Controls and Hardware Development of Multi-Level Miller Cycle Dynamic Skip Fire (mDSF) Technology 2021-01-0446

mDSF is a novel cylinder deactivation technology developed at Tula Technology, which combines the torque control of Dynamic Skip Fire (DSF) with Miller cycle engines to optimize fuel efficiency at minimal cost. mDSF employs a valvetrain with variable valve lift plus deactivation and novel control algorithms founded on Tula’s proven DSF technology. This allows cylinders to dynamically alternate among 3 potential states designated as: High Fire, Low Fire, and Skip (deactivation). The Low Fire state is achieved through an aggressive Miller cycle with Early Intake Valve Closing (EIVC). The three operating states in mDSF can be used to simultaneously optimize engine efficiency and driveline vibrations. Acceleration performance is retained using the all-cylinder, High Fire mode. mDSF can be implemented cost-effectively using an asymmetric intake valve lift strategy, with one high-flow power charging port and one high-efficiency Miller port.

Prototype mDSF cylinder heads were based on the EA888 Gen 3B engine by retrofitting the valvetrain with asymmetric intake cams, deactivatable roller finger followers and two oil control valves per cylinder. Event-based engine controls were developed to enable for each cylinder dynamic selection of the three mDSF operating modes: High Fire, Low Fire and Skip. Appropriate air estimation, fuel control and ignition control techniques were employed to ensure acceptable torque delivery and tailpipe emissions.

Engine dynamometer tests showed a 23% reduction in engine fuel consumption at 1500 rpm, 2 bar NMEP. Maximum torque and power from the baseline production engine up to 5000 rpm were also achieved. mDSF vehicle tests on the WLTC demonstrated a 6% reduction in CO₂ from Miller 2-step. Euro 6d compliant emissions were also reported. Further improvements in fuel economy, drivability and NVH may be possible by leveraging mixed firing densities more extensively.