Browse Topic: Combustion and combustion processes

Items (15,708)
In CPCB-IV+ Emissions regulations NOx & PM are reduced by 90% from CPCB-II limits in the power band 56 < kW ≤ 560. Obvious technology approach adopted by industry to meet this requirement is the introduction of CRDI fuel injection system & DOC+SCR+ASC aftertreatment technology, leading to substantial modifications at both engine & genset level. This result into huge development expenditure, high incremental product cost, timelines and increased total cost of ownership. This paper describes the frugal technology approach to keep development cost, product cost, development time to the minimum using electronically governed, high pressure mechanical fuel injection equipment, with DOC+SCR+ASC without any external thermal management strategy while comfortably achieving target CPCB-IV+ emission levels. This integrated approach also helped in completing the entire development in < 12 months. 1D-thermodynamic & 3D-combustion simulation approach was adopted to predict the engine out emissions
Arde, VasundharaJuttu, SimachalamKadam, AtitGothekar, SanjeevKarthick, KVandana, SuryanarayanaThipse, SKendre, Mahadev
This paper is to introduce a new catalyst family in gasoline aftertreatment. The very well-known three-way catalysts effectively reduce the main emission components resulting from the combustion process in the engine, namely THC, CO, and NOx. The reduction of these harmful emissions is the main goal of emission legislation such as Bharat VI to increase air quality significantly, especially in urban areas. Indeed, it has been shown that under certain operating conditions, three-way catalysts may produce toxic NH3 and the greenhouse gas N2O, which are both very unwanted emissions. In a self-committed approach, OEMs could want to minimize these noxious pollutants, especially if this can be done with no architecture change, namely without additional underfloor catalyst. In most Bharat VI gasoline aftertreatment system architectures, significant amounts of NH3 occur in two phases of vehicle driving: situations with the catalyst temperature below light-off, which appear after cold start or
Kuhn, SebastianMagar, AvinashKogel, JuliusLahousse, Christophe
Controlling the source vibrations in internal combustion engines is a crucial approach to minimizing the vibration levels experienced by the driver. The driver's subjective perception of vibration is primarily dictated by the vehicle's low-frequency response (<100 Hz). In an IC engine used in agricultural tractor applications, the primary sources of vibration include (a) 1st order inertial force, (b) couples generated by rotating and reciprocating components such as the piston assembly, connecting rod, and crankshaft, and (c) in-cylinder combustion. In this study, an order ranking analysis was conducted on a single-cylinder, air-cooled, naturally aspirated tractor engine within the driver’s operating range to identify the dominant contributors to source vibrations. The 1st order inertial force was observed to be the dominant contributor to the engine's vibration levels. Subsequently, an attempt was made to mitigate the unbalanced forces by implementing counterweight-based balancing
Bhuntel, AjayRajput, SurendraRawat, Ashish
The rising demand for electric vehicles (EVs) has pushed automakers to prioritize visual brand consistency across both EVs and internal combustion engine (ICE) vehicles. A main design factor which is influenced by this trend is the front grille. In order to achieve uniform aesthetic looks, passenger car manufacturers often reduce the front grille openings and limit airflow. This closed grille style is common in electric vehicle. However, this creates challenges for internal combustion engine (ICE) vehicles with snorkel-type air intake systems, leading to reduced airflow and higher temperatures in the engine bay and intake air which eventually gets sucked in the engine resulting in low volumetric efficiency. Maintaining a cooler intake air is vital for ICE performance. Adjusting snorkel position and airflow patterns in low temperature zones ensures the engine receives air at low temperatures. This improves the combustion efficiency, throttle response and eventually it reduces the risk
Sonone, Sagar DineshSingh, Nil KanthKolhe, Vivek MKulkarni, ChaitanyaMalekar, Hemant A
In alignment with its carbon reduction commitments, India is transitioning towards higher ethanol-blended fuels, with E20 set for nationwide implementation by 2025. Ethanol is a renewable, domestically produced biofuel produced through fermentation of biomass such as sugarcane, corn. It possesses a higher octane rating and oxygen content compared to conventional gasoline, making it a favorable additive for improving engine performance and reducing emissions. This study investigates the impact of E20 fuel on performance parameters of a 694 cc MPFI , water-cooled, twin-cylinder gasoline engine. For deriving maximum benefits of increased Octane rating of E20, compression ratio was increased to 12.5:1. Experimental analysis was conducted to assess the changes in combustion behavior, brake specific fuel consumption (BSFC), torque output, engine out emissions and thermal efficiency when operating on E20 compared to baseline gasoline (E10). Base results indicate that E20 promotes more
Kulkarni, DeepakMalekar, Hemant AThonge, RavindraKanchan, Shubham
This paper presents the design, structural analysis, structural test validation and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used the 2.5L and 3.0L (4-cylinder) engines that have standard power ratings based on existing requirements, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 15% uprate for 2.5L and 22% uprate for 3.0L from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. Multiple analysis led design iterations were performed using cutting edge CAE software such as Ansys, Dassault Systems fe-safe, and PTC Creo to ensure the structural integrity of the cylinder head under high thermal and mechanical loads, and to keep design margins within
Pathak, Arun JyotiAdiverekar, VaidehiSingh, RahulBiyani, Mayur
