Browse Topic: Exhaust systems

Items (3,003)

RDE Methodology Development for Motorcycle Emissions Assessment

2024-32-007304/18/2025

The transfer of conditions and regulations for RDE testing from passenger cars to motorcycles is a non-trivial undertaking. Motorcycles exhibit significant differences in construction and usage compared to cars, necessitating a distinct set of requirements for equipment and methodology. Currently available PEMS are hindered by their relatively large size and weight due to the embedded measurement technology and external power supply. The weight of, at least 50kg, poses a substantial additional load, leading to a deviation and, on average, higher load collective of the engine during RDE measurement rides. Beyond these structural parameters, the actual propulsion system and subsequent exhaust system introduce another challenge when employing PEMS on motorcycles. An unfavorable combination of the ratio of engine displacement to the volume of the exhaust system and long or unequal ignition intervals leads to pulsations, which has a considerable impact on the differential pressure-based

Schurl, Sebastian, Keller, Stefan, Lankau, Mathias, Hafenmayer, Christian, Schmidt, Stephan, Kirchberger, Roland

Studying the Lean Burn Operation in Two-Wheelers to Increase Fuel Efficiency and Investigate the Use of Lean NOx Trap Catalyst (LNT) for Lean Burn System

2024-32-005804/18/2025

This study offers an overview of the impact of lean burn technology in two-wheeler vehicles, specifically concentrating on enhancing the fuel economy and addressing the challenges associated with its adoption. Lean burn systems, characterized by a fuel-air mixture with a higher air content than stoichiometric ratio. The study focuses on technology which meets stringent emission standards while enabling the optimization of fuel efficiency. The lean burn system employs strategies to optimize air-fuel ratio using electronic fuel injection, ignition timing control, and advanced engine control algorithms like - updated torque modulation control algorithm for drivability, lambda control algorithm for rich and lean switch and NOx modelling algorithm for LNT catalyst efficiency tracking. The challenges related to lean burn systems, includes issues related to combustion stability, nitrogen oxide (NOx) emissions, and their impact on drivability, is summarized in the study. Mitigation strategies

Somasundaram, Karthikeyan, Sivaji, Purushothaman, John Derin, C, Vishal, Karwa, Manoj Kumar, S, Maynal, Rajesh

AIRS12242024 (Current)12/24/2024

A-20A Crew Station Lighting

AIR12122024A (Current)12/12/2024

A-6 Aerospace Actuation, Control and Fluid Power Systems

ARPTEST3008A (Current)12/12/2024

A-6 Aerospace Actuation, Control and Fluid Power Systems

AIR12092024 (Current)12/09/2024

A-6 Aerospace Actuation, Control and Fluid Power Systems

Automation 1730608826599

AIR12349999 (Current)11/08/2024

Automation Test Scope

A computational approach to Fretting Wear prediction of Steel Gaskets under Thermo-Mechanical load using Archards wear model

2024-26-027301/16/2024

IC Engine is the heart of an automobile. The failure in any component of the engine will directly affect the performance of the vehicle. The gaskets are among the many vital parts of an IC engine that are essential in ensuring appropriate sealing to prevent gas and liquid leakage and maintain optimal engine efficiency. Engines use a variety of gasket types to accommodate various sealing requirements. Among them the exhaust manifold gaskets is one of the critical gasket elements in IC engines which seals between Cylinder head and extremely hot Exhaust Manifold, this prevents the leakage of hot exhaust gasses produced during combustion. The gaskets are crucial components because they endure extremely high mechanical loads from the exhaust manifold sliding and banana-shaped bending brought on by thermal expansion, as well as extremely high thermal loads from the high exhaust gas temperatures, which are around 1000°C. These gaskets are additionally subjected to extremely high bolt loads

Reddy, Rajavardhan, Kulkarni, Sanjeev, R B, Govind, Mueller, Frank Oliver

Soot sensor elimination with DPF substrate failure monitoring.

2024-26-015301/16/2024

The automobile industry is going through one of the most challenging times, with increased competition in the market which is enforcing competitive prices of the products along with meeting the stringent emission norms. One such requirement for BS6 phase 2 emission norms is the inclusion of PM (Soot) sensor in diesel passenger cars. PM sensor detects soot leakage in case of DPF substrate failure. There is a cost factor along with extensive calibration efforts which are needed to ensure sensor works flawlessly. This paper deals with the development of an algorithm with which robust detection of DPF substrate failure is achieved. In order to achieve this, a thermodynamic model of DPF substrate was created using empirical relations between parameters like exhaust flow rate, exhaust gas temperature and soot mass content. The modeling was done in both empty (no soot) and filled (threshold soot content) substrate conditions. There were two methodologies, namely integration method and

