Browse Topic: Diesel exhaust emissions

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A Quantitative Approach for Mapping and Assessing Diesel Particulate Filter Regeneration Events in Diesel Engines2026-01-0377To be published on 04/07/2026
Regeneration of diesel particulate filters (DPFs) is crucial for maintaining the performance of diesel engines and minimizing harmful particulate matter (PM) emissions from exhaust. However, conventional regeneration strategies often suffer from incomplete soot removal and inefficient monitoring. These issues lead to increased exhaust back pressure, reducing engine efficiency, and potentially damaging the particulate filter. In this paper, a new approach is proposed for mapping and quantifying the real-world DPF regeneration process for diesel engines complying with the stringent emission standards. We introduce a novel metric, the differential pressure drop percentage (DPDP), to detect regeneration events and quantify soot burn quality. The proposed method utilizes real-time sensor data obtained through the vehicle’s On-Board Diagnostics (OBD) system. The algorithm processes sensor data and robustly maps the regeneration quality. The performance of regeneration event detection and
Bagga, Harleen Kaur, Nagare, Mukund B., Patil, Bhushan D., Ravishankar, Hariharan, Melapudi, Vikram, Patil, Abhijit
Peak SCR Efficiency for Ultra-Low NOx Using Electrically Heated Mixer for EU-VII and China-VII2026-01-0363To be published on 04/07/2026
Achieving ultra-low NOx emissions remains a major challenge in diesel emission control worldwide, especially as increasingly stringent regulations are introduced globally. Selective Catalytic Reduction (SCR), the leading NOx reduction technology in diesel systems, performs best when both heat and ammonia are available. At the same time, any proposed solution must also be cost-effective and economically viable. In this work, we present a low-cost Electrically Heated Mixer (EHM). EHM not only significantly reduces urea deposit formation, thereby lowering warranty costs and mitigating failure modes, but also enhances SCR efficiency, especially in challenging low-load conditions having low exhaust temperature. EHM is also ideal for rapid heat-up and urea injection during engine cold-start conditions ( <100 °C) enabling swift NH₃ formation and storage in the SCR catalyst. Additionally, it enables early urea injection (~ 130 - 150 °C), improving SCR efficiency in low temperatures below 200
Masoudi, Mansour, Poliakov, Nick
Study on the Effects of Different Catalyst Loadings on Diesel Engine Emission Characteristics with DOC Coupled SCR2026-01-0368To be published on 04/07/2026
DOC coupled with SCR is an important technical route for reducing gaseous pollutant emissions from diesel agricultural engines. Based on engine bench tests, this paper uses a diesel engine as a prototype to experimentally study the impact of different catalyst loadings on the emission characteristics of diesel engines when coupled with DOC and SCR. The results show that the higher the loading of the DOC catalyst, the greater the exhaust back pressure loss, with the maximum pressure difference reaching 4.9 kPa. The temperature difference before and after the DOC has a smaller impact with varying catalyst loadings. The higher the loading of the DOC catalyst, the stronger the catalytic activity for CO and THC. At medium and low loads, the impact of catalyst loading is more significant, while at high loads, it has a smaller impact. The higher the loading of the DOC catalyst, the stronger the oxidation ability for NO. Under external characteristic conditions, due to the higher engine
zhang, Yunhua, Junzhe, Li, Lou, Diming, Fang, Liang
Enhancing Understanding of State-of-the-Art Fe/zeolite Selective Catalytic Reduction Catalysts2026-01-0362To be published on 04/07/2026
Fe/zeolite selective catalytic reduction (SCR) catalysts are commercially used for NOx emissions reduction from diesel engines. In comparison to Cu/zeolite, these catalysts are widely reported to form less N2O as a byproduct of the SCR reactions between NOx and NH3, and Fe/zeolite SCR catalysts also achieve impressive deNOx at high temperatures. On the other hand, Fe/zeolite SCR is much less active than Cu/zeolite for low temperature NOx conversion under standard SCR conditions (NO+NH3). In this study, a state-of-the-art Fe/zeolite SCR catalyst is probed with a combination of BET surface area analysis, SEM/EDX physicochemical characterization, reactor-based performance and active site quantification, and in-situ DRIFTS. The results are split into 3 sections evaluating the impacts of: degreening, mild hydrothermal aging, and extreme hydrothermal aging. In a degreened condition, the impact of water vapor on standard and fast SCR is assessed, and the isothermal desorption of NH3 is
Ottinger, Nathan, Xi, Yuanzhou, Liu, Z. Gerald
Neural Surrogates and Reinforcement Learning for Heavy-Duty Diesel Torque Control: A Data-Driven Alternative to PID2026-01-0199To be published on 04/07/2026
Accurately reproducing the torque trace of regulatory drive cycles is central to heavy-duty diesel emissions certification and repeatable development testing. Conventional controllers—PI/PID with gain scheduling and feedforward mapping—can meet requirements but demand extensive hand-tuning and struggle with strong nonlinearities and time-varying delay. Building on prior work that quantified the limits and benefits of gain-scheduled and feedforward strategies under the FTP transient cycle, this work investigates a fully data-driven control framework. First, a recurrent neural network (LSTM) torque surrogate is trained on dynamometer data to capture engine dynamics from readily available signals (e.g., engine speed, commanded pedal/torque, recent torque history) and actuator constraints. Second, this learned “world model” is used to train a reinforcement learning (RL) policy that outputs pedal commands to minimize torque-tracking error while regularizing control effort and respecting
Cook, James, Puzinauskas, Paulius, Bittle, Joshua, Hall, Spencer
A Low Pressure Pumpless DEF Dosing System by using Compressed Air and an Air Assisted DEF Injection Nozzle2026-26-021901/16/2026
The study emphasizes on development of Diesel Exhaust Fluid (DEF) dosing system specifically used in Selective Catalytic Reduction (SCR) of diesel engine for emission control, where a low pressure pumpless DEF dosing system is developed, utilizing compressed air for pressurizing the DEF tank and discharging DEF through air assisted DEF injection nozzle. SCR systems utilize Diesel Exhaust Fluid (DEF) to convert harmful NOx emissions from diesel engines into harmless nitrogen and water vapor. Factors such as improper storage, handling, or refilling practices can lead to DEF contamination which pose significant operational challenges for SCR systems. Traditional piston-type, diaphragm-type, or gear-type pumps in DEF dosing systems are prone to mechanical failures leading to frequent maintenance, repairs, and costly downtimes for vehicles. To overcome the existing challenges and to create a more reliable and simple DEF delivery mechanism the pumpless DEF Dosing system is developed. The
