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DOE OSTI2019

Ultra Efficient Light Duty Powertrain with Gasoline Low Temperature Combustion (Final Report)

This document details the work completed during Project DE-EE0006839 ‘Ultra Efficient Light Duty Powertrain with Gasoline Low Temperature Combustion’. All tasks from the project’s Statement of Project Objectives are discussed. Final demonstration data is also presented and discussed. Further project details can be found in the Quarterly Technicial Reports that were submitted during the course of the project and are stored on the EERE Project Management Center Website. The goal of this project was to develop, implement and demonstrate a low temperature combustion approach called Gasoline Direct Injection Compression Ignition (GDCI) that provides high thermal efficiency with low NOx and PM emissions. The project target was to demonstrate a 35% fuel economy improvement over the baseline vehicle while meeting Tier 3 emissions levels. At the start of this project, GDCI was a moderately mature combustion technology, due in large part to advances made during a Delphi Technologies program funded through an earlier Department of Energy Advanced Technology Powertrains (ATP) opportunity; under that earlier contract, DE-EE0003258, Delphi Technologies assembled a team with complementary industrial and academic experience, and led this team to advance the technology from the original fundamental work to the state of art embodied by a first-generation (Gen 1) multi-cylinder GDCI engine. Key activities during that project centered on engine and combustion chamber design, and development of fuel injection equipment, valvetrain and advanced controls. Performance results with the Gen 1 engine in a development vehicle demonstrated that GDCI had the capability to operate using Low Temperature Combustion (LTC) over a broad speed-load range. Based on benchmarking work, efficiency for the Gen 1 GDCI engine compared favorably overall to production light-duty diesel engines. The second DOE funded project, DE-EE0006839, focused on a number of technical risks and issues that were left to be resolved for GDCI to become a production-viable technology. These risks were:GDCI combustion system refinement to achieve near-ideal air/fuel mixture preparation for high efficiency and low HC and CO emissions; Transient control development for low temperature combustion with high EGR levels during real-world transient driving maneuvers and over a broader range of ambient conditions; Aftertreatment system design that is effective in dealing with the low-temperature challenges of a highly efficient engine. The project was executed in two phases. Phase 1 leveraged the development vehicle from the Advanced Technologies Powertrain 1 (ATP1) project, DE-EE0003258. That vehicle was used as an initial test bed in the development of a high performance low temperature exhaust aftertreatment system. The vehicle was also used to develop calibration refinements for improved exhaust emissions and fuel efficiency. Samples of a new GDCI development level engine, called Gen2 GDCI (and developed outside of the first DOE funded project), were also used during Phase 1 to develop refined controller hardware and control algorithms, as well as improved sensors and actuators. The Gen2 engine was then retrofitted into the development vehicle from the ATP1 project and used for controls refinement and calibration of GDCI to achieve improved cold start, drivability and robustness to real world environments and fuel variations. During Phase 2 of the project, Gen3 versions of the GDCI engine were designed and built specifically for this project based on experience from the earlier engines. These engines were designed to be production-like in construction and, when combined with refined control systems and project specific low temperature exhaust aftertreatment, were intended to support the goal of meeting Tier 3 emissions levels at a vehicle level. Though great progress had been made advancing the GDCI combustion process, and despite extensive presentations of our work on the technology at various conferences and in direct meetings with automotive companies, none of the US domestic automotive OEMs had shown an interest in adopting this combustion process as part of their technology planning as the project approached the Go/No-Go point at the end of Budget Period 3. As a result of this low-level of interest both the US Department of Energy and Delphi Technologies received in this technology from domestic auto manufactures, Delphi Technologies elected a ‘No-Go’ status for the gate between Budget Period 3 and Budget Period 4 which terminated the project without spending any Budget Period 4 funds. The project team concluded that the dynamometer mapping of the most recent level of hardware, combined with the vehicle level simulation by Argonne National Laboratory, was sufficient to document the capabilities and potential of the combustion process without spending the time and money to do the controls development and full calibration necessary for a demonstration vehicle.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2014

