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High Load Expansion of Catalytic EGR-Loop Reforming under Stoichiometric Conditions for Increased Efficiency in Spark Ignition Engines

Oak Ridge National Laboratory-James P. Szybist, Josh Pihl, Shean Huff, Brian Kaul
Published 2019-04-02 by SAE International in United States
The use of fuel reformate from catalytic processes is known to have beneficial effects on the spark-ignited (SI) combustion process through enhanced dilution tolerance and decreased combustion duration, but in many cases reformate generation can incur a significant fuel penalty. In a previous investigation, the researchers showed that, by controlling the boundary conditions of the reforming catalyst, it was possible to minimize the thermodynamic expense of the reforming process, and in some cases, realize thermochemical recuperation (TCR), a form of waste heat recovery where exhaust heat is converted to usable chemical energy. The previous work, however, focused on a relatively light-load engine operating condition of 2000 rpm, 4 bar brake mean effective pressure (BMEP). The present investigation demonstrates that this operating strategy is applicable to higher engine loads, including boosted operation up to 10 bar BMEP. By controlling the reforming catalyst boundary conditions, it is possible to achieve fuel reforming without experiencing high temperature exotherms that could be damaging to the catalyst. Additionally, the thermodynamic air handling consequences of operating a highly dilute strategy at…
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Characterization of GDI PM during Vehicle Start-Stop Operation

Oak Ridge National Laboratory-John M. Storey, Melanie Moses-DeBusk, Shean Huff, John Thomas, Mary Eibl, Faustine Li
Published 2019-01-15 by SAE International in United States
As the fuel economy regulations increase in stringency, many manufacturers are implementing start-stop operation to enhance vehicle fuel economy. During start-stop operation, the engine shuts off when the vehicle is stationary for more than a few seconds. When the brake is released by the driver, the engine restarts. Depending on traffic conditions, start-stop operation can result in fuel savings from a few percent to close to 10%. Gasoline direct injection (GDI) engines are also increasingly available on light-duty vehicles. While GDI engines offer fuel economy advantages over port fuel injected (PFI) engines, they also tend to have higher PM emissions, particularly during start-up transients. Thus, there is interest in evaluating the effect of start-stop operation on PM emissions. In this study, a 2.5L GDI vehicle was operated over the FTP75 drive cycle. Runs containing cold starts (FTP-75 cycle Phases 1 & 2) and multiple runs containing hot starts (FTP-75 cycle Phases 3 & 4) were performed each day. Note that the FTP-75 Phases 3 & 4 are identical to Phases 1 & 2 except that…
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Development of a Cold Start Fuel Penalty Metric for Evaluating the Impact of Fuel Composition Changes on SI Engine Emissions Control

Oak Ridge National Laboratory-Josh Pihl, John Thomas, Sreshtha Sinha Majumdar, Shean Huff, Brian West, Todd Toops
Published 2018-04-03 by SAE International in United States
The U.S. Department of Energy’s Co-Optimization of Fuels and Engines initiative (Co-Optima) aims to simultaneously transform both transportation fuels and engines to maximize performance and energy efficiency. Researchers from across the DOE national laboratories are working within Co-Optima to develop merit functions for evaluating the impact of fuel formulations on the performance of advanced engines. The merit functions relate overall engine efficiency to specific measurable fuel properties and will serve as key tools in the fuel/engine co-optimization process. This work focused on developing a term for the Co-Optima light-duty boosted spark ignition (SI) engine merit function that captures the effects of fuel composition on emissions control system performance. For stoichiometric light-duty SI engines, the majority of NOx, NMOG, and CO emissions occur during cold start, before the three-way catalyst (TWC) has reached its “light-off” temperature. This light-off temperature depends on the exhaust composition, which changes with fuel formulation. Thus, the time to achieve light-off, and therefore the cold start emissions, depends on fuel composition. Since the time to reach light-off must be minimized to meet…
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Fuel Consumption Sensitivity of Conventional and Hybrid Electric Light-Duty Gasoline Vehicles to Driving Style

