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The reduction of the heat loss from the in-cylinder gas to the combustion chamber wall is one of the key technologies for improving the thermal efficiency of internal combustion engines. This paper describes an experimental verification of the “temperature swing” insulation concept, whereby the surface temperature of the combustion chamber wall follows that of the transient gas. First, we focus on the development of “temperature swing” insulation materials and structures with the thermo-physical properties of low thermal conductivity and low volumetric heat capacity. Heat flux measurements for the developed insulation coating show that a new insulation material formed from silica-reinforced porous anodized aluminum (SiRPA) offers both heat-rejecting properties and reliability in an internal combustion engine. Furthermore, a laser-induced phosphorescence technique was used to verify the temporal changes in the surface temperature of the developed insulation coating.

A free piston engine linear generator (FPEG) with potential for compact build, high efficiency and high fuel flexibility was developed in this study. The FPEG consists of a two-stroke combustion system, a linear generator, and a gas spring chamber. There are some technical challenges in ensuring an FPEG can achieve continuous operation over a long period, including lubrication, cooling, and piston motion control. Among these technical challenges, the piston motion control is the most significant factor in improving the robustness and efficiency of the FPEG because the combustion characteristics depend strongly on the piston motion, which is controlled by the linear generator. This paper describes a novel linear generator control method which realizes the simple harmonic oscillation governed by the piston mass and the air spring pressure. In general, the generating efficiency of linear generators is low in the low-speed region.

Free Piston Engine linear Generator (FPEG) that is thin and compact and has high efficiency and high fuel flexibility has been developed. The developed FPEG consists of a two-stroke combustion chamber, a linear generator, and a gas spring chamber. This paper focuses on the control logic of the linear generator, where the generator can be changed instantly to act as a driving motor, according to demand. Both the position and velocity of the piston are selected as feedback parameters for the control logic. The proposed feedback method realizes stable and robust control behavior with respect to abnormal combustion conditions, such as pre-ignition. In addition, the control logic must satisfy the following requirements. First, in order to achieve stable two-stroke combustion, the position of the piston is precisely controlled, especially near the top dead center (TDC) and the bottom dead center (BDC).

Free Piston Engine Linear Generator (FPEG) with features of thin and compact build, high efficiency and high fuel flexibility is developed. The FPEG consists of a two-stroke combustion chamber, a linear generator and a gas spring chamber. The key technologies to realize stable continuous operation are lubricating, cooling, and control logic. This paper proposes the original structure of the FPEG for enabling stable continuous operation. The main feature is a hollow circular step-shaped piston. The smaller-diameter side of the piston constitutes the combustion chamber, and the larger-diameter side constitutes the gas spring chamber. The larger cross-sectional area of the gas spring chamber leads to lower compression temperature of the gas spring chamber and consequently decreased heat loss. In addition, an oil cooling passage is built in the column stay, which ensures the enough cooling ability of the piston.

The aim of this work is to investigate the possibility of heat insulation by “Temperature Swing”, that is temperature fluctuation, on combustion chamber walls coated with low-heat-conductivity and low-heat-capacity materials. Adiabatic engines studied in the 1980s, such as ceramic coated engines, caused constantly high temperature on combustion wall surface during the whole cycle including the intake stroke, even if it employed ceramic thermal barrier coating methods. This resulted in increase in NOx and Soot, decrease in volumetric efficiency and combustion efficiency, and facilitated the occurrence of engine knock. On the other hand, “Temperature Swing” coat on the combustion chamber walls leads to a large change in surface temperature. In this case, the surface temperature with this insulation coat follows the transient gas temperature, which decreases heat loss with the prevention of intake air heating, and also which is expected to prevent NOx and Soot from increasing.

A computational and experimental study has been carried out to assess the high load efficiency and emissions potential of a combustion system designed to operate on low octane gasoline (or naphtha). The “naphtha engine” concept utilizes spark ignition at low load, HCCI at intermediate load, and compression ignition at high load; this paper focuses on high load (compression ignition) operation. Experiments were carried out in a single cylinder diesel engine with compression ratio of 16 and a common rail injector/fuel delivery system. Three fuels were examined: a light naphtha (RON∼59, CN∼34), heavy naphtha (RON∼66, CN∼31), and heavy naphtha additized with cetane improver (CN∼40). With single fuel injection near top dead center (TDC) (diesel-like combustion), excessive combustion noise is generated as the load increases. This noise limits the maximum power, in agreement with the CFD predictions. The noise-limited maximum power increases somewhat with the use of single pilot injection.