To address the imperative for decarbonizing the heavy-duty transport sector and advancing sustainable energy solutions, this paper presents a novel lean-boosted Direct Injection (DI) Hydrogen Internal Combustion Engine (H2 ICE) combustion system. This system is developed to retrofit existing flat-deck Diesel engines, offering a viable pathway towards drastically reduced emissions. Building on consolidated expertise from prior production-oriented Port Fuel Injection H2 engine development (DUMAREY 6.6ℓ V8), this research focuses on leveraging the distinct advantages of DI for hydrogen. An experimental assessment, supported by 1D and 3D-CFD analyses, demonstrates the system's capability to achieve highly efficient operation in Spark Ignition (SI) mode under ultra-lean and EGR-diluted conditions. The study confirms the elimination of combustion anomalies such as backfiring, pre-ignition, and knock, while achieving ultra-low engine-out NOx emissions and near-zero CO2, HC, CO, and PM. The
Gessaroli, DavideGolisano, RobertoPesce, FrancescoBoretto, GianmarcoAccurso, Francesco
Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges, particularly concerning cold startability. Low ambient temperatures and pressures intensify the cold start difficulties which are characterized by prolonged cranking, incidences of misfiring, compromised transient response and overall engine performance. This paper highlights the strategies and technologies employed to enhance cold start and transient performance of medium BMEP engines under such demanding environmental conditions. Investigations were conducted up to an altitude of 4500m and ambient temperatures as low as-20°C, utilizing only air heater at intake manifold as the sole cold start aid. This cost effective approach is integrated with an optimized combustion chamber design, along with minimal pilot injection timing and quantity to facilitate smooth ignition and stable combustion during cold start. The paper also explore the techniques to improve the
Saxena, HarshitLokare, PrasadSanthosh, AjithGandhi, NareshShinde, Prashant
The Indian automobile industry is experiencing a significant shift, propelled by environmental necessities and national climate obligations set at the CoP26 summit, aiming for a 45% decrease in CO₂ emissions by 2030 and reaching carbon neutrality by 2070 [1]. Transportation continues to be a significant source of air pollution; consequently, India is enhancing its regulatory frameworks with BS VI Stage 2 regulations, CAFE Phase III norms set for 2027, and CAFE Phase IV by 2032 [2]. Furthermore, the transition from MIDC to WLTP driving cycle is meant to increase the accuracy of the efficiency and emissions assessments [2]. To comply to these upcoming regulations, the automotive industry is moving toward producing high efficiency engines in India. A naturally aspirated (NA) 1.5L, 4-cylinder inline gasoline engine was selected from Indian market for this study. Maximum Brake Thermal Efficiency (BTE) of this engine is around 37%. Assessment of new technologies were performed by
Garg, ShivamFischer, MarcusEmran, AshrafJagodzinski, BartoschFranzke, Bjoern
The Bharat TREM V regulations in the off-highway segment mandates the use of Diesel Oxidation Catalyst (DOC) to reduce gaseous emissions and Diesel Particulate Filters (DPF) to trap solid particulates from engine exhaust. DPFs undergo regeneration, where trapped soot is burned, converting it into CO2 with ash as main byproduct. Regeneration can be active, using late post fuel injections to raise temperatures above 550°C, or passive, relying on NO2 formation at 300-400°C. Passive regeneration is preferred as a safer mode for both DPF health and longevity as well as reduction in fuel penalty and oil dilution. This paper highlights the selection and optimization of combustion hardware and Exhaust Aftertreatment System to achieve the desired NO2 formation which is suitable for passive regeneration. Key considerations in engine hardware selection include the design of piston bowl, injector hole configuration to increase heat release rate and combustion temperature resulting in higher NOx
Gautam, AmanRawat, SaurabhDogra, DaljitSinghSingh, SachleenRanjan, Piyush
Air pollution is profligate becoming a serious worldwide problem with the increasing population and its subsequent demands. Diesel, Gasoline, Natural Gas, Propane, etc., are some of the traditional fuels used in the power generation sectors. Diesel fuel, popularly utilized for backup power in critical operations, is valued for its swift activation time. This makes diesel generators a preferred choice for commercial properties and hospitals requiring reliable emergency power. Moreover, natural gas, distributed through local utility grids, provides a convenient and readily available fuel source for generators, eliminating the need for on-site fuel storage. On the other hand, CPCB has instructed to modify the emission regulations for genset engines for decarbonization and development clean fuel. The change from CPCB II to CPCB IV+ standard shows the commitment of the Indian government towards environmental sustainability and COP26. Pondering to the stringent emission norms, researchers
Bandyopadhyay, DebjyotiSutar, Prasanna SDhar, Rit PrasadSonawane, Shailesh BalkrishnaRairikar, Sandeep DThipse, Sukrut SSingh, SauhardMishra, Sumit KumarBera, TapanBadhe, RajeshTule, ShubhamAghav, YogeshLakshminarasimhan, Krishna
Original Equipment Manufacturers (OEM’s) are focusing on the fuel economy of passenger cars to meet the next generation emission norms. Few techniques such as downsizing engines, raising lubricant temperature, reducing combustion time and regulating the start-stop system of engines are various efforts being considered by Automobile OEMs to attain fuel efficiency along with next generation emission norms. On the other hand, lubricants used for such engines are also to be modified accordingly to meet more fuel efficiency. Lowering viscosity along with addition of friction modifiers for normalizing frictional losses is widely practiced as the most economical techniques. To achieve this lubricant formulator and additive manufacturers have moved towards modern base oils and advanced additive technologies. This study is done to understand key parameters which reduce friction and increase fuel economy using same viscosity grade oils. In the current study, we have formulated different low
Vabbina, Shiv KumarKatta, LakshmiJoshi, RatnadeepChaudhary, RameshwarSeth, SaritaBhardwaj, AnilArora, Ajay Kumar
Cylinder Deactivation technology is explored as an effective mechanism for enhancing the fuel economy and reducing emissions in internal combustion engines. The current exercise focuses upon the feasibility of Cylinder Deactivation technology in a 3-cylinder, 3.3-liter naturally aspirated, water-cooled diesel engine from the off-highway tractor application. A meticulous 1D thermodynamic simulation with individual cylinders deactivated one by one, has proved that deactivating the second cylinder yields the most favorable fuel economy, emissions and engine balancing, particularly at the loads lower than 54% and across all engine speeds. Upon deactivating the cylinders at Top Dead Centre (TDC) and Bottom Dead Centre (BDC), it has been concluded that the most effective deactivation point occurs at TDC, where the minimum air mass is trapped inside the cylinder. This results in a reduction of pumping and friction losses by maximum 34% and an increase in brake thermal efficiency by maximum 26