Jain, Praveer Kirtimohan, Yadav, Omkar, Chendil, Chellapandi

Optimized Soot Monitoring by Ammonia injection in a sDPF system for BS 6.2

2024-26-014101/16/2024

The BS6 norms (phase 1) were implemented in India from April 1, 2020 and replaced the previous BS4 norms. Phase 2 of the BS6 norms, which came into effect on April 1, 2023. In accordance with the regulation requirement, effective performance of after treatment systems like DPF and SCR demands critical hardware implementation and robust monitoring strategies in the extended operating zone. Effective OBD monitoring of DPF, which is common to all BSVI certified vehicles, such that the defined strategy detects the presence or absence of the component is imperative. A robust monitoring strategy is developed to detect the presence of the DPF in the real world incorporating the worst possible driving conditions including idling, and irrespective of other environmental factors subject to a location or terrain. The differential pressure sensor across the DPF is used to study the actual pressure drop across the DPF. Additional for BS 6 (phase 2) PM sensor becomes an important part to keep the

Sharma, Prashant, Hareesh, Sangaraju, V, Suryanarayanan, Palanisamy, Krishnaraj, P, Jagdesan, Rathiya, Akash

Novel Exhaust system architecture for Petroleum Oil Tanker Application vehicle

2024-26-034501/16/2024

A large amount of heat given off by ATS on BS-VI exhaust system vehicle. Heat shield is required to protect the surrounding components. As per PESO (Petroleum and Explosives safety organization) guidelines for POL Application vehicle is that,(i)the surrounding temperature should not be more than 180° C and (ii) there is no spillage of any petroleum product to the bare surface of exhaust part directly. In BS-VI vehicle the heat given off from ATS is higher than the BS-IV vehicle. Typically flexible or wrap around heat shield is provided over ATS. In BS-VI flexible heat shield is not possible as more sensors and components are coming. In this project the novel design of heat shield (combination of flexible and metallic sandwich) on exhaust system is used. This design ensures the surrounding temperature is below 180° C and there is no spillage of petroleum product to the bare surface of exhaust parts (Including Tail pipe, Exhaust main pipe and ATS) directly. Also this design protect the

Sahoo, Rajanikanta, Khandagale, Anup, Manoharan, Logeshwaran, Kumar, Pravin

Simulation Study on High Expansion Ratio Dedicated Hybrid Engine for Hybrid Commercial Vehicle Application

2023-01-700510/30/2023

The fuel economy and emission of the hybrid vehicle depend largely on the selected engine. And the dedicated hybrid engine (DHE) can be controlled to operate in the optimal operating range because DHE can be decoupled from the vehicle transmission system. The main purpose of this paper is to improve the thermal efficiency of the diesel engine under common operating conditions combined with high compression ratio (CR) and early or late intake valve closing (IVC) angle. According to the vehicle road spectrum data, the optimal operating range of the engine is determined to be 1200-1400 rpm and 70%-90% load. Then CR and IVC angle are optimized by using the calibrated one-dimensional thermodynamic model of the engine under limited peak combustion pressure (Pmax). The results show that the adjustment of IVC angle and CR can control the thermal state at the end of compression stroke. The combination of CR and IVC angle can achieve the optimal fuel consumption improvement. The minimum brake

Wang, Xiaosa, Lin, Zhiqiang, Wang, Hu, He, Hua, Liang, Depu

A Holistic Approach For Near Zero Emission Diesel Vehicles Using A Pre-Turbo-Catalyst-System – Ready For EU 7

2023-01-121106/26/2023

This work shows the newest results of a near-series Pre-Turbo-Catalyst (PTC) system reaching lowest emissions for electrified diesel passenger cars to address future emission legislation. The PTC system is developed using a state-of-the-art tool chain containing 1D & 3D simulation approaches and testing near-series exhaust gas aftertreatment systems under real-driving boundary conditions. The innovative concept of an SCR PTC and a PTC bypass path solve the challenge of a thermal handshake between PTC and underfloor SCR System as well as the challenge of a particular filter regeneration. The development of adaptive PTC bypass path operation strategies based on exhaust gas and catalyst conditions enables lowest NOx and NH3. Using this concept, near-zero emissions can be reached in a wide range of operating scenarios while sustaining full drivability and highest efficiency. Advanced catalyst technologies enable a high emission conversion and lowest secondary emissions. These results have

Conin, Michael, Beidl, Christian, Knaf, Daniel, Fiore, Luis, Kreuz, Joachim

Design, Manufacturability, Optimization, and Validation of a Reactive-Style Muffler for a Formula SAE Race Car

2025-01-002405/05/2023

The noise generated by internal combustion engines, particularly in high-performance vehicles like Formula SAE race cars, presents a significant challenge in adhering to strict competition noise regulations. To address this issue, mufflers are essential for reducing acoustic emissions. This study focuses on the design, manufacturability, optimization, and validation of a reactive-style muffler specifically for a Formula SAE combustion competition car. The proposed muffler utilizes two chambers to generate destructive interference, targeting the two dominant exhaust frequencies of the Honda CBR600RR engine to maximize transmission loss and reduce noise levels below the SAE-mandated range of 103–110 dB(C). A 3D model of the muffler was developed using SolidWorks, capturing the precise geometries required for acoustic optimization. The exhaust noise and muffler performance were simulated using GT-Suite, allowing for an evaluation of noise attenuation across engine speeds. Experimental