M, Hareni, Giridharan, Jyothivel, A.l, Suresh, V, Yuvaraj, Rajan, Bharath
Optimizing Diesel Emission Controls through Advanced Software Solutions for HC Desorb Fault in Diesel Oxidation Catalysts2026-26-042401/16/2026
After the implementation of BS-VI emission standards, effective exhaust after-treatment has become critical in minimizing harmful emissions from diesel engines. One significant challenge is the accumulation of hydrocarbons (HC) in the Diesel Oxidation Catalyst (DOC). Certain hydrocarbons may adsorb onto the catalyst surface yet remain unreactive, leading to potential operational inefficiencies. This phenomenon necessitates the desorption of unreactive hydrocarbons to allow space for more reactive species, thereby enhancing oxidation efficiency and overall catalyst performance. The process of desorption (DeSorb) is vital to maintaining the balance of reactive hydrocarbons within the DOC. When a vehicle is idling, unburnt fuel produces hydrocarbons that accumulate in the DOC. Upon acceleration, these hydrocarbons can lead to an uncontrolled rise in temperature, resulting in DOC push-out, catalyst damage, and downstream impacts on the Diesel Particulate Filter (DPF). To mitigate these
K, Sabareeswaran, K K, Uthira Ramya Bala, Raju, Manikandan, K J, Ramkumar, YS, Ananthkumar
Data-Driven Modeling for Emission Prediction and ATS Performance Benchmarking for Hydrogen and Diesel ICE Applications2026-26-038601/16/2026
This study presents a comprehensive methodology for benchmarking hydrogen and diesel internal combustion Engines, with emphasis on virtual Real-Drive Emission (RDE) test procedures for diesel and hydrogen application. Emission profiles for legal cycles and RDE scenarios are accurately predicted through integration and development of Artificial Neural Networks (ANN) based on Long Short-Term Memory (LSTM) models. Virtual evaluations of Selective Catalytic Reduction (SCR) system performance, Diesel Exhaust Fluid (DEF) dosing accuracy, and exhaust temperature dynamics enabled by integrated data pipelines and physics-based modeling are also explored for holistic prediction of output. Across models, validation demonstrates good prediction accuracy including temperature (R2 > 0.94, RMS error < 25°C), air flow (92% accuracy, RMSE = 28 kg/h), upstream NOx (93% accuracy, RMSE < 10 mg/s), and SCR (TP NOx accuracy = 91.82%, dosing accuracy = 87.73%). This approach has the potential to offer
Shah, Jash Vipin, S, Manoj Kumar, Ratnaparkhi, Aditya, H, Shivaprakash
Optimizing Diesel Emission Controls through Advanced Software Solutions for HC Desorb Fault in Diesel Oxidation Catalysts2026-26-006101/16/2026
After the implementation of BS-VI emission standards, effective exhaust after-treatment has become critical in minimizing harmful emissions from diesel engines. One significant challenge is the accumulation of hydrocarbons (HC) in the Diesel Oxidation Catalyst (DOC). Certain hydrocarbons may adsorb onto the catalyst surface yet remain unreactive, leading to potential operational inefficiencies. This phenomenon necessitates the desorption of unreactive hydrocarbons to allow space for more reactive species, thereby enhancing oxidation efficiency and overall catalyst performance. The process of desorption (DeSorb) is vital to maintaining the balance of reactive hydrocarbons within the DOC. When a vehicle is idling, unburnt fuel produces hydrocarbons that accumulate in the DOC. Upon acceleration, these hydrocarbons can lead to an uncontrolled rise in temperature, resulting in DOC push-out, catalyst damage, and downstream impacts on the Diesel Particulate Filter (DPF). To mitigate these
K, Sabareeswaran, K K, Uthira Ramya Bala, k, Janarthanan, A, Ravikumar, YS, Ananthkumar
Multi-Objective Optimization and Reduced-Order Modeling for Aftertreatment System Performance Prediction2026-26-042601/16/2026
As emission regulations grow increasingly stringent, aftertreatment system designs are becoming more complex, requiring robust performance across the full range of Engine Operating Points (EOPs). Traditionally, aftertreatment development has relied on Computational Fluid Dynamics (CFD) simulations conducted at a limited set of representative points, focusing primarily on single performance objectives such as minimizing back pressure, enhancing ammonia uniformity, or reducing Diesel Exhaust Fluid (DEF) deposits. However, these objectives are inherently interdependent, and optimizing for a single parameter often negatively impacts others, leading to suboptimal system performance across the full engine map. To address these challenges, this paper presents a multi-objective optimization framework combined with a reduced-order modeling approach to predict aftertreatment system behavior across the full engine operating range. The methodology captures the interactions among various
Nanduru, Enoch, Willey, Donald, Udhane, Tushar Sudam, Pal, Yash
Development of a Cost-Effective DCU for Diesel Emission Control: Design, Diagnostics, and Compliance2025-28-028611/06/2025
The Dosing Control Unit (DCU) is a vital component of modern emission control systems, particularly in diesel engines employing Selective Catalytic Reduction technology (SCR). Its primary function is to accurately control the injection of urea or Diesel Exhaust Fluid (DEF) into the exhaust stream to reduce nitrogen oxide (NOₓ) emissions. This paper presents the architecture, operation, diagnostic features, and innovation of a newly developed DCU system. The Engine Control Unit, using real-time data from sensors monitoring parameters such as exhaust temperature, NOₓ levels, and engine load, calculates the required DEF dosage. Based on DEF dosing request, the DCU activates the AdBlue pump and air valve to deliver the precise quantity of diesel exhaust fluid needed under varying engine conditions. The proposed system adopts a master-slave configuration, with the ECU as the master and the DCU as the slave. The controller design emphasizes cost-effectiveness and simplified hardware, and
Raju, Manikandan, K, Sabareeswaran, K K, Uthira Ramya Bala, Krishnakumar, Palanichamy, Arumugam, Arunkumar, YS, Ananthkumar
Predicting Transient Soot Emissions in Diesel Engines Using Physical and Machine Learning Models2025-32-001711/03/2025
In recent years, diesel engine emissions regulations have been strengthened worldwide, necessitating the evaluation of regulatory values under transient conditions. Consequently, the need to assess transient states in the development of diesel engines has increased significantly. The evaluation using MBD (Model Based Development) is considered a promising method for achieving both low fuel consumption and simultaneous reduction of NOx and soot emissions. However, the mechanism of soot formation is complex, making it challenging to model mathematically directly. In this paper, hybrid machine learning approaches combining a physical model and a machine learning model are used to validate the prediction of soot emissions under transient conditions in a diesel engine with an EGR system. Various parameters such as fuel consumption and emissions predicted by the physical model are compared with measurements to validate the accuracy of the physical model. The prediction of soot emissions by
