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High Efficiency Intake System Leveraging Exhaust Thermal Boost
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on April 14, 2020 by SAE International in United States
This IC engine amelioration tackles the hurdling barrier of ICE’s intrinsic efficacy limit through innovative mechanical design of a consolidated system encompassing intake bypass and coordinating injection mechanism. To be specific, a CFD-optimized passage is constructed alongside the intake and injection design which utilizes multi-stage variable mixing precisely, taking full advantage of exhaust temperature elevation. Regenerative heat gained through exhaust system gives rise to flexible amount of thermal dynamics adjustment to the intake. Furthermore, variable geometry intake port is developed based on maximizing air-fuel interaction rate under different circumstances, where high temperature turbulence optimization is implemented in ANSYS Fluent. Pin-slider mechanic design at intake interface enables modular variable intake routing supporting engine efficiency promotion. Regarding ECU development, integrated valve, intake airflow, as well as injection control are designed to cooperate with each other under the supervisory control module. First, optimal controlled valve system is devised at the junction of bypass, which achieves improved response accuracy and combustion sufficiency with flow and temperature regulation. Secondly, a closed-loop injection control strategy fulfills variable in-cylinder combustion tuning with established nozzle and injector models. To elaborate, through feedback from actuator model, the nozzle pressure difference is used to adapt compensation factors applied on the subsequent injections. Thirdly, in terms of intake swirl control unit, reinforcement learning algorithm takes care of analyzing effective mixing route and timing of intake operation. Mechanical architecture of the boosting bypass system is validated and optimized through finite element method, in terms of air-fuel-ratio, maximum temperature. Transient thermal analysis of bypass system alongside with intake and exhaust system is implemented and compared with benchmark boosted engine performance, such as torque, power density, fuel consumption and thermal stress.