Labao, Kai, Middleton, Nicholas, Nuszkowski, John

Infrared Signature of Fixed and Variable Area C-D Nozzle of Aircraft Engine

88-16-02-001101/02/2023

The use of converging-diverging (C-D) variable area nozzle (VAN) in military aeroengines is now common, as it can give optimal expansion and control over engine back pressure, for a wide range of engine operations. At higher main combustion temperatures (desired for supercruise), an increase in the nozzle expansion ratio is needed for optimum performance. But changes in the nozzle throat and exit areas affect the visibility of engine hot parts as the diverging section of the nozzle is visible for a full range of view angle from the rear aspect. The solid angle subtended by engine hot parts varies with change in visibility, which affects the aircraft infrared (IR) signature from the rear aspect. This study compares the performances of fixed and variable area nozzles (FAN and VAN) in terms of engine thrust and IR signature of the engine exhaust system in the boresight for the same increase in combustion temperature. This study is performed for two cases: (i) variable throat area and

Baranwal, Nidhi, Mahulikar, Shripad P.

Infrared Signature of Fixed and Variable Area C-D Nozzle of Aircraft Engine

01/02/2023

The use of converging-diverging (C-D) variable area nozzle (VAN) in military aeroengines is now common, as it can give optimal expansion and control over engine back pressure, for a wide range of engine operations. At higher main combustion temperatures (desired for supercruise), an increase in the nozzle expansion ratio is needed for optimum performance. But changes in the nozzle throat and exit areas affect the visibility of engine hot parts as the diverging section of the nozzle is visible for a full range of view angle from the rear aspect. The solid angle subtended by engine hot parts varies with change in visibility, which affects the aircraft infrared (IR) signature from the rear aspect. This study compares the performances of fixed and variable area nozzles (FAN and VAN) in terms of engine thrust and IR signature of the engine exhaust system in the boresight for the same increase in combustion temperature. This study is performed for two cases: (i) variable throat area and

Baranwal, Nidhi, Mahulikar, Shripad P.

Investigation on the Effect of Design feature on Acoustic Performance of Exhaust Muffler for Vehicle

2022-28-048811/18/2022

Primarily, Acoustic performance of muffler are evaluated by insertion loss (IL) and backpressure/restriction. Where Insertion loss is mainly depends upon proper selection of muffler volume, which is proportional to Engine Swept volume, along with internal design configuration, which drives the acoustic principle. Same time, meeting the vehicle level pass by noise (PBN) value as per regulatory norms and system level backpressure as per engine specification sheet are the key evaluating criteria of any good exhaust system. Here, a new Reactive/Reflective type muffler of tiny size have designed for heavy commercial vehicle application, which is unique in shape and innovative to meet desire performance. In this design, mainly sudden expansion, sudden contraction, flow through perforation and bell-mouth flow phenomenon are used. The performance of this tiny muffler are optimized using multilevel design of experiments (DoE) by the measurement of pass by noise (PBN) and near exhaust noise (NEN

Biswas, Sanjoy, Merchant, Preetam, Ghate, Asmita

Next Generation Diesel Particulate Filter for Future Tighter HDV/NRMM Emission Regulations

2022-01-066003/29/2022

HDV Diesel emission regulations are set to be tightened in the future. The introduction of PN PEMS testing for Euro VI-e, and the expected tightening of PM/NOx targets set to be introduced by CARB in the US beyond 2024 are expected to create challenging tailpipe PN conditions for OEMs. Additionally, warranty and the useful life period will be extended from current levels. Improved fuel efficiency (reduction of CO2) also remains an important performance criteria. Furthermore, future non-road diesel emission regulations may follow tighten HDV diesel emission regulations contents, and non-road cycles evaluation needs to be considered as well for future. In response to the above tightened regulation, for Diesel Particulate Filter (DPF) technologies will require higher PN filtration performance, lower pressure drop, higher ash capacity and better pressure drop hysteresis for improved soot detectability. Additionally, thermal management of aftertreatment system has become increasingly

Kurimoto, Yudai, Mishina, Ritsuko, Kato, Kyohei, Aoki, Takashi, Honda, Takahiro, Kaneda, Atsushi, Vogt, Claus Dieter

Investigation of a Second Exhaust Valve Lift to Improve Combustion in a Methane - Diesel Dual-Fuel Engine