Kitamura, Takahiro, Matsuoka, Ayano, Suematsu, Kosuke, Okano, Hiroaki
Probabilistic Thermal Modelling of AdBlue System Using Bayesian Networks2025-28-037010/30/2025
In Diesel engine exhaust after treatment system (ATS), Nitrogen Oxides (NOx) emissions control is achieved via Selective Catalytic Reduction (SCR) in which AdBlue or Diesel Exhaust Fluid (DEF) plays vital role. But AdBlue freezes below -11°C due to which in cold climate conditions system performance becomes critical as it affects efficiency as well as overall performance leading to safety and compliance with emission standards issue. So, it is essential to have a probabilistic thermal model which can predict the AdBlue temperature as per ambient temperature conditions. The present paper focuses on developing Bayesian Network (BN) based algorithm for AdBlue system by modelling probability of key factors influencing on its performance including AdBlue temperature, Ambient temperature, Coolant temperature, Coolant flow, Vehicle operating conditions etc. The BN Model predicts and ensures continuous learning and improvement of the system, based on operational data. Methodology proposed in
Thakur, Shivam, Salunke, Omkar
Influence of the SCR Reactivity on Passive Soot Oxidation for Vanadium-Coated and Uncoated (S)DPF2025-24-008609/07/2025
In modern diesel exhaust aftertreatment systems (EATS), combining a catalytic coating for selective NOx reduction (SCR) with a diesel particulate filter (DPF) enables simultaneous particulate filtration and NOx reduction. In such systems, soot regeneration is primarily influenced by the NO2 supply in the exhaust gas, particularly at low exhaust temperatures (250-400 °C). Several investigations found that in SCR-coated filters with urea-water solution (UWS) dosing upstream, particle oxidation is partially inhibited by NH3. However, at higher temperatures (>400 °C), this effect seems to be reduced. In this study, numerical modelling approaches based on engine test bench results are utilised to examine the impact of SCR reactivity on passive soot oxidation for a highly porous vanadium-coated SDPF. To identify the interaction mechanism between the SCR reaction and soot oxidation, further investigations were conducted using a filter with a washcoat without SCR-active component. The
Prchal, Niklas, Wegmann, Andreas, Müller, Werner, Günthner, Michael
Condensate Formation in Exhaust Systems during Cold Start2025-24-008109/07/2025
In order to minimize tailpipe emissions of vehicles with combustion engines, highest conversion rates of exhaust gas aftertreatment systems are indispensable. At low ambient temperatures, gaseous emissions increase due to inhomogeneous mixture formation and incomplete combustion. Simultaneously, formation of condensate on exhaust gas-carrying components is stimulated due to temperatures dropping below the dew point. The acidic condensates contain more than 95 vol.-% water and a small fraction of aliphatic and aromatic hydrocarbons. In acidic environments these hydrocarbons can be polymerized, forming insoluble deposits that become progressively less reactive with time. These deposits may harm components of exhaust systems by fouling. As low temperature conditions are particularly promoting condensate formation, the aim of this study is to investigate condensate formation and composition during cold start and early warm-up phases in the exhaust duct of state-of-the-art internal
Knapp, Sebastian, Hagen, Fabian P., Wagner, Uwe, Bockhorn, Henning, Trimis, Dimosthenis, Koch, Thomas
Experimental Investigations on the Effects of Injector Design and Operating Parameters on PCCI Combustion in a Light-Duty Diesel Engine03-18-04-002607/09/2025
Due to increasingly stringent emission regulations, advanced combustion strategies, such as premixed charge compression ignition (PCCI), have emerged promising solutions for achieving low NOx and soot emissions. However, challenges such as increased unburned hydrocarbon (HC), carbon monoxide (CO) emissions, and a restricted engine operating load range remain unsolved. Since conventional diesel engines are not inherently designed for PCCI operation, re-optimizing engine parameters is essential. The primary objective of this work is to investigate the influence of injector orientation and nozzle spray angle on combustion parameters, performance, and emissions in a PCCI diesel engine. Initial parametric studies revealed that early direct injection combined with high fuel injection pressure limited the PCCI load range to 30% and 60% of the rated capacity with diesel, without and with EGR, respectively, accompanied by higher HC and CO emissions. To address these limitations, the injector
Ranjan, Ashish Pratap, Krishnasamy, Anand
Experimental and Kinetic-Modeling Study of Ammonia/n-Heptane Combustion13-06-03-002004/09/2025
In recent years, researchers have increasingly focused on ammonia–diesel dual-fuel engines as a means of reducing CO2 emissions. Analyzing in-cylinder combustion processes is essential for optimizing the performance of ammonia–diesel dual-fuel engines. However, there is currently a lack of suitable reaction kinetics models for ammonia–diesel engine conditions. In this study, the ignition delay of ammonia/n-heptane mixtures was measured, and a reduced chemical mechanism was developed. Using rapid compression machine (RCM) experiments, the ignition delays of ammonia/n-heptane mixtures with different ammonia energy fractions (AEFs) (40%, 60%, and 80%) were measured. The test pressure ranged from 1.5 to 3.0 MPa, while the temperature ranged from 667 to 919 K, with an equivalence ratio of 1. The results showed that as the AEFs increased, the ignition delay of the premixed mixture also increased. When the AEF was 40%, the ammonia/n-heptane premixed mixture exhibited the negative temperature
Cai, Kaiyuan, Liu, Yi, Chen, Qingchu, Qi, Yunliang, Li, Li, Wang, Zhi
Formation and Decomposition of Ammonium Sulfate Species over a Small Pore Cu/Zeolite Catalyst2025-01-849304/01/2025
Cu/zeolite selective catalytic reduction (SCR) catalysts are used globally to reduce NOx emissions from diesel engines. These catalysts can achieve high NOx conversion efficiency, and they are hydrothermally durable under real world diesel exhaust environments. However, Cu/zeolite catalysts are susceptible to sulfur poisoning and require some type of sulfur management even when used with ultra-low sulfur diesel (ULSD). In the present study, the authors seek to better illuminate the chemical processes responsible for ammonium sulfate formation and decomposition occurring in Cu/zeolite SCR catalysts. Reactor-based experiments are first conducted with a real-world concentration of SO2 (0.5 ppmv) and a typical diesel exhaust water vapor concentration (7 vol.%) to quantify progressive effects of ammonium sulfate formation. A second group of experiments probe the chemical decomposition of ammonium sulfate via NO titration. The “movement” of sulfate species during this process is monitored
Ottinger, Nathan, Xi, Yuanzhou, Liu, Z. Gerald
Neural Network Based Modeling and Model Predictive Control for Reduction in Diesel Emissions2025-01-836904/01/2025