Gasoline Ultra Efficient Fuel Vehicle with Advanced Low Temperature Combustion

The objective of this program was to develop, implement and demonstrate fuel consumption reduction technologies which are focused on reduction of friction and parasitic losses and on the improvement of thermal efficiency from in-cylinder combustion. The program was executed in two phases. The conclusion of each phase was marked by an on-vehicle technology demonstration. Phase I concentrated on short term goals to achieve technologies to reduce friction and parasitic losses. The duration of Phase I was approximately two years and the target fuel economy improvement over the baseline was 20% for the Phase I demonstration. Phase II was focused on the development and demonstration of a breakthrough low temperature combustion process called Gasoline Direct- Injection Compression Ignition (GDCI). The duration of Phase II was approximately four years and the targeted fuel economy improvement was 35% over the baseline for the Phase II demonstration vehicle. The targeted tailpipe emissions for this demonstration were Tier 2 Bin 2 emissions standards.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2013

Characterization of Engine Control Authority on HCCI Combustion as the High Load Limit is Approached

While the potential emissions and efficiency benefits of homogeneous charge compression ignition (HCCI) combustion are well known, realizing the potentials on a production intent engine presents numerous challenges. In this study we focus on characterizing the authority of the available engine controls as the high load limit of HCCI combustion is approached. The experimental work is performed on a boosted single-cylinder research engine equipped with direct injection (DI) fueling, cooled external exhaust gas recirculation (EGR), and a hydraulic valve actuation (HVA) valve train to enable the negative valve overlap (NVO) breathing strategy. Valve lift and duration are held constant while phasing is varied in an effort to make the results as relevant as possible to production intent cam-based variable valve actuation (VVA) systems on multi-cylinder engines. Results presented include engine loads from 350 to 650 kPa IMEPnet and manifold pressure from 98 to 190 kPaa at 2000 rpm. It is found that in order to increase engine load to 650 kPa IMEPnet, it is necessary to increase manifold pressure and external EGR while reducing the NVO duration. Both NVO duration and fuel injection timing are effective means of controlling combustion phasing, with NVO duration being a coarse control and fuel injection timing being a fine control. NOX emissions are low throughout the study, with emissions below 0.1 g/kW-h at all boosted HCCI conditions, while good combustion efficiency is maintained (>96.5%). Net indicated thermal efficiency increases with load up to 600 kPa IMEPnet, where a peak efficiency of 41% is achieved. Results of independent parametric investigations are presented on the effect of external EGR, intake effect of manifold pressure, and the effect of NVO duration. It is found that increasing EGR at a constant manifold pressure and increasing manifold pressure at a constant EGR rate both have the effect of retarding combustion phasing. It is also found that combustion phasing becomes increasingly sensitive to NVO duration as engine load increases. Finally, comparisons are made between three commonly used noise metrics (AVL noise meter, ringing intensity (RI), and maximum pressure rise rate (MPRR)). It is found that compared to the AVL noise meter, RI significantly underestimates combustion noise under boosted conditions.

control sensitivity↗

DOE OSTI2012

Expanding Robust HCCI Operation with Advanced Valve and Fuel Control Technologies

Delphi Automotive Systems and ORNL established this CRADA to advance the commercialization potential of the homogeneous charge compression ignition (HCCI) advanced combustion strategy for gasoline engine platforms. HCCI combustion has been shown by others to produce high diesel-like efficiency on a gasoline engine platform while simultaneously producing low NOX and particulate matter emissions. However, the commercialization barriers that face HCCI combustion are significant, with requirements for a more active engine control system, likely with next-cycle closed-loop feedback control, and with advanced valve train technologies to enable negative valve overlap conditions. In the partnership between Delphi and ORNL, each organization brought a unique and complementary set of skills to the project. Delphi has made a number of breakthroughs with production-intent valve train technologies and controls in recent years to make a part time production-intent HCCI engine plausible. ORNL has extensive knowledge and expertise with HCCI combustion, and also has a versatile research engine with hydraulic valve actuation (HVA) that is useful for guiding production of a cam-based HCCI system. Partnering these knowledge bases and capabilities was essential towards making progress to better understand HCCI combustion and the commercialization barriers that it faces. ORNL and Delphi maintained strong collaboration throughout the project. Meetings were held regularly, with additional reports, presentations, and meetings as necessary to maintain progress. Delphi provided guidance to ORNL regarding operational strategies to investigate on their single-cylinder research engine with HVA and data from their experimental multi-cylinder engine for modeling. ORNL provided single-cylinder engine data and modeling results.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2012