03/29/2022

In recent years, the utilization of dual-fuel combustion has gained popularity in order to improve engine efficiency and emissions. With its high knock resistance, methane allows operation in high compression diesel engines with lower risk of knocking. With the use of diesel fuel as an ignition source, it is possible to exploit the advantages of lean combustion without facing problems to provide the high amount of ignition energy necessary to burn methane under such operating conditions. Another advantage is the variety of sources from which the primary fuel can be obtained. In addition to fossil sources, methane can also be produced from biomass or electrical energy.As the rate of substitution of diesel by methane increases, the trade-off between nitrogen oxide and soot is mitigated. However, emissions of carbon monoxide and unburned methane increase. Since carbon monoxide is toxic and methane has 25 times the global warming potential of carbon dioxide, these emission components pose

Mueller, Florian, Guenthner, Michael, Weigel, Alexander, Thees, Matthias

Thermomechanical behavior of an automotive exhaust aftertreatment application

2022-01-031903/29/2022

An aftertreatment system is the back-end component of an automotive exhaust system, used mainly to reduce pollutant emissions. This system is exposed to high thermal loads which can exceed temperatures of 900 oC , usually they operate at temperatures under 600 oC - 700 oC, depending of the engine application. The durability assessment of a system under thermomechanical loads can be challenging due to the complexity of the technical problem, which involves complex material behavior at high temperatures and results in high thermomechanical strains and stresses. This study presents a computational approach for the lifetime assessment of an exhaust aftertreatment system subjected to thermomechanical loading. The method is composed of a fluid flow analysis to compute the temperature fields which are mapped to a mechanical analysis combined with a nonlinear elastoviscoplastic material behavior. Lastly, the lifetime of the overall assembly is assessed through a fatigue analysis. The elasto

Serban, Alexandru

Exhaust Noise Development Based on System Model

2022-01-073603/29/2022

Exhaust noise performance has been developed using vehicle. Recently, the demand on reducing vehicles and untact development is increasing. In this study, the method for developing exhasut noise using system models was researched. The exhaust noise can be estimated using engine sound source and exhaust system's transfer functions. We measured engine sound source strength and exhaust system's insertion loss in experimental approach. We drew the theoretical equation leading to tail pipe noise with 2 systems' inherent property and considering connection point conditions such as impedences. We compared the estimated noise with measured using several vehicles. We concluded this approach is helpful for qualitative evaluation for the developing vehicle's exhaust noise without making vehicles. After estimating exhaust noise, we can set the system's target to meet the vehicle's target. Using this approach, it is expected that the exhaust noise can be estimated in advance of manufacturing

Park, Sangyoung

Monolithic Diesel Particulate Filters (DPF) substrate coated with CeO2-MnOx nanorods catalysts for soot oxidation

2022-01-066203/29/2022

Abstract Noble metal based Diesel Particulate Filters (DPF) are efficient aftertreatment devices to reduce the PM emissions of diesel engine at present. Because of the high-cost of noble metal, it is necessary to develop base metal soot combustion catalyst. In this work, CeO2-MnOx nanoparticles and nanorods catalysts were prepared by coprecipitation method using different precipitant. The crystal morphology of CeO2-MnOx nanomaterials is identified by a scanning electron microscope. The nitrogen physisorption and hydrogen temperature-programmed reduction results suggest that CeO2-MnOx nanorods has smaller specific surface area and greater redox capacity than CeO2-MnOx nanoparticles. The temperature programmed oxidation (TPO) tests were performed to evaluate the catalytic activity of the catalysts for soot oxidation. Results show that the CeO2-MnOx nanorods catalyst exhibits higher soot oxidation activity than CeO2-MnOx nanoparticles. Afterwards, the prepared CeO2-MnOx materials were

Hao, Shijie, Hu, Yifan, Yue, Jun, Lv, Yanan, Jiang, Jie, Zhang, Yun, Jia, xinyang

Pressure drop model development in Gasoline Particulate Filters for model based calibration

2022-01-067403/29/2022

Gasoline Particulate Filters (GPF) are widely employed in exhaust aftertreatment systems of gasoline engines to meet the stringent particulate emissions requirements of Euro6 and China6 standard. While providing an effective filtration of particles, the GPF increases the engine backpressure as a penalty. The pressure drop across GPF is an important performance characteristic which drives design decisions and lot of effort is spent on calibrating the same on dyno and vehicle level. A physics based back pressure predictive tool can help in reducing the hardware testing. In the present work, the development of a pressure drop model across the GPF using GT-Power for various conditions like clean, soot loaded and ash filled is described. Firstly, clean filter brick parameters like wall permeability and Forchheimer constant are fitted using bench data and then validated with dyno conditions. To fit soot parameters like soot permeability and soot density, pressure drop data under dyno

Kannan, Rajesh, Ramappan, Vijay, Mehta, Zubin, Govindula, Sunil S, Zielinski, Ashley, Thornton, Megan, Gillim, Austin, Paramadhayalan, Thiyagarajan

Modeling of gasoline particulate filter regeneration: sensitivity of numerical solutions