The paper illustrates the process and steps in the development of a neural network-based economic Model Predictive Control (MPC) strategy for reducing diesel engine feed gas emissions. This MPC controller performs fuel limiting and modifies intake manifold pressure and exhaust gas recirculation (EGR) rate set-points to the inner loop air path controller to reduce engine-out oxides of nitrogen (NOx) and Soot emissions. We examine two Recurrent Neural Network (RNN) options for a control-oriented emissions model which are based on a multi-layer perception (MLP) architecture and a long short-term memory (LSTM) architecture. These RNN models are trained for use as prediction models in MPC. Both models are defined in input-output form, assuming that measurements/estimates of current values of NOx and Soot are available. We discuss and compare their training using PyTorch. The formulation of economic MPC is detailed, including the definition of the cost function and soft constraints
Zhang, Jiadi, Li, Xiao, Kolmanovsky, Ilya, Tsutsumi, Munecika, Nakada, Hayato
Experimental and CFD Simulation Study of Heated and Cold Diesel Exhaust Fluid Spray Characteristics2025-01-848604/01/2025
This paper investigates heated and cold Diesel Exhaust Fluid (DEF) sprays with the aim of establishing the effect of temperature on the resulting spray characteristics. The work is motivated by the need to optimize active Selective Catalytic Reduction (SCR) systems to meet more stringent nitrogen oxide (NOx) emission regulations for internal combustion engines. Pre-heating DEF has the potential to improve evaporation of the injected fluid, increasing the NOx conversion efficiency of the SCR at low exhaust temperatures. Experiments are carried out using the MAHLE SmartHeat fluid heater and mounted atop a DEF injector, with an incorporated thermocouple for fluid temperature. The fluid temperature established by the heater in this configuration was about 130 °C. The fluid is injected into an atmospheric environment and Schlieren imaging is used to visualize the spray evolution. CFD simulations are also carried out to validate the experimental observations and further shed light on the
Liu, Zeyang, Peters, Nathan, Bunce, Mike, Pothuraju Subramanyam, Sai, Akih Kumgeh, Benjamin
The Impact of GCI Engines on Long-haul Trucks in the US and China2025-01-839604/01/2025
This study evaluates the impacts of the gasoline compression ignition (GCI) engine on heavy duty long-haul trucks in both the Chinese and US markets. The study examines various aspects such as vehicle performance requirements, fuel consumption, emissions, and ownerships costs, and how they influence the implementation and impact of new technologies in these markets. By considering a wide variety of drive cycles, including standard regulatory cycles and real-world cycles, the study aims to identify the impact of varying degrees of powertrain electrification using diesel and GCI engines on fuel consumption and emissions. Additionally, this paper explores the viability of powertrain electrification in long-haul trucks by analyzing factors such as levelized cost of driving (LCOD), manufacturing costs, and energy costs. These considerations play a crucial role in determining the economic feasibility and attractiveness of electrification technologies in various driving scenarios and market
Nieto Prada, Daniela, Vijayagopal, Ram, Yan, Ziming, Sari, Rafael, He, Xin
Prediction of Diesel Engine NO x Transient Emissions Based on a Combined Model with Convolutional Neural Network–Efficient Channel Attention–Bidirectional Gated Recurrent Unit03-18-02-001202/06/2025
Widely used as power equipment, diesel engines emit NO x , which significantly threatens the well-being of both the ecosystem and individuals. The SCR system, which is employed to reduce NO x emissions from diesel engines, relies on precise control of the NO x emission levels. Addressing the challenge that traditional NO x emission prediction methods struggle to accurately forecast the emissions under transient operating conditions, this article introduces a deep learning model that integrates CNN, ECA, and BIGRU. The model’s necessary experimental data were collected during the hot phase of the WHTC, and input parameters were screened through correlation analysis. The model employs a CNN for feature extraction, integrates an ECA module to refine key feature processing, and utilizes BIGRU to capture temporal dynamics and dependencies, yielding predictive outcomes. Additionally, the model employs the Adam optimizer and combines it with BWO to adjust hyperparameters, thereby elevating
Peng, Yunlong, Wang, Guiyong, Wang, Yuhua, Wang, Feiyang, Wang, Zhiyuan, He, Shuchao
Diesel Exhaust Fluid (DEF) Associated Corrosion Risk Prediction for Aftertreatment System2024-28-025812/05/2024
With emission regulations becoming increasingly stringent, the integration of Diesel Exhaust Fluid (DEF) in aftertreatment systems has become essential for reducing nitrogen oxide (NOx) emissions in compliance with these evolving standards. DEF dosing is a very critical component in Selective Catalytic Reduction (SCR) systems, where it chemically reacts with NOx in the exhaust stream to form harmless nitrogen and water vapor, thus significantly reducing the environmental impact of diesel engines. However, the introduction of DEF presents a challenge of corrosion risk within the aftertreatment system components. This study aims to predict the location of corrosion, and its risk associated with DEF usage in Diesel aftertreatment system, by employing a multi-faceted approach that includes physical testing and computational modelling. Specifically, the focus of this paper is on predicting corrosion locations from unsteady DEF spray analysis without modelling detailed corrosion chemistry
Udhane, Tushar Sudam, Nanduru, Enoch, Warwick, Michael, Willey, Donald, Giri, Nikhil, Parikh, Tanishq
Dynamic Modeling of Torque & Emissions: Digital Twin to Simulate Combustion Process and Exhaust Emissions for Diagnostics & Prognostics Applications2024-28-017212/05/2024
As a journey to green initiatives, one of the focus areas for automotive industry is reducing environmental impact especially in case of internal combustion engines. Latest digital twin technology enable modelling complicated, fast and unsteady phenomena including the changes of emission gases concentration and output torque observed during diesel emission and combustion process. This paper presents research on the emission and combustion characteristics of a heavy vehicle diesel engine, elaborating an engineered architecture for prognostics/diagnostics, state monitoring, and performance trending of heavy-duty vehicle engine (HDVE) and after treatment system (ATS). The proposed architecture leverages advanced modeling methodologies to ensure precise predictions and diagnostics, using data-driven techniques, the architecture accurately model’s engine and exhaust system behaviors under various operating conditions. For exhaust system, architecture demonstrates encouraging predictive
Singh, Prabhsharn, Thakare, Ujval, Hivarkar, Umesh
Deep Reinforcement Learning Based Application of Exhaust Gas Aftertreatment Control Using the Example of a Hydrogen Engine2024-24-004309/18/2024
