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The transportation sector, and commercial vehicles in particular, play an important role in global CO2 emissions. For this reason, the EU recently decided to reduce CO2 emissions from commercial vehicles by 30% until 2030. One alternative to conventional diesel propulsion is the usage of stoichiometric natural gas combustion. Due to the lowered C/H ratio and the cost effective exhaust after treatment (EAT) in form of a three way catalyst (TWC), less CO2 is emitted and it is possible to comply even with most stringent NOX legislations. However, the stoichiometric combustion of natural gas has also disadvantages. In particular, the throttling and retarded 50 % mass fuel burned (MFB50) positions due to knocking lead to efficiency losses. One way to minimize these is the usage of exhaust gas re-circulation (EGR), Miller cycle and water injection. The reduced knocking tendency allows the geometric compression ratio to be increased further, which leads to an additional efficiency advantage.

Internal combustion engines fall under increased environmental and social pressure. However, they will still play an important role in future transport, especially in hybrid propulsion systems. As a consequence, efficiency of SI engines has to be further increased. Lean burn operation provides a promising way to reach this target. An extremely downsized SI single cylinder research engine is used for the investigations. The engine features a stroke-to-bore ratio of 1.5, leading to higher piston speeds and hence increased tumble motion. The resulting increase in turbulent flame speed supports sufficient combustion performance of diluted mixtures. Although the mentioned provisions increase combustion stability for lean burn operation the reachable relative air/fuel ratio is limited. In order to extend the lean burn capabilities of the engine (λ ≥ 2.0) and further exploit the efficiency advantages of this combustion process the engine is upgraded with a hydrogen port fuel injection.

A single-stage turbocharger turbine is developed with the objective of enabling a gasoline spark-ignition engine to operate under lean-burn conditions with an air-to-fuel ratio of λ=2 in the range of the Worldwide Harmonized Light-Duty Vehicles Test Cycle. For this purpose, extensive 1-D engine simulations are performed using a combination of a simple compressor and simple turbine model as well as a combination of the stock compressor and a simple turbine model. The results show that an isentropic turbine efficiency of more than 70% over a wide operating range is required for the desired engine operation - especially with regard to the low-end-torque. Based on the crank-angle-resolved engine simulation data, turbine requirements are determined. Their evaluation shows that an axial turbine is a reasonable alternative to conventional radial turbines for this application. Next, a preliminary axial turbine is designed using 1-D/2-D design approaches.

For the NOx removal from diesel exhaust, the selective catalytic reduction (SCR) and lean NOx traps are established technologies. However, these procedures lack efficiency below 200 °C, which is of importance for city driving and cold start phases. Thus, the present paper deals with the development of a novel low-temperature deNOx strategy implying the catalytic NOx reduction by hydrogen. For the investigations, a highly active H2-deNOx catalyst, originally engineered for lean H2 combustion engines, was employed. This Pt-based catalyst reached peak NOx conversion of 95 % in synthetic diesel exhaust with N2 selectivities up to 80 %. Additionally, driving cycle tests on a diesel engine test bench were also performed to evaluate the H2-deNOx performance under practical conditions. For this purpose, a diesel oxidation catalyst, a diesel particulate filter and a H2 injection nozzle with mixing unit were placed upstream to the full size H2-deNOx catalyst.

The EU recently decided to reduce CO2 emissions of commercial vehicle fleets by 30% until 2030. One possible way to achieve this target is to convert commercial vehicle diesel engines into stoichiometric natural gas engines. Based on this, a commercial vehicle single cylinder diesel engine with variable valve actuation and high-pressure EGR is converted into natural gas operation to increase efficiency and thus reduce CO2. Additionally, a water injection system is integrated. All three technologies are investigated on their own and in combination. To reduce longer combustion durations caused by Miller valve timing and charge dilution, a piston bowl with extra high turbulence generation is designed. Additionally, a swirl variation is carried out. The results show, that high swirl motion and high turbulence can lead to a disadvantage in efficiency despite faster combustion durations due to higher wall heat losses.

Individual transport plays a considerable role in global greenhouse gas emissions. Hence, worldwide legislation increases the demands on the automotive industry with regard to emissions. Because internal combustion engines will likely play an important role in the future transport, particularly in hybrid propulsion systems, further improvement of the combustion system is necessary. Therefore, the potential of lean burn combustion in combination with other technologies is investigated. The primary focus is on the improvement of SI engine efficiency. For the investigations conducted, an extremely downsized SI single cylinder research engine is upgraded with various engine technologies. The stroke-to-bore ratio is increased to 1.5, leading to higher piston speeds. The resulting increase in tumble and hence turbulent flame speed supports the combustion performance of highly diluted mixtures.

