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The upcoming Bharat Stage VI (BS VI) emission legislation has put enormous pressure on the future of small diesel engines which are widely used in the Indian market. The present work investigates the emission reduction potential of a common rail direct injection single cylinder diesel engine by adopting a holistic approach of lowering the compression ratio, boosting the intake air and down-speeding the engine. Experimental investigations were conducted across the entire operating map of a mass-production, light-duty diesel engine to examine the benefits of the proposed approach and the results are quantified for the modified Indian drive cycle (MIDC). By reducing the compression ratio from 18:1 to 14:1, the oxides of nitrogen (NOx) and soot emissions are reduced by 40% and 75% respectively. However, a significant penalty in fuel economy, unburned hydrocarbon (HC) and carbon monoxide (CO) emissions are observed with the reduced compression ratio.

In a direct-injection (DI) engine, charge motion and mixture preparation are among the most important factors deciding the performance and emissions. This work was focused on studying the effect of injector positioning on fuel-air mixture preparation and fuel impingement on in-cylinder surfaces during the homogeneous mode of operation in a naturally aspirated, small bore, 0.2 l, light-duty, air-cooled, four-stroke, spark-ignition engine modified to operate under the DI mode. A commercially available, six-hole, solenoid-operated injector was used. Two injector locations were identified based on the availability of the space on the cylinder head. One location yielded the spray-guided (SG) configuration, with one of the spray plumes targeted towards the spark plug. In the second location, the spray plumes were targeted towards the piston top in a wall-guided (WG) configuration so as to minimize the impingement of fuel on the liner.

In this work methanol was port injected while diesel was injected using a common rail system in a single cylinder non-road CI engine. Experiments were conducted with single (SPI) and double (DPI - pilot and main) injection of the directly injected diesel at 75% load and at a constant speed of 1500 rpm. The effects of methanol to diesel energy share (MDES) and injection scheduling on combustion stability, efficiency and emissions were evaluated. Initially, in the SPI mode, the methanol to diesel Energy Share (MDES) was varied, while the injection timing of diesel was always fixed for best brake thermal efficiency (BTE). Increase in the MDES resulted in a reduction in NOx and smoke emissions because of the high latent heat of vaporization of methanol and the oxygen available. Enhanced premixed combustion led to a raise in brake thermal efficiency (BTE). Coefficient of variation of IMEP, peak pressure and BTE were deteriorated which limited the usable MDES to 43%.

This study deals with the development of an internal EGR (Exhaust Gas Recirculation) system for NOx reduction on a six cylinder, turbocharged intercooled, off-road diesel engine based on a modified cam with secondary lift. One dimensional thermodynamic simulation model was developed using a commercially available code. MCC heat release model was refined in the present work by considering wall impingement of the fuel as given by Lakshminarayanan et al. The NOx prediction accuracy was improved to a level of 90% by a generic polynomial fit between air excess ratio and prediction constants. Simulation results of base model were correlating to more than 95% with experimental results for ISO 8178 C1 test cycle. Parametric study of intake and exhaust valve events was conducted with 2IVO (Secondary Intake Valve Opening) and 2EVO (Secondary Exhaust Valve Opening) methods. Combinations of different opening angles and lifts were chosen in both 2IVO and 2EVO methods for the study.

Experiments were conducted on a single cylinder 160cc, four stroke gasoline SI engine. Preliminary experiments were conducted on the base engine to characterize the nature of CBC (cycle by cycle) variations and the influencing parameters. The results have indicated that as the ignition advances, Peak pressure increases and its COV (Coefficient of variation) reduces. IMEP increases up to MBT (Minimum advance for Best Torque) timing and its COV reduces. HC emission and BSFC are minimum at MBT timing. The best AFR (main jet) and spark timing are selected based on low CBC variations and good performance. The engine behavior with this best timing and AFR were taken as the base line data for comparison. The combustion geometry improvement method like dual spark plug and swirl chamber (SC) with multi torch ignition is considered to be more effective for combustion rate enhancement.

The ionization current across the spark plug gap is obtained by applying a constant voltage using DC power source across the spark gap after the high-voltage discharge. The methodology involves study and comparison of different knock detection methods (cylinder gas pressure, accelerometer and ion current) through literature survey, development of analytical models (ionization current, chemical equilibrium, kinetic Nitric Oxides) to estimate crank angle resolved cylinder gas pressure from the measured values of ionization current. Model refinements and validations, development of Ignition Coil integrated DC power source and ion current measurement circuit, Transistorized Coil Ignition and microcontroller based knock controller have been carried out. Experiments have been conducted to validate the model with the reference method (cylinder gas pressure).

In this work, a single-cylinder, water-cooled engine was operated in the Homogenous Charge Compression Ignition (HCCI) mode with diesel as the fuel. Conventional as well as Common Rail Injection (CRI) systems were employed to study the influence of different injection strategies. The injection timing was fixed at 90° crank angle bTDC with the conventional injection system for HCCI operation based on brake thermal efficiency. With the conventional system, the BMEP range was 2.2 to 4.3 bar with a single-axial-hole injector. However, in this case, the brake thermal efficiency was about 30% lower than the CI mode. In the case of the CRI system, a specially developed single-hole nozzle with single and multiple injection strategies was used. Here, there was an improvement in the brake thermal efficiency and emissions were also under control. The BMEP range was only 1 to 3 bar.