Choudhary, VasuSaini, SanjayMukherjee, NaliniNene, Devendra
Increasing ethanol blending in gasoline is significant from both financial (reducing dependency on crude oil) and sustainability (overall CO2 reduction) points of view. Flex Fuel is an ethanol-gasoline blend containing ethanol ranging from 20% to 85%. Flex Fuel emerges as an exceptionally advantageous solution, adeptly addressing the shortcomings associated with both gasoline and ethanol. Performance optimization of Flex Fuel is a major challenge as fuel properties like knocking tendency, calorific value, vapour pressure, latent heat, and stoichiometric air-fuel ratio change with varying ethanol content. This paper elaborates on the experimental results of trials conducted for optimizing engine performance with Flex Fuel for a 2-cylinder engine used in a small commercial vehicle. To derive maximum benefit from the higher octane rating of E85, the compression ratio is increased, while ignition timing is optimized to avoid knocking with E20 fuel. For intermediate blends, ignition timing
Kulkarni, DeepakMalekar, Hemant AUpadhyay, RajdipKatkar, SantoshUndre, Shrikant
Hydrogen Internal Combustion Engine (HICE) has the promise of zero carbon solution for the mobility industry. The key beneficiary would be the medium and heavy-duty segment of transportation which are likely to adapt the battery electric or fuel cell electric solution in longer term. This particular segment of engines need high low end torque, peak torque and rated power which cannot be compromised. Additionally, a competitive thermal efficiency w.r.t diesel engines would be advantageous. Direct Injection (DI) of hydrogen gives higher specific power and thermal efficiency as compared to Port Fuel Injection (PFI). This study focuses on the performance characteristics of these technology routes to aid in the HICE development process. Current work involves the use of 1-D thermodynamic simulation using GT-SUITE for modeling the performance of HICE. Both predictive and non-predictive methodologies of modeling the combustion were employed. Initially, the model validation of the PFI engine
Parthiban R, VarunKarthikeyan, K RNarayana Reddy, JParamasivam, PrakashManjunath, MKumar D, KishoreN R, VaratharajSuresh, KG, Yogesh BolarSadagopan, KrishnanPandey, Sunil Kumar
The CPCB-IV+ emission compliance for genset application is applicable with effect from 1st July 2023 as per as per GSR 804(E). The CPCB-II to CPCB-IV+ changeover in very stringent in emission front by almost 90 % emission reduction. It’s a significant advancement in environmentally sustainable powertrain technology. To meet the CPCB-IV+ Emission, combustion development & ATS technology plays an important role. First is the base engine need to optimize enough with combustion & associated parts. Second is the after treatment system which will carry the battle further to the engine emission with minimum margin of 10 % engineering target. This paper present the systematic approach followed to meet CPCB-IV+ emission norms for upgradation of 21 litre TCIC engine for the power range (56 < P ≤ 560). Here the challenge to avoid major changes in the existing CPCB-II FIE recipe & meet the CPCB-IV+ emission with ECU calibration & ATS system calibration with its potential. Here interesting parts
Rane, VikasJagtap, ShaileshGothekar, SanjeevPawar, Narendra VKhedkar, PrasadKagade, SamadhanKendre, MahadevG Bhat, PrasannaThipse, S
The work demonstrating a novel approach to the optimization of crankshaft design for heavy-duty commercial vehicle engines, specifically targeting non-automotive applications with elevated power ratings. The research focuses on a 6-cylinder, 5.6-litre diesel engine, originally rated at 160 kVA and upgraded to 200 kVA, where the challenge was to enhance the crank-train system’s robustness within existing packaging constraints. By fundamentally altering the crankshaft’s geometry and structural parameters, the new design achieves higher load-bearing capacity while inherently mitigating torsional vibrations, thereby eliminating the need for viscous dampers traditionally used in place of rubber dampers. Advanced simulation tools, notably AVL Excite, employed to iterate and evaluate the balance between crankshaft balance ratio, weight, and torsional behavior. The optimized design then validated through both simulation and physical vibration trials, with sixth-order angular displacement
Khandelwal, MehaKaundabalaraman, KaarthicRathi, Hemantkumar
Emission Regulations for NRMM in India have evolved significantly over past two decades. India has progressively adopted stricter standards to align with best practices carried out globally for curbing air pollution. The latest regulations have introduced stringent caps on nitrogen oxides (NOx), and other emission pollutants, ensuring compliance with environmental sustainability goals. Future legislative frameworks are expected to impose even more rigorous emission limits, while incorporating real-world emission monitoring. This will require powertrain manufacturers to integrate advanced after-treatment systems and adopt cleaner combustion technologies to meet compliance standards. To validate compliance with these stringent limits, rigorous testing methodologies are employed. Portable Emission Measurement Systems (PEMS) have become a crucial tool for real-world emission assessment. PEMS technology allows for on-road and field testing of NRMM under actual operating conditions
Rastogi, AadharGarg, VarunRagot, Nicolas
Hydrogen is a zero-carbon fuel suitable for the de-carbonization of power generation and the industrial sector. Green hydrogen produced via the electrolysis of water is the most sustainable fuel to achieve a net-zero carbon economy. Oxy-hydrogen (hydrogen and oxygen) generated onsite from the electrolyzer can be fed to engine with the intake air to enhance power and combustion efficiency with near-zero exhaust emissions. In this study, a 15 kVA two-cylinder natural gas spark-ignition generator set was used. The engine was retrofitted to operate on an oxy-hydrogen-air mixture. A maximum of 43% of rated engine load was achieved during the preliminary experiments. GT-Power software was used to calibrate the 1D model using experiment data and generate the burn profile of oxy-hydrogen-air mixture. The calibrated and validated 1D model was used for further predictive simulations. The power limiting factors were identified via simulations for flow and power improvement. The simulations