2022-01-067903/29/2022

Gasoline Direct-Injection (GDI) engine technology improves vehicle fuel economy toward future targets and simultaneously decreases CO2 emissions. The main drawback of this technology is the increased emission of particulates (when compared to their indirect injection-based technology counterpart). Thus, aftertreatment devices such as Gasoline Particulate Filters (GPFs) are today considered the most promising and practically adoptable solution to limit PM/PN out of GDI exhaust. The particulate filter traps soot particles resulting from fuel combustion and prevents their release into the atmosphere. Soot oxidation (also known as regeneration) is required at regular intervals to clean the filter, maintain a consistent soot trapping efficiency, and avoid the formation of soot plugs in the GPF channel. In this paper, starting from a multiphysics GPF model accounting for mass, momentum, and energy transport developed in our laboratory, a sensitivity analysis is carried out to choose the best

Levine, Kelsey, Pozzato, Gabriele, Onori, Simona

Concept-based Evaluation and Development of Close-Coupled DOC through Model in Loop Simulation supported by Experimental Investigations on 3L Light & Medium Duty BS - VI Diesel Engine

2022-01-067803/29/2022

The implementation of stringent BSVI norms from April 2020 has greatly revolutionized the automobile industry. With the plan for implementation of more stringent BSVI OBD-II norms from April 2023, in place, meeting legislative limits, particularly with CI engines, will be a challenge. The major challenge is the reduction in nitrogen oxides (NOx) which necessitates a selective catalytic reduction (SCR) together with effective calibration, to maintain the conversion efficiencies at the highest possible levels. The conversion efficiency is majorly dictated by temperature and exhaust mass flow. Hence, optimization of thermal management modes would be very important for meeting legislative emission limits. This is achieved by a close-coupled diesel oxidation catalyst (DOC). This paper describes the stepwise effectiveness of model based development to perform model in the loop simulation in virtual test bed (VTB), along with, experimental testing that goes hand in hand for development of a

R, Nishant Sharma, Lakhlani, Hardik

Performance Optimization of an Exhaust System for 4 Cylinder Engine by Implementation of Computational Fluid Dynamics, Acoustic and Thermal Analysis

2022-01-076503/29/2022

The engine system requirements have changed from being focused only on delivering engine power to now having to meet environmental emission standards. The exhaust system collects exhaust gases from the combustion cylinders, eliminates dangerous pollutants, decreases noise, and discharges the purified exhaust gases at a safe distance from the vehicle's occupants. Designs of lightweight models for exhausts were always aimed at using newer lighter materials. As the design of an exhaust is more or less fixed, this approach is hardly profitable anymore. The most important components of an exhaust system are the exhaust manifold, the catalytic converter, the muffler, the resonator and connecting all of them together are connecting exhaust pipes. In this paper, the optimization of the various elements of 4 cylinder 1.8L engine exhaust system is carried out with the help of analysis software ANSYS 19.2 workbench, by performing ‘Steady State Thermal Analysis’, ‘Acoustic Analysis’ and simulating

Aiyan, Mohammed, Sagar, S Sumanth, Raghav S, Sanjay

Idle sound quality enhancement with optimizing exhaust manifold structure on a H8 engine

2022-01-073703/29/2022

Idle sound quality for motorcycle is critical to engineers to achieve. People would like to have a strong individualized sound in idle, but linear and smooth sound in driving condition. Since the idle fluctuation noise is based on the engine firing order, the exhaust manifold structure and the idle frequency by cylinder numbers, thus, compared to the two or three cylinders engines, eight or six cylinders engine are really hard to get a fluctuated tailpipe sound since the its higher firing frequency. However, the surrogate methodology can be applied on these engines. Based on the noise cancellation process in phase and amplitude in the exhaust manifold tube, engineers can manipulate the noise with several lower peaks compare to other higher peaks. In this scenario, people can feel the noise with big fluctuations although the smaller noise peaks are still there but in the masking. In this paper, a special case is presented by this methodology. In that case, an eight cylinders horizontal

A CFD Investigation Comparing the Performance of an Alternative Valvetrain Design Against a Traditional Poppet Valvetrain

2022-01-076003/29/2022

The poppet valve is by far the most widely used cylinder head design in internal combustion engines; however, poppet valves themselves create significant flow restrictions during both the intake and exhaust strokes, thus causing a reduction in overall engine efficiency. By removing the restrictive poppet valve from the flow path of air into and out of the cylinder head and allowing air to flow unobstructed, any given ICE engine can achieve higher specific output and greater volumetric efficiency. A new alternative valvetrain design, the flow through barrel valve (FTBV) cylinder head, utilizes straight-cut flow passages that reduce such restrictions. The FTBV, designed by Vaztec, LLC., is a rotary valve system that is designed to be belt driven by the crankshaft, thereby replacing the camshaft and poppet valve system altogether. This paper will primarily explore the differences in flow characteristics between the FTBV and conventional poppet valve cylinder heads using both CFD and flow