Growing environmental concerns drive the increasing need for a more climate-friendly mobility and pose a challenge for the development of future powertrains. Hydrogen engines represent a suitable alternative for the heavy-duty segment. However, typical operation includes dynamic conditions and the requirement for high loads that produce the highest NOx emissions. These emissions must be reduced below the legal limits through selective catalytic reduction (SCR). The application of such a control system is time-intensive and requires extensive domain knowledge. We propose that almost human-like control strategies can be achieved for this virtual application with less time and expert knowledge by using Deep Reinforcement Learning. A proximal policy optimization (PPO) -based agent is trained to control the injection of Diesel exhaust fluid (DEF) and compared with the performance of a manually tuned controller. The performance is evaluated based on the restrictive emission limits of a
Itzen, Dirk, Angerbauer, Martin, Hagenbucher, Timo, Grill, Michael, Kulzer, Andre
Comparing Physical and Chemical Properties of Soot from Laboratory Tests and Heavy-Duty Engines Used in Field Operations04-18-01-000208/02/2024
Morphology, nanostructure, and composition of soot extracted from the oil sump of different heavy-duty engines operated under dynamometer and field conditions were investigated. Soot characteristics were then compared to a carbon black sample. Soot was extracted from used oil for transmission electron microscopy (TEM) analysis. Energy-dispersive X-ray (EDX) and X-ray photoelectron spectroscopy (XPS) analyses were also performed to assess soot composition. Two soot classes, I and II, can be identified based on their appearance under the TEM. Carbon black and class I particles have graphitic structures, while class II samples have a more sludge-like appearance. Similar aggregate sizes were observed among the samples. In all samples, the primary particle size distribution ranges from 16 nm to 22 nm in terms of mean diameter. Differences in the length and tortuosity of the graphitic fringes between the samples were observed. The findings suggest a greater degree of interaction between
Pacino, Andrea, La Rocca, Antonino, Cairns, Alasdair, Fay, Michael W., Smith, Joshua, Berryman, Jacqueline, Fowell, Mark
Optimizing Fuel Injection Timing for Multiple Injection Using Reinforcement Learning and Functional Mock-up Unit for a Small-bore Diesel Engine03-17-06-004105/03/2024
Reinforcement learning (RL) is a computational approach to understanding and automating goal-directed learning and decision-making. The difference from other computational approaches is the emphasis on learning by an agent from direct interaction with its environment to achieve long-term goals [1]. In this work, the RL algorithm was implemented using Python. This then enables the RL algorithm to make decisions to optimize the output from the system and provide real-time adaptation to changes and their retention for future usage. A diesel engine is a complex system where a RL algorithm can address the NOx–soot emissions trade-off by controlling fuel injection quantity and timing. This study used RL to optimize the fuel injection timing to get a better NO–soot trade-off for a common rail diesel engine. The diesel engine utilizes a pilot–main and a pilot–main–post-fuel injection strategy. Change of fuel injection quantity was not attempted in this study as the main objective was to
Vaze, Abhijeet, Mehta, Pramod S., Krishnasamy, Anand
Reducing Emissions from Lean-Burn Hydrogen Combustion Engines Using a State-of-the-Art Oxidation Catalyst and a VWTi-Based SCR Catalyst: Potentials and Challenges2024-01-263404/09/2024
Hydrogen (H2) is commonly considered as one of the most promising carbon-free energy carriers allowing for a decarbonization of combustion applications, for instance by retrofitting of conventional diesel internal combustion engines (ICEs). Although modern H2-ICEs emit only comparably low levels of nitrogen oxides (NOx), efficient catalytic converters are mandatory for exhaust gas after-treatment in order to establish near-zero emission applications. In this context, the present study evaluates the performance of a commercial state-of-the-art oxidation catalyst (OC) and of a catalyst for selective catalytic reduction (SCR) that are typically used for emission reduction from diesel exhausts under conditions representative for H2-fueled ICEs, namely oxygen-rich exhausts with high water vapor levels, comparably low temperatures, and potentially considerable levels of unburnt H2. Herein, the OC is supposed to convert H2 slippage, which can occur due to incomplete combustion, and to oxidize
Lott, Patrick, Schäfer, Kathrin, Deutschmann, Olaf, Werner, Manuel, Weinmann, Philipp, Zimmermann, Lisa, Toebben, Heike
Particulate filter performance mapping for in-service conformity2024-01-238204/09/2024
The proposed Euro-7 regulations are expected to build on the significant emissions reductions that have already been achieved using advanced Euro VI compliant after treatment systems (ATS). The introduction of in-service conformity (ISC) requirements during Euro VI paved the way for enabling compliance during real-world driving conditions. The diverse range of applications and resulting operating conditions greatly impact ATS design and the ability of the diesel particulate filter (DPF) to maintain performance under the most challenging boundary conditions including cold starts, partial/complete regenerations, and high passive soot burn operation. The current study attempts to map the particle number (PN) filtration performance of different DPF technologies under a variety of in-use cycles developed based on field-data from heavy duty Class-8 / N3 vehicles. Access to such performance maps can allow original equipment manufacturers (OEMs) to select DPF technologies to suit different
Viswanathan, Sandeep, Sadek, Ghadi, Reddy, Vishal, He, Suhao, Alam, Rabeka
Comparison and Feasibility Study of Hexanol/Diesel/Pongamia Biodiesel Blend on Engine Characteristics of a Common Rail Direct Injection Diesel Engine2023-01-515502/23/2024
In this work, the impact of hexanol/diesel/biodiesel blend on engine characteristics of a common rail direct injection (CRDI) diesel engine was studied. Biodiesel is more viscous in nature and higher cetane count, hexanol has a lower viscosity and cetane count. The drawbacks of both biodiesel and hexanol can be overcome by blending both hexanol and biodiesel with diesel fuel in the right proportion. Tests were carried out using a 4-stroke CRDI engine with two cylinders. Biodiesel and 1-hexanol were blended in a ratio of 10% each by volume with diesel and compared with B10D90 and B20D80 blends. It was noted that the addition of hexanol enhances the combustion characteristics of the engine. At 20% load H10B10D80 showed71.34 bar which is highest compared to other fuels in the test. The blends had a positive effect on emissions, there was drastic reduction in NOx was noticed, also HC and CO emission was lower than diesel emissions. The lowest CO, and HC emission is obtained for H10B10D80
Santhosh, K., Shahapur, Saikumar, Kumar, G.N., Ravikumar, K.N., Raghavendra Reddy, N.V.
