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A new type of drive system has been designed, analyzed, patented, prototyped, and tested. The drive’s unique capabilities include the ability to vary the bottom dead center position to reduce the stroke, and simultaneously vary the top dead center position to achieve the desired compression ratio with one simple, low friction mechanism. The purpose of the concept is to reduce losses associated with operation at partial load as most engines spend a preponderance of their operating life at partial load. This paper covers the design and analysis, prototyping, and testing of the unit as an air compressor. Engine simulation of the unit configured as a gasoline engine showed a ~30% improvement in fuel economy on a 10-mode weighted cycle and is covered in SAE 2021-01-0442, “Continuously Variable Displacement Drive for Engines Part 1, Performance Simulation.”

A new type of drive system has been designed, analyzed, patented, prototyped, and tested. The drive’s unique capabilities include the ability to vary the bottom dead center position to reduce the stroke, and simultaneously vary the top dead center position to achieve the desired compression ratio with one simple, low friction mechanism. The purpose of the concept is to reduce losses associated with operation at partial load as most engines spend a preponderance of their operating life at partial load. Cummins sponsored engine simulation of the CVD configured as a 9-cylinder gasoline engine cycle and a baseline engine which was a conventional V8 engine of the same displacement and compression ratio. The study showed a ~30% improvement in fuel economy on a 10-mode weighted cycle that was designed by Cummins to simulate the FTP cycle.

Four high-efficiency alternative combustion modes were modeled to determine the potential brake thermal efficiency (BTE) relative to a traditional lean burn compression ignition diesel engine with selective catalytic reduction (SCR) aftertreatment. The four combustion modes include stoichiometric pilot-ignited gasoline with EGR dilution (SwRI HEDGE technology), dual fuel premixed compression ignition (University of Wisconsin), gasoline partially premixed combustion (Lund University), and homogenous charge compression ignition (HCCI) (SwRI Clean Diesel IV). For each of the alternative combustion modes, zero-D simulation of the peak torque condition was used to show the expected BTE. For all alternative combustion modes, simulation showed that the BTE was very dependent on dilution levels, whether air or EGR. While the gross indicated thermal efficiency (ITE) could be shown to improve as the dilution was increased, the required pumping work decreased the BTE at EGR rates above 40%.

As turbocharged diesel engines have evolved to higher brake mean effective pressure (BMEP) levels, with ultra-low levels of regulated emissions, it has become increasingly difficult to match the turbine and compressor in conventional turbocharger and achieve the desired level of performance and responsiveness. Emissions regulations result in the use of ultra-high levels of Exhaust Gas Recirculation (EGR) to control NOx and Diesel Particulate Filters (DPF) to control soot and particulate emissions. These technologies exacerbate the compressor/turbine matching issue by reducing the turbine corrected flow to as little as half the compressor corrected flow. A new design concept is presented in this paper that significantly improves the performance of the turbine by changing the work/speed relationship of the compressor.

This paper reports on the development of the Low Speed Turbocharger (LST), a single shaft turbocharger capable of pressure ratios in excess of 5/1. Key decisions regarding the fundamental design concept are discussed as well as compressor design, analysis methodology and performance results; turbine design challenges and resulting tested performance; rotor-dynamics analysis and bearing system design.

The State of California considers greenhouse gases (GHGs) to be air pollutants and has directed the Air Resources Board to adopt cost effective regulations for GHG emissions from motor vehicles. The northeastern states and Canada through NESCCAF have worked closely with CARB and CO2 equivalent emission regulations have been proposed. The eventual status of these regulations may not be clear, but what is clear is that there is a need to develop cost effective technology to reduce GHG emissions. This paper presents such technology. Advances in turbocharging technology relevant to both gasoline and diesel engines are described. Turbocharging, as a technology has been around for 70 years, but just like the internal combustion engine itself, it is far from being mature. Conventional evolutionary development of turbocharging such as inertia reduction, aerodynamics and bearing improvements have been ongoing.

Over the past decade, the dramatic improvements in power density, responsiveness and low emissions in both turbo-diesel passenger vehicle and commercial vehicle engines have demanded significant alterations to the basic architecture of turbochargers. The emissions regulations already enacted worldwide, but not yet in force will demand further reaching changes to the basic concept of turbocharging. This paper explores the complex linkage between the aerodynamic machine (the turbocharger), the positive displacement machine (the engine), their new role as feed-gas generators for aftertreatment devices, and the divergence in requirements between passenger vehicle and commercial vehicle applications. The next generation requirements (2007) for both passenger vehicle and commercial vehicle diesel engines will be driven by the need for increased EGR rates.

Diesel engines face increasingly stringent emissions regulations worldwide. The trade-off between fuel economy and NOx emissions and between NOx and particulate emissions is becoming more critical. In light of these regulations and design trade-offs among many variables, engine-boosting systems have become increasingly important. An advanced variable nozzle turbocharger (AVNT™) is described. The innovative design is described along with key characteristics. The design features a minimization of additional parts associated with the variable geometry mechanism and electro-hydraulic actuation integrated with the bearing system. The impact of variable geometry turbocharging on diesel engine performance, fuel economy, torque, emissions and braking capability is described. It is shown that significant improvements in all five variables are readily possible with the use of this variable geometry turbocharger.

Heavy-duty diesel engines face increasingly stringent emissions regulations. The trade-off between fuel economy and NOx emissions and between NOx and particulate emissions is becoming even more critical. In the light of these regulations and the trade-off among many variables, air handling and exhaust gas recirculation (EGR) systems become increasingly important. Three advanced turbocharging technologies - variable nozzle turbochargers, integral EGR pump and an ultra-high pressure ratio, long life compressor are described. In this paper an overview of the designs and their impact on fuel economy, low speed torque, emissions and durability is described. It is shown that significant improvements in all four variables are readily possible with the use of these advanced turbocharging technologies. It is shown that variable nozzle (VNT) turbocharging reduces smoke particularly at low speeds by a factor of 5, improves torque at low engine speeds and improves fuel economy by about 3%.