SAE International Journal of Fuels and Lubricants

Oak Ridge National Laboratory-John Thomas, Shean Huff, Brian West, Paul Chambon
  • Journal Article
  • 2017-01-9379
Published 2017-08-11 by SAE International in United States
Aggressive driving is an important topic for many reasons, one of which is higher energy used per unit distance traveled, potentially accompanied by an elevated production of greenhouse gases and other pollutants. Examining a large data set of self-reported fuel economy (FE) values revealed that the dispersion of FE values is quite large and is larger for hybrid electric vehicles (HEVs) than for conventional gasoline vehicles. This occurred despite the fact that the city and highway FE ratings for HEVs are generally much closer in value than for conventional gasoline vehicles. A study was undertaken to better understand this and better quantify the effects of aggressive driving, including reviewing past aggressive driving studies, developing and exercising a new vehicle energy model, and conducting a related experimental investigation. The vehicle energy model focused on the limitations of regenerative braking in combination with varying levels of driving-style aggressiveness to show that this could account for greater FE variation in an HEV compared to a similar conventional vehicle. A closely matched pair of gasoline-fueled sedans, one an HEV…
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Highway Fuel Economy Testing of an RCCI Series Hybrid Vehicle

Oak Ridge National Laboratory-Scott Curran, John Storey, Shean Huff
University of Wisconsin-Reed Hanson, Shawn Spannbauer, Christopher Gross, Rolf D. Reitz
Published 2015-04-14 by SAE International in United States
In the current work, a series-hybrid vehicle has been constructed that utilizes a dual-fuel, Reactivity Controlled Compression Ignition (RCCI) engine. The vehicle is a 2009 Saturn Vue chassis and a 1.9L turbo-diesel engine converted to operate with low temperature RCCI combustion. The engine is coupled to a 90 kW AC motor, acting as an electrical generator to charge a 14.1 kW-hr lithium-ion traction battery pack, which powers the rear wheels by a 75 kW drive motor.Full vehicle testing was conducted on chassis dynamometers at the Vehicle Emissions Research Laboratory at Ford Motor Company and at the Vehicle Research Laboratory at Oak Ridge National Laboratory. For this work, the US Environmental Protection Agency Highway Fuel Economy Test was performed using commercially available gasoline and ultra-low sulfur diesel. Fuel economy and emissions data were recorded over the specified test cycle and calculated based on the fuel properties and the high-voltage battery energy usage.The results were used to provide estimates of fuel economy and emissions performance with comparisons to a commercially available hybrid vehicle. The estimates also provide…
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Fuel Economy and Emissions Effects of Low Tire Pressure, Open Windows, Roof Top and Hitch-Mounted Cargo, and Trailer

SAE International Journal of Passenger Cars - Mechanical Systems

Oak Ridge National Laboratory-John Thomas, Shean Huff, Brian West
  • Journal Article
  • 2014-01-1614
Published 2014-04-01 by SAE International in United States
To quantify the fuel economy (FE) effect of some common vehicle accessories or alterations, a compact passenger sedan and a sport utility vehicle (SUV) were subjected to SAE J2263 coastdown procedures. Coastdowns were conducted with low tire pressure, all windows open, with a roof top or hitch-mounted cargo carrier, and with the SUV pulling an enclosed cargo trailer. From these coastdowns, vehicle dynamometer coefficients were developed which enabled the execution of vehicle dynamometer experiments to determine the effect of these changes on vehicle FE and emissions over standard drive cycles and at steady highway speeds. In addition, two minivans were subjected to coastdowns to examine the similarity in derived coefficients for two duplicate vehicles of the same model.The FE penalty associated with the rooftop cargo box mounted on the compact sedan was as high as 25-27% at higher speeds, where the aerodynamic drag is most pronounced. For both vehicles, use of a hitch mounted cargo tray carrying a similar load resulted in very small FE penalties, unlike the rooftop cargo box. The results for the…
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Effect of Air Filter Condition on Diesel Vehicle Fuel Economy