The Effect of Different Air Path Based ATS Thermal Management Strategy on a Non- EGR Medium Duty Diesel Engine’s Performance and Emissions2024-26-003801/16/2024
The major objective of this paper is to develop thermal management strategy targeting optimum performance of Selective Catalytic Reduction (SCR) catalyst in a Medium Duty Diesel Engine performing in BS6 emission cycles. In the current scenario, the Emissions Norms are becoming more stringent and with the introduction of Real Drive Emission Test (RDE) and WHTC test comprising of both cold and hot phase, there is a need to develop techniques and strategies which are quick to respond in real time to cope with emission limit especially NOx. SCR seems to be suitable solution in reducing NOx in real time. However, there are limitations to SCR operating conditions, the major being the dosing release conditions which defines the gas temperature at which DEF (Diesel Exhaust Fluid) can be injected as DEF injection at lower gas temperatures than dosing release will lead to Urea deposit formation and will significantly hamper the SCR performance. The second factor for optimum SCR operation is to
Sharma, Ajeet Kumar, Kreuzig, Gerhard, Gupta, Ayush, Goyal, Dinesh, Garg, Varun
A Novel Method for Urea Concentration Deterioration Detection in BSVI Heavy Duty Engine2024-26-015401/16/2024
Diesel Exhaust Fluid (DEF) concentration monitoring is done to detect the concentration at which the emission thresholds are exceeded in BSVI engines [1]. This paper introduces a novel method to model the fault monitoring system with enable conditions designed to detect deterioration in DEF concentration, while reducing misdetection. This eliminates the need for dedicated sensor, reduces complexity, cost, and potential sensor-related failure modes. Traditionally, Diesel Exhaust Fluid quality sensors have been employed to measure the absolute concentration of Diesel Exhaust Fluid in the aqueous solution of urea [2]. This information is used to detect usage of poor quality DEF which results in increase in NOx emission beyond legal limits. The proposed method leverages the strong relationship between catalyst conversion efficiency and Diesel Exhaust Fluid concentration for modelling a fault monitoring system which also takes inputs from various other sensors, to make the system fault
Venkat, Harish, Kumar, Gokul Elumalai, Kumar, Kosalaraman, G, Vijayakumar
Understanding the Complexities and Validation of Exhaust System Components for New Emission Requirement with Thermal Load and Multi-Axis Vibration2024-26-033001/16/2024
The new emission requirement norms in India calls for a robust Exhaust and After Treatment System (EATS) in automobiles. Its main purpose is to reduce the emission of harmful pollutants into the environment. EATS have a series of components that cleans the diesel exhaust emitted by the engine prior to releasing it through the tailpipe to the outside air. All the EATS components must undergo stringent testing protocol prior to its implementation in vehicle. During the exhaust treatment process, a very high temperature of about 550°C is produced in the EATS system. Hence, the effect of this higher temperature needs to be considered for validation. Moreover, the components will undergo multi-axial vibration in real road conditions which also need to be simulated during validation. In addition, engine vibrations are directly transmitted through a flex bellow to EATS system. These vibrations need to be captured and simulated in component level testing. In this paper, we detailed on various
Sundarrajan, Manikandan, Narasimman, Obuli Karthikeyan, Nagarajan, Gopikannan, Rajaraman, Manikandan, R, Suresh
Numerical Analyses of AdBlue® Thawing Performance According to EU Norms2024-26-026301/16/2024
Controlling NOx emission demand is getting more severe with Euro 7 legislation. In turn, this brings more focus on SCR (Selective Catalytic Reduction) technology, which uses a eutectic mixture of Urea (32.5%)– Water (67.5%) solution, more popularly known as Diesel Exhaust Fluid (DEF/ AdBlue®). Under extreme winter conditions, AdBlue® freezes as the ambient reaches below the freezing point (-11°C). Due to Legislation requirements (EU), estimating the time required to thaw a desired volume of frozen AdBlue® using forced heating is a matter of interest, leading to the concept of overall Melting/Thawing performance. So far, testing has been the primary method for arriving at a suitable melting mechanism and for designing electrical coils or hot coolant lines, which is expensive. This paper proposes a novel digital method using the 3D CFD tool STAR CCM+ to study the melting behavior of AdBlue®. The method is characterized by capturing phase change using the popular multiphase (VOF) approach
Govindarajan, Vaishali, Varughese, Shibu, Banik, Soumendu, R, Vineeth
Flexible Heating and Heat Retention Technology for Efficient Treatment of Exhaust Gases in Diesel Engines2024-26-014401/16/2024
In the Journey towards Zero Emission and decarbonization, with emerging advancement in technology form current BS6 to near future EURO7 standards of emission, these emission norms are achievable when we amalgamate with an assistive technology of Electrically Heated System for thermal management in Diesel emission control i.e., called CatVap®. With the increasingly stringent limits on vehicle pollutants- including NOx emission levels are fulfilled with Twin Urea Dosing mechanism. These comprehensive lists of advanced technology to converge lowest NOx emissions without increasing CO2 emissions. The Major effort in the existing structure is to accelerate the SCR temperature and enhance the conversion efficiency of NOx in Real Drive Emission during cold start and low load duty cycle. CatVap®system provides sufficient thermal energy to facilitate rapid heating in the course of low load cycles and cold city rides for efficient gas conversion. As they are used to accelerate the light-off
YS, Ananthkumar, K, Sabareeswaran, M, Jayashree
Diesel Emissions and Their Control, Second EditionR-53312/20/2023
Engineers, applied scientists, students, and individuals working to reduce emissions and advance diesel engine technology will find the second edition of Diesel Emissions and Their Control to be an indispensable reference. Whether readers are at the outset of their learning journey or seeking to deepen their expertise, this comprehensive reference book caters to a wide audience. In this substantial update to the 2006 classic, the authors have expanded the coverage of the latest emission technologies. With the industry evolving rapidly, the book ensures that readers are well-informed about the most recent advances in commercial diesel engines, providing a competitive edge in their respective fields. The second edition has also streamlined the content to focus on the most promising technologies. This book is rooted in the wealth of information available on DieselNet.com, where the "Technology Guide" papers offer in-depth insights. Each chapter includes links to relevant online materials
Majewski, Addy, Jaaskelainen, Hannu
Development and Testing of End-of-Line (EOL) Tester for Diesel Engine2023-01-505808/25/2023