Robinson, Austin Clay, Garrett, Norman, Vaseleniuck, Darrick, Uddin, Mesbah

Investigations of Process and Component Parameters for the Number of Particles and Size Distribution of a Supercharged DI-SI Engine

2022-01-070003/29/2022

Due to the short mixture formation times in the direct injection of modern gasoline engines, there is an increase in the emission of undesirable particle emissions in gasoline engines. As a result of previous studies with a portable emission measurement system (PEMS) of raw emissions and cleaned emissions, the particle number (PN) of the sampling point after the catalyst was higher than before the catalyst at the same process parameters and engine operating points. Based on this reproducible phenomenon, several theories were proposed. The theories set up dealt on the one hand with the question of process control with regard to the formation of particles, but also fundamentally with the question of whether conventional exhaust gas aftertreatment systems (3-way catalytic converters) are suitable for influencing the number of particles. In addition, studies of the oil consumption via the blow-by system and its influence on particle emissions also played a role. To verify these theories

Dost, Tobias, Schambach, Ricardo, Getzlaff, Joern

Design and Optimization of an SUV Engine Compartment Undershield based on Latin Hypercube Design Method and Multi-island Genetic Algorithm

2022-01-020103/29/2022

Vehicle engine compartment thermal management performance ensures engine performance and reduces pollutant emissions, and a suitable temperature range in the engine compartment during vehicle operation is critical to reducing carbon emissions. The design of the engine compartment components affects the thermal fluid flow performance in the engine compartment, which in turn affects the engine compartment thermal management performance, so it is necessary to explore the optimization of engine compartment components. In this paper, based on the phenomenon that the engine compartment undershield of an SUV caused abnormally high temperature on the surface of the engine compartment parts due to design defects, the engine compartment was modeled and simulated by STAR-CCM+, and it was found that the undershield caused hot air flow back, which was not conducive to engine compartment heat dissipation, so the undershield needed to be redesigned. The shape of the undershield was redesigned and

Performance Optimisation of an Exhaust System for 4 Cylinder Engine by Implementation of Computational Fluid Dynamics, Acoustic and Thermal Analysis

2022-01-067703/29/2022

The engine system requirements have changed from being focused only on delivering engine power to now having to meet environmental emission standards. The exhaust system collects exhaust gases from the combustion cylinders, eliminates dangerous pollutants, decreases noise, and discharges the purified exhaust gases at a safe distance from the vehicle's occupants. Designs of lightweight models for exhausts were always aimed at using newer lighter materials. As the design of an exhaust is more or less fixed, this approach is hardly profitable anymore. The most important components of an exhaust system are the exhaust manifold, the catalytic converter, the muffler, the resonator and connecting all of them together are connecting exhaust pipes. In this paper, the optimization of the various elements of 4 cylinder 1.8L engine exhaust system is carried out with the help of analysis software ANSYS 19.2 workbench, by performing ‘Steady State Thermal Analysis’, ‘Acoustic Analysis’ and simulating

Aiyan, Mohammed, Raghav S, Sanjay, Sagar, S Sumanth

Development of 1.5L Diesel Engine for Stage V with common rail system

2022-32-005201/09/2022

Recently, EU StageV emissions regulations have been enforced in the European market since 2019, increasing environmental requirements for diesel engines. EU StageV has been tightened compared to EPA Tier4 regulation, which demand PM (Particulate Matter) reduction and added new PN (Particle Number) regulations. Until the previous regulation EU Stage IIIA, the power category of 19kW or more and less than 37 kW had adopted mechanical IDI (Indirect-Injection). This mechanical engine is characterized by compactness and lightweight because of simple structure. Therefore, this engine is appreciated by customer with easy installation. On the other hand, to achieve EU StageV, it is necessary to adopt the electronic direct injection common rail system with more precise fuel injection and advanced exhaust gas aftertreatment device. The newly developed V1505-CR-T engine is not only small displacement of 1.5L, but also four-cylinders, and it is low vibration in addition compactness and lightweight

Okimi, Shoichi, Nagai, Kentaro, Yoshida, Reo, Akitomo, Tomoya, Yamazaki, Takahiro

Improvement of Transient Response on a Downsized 4 Cylinder Engine for Automobile Application

2021-28-028010/01/2021

The automobile industry is one among the fastest in terms of adapting the technological advancements and evolving based on changing customer requirements. Researchers are focusing on making the automobiles better by means of making the vehicles more efficient, powerful and less polluting. In this study, venues of improving low end torque via improvement in volumetric efficiency as well as proper selection of turbochargers. An in-depth analysis of gas dynamics with respect to valve timing is studied along with the AVL boost simulation. It was found that volumetric efficiency starts to improve when there is a reduction in exhaust – exhaust valve overlap. There is an improvement found in the fresh air ratio (lambda) as the residual gas content is reduced. After the selection of valve timing, turbocharger optimization is done with comparison between two turbine sizes. Along with turbocharger comparison, technology comparison is also done namely between normal electronic VGT (Variable

