The science and technology of materials in automotive engines

325 Pages·16.029 MB·English

by  Hiroshi Yamagata, Institute of Materials, Minerals, and Mining

i
Advanced direct injection combustion engine technologies
and development
ii
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iii
Advanced direct
injection
combustion engine
technologies and
development
Volume 1: Gasoline and gas engines
SUPERIOR DOWNSIZING
OUR COMPETENCE FOR YOUR SUCCEEdSSited 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,
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Published in North America by CRC Press LLC, 6000 Broken Sound Parkway, NW, Suite 300,
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First published 2010, Woodhead Publishing Limited and CRC Press LLC
© 2010, Woodhead Publishing Limited; Ch 3 © J.W.G. Turner and R.J. Pearson
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Woodhead Publishing ISBN 978-1-84569-389-3 (book)
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v
Contents
Contributor contact details ix
Preface xi
1 Overview of gasoline direct injection engines 1
H. Zhao, Brunel University, UK
1.1 Introduction 1
1.2 Overview of direct injection gasoline engines 2
1.3 Potential and technologies for high-efficiency direct
injection (DI) gasoline engine 5
1.4 High-pressure fuel injection system 11
1.5 Exhaust emissions and aftertreatment devices 14
1.6 Summary 17
1.7 References 18
2 Stratified-charge combustion in direct injection gasoline
engines 20
U. Spicher and T. Heidenreich, Universität Karlsruhe (TH),
Germany
2.1 Introduction 20
2.2 Thermodynamic and combustion process 21
2.3 Production engines with stratified gasoline direct
injection (GDI) 36
2.4 Future trends 42
2.5 References 43
3 The turbocharged direct injection spark-ignition engine 45
J. W. G. Turner and R. J. Pearson, Lotus Engineering, UK
3.1 Introduction 45
3.2 Historical background: turbocharging for high specific output 46
3.3 Problems and challenges associated with turbocharging the
spark-ignition (SI) engine 51
vi Contents
3.4 Advantages of combining direct injection and turbocharging in
spark-ignition (SI) engines 65
3.5 Challenges of applying direct injection to a turbocharged
spark-ignition (SI) engine 74
3.6 Future trends and possibilities 75
3.7 Summary 83
3.8 References 84
4 The lean boost combustion system for improved fuel
economy 91
T. Lake, J. Stokes, R. Osborne, R. Murphy and M. Keenan,
Ricardo UK Ltd, UK
4.1 Pressures on the gasoline engine 91
4.2 Downsizing strategies 93
4.3 The lean-boost direct injection (LBDI) concept 93
4.4 Exhaust emissions control: drive-cycle emissions 99
4.5 Exhaust emissions control: off-cycle emissions 99
4.6 Selective catalytic reduction (SCR) NO control as an
x
alternative to lean NO trap (LNT) 101
x
4.7 Conclusions 103
4.8 Future trends 104
5 Exhaust gas recirculation boosted direct injection
gasoline engines 105
A. Cairns, H. Blaxill and N. Fraser, MAHLE Powertrain
Ltd, UK
5.1 Introduction 105
5.2 Fundamentals of wide-open-throttle exhaust gas recirculation
(WOT- EGR) operation 108
5.3 Exhaust gas recirculation (EGR) circuit design 115
5.4 Exhaust gas recirculation (EGR) operating maps 124
5.5 In-vehicle requirements 127
5.6 Future trends 130
5.7 References 131
6 Direct injection gasoline engines with autoignition
combustion 133
H. Zhao, Brunel University, UK
6.1 Introduction 133
6.2 Principle of autoignition combustion in the gasoline engine 135
6.3 Approaches to autoignition combustion operation in gasoline
engines 137
Contents vii
6.4 Operation and control of direct injection gasoline engines with
autoignition combustion 146
6.5 Development of practical gasoline engines with autoignition
and spark-ignition (SI) combustion 158
6.6 Future trends 161
6.7 References 163
7 Design and optimization of gasoline direct injection
engines using computational fluid dynamics 166
J. Yi, Ford Research and Advanced Engineering, Research and
Innovation Center, USA
7.1 Introduction 166
7.2 Direct injection spark-ignition (DISI) injector technologies 169
7.3 Homogeneous-charge direct injection (DI) system design
and optimization 173
7.4 Stratified-charge direct injection (DI) combustion system
design and optimization 189
7.5 Turbo-charged or super-charged direct injection (DI)
combustion system design and optimization 192
7.6 Future trends 194
7.7 References and further reading 196
8 Direct injection natural gas engines 199
D. Zhang, Westport Innovations Inc., Canada
8.1 Introduction 199
8.2 Technologies 200
8.3 Potential applications 221
8.4 Strengths and weaknesses 222
8.5 Future trends 225
8.6 Sources of further information and advice 227
8.7 References 228
9 Biofuels for spark-ignition engines 229
J. D. Pagliuso, University of São Paulo, Brazil and M. E. S.
Martins, Sygma Motors, Brazil
9.1 Introduction 229
9.2 Types and sources of biofuels 231
9.3 Performance 237
9.4 Emissions 246
9.5 Operation 253
9.6 Conclusions 255
9.7 References 256
viii Contents
10 Optical diagnostics for direct injection gasoline engine
research and development 260
V. Sick, The University of Michigan, USA
10.1 Need for and merit of optical diagnostics 260
10.2 Applications of optical diagnostics 262
10.3 Future trends 278
10.4 Conclusions 279
10.5 References 279
Index 287
ix
Contributor contact details
(*= main contact)
Chapter 1 Chapter 3
Professor Hua Zhao James W. G. Turner* and Dr
Brunel University Richard. J. Pearson
West London Lotus Engineering
Uxbridge UB8 3PH Hethel
UK Norwich
Norfolk NR18 4EZ
Email: [email protected] UK
E-mail: [email protected];
Chapter 2
[email protected]
Professor Dr Ulrich Spicher* and
Thomas Heidenreich Chapter 4
Institut für Kolbenmaschinen
Universität Karlsruhe (TH) Dr Tim Lake,* J. Stokes, R.
PO box 6980 Osborne, R. Murphy and M.
76128 Karlsruhe Keenan
Germany Ricardo UK Ltd
UK
Email: [email protected]
karlsruhe.de; thomas.heidenreich@ Email: [email protected]
ifkm.uni-karlsruhe.de
Chapter 5
Dr Alasdair Cairns*, Hugh Blaxill
and Neil Fraser
MAHLE Powertrain Ltd
Northampton
UK
E-mail: [email protected]