HCCI Load Expansion Opportunities Using a Fully Variable HVA Research Engine to Guide Developments of a Production Intent Cam-Based VVA Engine: The Low Load Limit

While the potential emissions and efficiency benefits of HCCI combustion are well known, realizing the potentials on a production intent engine presents numerous challenges. In this study we focus on identifying challenges and opportunities associated with a production intent cam-based variable valve actuation (VVA) system on a multi-cylinder engine in comparison to a fully flexible, naturally aspirated, hydraulic valve actuation (HVA) system on a single-cylinder engine, with both platforms sharing the same GDI fueling system and engine geometry. The multi-cylinder production intent VVA system uses a 2-step cam technology with wide authority cam phasing, allowing adjustments to be made to the negative valve overlap (NVO) duration but not the valve opening durations. On the single cylinder HVA engine, the valve opening duration and lift are variable in addition to the NVO duration. The content of this paper is limited to the low-medium operating load region at 2000rpm. Using different injection strategies, including the NVO pilot injection approach, the single-cylinder engine is operated over a load range from 160-390 kPa net IMEP at 2000 rpm. Changes to valve opening duration on the single-cylinder HVA engine illustrate opportunities for load expansion and efficiency improvement at certain conditions. For instance, the low load limit can be extended on the HVA engine by reducing breathing and operating closer to a stoichiometric air fuel ratio (AFR) by using valve deactivation. The naturally aspirated engine used here without external EGR confirmed that as operating load increases the emissions of NOx increases due to combustion temperature. NOx emissions are found to be one limitation to the maximum load limitation, the other being high pressure rise rate. It is found that the configuration of the production intent cam-based system represents a good compromise between valve lift and duration in the low to medium load region. Changing the extent of charge motion and breathing via valve deactivation prove beneficial at moderating the pressure rise rate and combustion stability and extending the low load limit at 2000rpm on the HVA engine. It also confirms that strategies using a pilot fuel injection are beneficial at low operating loads but that as operating load is increased, the benefits of multiple injection diminish to the point where a single injection offers the best performance.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2012

HCCI Load Expansion Opportunities using a Fully Variable HVA Research Engine to Guide Development of a Production Intent Cam-based VVA Engine: The Low Load Limit

While the potential emissions and efficiency benefits of HCCI combustion are well known, realizing the potentials on a production intent engine presents numerous challenges. In this study we focus on identifying challenges and opportunities associated with a production intent cam-based variable valve actuation (VVA) system on a multi-cylinder engine in comparison to a fully flexible, naturally aspirated, hydraulic valve actuation (HVA) system on a single-cylinder engine, with both platforms sharing the same GDI fueling system and engine geometry. The multi-cylinder production intent VVA system uses a 2-step cam technology with wide authority cam phasing, allowing adjustments to be made to the negative valve overlap (NVO) duration but not the valve opening durations. On the single cylinder HVA engine, the valve opening duration and lift are variable in addition to the NVO duration. The content of this paper is limited to the low-medium operating load region at 2000rpm. Using different injection strategies, including the NVO pilot injection approach, the single-cylinder engine is operated over a load range from 160-390 kPa net IMEP at 2000 rpm. Changes to valve opening duration on the single-cylinder HVA engine illustrate opportunities for load expansion and efficiency improvement at certain conditions. For instance, the low load limit can be extended on the HVA engine by reducing breathing and operating closer to a stoichiometric air fuel ratio (AFR) by using valve deactivation. The naturally aspirated engine used here without external EGR confirmed that as operating load increases the emissions of NOx increases due to combustion temperature. NOx emissions are found to be one limitation to the maximum load limitation, the other being high pressure rise rate. It is found that the configuration of the production intent cam-based system represents a good compromise between valve lift and duration in the low to medium load region. Changing the extent of charge motion and breathing via valve deactivation prove beneficial at moderating the pressure rise rate and combustion stability and extending the low load limit at 2000rpm on the HVA engine. It also confirms that strategies using a pilot fuel injection are beneficial at low operating loads but that as operating load is increased, the benefits of multiple injection diminish to the point where a single injection offers the best performance.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2011