In this work a novel mixture injection system has been developed and tested on a two stroke scooter engine. This system admits finely atomized gasoline directly into the combustion chamber. It employs many components that were individually developed, fabricated, tested and then coupled together. A small compressor driven by the engine sends pressurized air at the correct crank angle through a timing valve. This is connected to a mechanical injector through a high pressure pipe. Fuel is metered into the high pressure pipe using a standard low pressure injector. The developed mixture injection system resulted in considerable improvements in thermal efficiency and reduction in HC emissions over the manifold injection method at all engine outputs. A considerable reduction in short circuiting losses was seen. The highest brake thermal efficiency achieved was 25.5% as against 23% with the manifold injection system.

Use of water diesel emulsions in diesel engines reduces simultaneously smoke and NOx emissions. However the ignition delay increases and there is a rise in the HC and CO levels as well. In this work hydrogen peroxide was added to water diesel emulsion and tested in a diesel engine. Initially the engine was run with water diesel emulsion (water to diesel ratio of 0.4:1). The water diesel emulsion with a H2O2/diesel ratio of 0.05 was used. The single cylinder diesel engine was tested at the rated speed of 1500 rpm. Brake thermal efficiency increased with hydrogen peroxide from 32.6% to 33.5% as compared to the plain emulsion at full load. These values are even better than neat diesel operation. CO and HC levels decreased significantly with the addition of H2O2. HC with the neat diesel engine at full load was 50 ppm. It rose to 75 ppm with water diesel emulsion and was controlled to 50 ppm when H2O2 was used. This is due to the strong oxidizing nature of H2O2.

In the case of small SI engines for two-wheelers emission reduction will preferably be achieved through the use of lean mixtures since catalytic converters will increase the cost. In such cases a very close control over the air fuel ratio will be needed. In this work a carbureted 125cc small capacity two-wheeler engine was modified to operate with Port Fuel Injection (PFI) for improved control over the air fuel ratio. A throttle body was specially made to house the injector and a position sensor. A cam position sensor, crank angle sensor, manifold air pressure (MAP) sensor, 60-2 toothed wheel for precise control of the events on the angle basis were used. Extensive tests were conducted with the throttle body and fuel injector to obtain the mathematical models for the inlet manifold and fuel injector. These were used to make the model based controller. The dSPACE - Micro Auto Box platform was used to develop and test the control algorithms. Software was written using SIMULINK.

Exhaust gas recirculation (EGR) is an effective means to reduce NOx emissions in Diesel engines. An innovative concept of EGR admission was developed for diesel engine of heavy-duty application. A 4-cylinder, naturally aspirated, water-cooled engine was selected for experimental investigation. One-dimensional simulation software was used to predict emission and performance parameters. The engine model was initially validated with experimental data and then used for parametric study for EGR. The best EGR flow rates were determined for experimental study, to study the effect of EGR on engine emissions. A significant reduction in emissions of NOx with minimal increase in CO and HC emission was achieved. Based on number of experiments and simulations an innovative EGR system was developed to control flow of hot exhaust back into the intake manifold for NOx reduction.

In this work a two-wheeler two-stroke spark ignition engine was modified to work in the air assisted direct injection (AADI) mode with gasoline as the fuel. Standard mechanical hardware was used. The controller for this system was developed in-house using a FPGA based system-using Labview software. The system controlled the fuel injection, mixture injection, lubricant pump frequency and the spark timing. Preliminary experiments were conducted at 3000 rpm to determine the influencing variables and potential of this system. Mixture injection timing was an important variable. The AADI system reduced short-circuiting of the fuel and the maximum brake thermal efficiency went up from about 21% with the carbureted version to 26%. There was a significant drop in HC levels from about 1500 ppm to 400 ppm with the AADI mode. NO levels went up slightly due to improved combustion.

The homogeneous charge compression ignition (HCCI) engines emit low levels of smoke and NOx emissions. However, control of ignition, which is mainly controlled by fuel composition, the equivalence ratio and the thermodynamic state of the mixture, is a problem. In this work, acetylene was as the fuel for operating a compression ignition engine in the HCCI mode at different outputs. The results of thermal efficiency and emissions have been compared with base diesel operation in the (compression ignition) CI mode. The relatively low self ignition temperature, wide flammability limits and gaseous nature were the reasons for selecting this fuel. Charge temperature was varied from 40 to 110°C. Thermal efficiencies were almost equal to that of CI engine operation at the correct intake charge temperature. NO levels never exceeded 20 ppm and smoke levels were always lower than 0.1 BSU. HC emissions were higher and were sensitive to charge temperature and output.