Following the ongoing software development, the continuously increasing accuracy of 0D/1D-simulation of combustion engines and chemical mechanisms for the use in reaction kinetic calculation open up a new possibility to calculate combustion processes. Particularly combustion processes with high dependency on reaction kinetics, such as knocking events, can be predicted. The simulation of knock events further allows a characterization of the knock behavior of LNG mixtures. This paper focuses on 1D-simulative investigation of knocking events to determine the Service Methane Number of different LNG mixtures and their dependency on single gas components. This is realized with two different approaches, which are presented in this work. In the first approach, measurement data and a Three-Pressure-Analysis-model are used to describe the in-cylinder condition at inlet valve closes.

Liquefied natural gas (LNG) plays an increasingly important role as a climate-friendly fuel for a sustainable mobility. Compared to diesel, LNG has a CO2 reduction potential of around 20%. There is also the possibility of reducing GHG by adding biogas or synthetic natural gas. The Methane Number (MN) characterizes the knocking properties of gaseous fuels and was defined by AVL. There is no standardized measurement procedure for the MN. Instead, there are some algorithms to calculate the MN from the gas mixture composition. Most of them are based on the original AVL measurement data, e.g. the NPL algorithm. In the AVL study, the different knocking properties of n- and iso-components of the alkanes were not investigated. This paper focuses on the experimental investigation of the knock resistance of different alkanes in LNG mixtures and the improvement of the NPL algorithm based on these results.

Investigations were performed, in which the emission behavior of renewable and conventional fuels of different composition and renewable fuel components was observed. The influence of the start of injection on the emissions at WOT was investigated. This shows how much wall and valve wetting as well as the available evaporation time affects the mixture formation of the different fuels. Further, the air fuel ratio in an operating point for catalytic converter heating, with medium engine temperatures, was varied. This shows the ability of evaporation of the fuels at engine warm-up conditions and sub-stochiometric λ-values. The studied fuels were four fuel mixtures of significantly different composition of which three were compliant with the European fuel standard EN 228. A RON 98 in-field fuel, a Euro 6 reference fuel, an Anti-Spark-Fouling (ASF) fuel (designed for minimum soot production) and a potentially completely renewable, thus CO2-neural, fuel, which is designed by Dr. Ing. h.c.

Catalyst fouling by deposit formation on components in the exhaust aftertreatment system is critical since RDE limits must be obtained at any time. Besides, uncontrolled oxidation of carbonaceous deposits might damage the affected exhaust aftertreatment component. To comply with current and future emission standards, diesel engines are usually operated with high EGR rates leading to increased soot and hydrocarbon emissions, which increases the likeliness of the formation of carbonaceous deposits on EAT components. With this background, a research project investigating the influencing parameters and mechanisms of deposit formation on DOCs was carried out. In a follow-up project, the results will be used in order to compare different deposit removal strategies. Within the scope of the presented project, a reference driving cycle was developed in order to create deposits within a short time.

Investigations were performed, in which fuels and fuel components were compared regarding gaseous as well as particulate number (PN) emissions. The focus on the selection of the fuel components was set on the possibility of renewable production, which lead to Ethanol, as the classic bio-fuel, Isopropanol, Isobutanol and methyl tert-butyl ether (MTBE). As fuels, a Euro 6 (EU6) reference fuel, an anti-spark-fouling (ASF) fuel, a European Super Plus (RON 98) in-field fuel and a potentially completely renewable fuel, which was designed by Porsche AG (named POSYN), were chosen. The composition of the fuels differs significantly which results in large differences in the exhaust gas emissions. The fuels, except ASF, are compliant with the European fuel standard EN 228.The experiments chosen were a variation of the start of injection (SOI) at different load points at a constant engine speed of 2000 rpm, amongst others.

This paper presents a newly developed 2-stage ignition delay model for pilot ignited medium speed dual-fuel (DF) engines. This provides the first major step towards a new combustion model for the prediction of the DF combustion in the context of 0D/1D simulation. The combustion models known from literature are based on empirical models of a steady jet. Here in most cases the package model of Hiroyasu is used. Because in a DF engine the injection timing of the diesel fuel is very early and the injection ends before ignition, the spray behavior differs from that of a steady jet. Especially the end-of-injection transients lead to stronger entrainment and therefore affect the ignition delay. In addition, the presence of natural gas in the cylinder extends the ignition delay at the chemical level. In this paper the 1D transient spray model of Musculus and Kattke is used to describe the spray behavior.

Legislative and customer demands in terms of fuel consumption and emissions are an enormous challenge for the development of modern combustion engines. Downsizing in combination with turbocharging and direct injection is one way to increase efficiency and therefore meet the requirements. This results in a reduction of the displacement and thus the bore diameter. The emerging trends towards long-stroke engine design and hybridization make the use of small bore diameters in future gasoline engines a realistic scenario. The application of direct injection with small cylinder dimensions increases the probability of the interaction of liquid fuel with the cylinder walls, which may result in disadvantages concerning especially particulate emissions. This leads to the question which bore diameter is feasible without drawbacks concerning emissions as a result of wall wetting.