Jain, Praveer Kirtimohan, Chendil, Chellapandi, Asthana, Shivam, Sanjay, Nehal, Meda, Venkata Saikumar, R, Sivasubramamanian, Daithankar, Parag, Ramadandi, Padmavathi, RS, Ranganathan, A, Guru Sankar

Integrated exhaust manifold design & optimization of it through HCF and LCF simulations for a BS6 compliant Diesel engine

2021-28-016810/01/2021

This paper discusses design aspects of an integrated design of exhaust manifold with turbocharger for a 3 cylinder diesel engine, simulation activities (CAE and CFD), and validation of manifold while upgrading to meet current BS6 emissions. Exhaust after-treatment system needs to be upgraded from a simple DOC (Diesel Oxidation Catalyst) to a complex DOC+sDPF (Selective catalytic reduction coated on Diesel Particulate Filter) to meet the BS6 emission norms. To avoid thermal losses and achieve a faster light-off temperature in the catalyst, the exhaust after-treatment (EATS) system needs to be placed close to the engine – exactly at the outlet of the turbocharger. This has given to challenges in packaging the EATS. The turbocharger in case of BS4 is placed near the 2nd cylinder of the engine, but this position will not allow placing the BS6 EATS. Hence, the turbocharger position must be shifted to such an extent that it is placed before the first cylinder resulting in an overhanging

vinaya murthy, vijayendra, NAMANI, Prasad, Vellandi, Vikraman, Rengaraj, Chandrasekaran

Full Load Investigation of CNG—Diesel Dual-Fuel Heavy-Duty Engine with Selective Catalytic Reduction on Engine Performance and Emissions for Its Potential Use

03-15-03-002009/28/2021

The application of compressed natural gas (CNG) as fuel for compression ignition (CI) engines under dual-fuel (DF) mode operation is not attempted in countries like India for commercial purposes. A commercial heavy-duty turbocharged six-cylinder common-rail direct-injected diesel engine has been converted into a DF mode of operation using CNG and diesel for its potential usage and study on its performance along with Selective Catalytic Reduction (SCR). CNG is inducted through the intake manifold at varying energy substitution rates (ESR) with a flow rate of 0.67-1.54 kg/h while diesel fuel is controlled through the engine electronic control unit (ECU). For a maximum ESR of 10.2% with CNG, an increase in power by 8.9% and a 5.8% increase in torque were observed. While there was an increase in brake thermal efficiency (BTE), volumetric efficiency marginally decreased, therefore, to have higher brake power with a DF engine, a dedicated turbocharging system is necessary. The brake-specific

Muralidharan, M., Srivastava, Ajay, Subramanian, M.

A Study of Emission Durability and Ash Accumulation of “Advanced Three-Way Catalyst Integrated on Gasoline Particulate Filter” for BS6 (Stage2) Applications

2021-26-018209/22/2021

India BS6 Stage2 (2023) regulations demands all Gasoline direct injection (GDI) vehicles to meet particulate number emissions (PN) below 6x10+11# per km. Gasoline particulate filters (GPF) are a proven technology and enable high PN filtration efficiencies throughout the entire vehicle lifetime. One challenge for GPF applications could be the changing emission performance characteristics as a function of mileage due to collected ash and/or soot deposits with implications on back pressure losses and well due to aging of active catalytic components like PGM and Washcoat. The main objective of this technical contribution is to study the above-mentioned challenges while applying Indian driving conditions and typical Indian climate and other ambient conditions. The substrate technology selected for this study is a high porosity GPF designed to enable the integration of a Three-Way functionality into the GPF, commonly described as coated GPF. In this study, the entire Three-Way Catalyst (TWC

Rose, Dominik, Tao, Tinghong, Kataria, Rohit, Boger, Thorsten, Kuehn, Nikolas, Kunert, Susanne, Richter, Joerg Michael, Magar, Avinash

Study of Fuel in Oil Dilution Due to Aftertreatment Regeneration in Automotive Diesel Engine

2021-26-018409/22/2021

The Bharat Stage VI emission norms in India is driving the use of more complex after treatment systems for diesel engines. The after-treatment system typically includes DOC, DPF and SCR to reduce the engine out hydrocarbon, particulates & NOx respectively. For a durable functioning of the after-treatment system, cleaning of these components at regular intervals is required. One such method is to burn the diesel fuel inside DOC, to clean the DPF and SCR, a process called regeneration. Regeneration involves using extra diesel fuel injected into the exhaust stream, which gets oxidized in the DOC thereby regenerating the DPF or SCR. Present technology uses the existing injectors in the diesel engine for regeneration which is cost effective and simpler compared to the external hydrocarbon dosing system. In-cylinder hydrocarbon dosing is associated with the risk of fuel getting mixed with engine oil. This happens because the regeneration fuel is injected in the exhaust stroke where the