Marwaha, AksheyTule, ShubhamMishrikotkar, PrasadAghav, Yogesh
Hydrogen combustion in internal combustion engines offers numerous advantages, such as zero CO2 emissions and high flame speed, which make it a promising alternative fuel for green vehicle solutions. In order to maximize the engine performance with hydrogen, however, meticulous calibration of the air-fuel mixture must be performed, particularly when lean and stoichiometric combustion conditions are considered. Lean burning, i.e., excess air, offers better thermal efficiency and lower NOx emissions but can cause lower engine power and combustion instability. Stoichiometric combustion, however, ensures complete combustion of the fuel-air mixture, but at the cost of higher combustion temperatures and consequently, high NOx emissions. Calibration strategies for hydrogen engines are presented in this paper by comparing the lean and stoichiometric strategies and their implications on engine power output, efficiency, and emissions. Test data from several hydrogen engine configurations
Jadhav, AjinkyaBandyopadhyay, DebjyotiSutar, Prasanna SSonawane, Shailesh BalkrishnaRairikar, Sandeep DThipse, Sukrut S
Noise quality at idle condition is an important factor which influences customer comfort. Modern diesel engines with stringent emission norms together with fuel economy requirements pose challenges to noise control. Common rail engine technology has advantage of precise fuel delivery and combustion control which needs optimization to achieve the conflicting requirements of noise, emission and fuel efficiency. Engine noise at low idle condition is dominated by combustion noise which depends on rate of pressure rise inside the cylinder during combustion. The important parameters which influence cylinder pressure rise are fuel injection timing, pilot injection quantity and its separation, rail pressure and EGR valve position. The study on effect of these parameters at varying levels demand large no of experiments. Taguchi design of experiments is a statistical technique which can be used to optimize these parameters by significantly reducing no of experiments needed to achieve the desired
P, PriyadarshanChavan, AmitA, KannanswamyPatil, SandeepChaudhari, Vishal V
The adoption of flex-fuel vehicles (FFVs) in India presents a significant opportunity to reduce dependence on fossil fuels, lower greenhouse gas emissions, and ensure compliance with the country’s evolving emission norms. This paper explores the key aspects of flex-fuel technology in the context of Indian four-wheeler regulations, particularly Bharat Stage VI and potential future emission norms. The study begins with an overview of flex-fuel technology, detailing its advantages and associated challenges. A critical focus is placed on blend identification techniques, which play a vital role in optimizing combustion efficiency and ensuring seamless transitions between different ethanol-gasoline blends. Furthermore, the impact of ethanol blending on various fuel properties is examined, including changes in energy content, latent heat of vaporization, octane number rating, and stoichiometric air-fuel ratio. These factors significantly influence engine performance and emission
Balasubramanian, KarthickKR, PrabhakarKallahallii Somu, Santhosh Kumar
The stringent emission norms over the past few years have driven the need to use low-carbon fuels and after treatment technology. Natural gas is a suitable alternative to diesel heavy-duty engines for power generation and transportation sectors. Stoichiometric combustion offers the advantages of complete combustion and low carbon dioxide emissions. Turbocharging and cooled exhaust gas recirculation (EGR) technology enhances the power density along with reduced exhaust emissions. However, there are several constraints in the operation of natural gas spark ignition engine such as exhaust gas temperature limit of 780 °C, sufficient before turbine pressure for EGR drivability, boost pressure, peak cylinder pressure limit and knocking. These limits coulld restrict the engine BMEP (brake mean effective pressure). In the present study, tests were conducted on a V12, 24 liters, heavy duty natural gas fuelled spark ignition engine (600 HP) with different EGR and turbocharger configurations to
Khaladkar, OmkarMarwaha, Akshey
Ammonia has emerged as a promising alternative fuel for transportation because of its high energy density (NH3 has more hydrogen than propane in a similar size tank), simple and carbon-free combustion, and potential to produce sustainably. This paper investigates the feasibility of using ammonia as fuel for internal combustion engines (ICE) and fuel cells in automotive applications. In many ways, ammonia captures these benefits by being produced from renewable energies and having the potential to reduce reliance on fossil fuels. There are significant drawbacks of ammonia however, such as its decreased energy content per unit volume, NOx emissions potential, and necessary engine adaptations. This paper discusses the combustion characteristics of ammonia and how it functions in typical ICE's as well as new fuel cell technology, and the necessary infrastructure to produce, store, and distribute ammonia for automotive applications. The study compares operations to conventional fuels
Jadhav, AjinkyaBandyopadhyay, DebjyotiSutar, Prasanna SSonawane, Shailesh BalkrishnaRairikar, Sandeep DThipse, Sukrut S
Validation of hydrogen-fuelled internal combustion engine (H2 ICE) is critical to assess its feasibility as sustainable transportation with zero carbon emissions. This experimental analysis conducted on Ashok Leyland’s 6cylinder 2V engine to evaluate the engine performance & durability with hydrogen fuel. Combustion behaviour of hydrogen ICE needs to be closely monitored during continuous operation of validation testing, due to its unique properties compared to other conventional fuels. During engine run, a pre-ignition source can cause knock event leading to instant failure of critical parts like piston assembly, spark plug, liner, valves & cylinder head. Also, hotspots inside IMF leads to backfire affecting the air intake & fuel injection assembly. This study emphasizes the significance of precise instrumentation of thermocouples across engine on cylinder head, intake manifold & exhaust manifold, to detect performance detoriation and combustion abnormalities causing knocking
