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In order to fulfill future emissions standards, there is a need for new exhaust-gas aftertreatment concepts, with NOx-emissions reduction in passenger car diesel engines being of particular importance. The NOx storage catalyst is one of the technologies currently under discussion with high NOx conversion potential, and which is under development at DaimlerChrysler for EURO IV standards. With this system, the nitrogen oxides contained in the diesel exhaust gas are stored under lean exhaust-gas conditions and are reduced in the catalyst through an enriched air-fuel ratio of the exhaust-gas and favorable thermal conditions. Hydrocarbons, carbon monoxide and hydrogen are used as reducing agents. DaimlerChrysler has analyzed the effect of sulphur contained in the fuel on the operation of various catalysts during laboratory and engine testing. The sulphur dioxide in the exhaust gas generates sulfates, which remain on the catalyst when nitrate compounds are regenerated briefly.

A common rail injection system was applied to port-loop and uniflow scavenged two-stroke DI-Diesel engines. While the uniflow scavenged configuration was operated with a swirl level comparable to that of 4-stroke DI-Diesel engines, no swirl motion was realized with the port-loop scavenged arrangement. The results show that, in spite of disadvantages in the mixture formation process, the high mixture formation energy observed with the common rail injection makes a swirl-free Diesel combustion possible. However, at part load the combustion process and emission level with the port-loop scavenged engine is not satisfactory. At full load, disadvantages in the scavenging process are observed in addition to the poorer mixture formation with the loop scavenged two-stroke concept. Consequently, the expected specific power output of the port-loop scavenged arrangement is with 20 kW/l far lower than about 45 kW/l predicted for the uniflow scavenged engine.

In conjunction with throttle-free load control on a 4-valve, single-cylinder spark-ignition engine, the influencing variables of charge cycle, mixture formation and combustion process are presented both as computer calculations and on the basis of test results. The influences of the position of the maximum of the inlet valve stroke, the position of the inlet close, the shape of the valve stroke and the load motion in relation to the maximum power and minimum fuel consumption are investigated in full load by computer calculations and in partial load by engine tests.

The principle strategy, the development emphasis, and the investigation parameters of a DI gasoline engine are discussed. Several different combustion systems are briefly described and one system where the spark plug is located near the fuel injector is investigated. In addition, the influence of different operating parameters are studied. Some reasons for the improvement in the efficiency of a DI gasoline engine are shown with the help of thermodynamic analysis and simulation calculations. These show that at a constant operating point (engine speed = 2000 rpm, bmep = 2 bar) there is a reduction of the fuel consumption of 23% at unthrottled conditions in comparison to the homogeneous stoichiometric operation. In particular, the reduction of the pumping and heat losses and the reduction of the exhaust gas energy are responsible for this fuel consumption reduction.

The comparison of a light weight crankcase to the production cast iron crankcase of the new Mercedes Benz 2.9-liter direct injection (DI) five-cylinder turbo diesel engine with intercooler is described. The light weight crankcase is cast from the aluminum alloy A 356 while other engine components like oil pan, timing case cover and brackets are manufactured from a magnesium alloy. This paper describes the engine design with the simultaneous calculation, the mechanical development and the acoustic measurements. In this study an engine weight reduction of about 30 kg with comparable noise emission compared to the production engine with cast iron crankcase is realized.

The influence of different port designs on the generation of a swirl flow is described on the basis of stationary and non-stationary flow analyses. Subsequently, engine test bench analyses with a 3-valve one-cylinder engine were performed to assess the aforementioned port configurations with respect to their influence on the lean-burn behaviour. The most favourable port design was then used to analyse various combustion chamber shapes in order to further improve the engine behaviour during lean-burn operation and to select the most promising combustion chamber variant. Finally, the port and combustion chamber configurations thus identified were applied in vehicle simulation tests with lean-burn and EGR-burn operation to check the emission behaviour for compliance with the future European level 3 emission limits.