Decades ago, like the 1990s automobile industry, the off-highway industry was purely recognized as a mechanical entity. In the mechanical system, accuracy and troubleshooting of faults were significant concerns. Additionally, the continuous stringent emission norms by the government call for the adaptation of the aftertreatment and DeNOx led to more complexity and challenges. To meet the government emission regulation and product performance, thorough functionality testing of manufactured units was crucial. For this purpose, EOL/diagnostics testers are developed. Diagnostic protocol CAN establish the connection between ECU and tester due to its robustness and data handling capabilities. This paper aims to develop and test the end-of-line (EOL) tester for off-highway diesel engines. The communication between the tester and ECU will be over UDSonCAN, conforming to standard ISO14229. This tester will cover the synchronization of various components used to assemble the engine and maintain
Khond, Nikita Anil, Gandhi, Naresh, Kakade, Suhas
Laboratory sulfation of an ammonia slip catalyst with a real-world SO 2 concentration2023-01-038004/11/2023
Upcoming, stricter diesel exhaust emissions standards will likely require aftertreatment architectures with multiple diesel exhaust fluid (DEF) introduction locations. Managing NH3 slip with technologies such as an ammonia slip catalyst (ASC) will continue to be critical in these future aftertreatment systems. In this study, we evaluate the impact of SO2 exposure on a state-of-the-art commercially available ASC. SO2 is co-fed at 0.5 or 3 ppmv to either approximate or accelerate a real-world exhaust SO2 impact. ASC performance during sulfur co-feeding is measured under a wide variety of simulated real-world conditions. Results indicate that the loss of NO conversion during SCR is dependent on the cumulative SO2 exposure, regardless of the inlet SO2 concentration. Meanwhile, N2O formation under SCR conditions is nonlinearly affected by SO2 exposure, with formation increasing during 0.5 ppmv SO2 exposure but decreasing in the presence of 3 ppmv SO2. TPO experiments reveal the formation of
Ottinger, Nathan, Xi, Yuanzhou, Kiani, Daniyal, Liu, Z. Gerald
Evaluation of the Effectiveness of Diesel Particulate Filter Cleaning Methods and their Effect on Fuel Consumption2023-01-037604/11/2023
The negative effects of long-term exposure to soot and particulate matter emissions from diesel exhaust on the human health have been widely acknowledged due to the harmful substances that exhaust gas contains. Regulators have established strict programs to determine the performance and reliability of emissions after-treatment systems and devices. Tests were conducted to evaluate the efficacy of three diesel particulate filter (DPF) cleaning methods: 1) thermal and pneumatic cleaning, 2) ultrasonic cleaning, and 3) aqueous cleaning methods. A novel non-destructive method to quantify soot and ash deposits in the filters was developed, validated and used to determine the effectiveness of the identified cleaning methods. Given the number of different cleaning methods available, testing against a set of standard parameters provided accurate comparative results. Test results showed at least satisfactory ratings for all cleaning systems that were evaluated, while two systems stood out with
Bonsi, Adime Kofi, Surcel, Marius-Dorin, Szathmary, Gabor
The Effect of Exhaust Emission Conditions and Coolant Temperature on the Composition of Exhaust Gas Recirculation Cooler Deposits2023-01-043804/11/2023
Exhaust Gas Recirculation (EGR) coolers are widely used on diesel engines to reduce in-cylinder NOx formation. A common problem is the accumulation of a fouling layer inside the heat exchanger, mainly due to thermophoresis that leads to deposition of particulate matter (PM), and condensation of hydrocarbons (HC) from the diesel exhaust. From a recent investigation of deposits from field samples of EGR coolers, it was confirmed that the densities of their deposits were much higher than reported in previous studies. In this study, the experiments were conducted in order to verify hypotheses about deposit growth, especially densification. An experimental set up which included a custom-made shell and tube type heat exchanger with six surrogate tubes was designed to control flow rate independently, and was installed on a 1.9 L L-4 common rail turbo diesel engine. The test cycle and conditions were higher PM/ lower HC with 75°C coolant temperature for 1.5h, then lower PM/ higher HC with 75°C
Tomuro, Minato, Bhadra, Kaustav, Hebert, Jason, Boehman, Andre
A Multi-Function, Heated Mixer for Rapid Heat-up, Low-Temperature Ammonia Demand, Deposit Prevention and to Meet Ultra-Low NOx Regulations2023-01-035604/11/2023
Selective Catalytic Reduction (SCR) operation depends strongly on both heat and ammonia availability (stored or incoming). These requirements make high efficiency SCR challenging in lower temperature cycles where SCR is relatively cold, and Diesel Exhaust Fluid (DEF) injection is largely absent due to deposit risks. Examples include low temperature cycles such as low-idling, stop-and-go or low-load cycles such as city driving or local delivery cycles. An Electrically Heated Mixer/ EHM™ is utilized to address these challenges in a single component. EHM simultaneously provides heat for rapid SCR heat-up during the cold phase or in other low-temperature operations, steady or transient. Second, its heating mechanism makes deposit risks nearly non-existent. Third, EHM enables DEF injection at 130 °C, markedly enhancing the low temperature SCR impact. It is shown that these capabilities collectively make EHM a promising pathway for meeting ultra-stringent NOx targets including California
Masoudi, Mansour, Poliakov, Nick, Noorfeshan, Sahm
PERFORMANCE SPECIFICATION FOR AUTOMOTIVE WIRE HARNESS RETAINER CLIPSUSCAR44-2 (Current)03/23/2023
This specification describes a method and acceptance criteria for testing automotive wire harness retainer clips. Retainer clips are plastic parts that hold a wire harness or electrical connector in a specific position. Typical plastic retainers work by having a set of “branches” that can be inserted into a hole sized to be easy to install but provide acceptable retention. This specification tests retainer clips for mechanical retention when exposed to the mechanical and environmental stresses typically found in automotive applications over a 15-year service life. This specification has several test options to allow the test to match to the expected service conditions. The variability of applications typically arises from different ambient temperatures near the clip, different proximity to automotive fluids, different exposure to standing water or water spray, and different thicknesses of the holes that the clip is inserted into. Clips are typically inserted into sheet or rolled metal
USCAR
Application of Model-Based Controller on a Heavy-Duty Dual Selective Catalytic Reduction Aftertreatment03-16-05-004003/08/2023
Commercial vehicles require advanced engine and aftertreatment (AT) systems to meet upcoming nitrogen oxides (NOx) and carbon dioxide (CO2) regulations. This article focuses on the development and calibration of a model-based controller (MBC) for an advanced diesel AT system. The MBC was first applied to a standard AT system including a diesel particulate filter (DPF) and selective catalytic reduction (SCR) catalyst. Next, a light-off SCR (LO-SCR) was added upstream of the standard AT system. The MBC was optimized for both catalysts for a production engine where the diesel exhaust fluid (DEF) was unheated for both SCRs. This research shows that the tailpipe (TP) NOx could be reduced by using MBC on both catalysts. The net result was increased NOx conversion efficiency by one percentage point on both the LO-SCR and the primary SCR. The CO2 emissions were slightly reduced, but this effect was not significant. Finally, the MBC was used with a final setup representative of future AT
Meruva, Prathik, Matheaus, Andrew, Zavala, Bryan, Sharp, Christopher A., McCarthy Jr., James E.