Vasudevan, SindhujaJ, Narayana ReddyBolar, Yogesh GaneshPandey, SunilN, HarishN R, VaratharajKarthikeyan, KKumar D, Kishore
Compressed Natural Gas (CNG) offers a compelling alternative fuel solution due to its lower carbon emissions and cost-effectiveness compared to conventional gasoline. However, the dry combustion characteristics of CNG, coupled with higher combustion temperatures, often accelerate Exhaust valve face and Exhaust seat insert wear in internal combustion engines. Intake valve face and Intake seat insert are exposed to fresh air charge and temperature during engine operation remain with in limit and no issue reported in Intake valve side. This study addresses the critical challenge of premature exhaust valve wear in CNG applications by investigating the root cause and implementing improvements in the exhaust valve facing material, aiming to enhance durability and reliability for widespread CNG vehicle adoption. Exhaust valve face in CNG engine subjected to extreme condition leads to excessive valve face wear and cracking. To address these challenges, various technologies like hard material
Poonia, SanjayKumar, ChandanKundu, SoumenKumar, PrabhakarVats, RajeshKhan, PrasenjitSharma, Shailender
India’s commitment to carbon neutrality is significantly shaping the future architecture of commercial vehicle powertrains. While the use of CO₂-free technologies such as battery-electric drivetrains has already been successfully demonstrated across various applications, challenges related to limited range and the lack of high-power charging infrastructure continue to hinder widespread adoption, particularly for productivity-critical commercial vehicles. This has shifted the spotlight toward sustainable fuels, which offer the advantage of fast refueling times. Among these, hydrogen internal combustion engines (H₂ ICE) have gained increasing attention in recent years. In regions such as the European Union, the primary motivation for hydrogen is CO₂ reduction. In contrast, for markets like India, hydrogen also presents a strategic opportunity for reducing dependency on fossil fuel imports. Over the past four years, multiple performance and emission development projects across various H
Arnberger, AntonDanninger, AloisMannsberger, StefanBreitegger, Bernhard
The pursuit of sustainable transportation solutions requires continuous improvement in engine efficiency and performance. This study presents a comprehensive parametric analysis of high-horsepower diesel engine combustion modeling, focusing on fuel injector configurations to optimize power density and overall engine efficiency. The model was first validated with experimental data. Based on the validated model, a series of Design of Experiments (DoE) simulations were conducted, examining four distinct fuel injector hole configurations, each with four different spray inclusion angle (umbrella angle) variations. The set of different fuel injector configurations was selected through benchmarking analysis. The primary objective was to identify the most effective injector design for improved combustion characteristics and engine performance. Upon determining the superior configuration, further simulations were performed with increased injector through – flow to fine-tune the optimal design
Ailaboina, AkhilGandhi, NareshMarwaha, AksheyG, SuwarnaChogule, VijayBhat, Vishal
There is continuous push from the legislation for stringent fuel economy and emission regulations while the modern customers are demanding more engaging driving experience in terms of performance and refinement. To meet this Tata Motors has developed an advanced 1.2L 3-cylinder turbocharged gasoline direct injection engine. This next-generation powertrain delivers optimum efficiency, reduced emissions, superior performance with refined NVH characteristics. The key features used to enable these demanding requirements includes a 35 MPa fuel injection system, Miller Cycle operation and electrically actuated variable nozzel turbocharger (VNT). A uniquely designed BSVI complaint (WLTP ready) exhaust after-treatment system with Four-Way Conversion Catalyst (FWC+TM) ensures optimum emission control. A centrally mounted variable cam phaser minimizes pumping losses. The lightweight yet rigid all-aluminum engine structure, featuring an integrated structural oil sump, enhances durability and
Hosur, ViswanathaGhadge, Ganesh NarayanJoshi, ManojJadhav, AashishPanwar, Anupam
Emissions regulations, such as Euro VI, drives the Automotive industry to innovate continuously in Engine development. One significant challenge is the engine oil pumping from the crankcase into the combustion chamber, where it participates in combustion, which contributes to increased Particulate Numbers and fails to meet Euro VI emission compliance. This issue is most noticeable during engine idling and motoring conditions. During this time, a higher negative pressure difference develops between the intake manifold, which is acting above the combustion chamber and the engine crankcase. This pressure difference drives oil-laden blow-by aerosols past piston rings during the intake stroke and through the valve stem seals, allowing oil into the combustion chamber. The impact of the pressure difference between the intake manifold and crankcase was studied by varying the crankcase pressure through crankcase ventilation system. The results confirm that oil entry into the combustion chamber
R, Mahesh BharathiBondfale, ShubhamJeyaprakasan, Dharoon Gautham
With the expansion of compressed natural gas (CNG) filling station in India, bi-fuel vehicles are gaining popularity in recent times. Bi-fuel engine runs on more than one fuel, say in both CNG and petrol. Hence, the engine must be optimized in both the fuel modes for performance and emissions. However, due to the inherent differences in combustion characteristics: ignition dynamics and fuel properties, they pose a significant challenge in case of detection of misfires. Misfires are caused because of faulty injection systems and ignition systems and incorrect fuel mixture. Accurate detection is essential as misfires deteriorate the catalysts performance and may impacts emission. Misfires (or engine roughness) is calculated from engine crankshaft speed signal. In this study, the effectiveness of crankshaft-based misfires detection method, comparison of misfire signals magnitude in bi-fuel modes and practices developed for accurate detection of misfires is presented.