Valve actuation parameters like lift, opening and closing times affect performance and emissions of an engine. In this work, a new hydraulic variable valve actuation (VVA) concept is explained, simulated and analyzed using MATLAB. The system applies differential hydraulic pressure on two sides of a piston to open the inlet valve. A system of orifices, one of fixed diameter and the other of variable diameter is used to control the differential pressure. Some of the key parameters, which affect the performance of the system, are fluid supply pressure, damping, orifice diameters, displacement of the plunger controlling the orifice and the spring stiffnesses. The variation of parameters like the plunger movement, inlet and exit areas in a certain way was found to reduce the response time as well as increase the lift. It was also observed that the valve lift could be varied from 3.5 mm to 8 mm by just a 1.5 mm movement of the solenoid actuator.

In this work, a 7.45 cc capacity glow plug based two-stroke engine for mini aircraft applications was evaluated for its performance, emissions and combustion. It uses a fuel containing 65% methanol, 25% castor oil and 10% nitromethane by volume. Since test rigs are not readily available for such small engines, a reaction type test bed with low friction linear and rolling element bearings was developed and used successfully. The propeller of the engine acted as the load and also the flywheel. Pressure time diagrams were recorded using a small piezoelectric pressure transducer. Tests were conducted at two different throttle positions and at various equivalence ratios. The brake thermal efficiency was generally in the range of 4 to 17.5% depending on the equivalence ratio and throttle position. IMEP was between 2 and 4 bar. It was found that only a part of the castor oil that was supplied participated in the combustion process.

A novel, fully mechanical, simple, compact and cost effective variable valve timing system for two-wheeler application was developed. The details of the system and the performance are discussed. The system uses flyweights to exert a force on a cam, which floats on a shaft against a spring. The movement of the cam is axial and rotational due helical groves on the shaft. The system could start retarding the cam phasing after a predetermined speed. The system when implemented on a small scooter engine of 125 cc resulted in an increase in the volumetric efficiency at low speeds by 8%. The torque was improved by 10%. There was a reduction in the fuel consumption due to reduced throttling losses and leaner mixtures. When the system was implemented on a two-wheeler and tested on a chassis dynamometer on the Indian Driving Cycle a reduction in fuel consumption of 5% was noted. The emissions were also within limits.

A diesel engine was operated with karanja oil, bio-diesel obtained from karanja oil (BDK) and diesel as pilot fuels while LPG was used as primary fuel. LPG supply was varied from zero to the maximum value that the engine could tolerate. The engine output was kept at different constant levels of 25%, 50%, 75% and 100% of full load. The thermal efficiency improved at high loads. Smoke level was reduced drastically at all loads. CO and HC levels were reduced at full load. There was a slight increase in the NO level. Combustion parameters indicated an increase in the ignition delay. Peak pressure and rate of pressure rise were not unfavorably affected. There was an increase in the peak heat release rate with LPG induction. The amount of LPG that could be tolerated with out knock at full load was 49%, 53% and 61% on energy basis with karanja oil, BDK and diesel as pilots.

In a dual fuel engine a primary fuel that is generally a gas is mixed with air, compressed and ignited by a small pilot- spray of diesel as in a diesel engine. Dual fuel engines generally suffer from the problem of lower brake power and lower peak engine cylinder pressure due to lower volumetric efficiency, although an improvement in brake specific energy consumption is observed compared to pure diesel mode. Results indicate that with an increase in percentage of CNG substitution the brake power decreases. The exhaust gas temperature and peak cylinder pressure also decrease. The rate of pressure rise is higher at lower engine speeds (1100, 1400 rev/min), although at 1700 and 2000 rev/min it is lower. The delay period throughout the engine speed shows an increasing trend. The coefficient of variation is also higher throughout the engine speeds and shows an increasing trend. The brake specific energy consumption is lower at 1100, 1400 and 1700 rev/min and at 2000 rev/min it is higher.

The increasing use of natural gas as a vehicle fuel has generated considerable research activity to characterize the performance of engines utilizing this fuel. A light duty prechamber diesel engine was run under naturally aspirated and turbocharged CNG- Diesel dual fuel mode at four engine speeds 1100, 1400, 1700 and 2000 rpm. The maximum percentage of CNG substitution continues up to the engine knock limited power. The experimental results indicate a fall in brake power under naturally aspirated CNG-Diesel dual fuel mode compared to neat diesel operation. It was due to decrease in volumetric efficiency and slower combustion. Although turbocharged dual fuel operation shows an increase in brake power as well as an improvement in brake specific energy consumption as it provides a better air/fuel mixing and improves the homogeneous natural gas/air charge.

Experiments were conducted on a single cylinder, four stroke S.I. engine fuelled with biogas to characterize the nature of cycle by cycle variations (CCV) at different equivalence ratios. A full cycle simulation program using a two zone model with the capability to study the effects of fluctuations in equivalence ratio on hydrocarbon emissions was developed. CCV have been modeled using the Monte Carlo simulation scheme. The scheme has the capability to account for the deterministic and stochastic effects on the inputs. The model was validated using steady state experimental data and then applied to predict UBHC (Un Burned Hydro Carbon) emissions under conditions of low to high CCV. The predictions agreed fairly well with experimental results. The model can be used to determine the influence of adjusting spark ignition timings of cycles based on individual cycle equivalence ratios.