Detailed Compositional Comparison of Hydrogenated Vegetable Oil with Several Diesel Fuels and Their Effects on Engine-Out Emissions04-16-03-001512/08/2022
The Coordinating Research Council (CRC) is actively involved in developing and applying advanced analytical techniques to the chemical characterization of transportation fuels. This article complements a 2017 CRC project to quantify and compare the effects of a commercially available renewable diesel fuel (hydrotreated vegetable oil [HVO]) and an ultralow sulfur diesel (ULSD) fuel on engine-out gaseous and particulate matter (PM) emissions from a light-duty vehicle. Results showed that the combustion of HVO fuel had an advantage over ULSD in terms of lowering engine-out emissions (THC, CO, NOx, etc.). Furthermore, this advantage is strongly related to the fuel composition. This article summarizes the results of advanced and comprehensive analytical tests on the same ULSD and HVO fuels and attempts to connect some of the engine-out emissions results to fuel composition and specific chemical structures. A variety of test methods, generally unavailable in combination, were employed, such
Bays, J. Timothy, Gieleciak, Rafal, Viola, Michael B., Lewis, Russ P., Cort, John R., Campbell, Kristen B., Coffey, Gregory W., Linehan, John C., Kusinski, Matthew
Heavy-Duty Diesel Truck In-Use NO x Emissions Evaluation Using On-Board Sensors2022-01-509811/21/2022
Governments and regulatory agencies in North America are evaluating the nitrogen oxides (NOx) emissions of heavy-duty on-road vehicles to effectively regulate these emissions in order to improve public health and meet air quality requirements. This paper provides results from real-world Class 8 tractor-trailer truck activity and emissions data gathering conducted in the Northeast and Mid-Atlantic United States. Unlike some other areas of the United States (US), there is little available data on in-use operation and emissions performance from heavy-duty trucks in this region where temperatures can be consistently cold in winter. The purposes of this study are to add to the literature on real-world truck operation and emissions in the Northeast and Mid-Atlantic regions; to analyze the captured emissions data using recently established calculation methods implemented by the California Air Resources Board (CARB), which have not yet been applied to data from this region; and to assist air
Humphries, Kieran, Cooper, Coralie, Ahmadi, Mahdi
Effect of Fuel Reactivity on Engine Performance and Exhaust Gas Emissions in a Diesel Engine04-16-02-001211/10/2022
Using a compression engine with dual fuel is the most promising technology to control emissions and for fuel economy, to meet the upcoming legislative norms. This experimental study was conducted to understand the effect of fuel reactivity on engine performance and emission in a compression ignition (CI) engine. The effect of injection timing, gasoline ratio, and exhaust gas recirculation (EGR) rate on emission is compared to the conventional diesel engine. In this study, high-octane fuel (gasoline) is injected manifold the intake of a diesel engine (high-reactivity fuel) to primarily investigate the effects of balance between fuels having low and high reactivity. Fuel reactivity is optimized on different load and speed conditions by varying the diesel and gasoline quantity. Experimental results indicate that dual fuel helps to avoid nitrogen oxides (NOx) and soot trade-off, mitigating both to near-zero values. The engine was tested at a constant speed of 1520 rpm and showed a
Barman, Jyotirmoy, Deshmukh, Devendra
A New Electrically Heated Mixer (EHM) for Efficient SCR of NOx in Low Load Cycles2022-01-115309/13/2022
Low temperature Diesel exhaust operations such as during low-load cycles are some of the most difficult conditions for SCR of NOx. This, along with newer regulations targeting substantial reduction of the tailpipe NOx such as California-2024/2027 NOx regulations, adds to challenges of high efficiency SCR of NOx in low temperature operations. A novel design, low-cost, low-energy Electrically Heated Mixer (EHM™), energized via the 12, 24 or 48 V vehicle electrical system, is used to accelerate formation of reductants (ammonia, isocyanic acid) in low temperature exhaust (low load cycles), so to enable high efficiency SCR of NOx in most challenging SCR conditions, while also mitigating urea deposit formation. EHM™ is also used to heat the cooler exhaust flow during engine cold-start. It easily fits common exhaust configurations and can be utilized on light, medium or heavy duty Diesel aftertreatment systems, on- or non-road or in stationary systems.
Masoudi, Mansour, Poliakov, Nick, Noorfeshan, Sahm
From emissions tech to EV electronics22AUTP09_0309/01/2022
Eberspaecher's Electronics unit is enabling big growth in EV and AV business. A recent visit to Eberspaecher's North American engineering and manufacturing complex reveals how a global Tier-1 rooted in combustion-engine technology is profitably navigating the transition to the electrified future. In the Brighton, Michigan, plant, which produces 40% of U.S. Class-8 diesel exhaust systems, catalyst bricks are being canned and prepared for shipment to OEMs. Meantime in the facility's engineering offices, work is progressing on next-generation heating systems for passenger and commercial EVs, power electronics, automated-driving systems, and high-voltage switching solutions. Best known for 90 years as an exhaust-systems and climate-controls supplier, the Germany-based company now is a parallel force in electric power switching and distribution. Since establishing its Electronics business unit in the early 2000s, Eberspaecher has produced 30 million electronic control modules, more than 17
Brooke, Lindsey
The DAAAC Protocol: A Procedure for Developing Accelerated Aging Cycles for Diesel Aftertreatment2022-01-101708/30/2022
Accelerated aging of automotive gasoline emissions catalysts has been performed on bench engines for decades. The EPA regulations include an accelerated aging cycle called the Standard Bench Cycle (SBC) that is modeled on the RAT-A cycle developed by GM Corp. and published in 1988. However, this cycle cannot be used for diesel aftertreatment components because it is based on stoichiometric operation, whereas diesel engines typically operate under excess air (lean) conditions. The need for accelerated aging cycles for diesel emissions systems can be illustrated by considering that the full useful life (FUL) requirement in the United States for an on-highway truck is 435,000 miles, and an off-road application may be 8,000 hours. With the recent CARB Omibus legislation, the durability duration will be increasing for on-road applications by as much as 80 percent in the next decade. Additionally, regulators have implemented much more stringent durability demonstration requirements which
Eakle, Scott, Zavala, Bryan, Sharp, Christopher
Meeting Future NO X Emissions Over Various Cycles Using a Fuel Burner and Conventional Aftertreatment System2022-01-053903/29/2022
The commercial vehicle industry continues to move in the direction of improving brake thermal efficiency while meeting more stringent diesel engine emission requirements. This study focused on demonstrating future emissions by using an exhaust burner upstream of a conventional aftertreatment system. This work highlights system results over the low load cycle (LLC) and many other pertinent cycles (Beverage Cycle, and Stay Hot Cycle, New York Bus Cycle). These efforts complement previous works showing system performance over the Heavy-Duty FTP and World Harmonized Transient Cycle (WHTC). The exhaust burner is used to raise and maintain the Selective Catalytic Reduction (SCR) catalyst at its optimal temperature over these cycles for efficient NOX reduction. This work showed that tailpipe NOX is significantly improved over these cycles with the exhaust burner. In certain cases, the improvements resulted in tailpipe NOX values well below the adopted 2027 LLC NOX standard of 0.05 g/hp-hr
McCarthy, Jr., James, Matheaus, Andrew, Zavala, Bryan, Sharp, Christopher, Harris, Thomas
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