Thiyagarajan, AbhinavN, GobalakrishnanR, Hema
This study investigated the combustion processes in hydrogen dual-fuel operation using hydrotreated vegetable oil (HVO) and diesel fuel as pilot fuels. The visualizations of hydrogen dual-fuel combustion processes were conducted using hydroxyl radical (OH*) chemiluminescence imaging in an optically accessible rapid compression and expansion machine (RCEM), which can simulate a compression and expansion stroke of a diesel engine. Pilot injection pressures of 40 and 80 MPa and injection quantities of 3, 6 mm3 for diesel fuel and to match the injected energy, 3.14, 6.27 mm3 of HVO were tested. The total excess air ratio was kept constant at 3.0. The RCEM was operated at a constant speed of 900 rpm, with in-cylinder pressure at top dead center (TDC) set to approximately 5.0 MPa. Results demonstrated that using HVO as pilot fuel, compared to diesel fuel, led to shorter ignition delay and combustion duration. OH* chemiluminescence imaging revealed that longer ignition delays observed with
Mukhtar, Ghazian AminUne, NaotoHoribe, NaotoHayashi, JunKawanabe, HiroshiHiraoka, KenjiKoda, Kazuyuki
In this study, a novel dual-fuel combustion strategy is investigated, employing late pilot injection in diesel–methane engines to improve performance and reduce emissions. The engine was first tested with conventional diesel and methane, exploring a wide range of pilot injection timings, injection pressures, and intake boost pressures. Subsequently, experiments were repeated using a methane/hydrogen blend to assess the influence of hydrogen addition. Results show that, when using only methane, delayed pilot injections have minimal effects on engine performance. In naturally aspirated operation, unburned hydrocarbons and carbon monoxide are reduced, while in supercharged conditions, emissions increase; however, they remain within acceptable limits. Nitrogen oxides and particulate matter reach their lowest levels with delayed injection. Introducing hydrogen reduces engine performance and hydrocarbons and carbon monoxide emissions; notably, it suppresses the typical nitrogen oxides
Carlucci, Antonio PaoloStrafella, LucianoFicarella, Antonio
With the implementation of increasingly stringent regulations for pollutant emissions, such as Proconve L8 [1], which requires a 37% reduction in NOx and non-methane organic gases (NMOG) emissions for light passenger vehicles compared to previous regulations, the automotive engineering community is constantly evolving to develop prediction models that are capable of predicting the performance of Internal Combustion Engines (ICE). With this, the society search solutions to increase fuel conversion efficiency and reduce fuel emissions. In a special case, related to the study of the turbulent jet ignition (TJI) engine, there was a need to develop a refined numerical model that allows for the accurate design of the ignition pre-chamber geometry. In view of this, a one-dimensional modeling was carried out in the GT-SUITE ® software, in its modeling environment for Internal Combustion Engines (ICE), GT-POWER ®, with the objective of determining its ideal volume, parameters such as internal
Silva, Arthur MedeirosSouza, Ediwaldo Júnio deRocha, Hiago Tenório Teixeira SantanaFilho, Fernando Antônio RodriguesGuzzo, Márcio ExpeditoOliveira, Wender Pereira deBaeta, José Guilherme Coelho
This study investigates a method for determining the indicated power of a combustion engine. To accomplish this, it was necessary to obtain the combustion pressure curve for each cylinder as a function of the crankshaft’s angular position, along with the geometric data of the connecting rod and crank mechanism. The combustion pressure was used to calculate the work transferred from the gas to the engine piston. Pressure measurements were obtained using a piezoelectric pressure transducer, which operates on the piezoelectric effect: a quartz crystal subjected to pressure generates an electrical signal. This signal is then converted into a proportional and linear signal that can be analyzed by a data acquisition system. Once acquired, the data were evaluated using a log P–log V diagram to verify quality and ensure the measurements accurately represented the physical phenomenon. The pressure versus volume (P–V) diagrams were generated, and the area under these curves during the
da Silva, Nerivaldo RodriguesGlauco, Caio
Growing interest in cleaner energy has spurred progress in engine technology, focusing on greater efficiency and lower emissions. Methane-based fuels, like compressed natural gas (CNG), have become an alternative for spark-ignition engines, especially in Brazil. Among performance strategies, dethrottled operation stands out by reducing intake restrictions and minimizing pumping losses, a major inefficiency in conventional spark ignition engines. This improves thermal efficiency and reduces both fuel consumption and emissions. This study experimentally examines the performance and combustion of a CNG-powered Hyundai HR 2.5 16V engine, converted from diesel to spark ignition with natural gas, comparing factory (omega) and custom (reentrant) piston geometries under both conventional and dethrottled modes. The research evaluates how piston design affects combustion stability, efficiency, and emissions across different load strategies. Tests were conducted at 7, 8, and 9 bar loads, as well
Silva, Cristian Douglas Rosa daGarlet, Roberto AntonioDapper, Jackson MayerFagundez, Jean Lucca SouzaLanzanova, Thompson Diórdinis MetzkaMartins, Mario Eduardo Santos