Oak Ridge National Laboratory-John Thomas, Brian West, Shean Huff
Published 2013-04-08 by SAE International in United States
Proper maintenance can help vehicles perform as designed, positively affecting fuel economy, emissions, and overall driveability. This paper addresses the issue of whether air filter replacement improves fuel economy. Described are measured results for increasing air filter pressure drop in turbocharged diesel-engine-powered vehicles, with primary focus on changes in vehicle fuel economy but also including emissions and performance. Older studies of carbureted gasoline vehicles have indicated that replacing a clogged or dirty air filter can improve vehicle fuel economy and, conversely, that a dirty air filter can be significantly detrimental to fuel economy. In contrast, a recent study showed that the fuel economy of modern gasoline vehicles is virtually unaffected by filter clogging due to the closed loop control and throttled operation of these engines. Because modern diesel engines operate without throttling (or with minimal throttling), a different result could be anticipated. The effects of clogged air filters on the fuel economy, acceleration, and emissions of three late model turbocharged diesel-powered vehicles were examined. The vehicles were powered by turbocharged diesel engines with different displacements…
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Predicting Light-Duty Vehicle Fuel Economy as a Function of Highway Speed

SAE International Journal of Passenger Cars - Mechanical Systems

Oak Ridge National Laboratory-John Thomas, Ho-Ling Hwang, Brian West, Shean Huff
  • Journal Article
  • 2013-01-1113
Published 2013-04-08 by SAE International in United States
The fueleconomy.gov website provides information such as “window label” fuel economy for city, highway, and combined driving for all U.S.-legal light-duty vehicles from 1984 to present. The site is jointly maintained by the U.S. Department of Energy and the U.S. Environmental Protection Agency (EPA), and also offers a considerable amount of consumer information and advice pertaining to vehicle fuel economy and energy-related issues. Included with advice pertaining to driving styles and habits is information concerning the trend that as highway cruising speed is increased, fuel economy will degrade. An effort was undertaken to quantify this “conventional wisdom” through analysis of dynamometer testing results for 74 vehicles at steady-state speeds from 50 to 80 mph. Using this experimental data, several simple models were developed to predict individual vehicle fuel economy and its rate of change over the 50-80 mph speed range interval. The models presented require a minimal number of vehicle attributes. The simplest model requires only the EPA window label highway mpg value (based on the EPA-specified estimation method for 2008 and beyond). The most…
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Effects of Air Conditioner Use on Real-World Fuel Economy

Oak Ridge National Laboratory-Shean Huff, Brian West, John Thomas
Published 2013-04-08 by SAE International in United States
On-road and laboratory experiments with a 2009 Ford Explorer and a 2009 Toyota Corolla were conducted to assess the fuel consumption penalty associated with air conditioner (A/C) use at idle and highway cruise conditions. Vehicle data were acquired on-road and on a chassis dynamometer. Data were gathered for various A/C settings and with the A/C off and the windows open. At steady speeds between 64.4 and 113 kph (40 and 70 mph), both vehicles consumed more fuel with the A/C on at maximum cooling load (compressor at 100% duty cycle) than when driving with the windows down. The Explorer maintained this trend beyond 113 kph (70 mph), while the Corolla fuel consumption with the windows down matched that of running the A/C at 121 kph (75 mph), and exceeded it at 129 kph (80 mph). The incremental fuel consumption rate penalty due to air conditioner use was nearly constant with a slight trend of increasing consumption with increasing vehicle (and compressor) speed. A lower fuel penalty due to A/C operation is observed at idle for…
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Effect of Intake Air Filter Condition on Light-Duty Gasoline Vehicles

Oak Ridge National Laboratory-John Thomas, Brian West, Shean Huff, Kevin Norman
Published 2012-09-10 by SAE International in United States
Proper maintenance can help vehicles perform as designed, positively affecting fuel economy, emissions, and the overall drivability. This effort investigates the effect of one maintenance factor, intake air filter replacement, with primary focus on vehicle fuel economy, but also examining emissions and performance. Older studies, dealing with carbureted gasoline vehicles, have indicated that replacing a clogged or dirty air filter can improve vehicle fuel economy and conversely that a dirty air filter can be significantly detrimental to fuel economy. The effect of clogged air filters on the fuel economy, acceleration and emissions of five gasoline fueled vehicles is examined. Four of these were modern vehicles, featuring closed-loop control and ranging in model year from 2003 to 2007. Three vehicles were powered by naturally aspirated, port fuel injection (PFI) engines of differing size and cylinder configuration: an inline 4, a V6 and a V8. A turbocharged inline 4-cylinder gasoline direct injection (GDI) engine powered vehicle was the fourth modern gasoline vehicle tested. A vintage 1972 vehicle equipped with a carburetor (open-loop control) was also examined.Results reveal…
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