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The effect of fuel injection atomization on engine performance has been known to improve fuel economy and to reduce emissions. Hitachi America, Ltd. Research and Development along with Hitachi Research Laboratory in Japan have studied the effects and the operation of the air assist injection system which was developed and studied to help meet future Low Emission Vehicles (LEV) regulations and also Ultra Low Emission Vehicles (ULEV) regulations. The system consisted of newly designed air assist injectors having a spray angle of 15° at 170 kPa (absolute air pressure) with 370 kPa (absolute fuel pressure). The air assist injector generates highly atomized fuel droplets by swirling the fuel clockwise and the air counterclockwise. The fuel and air flowing in opposite directions collide, thereby producing particles around 30 μm in size at 274 kPa air pressure. These characteristics improve cold start, cold coolant conditions and fully warm engine conditions.

Emissions tests were performed to study the operating characteristics of a wide range air/fuel ratio (AFR) sensor in closed loop control. The AFR sensor used here has an output voltage with respect to AFR that is linear and can be characterized by a fourth order polynomial function. For this study the output signal of the AFR sensor was fed into a General Control Unit (GCU). The GCU converted this analog input signal into a square wave similar to a lambda sensor. The output from the GCU was fed into the Engine Control Unit (ECU) of the 3.8L, V6 test engine to control the engine A/F ratio. Emissions tests were conducted in closed loop mode under steady state and transient condition. Emissions of HC, CO and NOx using the AFR sensor will be shown. Results of these tests showed that the AFR sensor allowed for precise control of the AFR at the stoichiometric point (λ = 1.0).

To detect an air-fuel ratio in wide range is very important to control the automotive engines with low fuel consumption and low exhaust emissions. Although the application of zirconia electrolyte for this purpose has been proposed by the authors several years ago, there remained several problems due to the contamination of gas diffusion apertures which are exposed to the exhaust gas environment. Here the behavior of ions transported in zirconia electrolyte have been analyzed to optimize the structure and characteristics, and to guarantee the long life operation of sensor. Gas contents and their reactions in combustion process under the wide range air-fuel ratio have been analyzed, and these results were reflected to the analysis of ion transportation in zirconia electrolyte. Experimental results supported the analytical results, and they showed the possibilities of long life operation of zirconia air-fuel ratio sensor utilizing ion transportation phenomena.