Internal combustion engines have been developed and widely used since the last century, and they continue to be extensively employed today. Engine development has progressed significantly, and due to the environmental impacts caused by their use, new technologies are being developed to reduce pollutant formation after the combustion process and to increase thermal efficiency. Computational modeling is a tool that has supported this development and can be categorized into three types: zero-dimensional, quasi-dimensional, and three-dimensional models. The 0D and 1D models offer a good balance between computational processing time and result uncertainty when compared to three-dimensional models. The Wiebe function is a simple analytical approach capable of describing the fuel burn rate in combustion engines. Previous studies have shown that applying this function yields results that accurately describe the apparent heat release rate in PFI engines.The present study aims to determine the
Souza Pereira, Felipe Augusto deAraújo Moreira, Thiago Augusto deFilho, Fernando Antônio Rodrigues
The sustainability of the transportation sector demands the continuous development of new technologies in internal combustion engines, aiming at reducing pollutant and greenhouse gas emissions while increasing fuel conversion efficiency. Pre-chamber (PC) ignition systems have recently emerged as an important technological pathway to explore. These systems generate turbulent combustion gas jets capable of accelerating flame propagation in the main chamber. The use of this mechanism enables a more homogeneous and efficient combustion, as well as allowing an increase in the compression ratio, resulting in improvements in engine performance and a reduction in pollutant emissions. One of the strategies to further enhance the benefits of pre-chambers is the introduction of air injectors. The objective of this modification is to promote the cleaning of residual gases that remain in the pre-chamber after combustion, mitigating adverse effects such as mixture dilution and ignition instabilities
Rocha, Hiago Tenório Teixeira SantanaOliveira, Wender Pereira deFilho, Fernando Antonio RodriguesBaeta, José Guilherme CoelhoGuzzo, Márcio ExpeditoAssis, Marcelo Suman SilvaMoreira, Thiago Augusto Araujo
The activation of the fuel injector affects both engine performance and pollutant emissions. However, the automotive industry restricts access to information regarding the circuits and control strategies used in its vehicles. One way to optimize fuel injections is using piezoelectric injectors. These injectors utilize crystals that expand or contract when subjected to an electric current, moving the injector needle. They offer a response time up to four times faster than solenoid-type injectors and allow for multiple injections per combustion cycle. These characteristics result in higher combustion efficiency, reduced emissions, and lower noise levels, making piezoelectric injectors widely used in next-generation engines, where stricter emission and efficiency standards are required. This study aims to design a drive circuit for piezoelectric injectors in a common rail system, intended for use in a diesel injector test bench. Experimental measurement of voltage was obtained from an
Moreira, Vinicius GuerraSilveira, Hairton Júnior José daMorais Hanriot, Sérgio deEuzébio, Wagner Roberto
In recent decades, interest in alternative fuels has grown exponentially. Hydrogen has been researched as total or partial substitutes for gasoline in light vehicles, showing great potential. However, this fuel has unique characteristics and properties that can bring improvements or limitations in engine performance. Therefore, a quick analysis of the pressure and HRR curve can highlight changes in combustion and performance. To this end, the aim of this work is to develop a visual interface generated by MATLAB capable of showing the performance parameters of a spark ignition engine when using hydrogen as fuel, initially. This graphic interface is supported with a zero-dimensional model based on the Wiebe function and Woschni correlation to estimating the pressure and HRR values. The interface is designed to receive operating conditions and geometry of the engine, as well as combustion angles. From the information entered, it is possible to visualize mass fraction burned, heat transfer
Rincon, Alvaro Ferney AlgarraAlvarez, Carlos Eduardo CastillaOliveira Notório Ribeiro, Jéssica
In alignment with the International Maritime Organization’s 2023 GHG Strategy and the Paris Agreement, this study investigates the viability of ternary blends of marine diesel, biodiesel, and ethanol as low-emission marine fuels. While previous studies have established the physicochemical behavior and storage stability of such blends, particularly the co-solvency role of biodiesel to prevent phase separation, limited data exists on their combustion performance under engine-relevant conditions. This work addresses this gap through a series of controlled experiments conducted in a Rapid Compression Machine (RCM), which enables the approximate a single-cycle combustion in a compression ignition engine. The tested blends included varying proportions of ethanol (up to 20% in volume) in a blend of fossil fuel with 25% of biodiesel (25%), and their combustion were evaluated across different injection timings. Key performance metrics such as ignition delay, maximum temperature and pressure
Lobato, Maria Letícia CostaSánchez, Fernando ZegarraTicona, Epifanio MamaniPradelle, Renata Nohra ChaarBraga, Sergio LealCoelho, Lucas Dos SantosPradelle, Florian
