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Ever increasing specific power of diesel engines has put huge demand on effective thermal management of the pistons for the desired reliability and durability. The piston temperature control is commonly achieved by injecting cooling oil into piston galleries, but the design of the cooling system as well as the boundary conditions used in FEA simulations have so far relied mostly on empirical methods. A numerical procedure using 3D computational fluid dynamics (CFD) has therefore been developed to simulate the cooling process and to estimate the cooling efficiency of gallery. The model is able to predict the detailed oil flow and heat transfer in gallery, of different designs and engine applications, under dynamic conditions. The resulted spatially resolved heat transfer coefficient from the CFD model, with better accuracy, enables improved prediction of piston temperature in finite element analysis (FEA).

The gas components CO, CO2, HC, NOx and the AFR in the exhaust from a SI engine, both upstream and down-stream of a Pd/Rh catalytic converter, have been monitored using fast response analyzers. Regular sequential step changes in the upstream air/fuel ratio (AFR), between two pre-set levels, have been implemented with both long and short periods between the steps. For transitions from rich to lean conditions, and vice-versa, several distinct zones for the output emissions characteristics, corresponding to different states of the catalyst surface, have been identified. These results suggest that, under reducing conditions, hydrogen is stored on the catalyst surface whereas under oxidizing conditions oxygen is stored by two different processes. These chemical insights facilitate the development of realistic models for tailpipe emissions from engines which are perturbed from steady state running.

The dynamic behavior of three-way catalysts has significant impact on tailpipe emissions levels, but remains one of the last unknowns in the overall vehicle emissions model. A simple empirical model (appropriate for use in real-time engine control and on-board diagnostic strategies) has therefore been identified using fast response input / output measurements of the actual process. The model is able to characterize the (significant) dynamic behavior which has recently been observed under rich conditions, as well as the more well known dynamics which arise from oxygen storage. The results therefore compare well with measured responses over a wide range of air / fuel ratio conditions.