The effects of an increasing boost pressure, a high EGR rate and a high injection pressure on exhaust emissions from an HSDI (High Speed Direct Injection) diesel engine were examined. The mechanisms were then investigated with both in-cylinder observations and 3DCFD coupled with ϕT-map analysis. Under a high-load condition, increasing the charging efficiency combined with a high injection pressure and a high EGR rate is an effective way to reduce NOx and soot simultaneously, which realized an ultra low NOx of 16ppm at 1.7MPa of IMEP (Indicated Mean Effective Pressure). The flame temperature with low NOx and low soot emissions is decreased by 260K from that with conventional emissions. Also, the distribution of the fuel-air mixture plot on a ϕT-map is moved away from the NOx and soot formation peninsula, compared to the conventional emissions case.

The effects of multiple-injection on exhaust emissions and performance in a small HSDI (High Speed Direct Injection) Diesel engine were examined. The causes for the improvement were investigated using both in-cylinder observation and three-dimensional numerical analysis methods. It is possible to increase the maximum torque, which is limited by the exhaust smoke number, while decreasing the combustion noise under low speed and full load conditions by advancing the timing of the pilot injection. Dividing this early-timed pilot injection into two with a small fuel amount is effective for further decreasing the noise while suppressing the increase in HC emission and fuel consumption. This is realized by the reduced amount of adhered fuel to the cylinder wall. At light loads, the amount of pilot injection fuel must be reduced, and the injection must be timed just prior to the main injection in order to suppress a possible increase in smoke and HC.

Exhaust emissions and combustion characteristics from well-characterized diesel test fuels have been measured using two types of single-cylinder HSDI diesel engines. Data were collected at several fixed speed/load conditions representative of typical light-duty operating conditions and full-load performance (smoke-limited maximum torque) points. In addition, in-cylinder soot formation processes of these fuels were investigated via Laser Induced Incandescence (LII) using an optically accessible single-cylinder engine. The test fuels used in this study have been formulated with a sophisticated blending algorithm that systematically varies the hydrocarbon molecular structure in the fuels while maintaining the distillation characteristics of market diesel fuels. The following results have been obtained from this study. (1) The lowest PM emissions were observed with a fuel containing approximately 55% iso-paraffins and 39% n-paraffins with CN=52.5.

The cause of the exhaust smoke and its reduction methods in a small DI Diesel engine with a small-orifice-diameter nozzle and common rail F.I.E. were investigated under high-speed and high-load condition, using both in-cylinder observations and Three-dimensional numerical analyses. The following points were clarified during this study. At these conditions, fuel sprays are easily pushed away by a strong swirl, and immediately flow out to the squish area by a strong reverse squish. Therefore, the air in the cavity is not effectively used. Suppressing the airflow in a piston cavity, using such ideas as enlarging the piston cavity diameter or reducing the port swirl ratio, decreases the excessive outflow of the fuel-air mixture into the squish area, and allows the full use of air in the whole cavity. Hence, exhaust smoke is reduced.

Means for reducing the particulate matter (PM) from swirl chamber type diesel engines were searched out, and the reducing mechanisms were examined using an optically accessible engine. The following points were clarified in this study. 1. At light load, the suppression of the initial injection rate reduces PM, because SOF is reduced by the change in ignition point and smoke is reduced by the retarded flowout of the dense soot from the swirl chamber 2. Under medium and high load conditions, the main cause of the exhaust smoke is fierce spray-wall impingement which leads to fuel adhesion on the wall and the stagnation of a rich fuel-air mixture. 3. Enlarging swirl chamber volume ratio suppresses the formation of dense soot in the swirl chamber. In the main chamber, however, the soot oxidization becomes insufficient due to the mixing effect reduced by the essentially decreased chamber depth. 4.