The demand for electrified vehicles has been increasing over the last few years, near to 180 thousand units were sold only in 2024, which represented around 7% of total sales of this type of vehicle in Brazil. By the year 2030, it is expected that at least 40% of sales volume will be electrified vehicles, considering mild hybrids. These results show that vehicle manufacturers are moving towards electrification and reducing carbon emission rates. Different levels of electrification are applied in their portfolio: from mild hybrid or rechargeable vehicles to fully electric vehicles. When analyzing the number of components in each automotive system, it is possible to notice a huge reduction. Electric vehicles have 90% fewer moving parts in the engine than combustion vehicles. In brake systems, the reduction can be up to 20% in hybrid and electric vehicles, which can use the same solutions. This paper aims to present the changes in the sets of braking components from combustion vehicles to
Romão, BrunoBatagini, EmersonHorschutz, Everton
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Pasa, Bruno RobertoSilveira, Juliano PereiraFagundez, Jean Lucca SouzaLanzanova, Thompson Diórdinis MetzkaMartins, Mario Eduardo SantosSalau, Nina Paula Gonçalves
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Assis, GuilhermeSánchez, Fernando ZegarraPradelle, Renata Nohra ChaarBraga, Sergio LealTicona, Epifanio MamaniSouza Junior, JorgePradelle, Florian
The transition to renewable fuels is critical to reduce greenhouse gas emissions and achieve carbon neutrality in the transportation sector. Ethanol has emerged as a promising biofuel for compression ignition (CI) engines due to its renewability and low-carbon profile. However, its low cetane number, high latent heat of vaporization, poor lubricity, and corrosive properties severely limit its auto-ignition capability and durable operation under conventional CI conditions. Building upon previous work using a Rapid Compression Machine (RCM) to assess ignition improvers for ethanol, this study explores a broader range of fuel formulations to enhance ethanol-based combustion. A total of nine blends were prepared, consisting predominantly of hydrated ethanol (50-80% by volume), combined with 5-25% biodiesel and up to 5% of a commercial ignition improvers. The biodiesel component acted both as a co-solvent and as a combustion stabilizer, particularly under cold-start conditions. Tests were
Bacic, Denise AmatoSánchez, Fernando ZegarraTicona, Epifanio MamaniPradelle, Renata Nohra ChaarSantos Coelho, Lucas dosMota, Crislane Almeida Pereira daPradelle, Florian
Flex-fueled vehicles (FFV) dominate the Brazilian market, accounting for over 75% of the national fleet. Ethanol fuel is widely used, primarily in the form of hydrated ethyl alcohol fuel (HEAF). Given the similar physicochemical properties of ethanol and methanol, fuel adulteration is a growing concern, often involving the addition of anhydrous ethanol, methanol, or even water to hydrated ethanol. These adulterants are visually imperceptible and can only be detected through analyses conducted by regulatory agencies using specialized instruments. However, they can significantly affect vehicle performance and accelerate engine component deterioration. The experiment was performed with a small displacement 3-cylinder port fuel injection flex-fuel engine on an engine test bench (dynamometer) and compared when fueled with ethanol and methanol. Data acquisition included combustion pressure, spark plug temperature, torque, air-fuel ratio, fuel flow, spark maps, and the overall effects of
Mascarenhas, Giovana RebellatoGomes, EdersonCruz, DiegoDuque, Edson Luciano
Reducing pollutant emissions remains a major challenge for the automotive industry, driven by increasingly stringent environmental regulations. While solutions such as electric vehicles (EVs) and hybrid electric vehicles (HEVs) have been developed, internal combustion engines (ICEs) continue to dominate many markets, requiring additional emission control strategies. Traditional technologies like catalytic converters and advanced injection systems primarily optimize performance once the engine reaches its operating temperature. However, during the cold start phase, when engine temperatures are below optimal, combustion efficiency drops, resulting in increased emissions of non-methane organic gases (NMOG) and nitrogen oxides (NOx). This phase is further compromised by factors such as fuel droplet size and suboptimal catalyst performance. In response, this work presents the development of a Hardware-in-the-Loop (HiL) platform to study the impact of heated injection technology on cold
Triviño, Juan David ParraTeixeira, Evandro Leonardo SilvaDe Lisboa, Fábio CordeiroAguilar, Raul Fernando SánchezOliveira, Alessandro Borges De Sousa
Vehicles powered by internal combustion engines play a crucial role in urban mobility and still represent the vast majority of vehicles produced. However, these vehicles significantly contribute to pollutant emissions and fossil fuel consumption. In response to this challenge, various technologies and strategies have been developed to reduce emissions and enhance vehicle efficiency. This paper presents the development of a solution based on optimized gear-shifting strategies aimed at minimizing fuel consumption and emissions in vehicles powered exclusively by internal combustion engines. To achieve this, a longitudinal vehicle dynamics model was developed using the MATLAB/Simulink platform. This model incorporates an engine combustion simulation based on the Advisor (Advanced Vehicle Simulator) tool, which estimates fuel consumption and emissions while considering catalyst efficiency under transient engine conditions. Based on these models, an optimization method was employed to
Da Silva, Vitor Henrique GomesCarvalho, Áquila ChagasLopez, Gustavo Adolfo GonzalesCasarin, Felipe Eduardo MayerDedini, Franco GiuseppeEckert, Jony Javorski
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