In view of the current political debate, it can be assumed that the nitrogen oxide limits for commercial vehicles will be further reduced. This is also demonstrated by the currently voluntary certification of the CARB Optional Low NOX legislation, which requires nitrogen oxide emissions of 0.027 g/kWh. This corresponds to a reduction of 93 % compared to the current EU VI standard. Therefore, the optimization of EAT systems represents an essential research focus for future commercial vehicle applications. One way to optimize the EAT system may be the usage of variable valve actuation. Existing investigations show an exhaust gas temperature increase with intake valve timing adjustment, also known as Miller timing. But the authors conclude that it cannot accelerate the warm up process. With regard to the effects on the exhaust aftertreatment system and the resulting tailpipe emissions, only improved HC and CO oxidation could be identified so far.

Downsizing of SI engines in combination with turbocharging is state of the art to reach future CO2 emission limits. A single stage turbocharged engine has a conflict of objectives between high rated power and high low-end-torque. To expand the stable map area of the compressor a variable compressor is investigated on an engine test bench supported by the use of engine process simulation. The measurements were carried out on a radial compressor with high trim compressor wheel. The limiting factor of the feasible low end torque is the surge line. Different inlet cross sections are investigated to shift the surge line to lower mass flow. The compressor maps are measured simultaneously on a hot gas and an engine test bench. A combination of both maps provides the input data for a 1D-simulation model of the test engine, which is presented in this paper. A predictive combustion model is validated for full and part load operating points up to 5000 rpm based on the serial production engine.

Variable valve trains offer the opportunity to apply advanced combustion process strategies such as the Miller cycle. As is well known, applying Miller timing for CI engines is an effective way to reduce NOX emissions and can lead to an increase in engine efficiency. Because of the intended future NOX and GHG limits for on-road HD CI engines, the use of variable valve trains become more and more inevitable. Previous studies of the authors have shown that the improvement potential highly depends on the achievable cylinder charge level. Increasing this (through additional increase in boost pressure) results in a significant decrease in ISFC as well as in an improved NOX-PM trade-off. However, in these considerations the pressure difference of the charge air and the exhaust back pressure was kept on the same level. The present paper investigates the improvement potentials for heavy duty CI engines taking a two-stage turbocharging group into account.

LNG is a fuel that is under increasing discussion for transport purposes. It differs from CNG because it often has a higher concentration of hydrocarbons > C4. This affects knocking in a negative way. The knocking properties of a gaseous fuel are characterized by the Methane Number (MN) which is defined as the methane content in a mixture of methane and hydrogen which has the same knocking properties as the gas under investigation. It was defined by AVL in the late 1960s. In contrast to the Octane or Cetane Number there is no standardized measurement procedure for the MN, because the equipment AVL used was unique and does not exist anymore. But AVL created a calculation methodology based on the large amount of data they had measured. There are several software implementations of this methodology. Further there are other algorithms which are not based on the AVL data. If an MN is measured on an arbitrary engine the result is called a Service Methane Number (SMN).

In view of the rapidly increasing complexity of conventional as well as hybrid powertrains, a systematic composition platform seeking for the global optimum powertrain is presented in this paper. The platform can be mainly divided into three parts: the synthesis of the transmission, the synthesis of the internal combustion engine (ICE) and the optimization and evaluation of the entire powertrain. In regard to the synthesis of transmission concepts, a systematical and computer-aided tool suitable both for conventional und hybrid transmissions is developed. With this tool, all the potential transmission concepts, which can realize the desired driving modes or ratios, can be synthesized based on the vehicle data and requirements.

There are numerous methods for accelerated ash loading of particulate traps known from literature. However, it is largely unknown if a combination of these methods is possible and which one generates the most similar ash compared to ash from real particulate filters. Since the influencing variables on the ash formation are not yet fully understood, ashing processes are carried out under carefully controlled laboratory conditions on an engine test bench. The first ashing takes place with low sulfated ash phosphorus and sulfur oil without any methods to increase the quantity of produced ash. The obtained ash is used as a reference and is compared hereinafter with the process examined. Four methods to increase the ash production ratio are investigated. The first one is an increase of the ash content of the lubrication oil through an increase of the additives in the oil. The second one is the additional generation of ash with a burner system where oil is injected into the flame.

This work is based on calculations about extreme mean effective and maximum pressures which were published earlier by the author and colleagues. The motivation for the work presented in this paper is to reduce the maximum pressure while keeping a high mep without sacrificing efficiency. It is investigated in a theoretical study in how far this can be accomplished via turbocompounding. The basis is a 320 mm bore four stroke medium speed engine. It is equipped with a state-of-the-art two stage turbocharging system. As a first step turbocompounding is investigated for mean effective pressures from 22 to 80 bar. The bsfc of the turbocharged engine is in the range of 175 to 185 g/kWh depending on mep. With turbocompounding the exhaust pressure before turbine is optimised and figures between 160 and 165 g/kWh are reached. Thermal loading of the engine increases. In the second step strategies to reduce maximum pressure are investigated for an mep of ca. 50 bar.