E85 Optimized Engine through Boosting, Spray-Optimized DIG, VCR and Variable Valvetrain

The use of biofuels for internal combustion engines has several well published advantages. The biofuels, made from biological sources such as corn or sugar cane, are renewable resources that reduce the dependence on fossil fuels. Fuels from agricultural sources can therefore reduce a countries energy dependency on other nations. Biofuels also have been shown to reduce CO2 emissions into the atmosphere compared to traditional fossil based fuels. Because of these benefits several countries have set targets for the use of biofuels, especially ethanol, in their transportation fuels. Small percentages of ethanol are common place in gasoline but are typically limited to 5 to 8% by volume. Greater benefits are possible from higher concentrations and some countries such as the US and Sweden have encouraged the production of vehicles capable of operating on E85 (85% denatured ethanol and 15% gasoline). E85 capable vehicles are normally equipped to run the higher levels of ethanol by employing modified fuel delivery systems that can withstand the highly corrosive nature of the alcohol. These vehicles are not however equipped to take full advantage of ethanol's properties during the combustion process. Ethanol has a much higher blend research octane number than gasoline. This allows the use of higher engine compression ratios and spark advance which result in more efficient engine operation. Ethanol's latent heat of vaporization is also much higher that gasoline. This higher heat of vaporization cools the engine intake charge which also allows the engine compression ratio to be increased even further. An engine that is optimized for operation on high concentrations of ethanol therefore will have compression ratios that are too high to avoid spark knock (pre-ignition) if run on gasoline or a gasoline/ethanol blend that has a low percentage alcohol. An engine was developed during this project to leverage the improved evaporative cooling and high octane of E85 to improve fuel economy and offset E85's lower energy content. A 2.0 L production Direct Injection gasoline, (DIg) engine employing Dual Independent Cam Phasing, (DICP) and turbo charging was used as the base engine. Modified pistons were used to increase the geometric compression ratio from 9.2:1 to 11.85:1 by modifying the pistons and adding advanced valvetrain to proved control of displacement and effective compression ratio through valve timing control. The advanced valvetrain utilized Delphi's two step valvetrain hardware and intake cam phaser with increased phasing authority of 80 crank angle degrees. Using this hardware the engine was capable of operating knock free on all fuels tested from E0-E85 by controlling effective compression ratio using a Late Intake Valve Closing, (LIVC) strategy. The LIVC strategy results in changes in the trapped displacement such that knock limited torque for gasoline is significantly lower than E85. The use of spark retard to control knock enables higher peak torque for knock limited fuels, however a loss in efficiency results. For gasoline and E10 fuels, full effective displacement could not be reached before spark retard produced a net loss in torque. The use of an Early Intake Valve Closing, (EIVC) strategy resulted in an improvement of engine efficiency at low to mid loads for all fuels tested from E0- E85. Further the use of valve deactivation, to a single intake valve, improved combustion stability and enabled throttle-less operation down to less than 2 bar BMEP. Slight throttling to trap internal residual provided additional reductions in fuel consumption. To fully leverage the benefits of E85, or ethanol blends above E10, would require a vehicle level approach that would take advantage of the improved low end torque that is possible with E85. Operating the engine at reduced speeds and using advanced transmissions (6 speeds or higher) would provide a responsive efficient driving experience to the customer. The vehicle shift and torque converter lockup points for high ethanol blends could take advantage of the significant efficiency advantage of down-speeding and operating at higher loads to deliver the required power.

02 PETROLEUM↗