259
7.5 References 265
Part II Heavy-duty direct injection diesel engines
8 Overview of heavy-duty diesel engines 269
Z. Liu, Navistar, Inc., USA
8.1 Introduction 269
8.2 A survey of current heavy-duty diesel engines 273
8.3 Approaches to meet future emissions legislation and
CO targets 281
2
8.4 Summary 287
8.5 References 287
9 Fuel injection systems for heavy-duty diesel engines 289
P. J. G. Dingle, Delphi Diesel Systems, USA
9.1 Introduction 289
9.2 History of heavy-duty fuel injection equipment (FIE) 290
9.3 Current choices of fuel injection equipment (FIE) 290
9.4 Detailed fuel injection equipment (FIE) descriptions 293
9.5 Nozzle developments 306
9.6 Synergies with light-duty fuel injection equipment (FIE) 308
viii Contents
9.7 Future trends 309
9.8 References 316
10 Turbocharging technologies for heavy-duty diesel
engines 318
J. Carter, N. K. Sharp and H. Tennant, Cummins Turbo
Technologies, UK
10.1 Scope 318
10.2 Turbocharger technology state of the art 319
10.3 Engine performance requirements and operating
characteristics 321
10.4 Turbocharger architectures and aerodynamic design
considerations 328
10.5 Durability 343
10.6 Actuation 349
10.7 Future trends 356
10.8 Sources of further information and advice 357
10.9 References 357
11 Alternative combustion system for heavy-duty diesel
engines 358
W. Su, Tianjin University, China
11.1 Introduction 358
11.2 Premixed charge compression ignition (PCCI) combustion
organized by early direct injection 361
11.3 Lean diffusion combustion 367
11.4 Summary 373
11.5 References 373
12 Heavy-duty diesel engine system design 376
Q. Xin, Navistar, Inc., USA
12.1 Overview of analytical engine design process and system
simulation approach 376
12.2 Fundamentals of in-cylinder cycle computation and air
system steady-state performance 385
12.3 Engine–vehicle matching analysis for powertrain system
design in engine firing and braking 415
12.4 Emissions calibration optimization development and
engine performance design target 441
12.5 Diesel aftertreatment integration and matching 458
12.6 Engine heat rejection and base engine characteristics 467
12.7 Pumping loss theory and the principle of engine air
system design 479
Contents ix
12.8 Transient powertrain performance modeling and engine
electronic controls 499
12.9 Engine system specification design and subsystem
interaction optimization 511
12.10 Analytical design of mechanical components for system
performance improvement 520
12.11 Future trends 534
12.12 References 537
Part III Exhaust emission abatement, diesel combustion
diagnostics and modelling
13 Fuel reforming for diesel engines 543
A. Megaritis, Brunel University, UK, A. Tsolakis and M. L. Wyszynski,
University of Birmingham, UK, and S. E. Golunski, Johnson Matthey
Technology Centre, UK
13.1 Why fuel reforming in diesel engines? 543
13.2 Diesel fuel reforming theory 546
13.3 Diesel fuel reforming process parameters and catalyst
screening 553
13.4 Diesel fuel reforming applications: trends 555
13.5 Summary 558
13.6 References 558
14 Exhaust gas aftertreatment for light-duty diesel
engines 562
P. Eastwood, Ford Motor Company Limited, UK
14.1 Introduction 562
14.2 Emissions legislation 563
14.3 Oxidation catalysts 568
14.4 Particulate filters 568
14.5 Selective catalytic reduction 572
14.6 Lean NO traps (LNT) 576
x
14.7 Integrated systems 581
14.8 Summary 585
14.9 Future trends 587
14.10 References 589
14.11 Appendix: Acronyms 594
15 Overview of diesel emissions and control for
heavy-duty diesel engines 595
T. Johnson, Corning Incorporated, USA
15.1 Introduction 595
x Contents
15.2 Heavy-duty regulatory developments 596
15.3 NO control technologies 599
x
15.4 Particulate matter (PM) control technologies 604
15.5 Integrated NO /PM systems 611
x
15.6 Future trends 612
15.7 Sources of further information and advice 613
15.8 References 613
16 Optical diagnostics in diesel combustion engines 617
C. Schulz, University of Duisburg-Essen, Germany
16.1 Introduction 617
16.2 Liquid spray diagnostics 619
16.3 Vapour-phase fuel distribution 620
16.4 Two-phase flows 623
16.5 Ignition and combustion 624
16.6 Pollutant measurements 626
16.7 Soot volume fraction laser-induced incandescence (LII) 630
16.8 Temperature 631
16.9 Future trends 634
16.10 Conclusions 634
16.11 References 635
17 In-cylinder spray, mixing, combustion, and
pollutant-formation processes in conventional and
low-temperature-combustion diesel engines 644
M. P. B. Musculus and L. M. Pickett , Sandia National
Laboratories, USA
17.1 Introduction 644
17.2 Conventional diesel combustion 645
17.3 Positive ignition-dwell low-temperature diesel combustion 657
17.4 Quasi-steady low-temperature diesel combustion 664
17.5 Closing remarks on low-temperature combustion (LTC)
diesel research needs 669
17.6 References 670
18 Advanced computational fluid dynamics modeling of
direct injection engines 676
R. D. Reitz, University of Wisconsin-Madison, USA, and Y. Sun,
General Motors Company, USA
18.1 Introduction 676
18.2 Basic approach 677
18.3 Turbulence modeling 678
18.4 Spray modeling 680