INVESTIGATION ON THE EFFECTS OF PASSIVE PRE-CHAMBER IGNITION SYSTEM AND GEOMETRY ON ENGINE KNOCK INTENSITY.
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Microwave ignition systems with a launcher affixed to or located within a gun spindle. Use of a planar, impedance matched system that include a launcher affixed to or located within a gun spindle and a receiver affixed the propelling charge, where the receiver is engineered and impedance matched to efficiently deposit energy into the receiving igniter material, may result in significantly better timing and reliability than conventional mechanical gun ignition systems and other microwave ignition systems. A pressure-tolerant feed through system can route the microwave energy to the inside of the breech.
This project explored advanced ignition technologies to significantly enhance efficiency and reduce operating costs for heavy-duty natural gas engines operating at stoichiometric conditions, while meeting ultra-low NOx emission standards. The main goal was to develop and validate a plasma-assisted pre-chamber ignition system that could deliver at least a 2% increase in brake thermal efficiency (BTE) and a 4% decrease in total cost of ownership (TCO) compared to a typical multi-cylinder engine with three-way catalyst aftertreatment, ensuring compatibility with the expected 2027 EPA/CARB regulations. In the first half of the project, the research team concentrated on developing and testing plasma-assisted pre-chamber ignition using nanosecond pulsed discharges. Extensive experiments were conducted in an optically accessible rapid-compression and expansion machine, a constant-volume chamber, and an optical single-cylinder engine. Experiments were coupled with CFD simulations. The work produced unique insights into pre-chamber flame formation, jet ignition, dilution effects, and flame quenching at pressures, temperatures, and dilution levels relevant to engines. Although plasma-assisted ignition showed promise in controlled lab settings, the research also identified fundamental and practical challenges when applying this technology to real engine conditions. Midway through the project, a crucial pivot was made, guided by three key findings. First, the power electronics required for nanosecond plasma discharges were found to be too costly for commercial use, undermining the project’s cost-of-ownership goals. Second, nanosecond plasma ignition was highly sensitive to turbulent flow in the pre-chamber, resulting in lower ignition reliability than traditional spark under engine-like conditions. Third, achieving a truly diffuse low-temperature plasma at high pressures near top dead center was not possible, reducing the anticipated chemical enhancement benefits. These results collectively suggested that continuing with plasma-assisted ignition was unlikely to meet both efficiency and cost objectives. In response, the project shifted focus to a more realistic approach: enhancing traditional spark-based pre-chamber ignition with significantly less spark energy. Using insights gained earlier in the project, the team redesigned the pre-chamber to maintain high dilution tolerance and quick combustion, even with lower ignition energy. Testing confirmed that with optimized pre-chamber design and combustion timing, a lower-energy spark could reliably ignite highly diluted stoichiometric mixtures, reduce burn time, and boost thermal efficiency. Final engine testing and techno-economic analysis verified that this revised approach successfully achieved the project goals. The optimized pre-chamber ignition system provided over a 2% increase in calculated brake thermal efficiency compared to the baseline engine. Notably, the lower ignition energy and simplified hardware reduced component stress, extended maintenance intervals, and lowered the total cost of ownership. When used with stoichiometric operation and traditional three-way aftertreatment, the system remained compatible with near-zero NOx emissions targets without increasing cost or complexity in the emissions control system. In summary, although the project deviated from its initial plasma-assisted ignition idea, the work produced a more practical and commercially viable solution. The results show that precisely optimized, low-energy pre-chamber spark ignition can significantly improve efficiency and reduce overall ownership costs for heavy-duty natural gas engines. This directly aligns with DOE goals for cleaner, more efficient, and cost-effective transportation technologies.
A plasma assisted spark ignition system includes an ignitor and a power supply. The first ignitor includes: a casing having a first end, a second end that forms a first electrode, and a longitudinally extending passage, a second electrode which protrudes longitudinally outward from an opening at the second end of the casing and laterally spaced inwardly to form a spark gap, and an electrical insulator (dielectric) surrounding a portion of the second electrode, and which has a terminus that is at least closely spaced to an interior surface of the end of the casing. The power supply supplies a plurality of voltage pulses to the ignitor per ignition event to generate a flash over on the dielectric. Subsequent pulses in an ignition event may be at lower amplitude than an initial pulse in the ignition event. Pulses may, for example, have a duration on the order of a nanosecond.
The impact of passive pre-chamber (PC) internal volume, nozzle hole pattern (i.e. with and without a central axial nozzle), and PC igniter plug type on performance and emissions was investigated in an optically accessible, single-cylinder, gasoline research engine. The two PC igniter plugs investigated were a conventional inductive coil spark plug and a nanosecond repetitively pulsed (NRP) plasma discharge system previously demonstrated to accelerate early flame propagation. The baseline PC design featured a funnel shaped internal volume with a PC tip that contained six radial nozzles and a larger central axial nozzle. Two additional PC tip geometries were evaluated where either the baseline internal volume was increased or the axial nozzle was removed and the radial nozzle diameters were increased. A sweep of charge equivalence ratios ( ϕ) from nearly stoichiometric to the lean limit was performed for a fixed engine speed (1300 revolutions per minute), and engine load (3.5 bar gross indicated mean effective pressure). Time-resolved PC and main chamber (MC) pressure data as well as MC emissions data were collected to analyze engine performance and emissions characteristics. Combustion in the MC was further investigated using high-speed excited methylidyne radical (CH*) chemiluminescence imaging. Collected results highlighted that while all PC tips and ignition systems exhibited similar performance and emissions down to ϕ = 0.8, relevant differences in thermal efficiency and emissions for leaner charge mixtures were observed, with the results highly dependent on the nozzle pattern and ignition system. Major deviations were correlated to preferential de-pressurization of the PC through the axial nozzle for lean conditions that was not observed for mixture conditions closer to stoichiometric. Results show that a combination of radial and axial nozzle patterns in the PC extended lean-stability limits at the low-load condition evaluated. Further benefits were observed with the use of NRP ignition systems due to faster combustion within the PC volume provided that the volume was sufficiently large.
Pre-chamber spark-ignition (PCSI), either fueled or non-fueled, is a leading concept with the potential to enable diesel-like efficiency in medium-duty (MD) and heavy-duty (HD) natural gas (NG) engines. However, the inadequate scientific base and simulation tools to describe/predict the underlying processes governing PCSI systems is one of the key barriers to market penetration of PCSI for MD/HD NG engines. To this end, experiments were performed in a heavy-duty, optical, single-cylinder engine fitted with an active fueled PCSI module. Furthermore, the spatial and temporal progress of ignition and subsequent combustion of lean-burn natural gas using PCSI system were studied using optical diagnostic imaging and heat release analysis based on main-chamber and pre-chamber pressure measurements.
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Presentation made at the 2024 DORMA Annual Merit Review.
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