Vinay P, Ashwyn, Verma, Utkarsh, Goswami, Imon, Suresh, Swathy

MULTI-ENVIRONMENT ACCELERATED DURABILITY TEST FOR EXHAUST SYSTEM FLANGE JOINTS

2021-26-047209/22/2021

Accelerated testing is vital to meet stringent project timelines and is a key consideration for developing new testing methodology. Specifically, durability testing is one of the key fields of interest to deal with all aspects. Fatigue with exposure to multiple environments is a major cause of exhaust system flange joint failure. Physical verification of increased design life expectancy, demands longer testing time, while shorter time to market is main differentiator for competitiveness. Government policy induced timeline pressures added to the need of accelerated tests. The methodology described in this paper embraces these aspects to ensure a quicker flange joint testing, with due consideration to environmental impact. Until the BSVI norms, marginal leakage through the system joints was usual and acceptable. Stringent emission norms demand ‘near-zero’ leakage from exhaust systems. The system joints essentially being the most probable leakage zones, became the focus area

Dhumal, Sagar Prakash, Suryawanshi, Sachin, Mone, Manasi

Component S/N Curve Testing Methodology for Exhaust System Validation

2021-26-045109/22/2021

The exhaust system design and development needs to be more flexible and easily adaptable for the dynamic changes with the introduction of new emission and noise regulations. Conventionally, bending moment testing is used to validate significant components like inlet and outlet pipe/cone joints and bend pipes through Bi-Ax test rig. Road load re-production test is an improvement of the conventional approach to predict component durability. However, it is more time consuming and involves the sequential process of acquiring road load data such as sensor instrumentation, strain measurement at the test track, data processing and input to Bi-Ax testing. S/N Curve testing is introduced recently as an alternate method to minimize the use of RLDA. It can be done upfront during vehicle unavailability and other challenging conditions and also as a parallel activity along with RLDA. Our objective is to show the simulation and validation process of Component S/N Curve testing with a LNT+DPF system

Rajadurai, Sivanandi, Natarajan, Suresh, Srivatsan, Rajesh, Sivalingam, Ananth

Design and development of Helmholtz resonator for low frequency exhaust noise reduction in commercial vehicles

2021-26-027909/22/2021

In recent times there has been rising demand for noise level reduction in commercial vehicles. Vehicle engine exhaust system is one of the key sources of noise at driver ear, especially in smaller wheel base trucks, as well as critical for meeting pass by regulations. Several techniques are used to reduce the noise level of an exhaust system such as resonators, dissipative mufflers for low & high frequencies respectively. In this paper sound transmission loss (STL) measurement for a LMD bus exhaust system was carried out at rig level. It has been found from the measured data that noise attenuation of current exhaust system is poor in low frequency zone & therefore lower STL frequencies were identified. To attenuate the noises at identified frequencies Helmholtz resonator was introduced, which is particularly effective for low frequency noise attenuation. A design is conceptualized and developed based on Helmholtz resonator calculation for target frequencies and duty cycle gas

Kasliwal, Rajat, Saxena, Saahil, Jadhav, Sourabh

Characterization and Improvement of Two-wheeler Exhaust System Component using Vibro-Acoustic Technique

2021-26-027609/22/2021

Exhaust system is a key component defining the noise character of any two-wheeler. With increased demand by customers for vehicle refinement, exhaust system has to face the challenge of imparting noise character to the vehicle and be refined at the same time. Apart from noise character of the vehicle, homologation requirement is also an important factor from exhaust system performance point of view especially with new and stringent norms being introduced. Exhaust mufflers play an important role in performance of exhaust system and hence muffler characterization is always done in detail as per standard practices. However, it is equally important to consider entire exhaust system for performance study. This paper deals with identification of an irritant noise perceived from two-wheeler. The source of this noise character was exhaust system component of the vehicle other than muffler. Further, characterization of exhaust system component using vibro-acoustic technique was done in order to

Dixit, Pushkar, Askhedkar, Amlesh, Arimboor, Kuriyan

Methodology development for Open Station Tractor OEL Noise Assessment in the Virtual Environment

2021-26-031009/22/2021

There is a higher demand for quieter tractors in the agri-industry, as the continued exposure to noise levels have disastrous effects on operator’s health. To meet the world-wide regulatory norms and to be the global market leader, its mandatory to develop the comfortable tractor which meets homologation requirements and customer expectations. Typically, Operator Ear Level (OEL) noise has been evaluated in the test, after First Proto has been made. This approach increases cost associated with product development due to late changes of modifications and testing trails causing delay in time-to-market aspect. Hence, there is a need to develop the methodology for Predicting tractor OEL noise in virtual environment and propose changes at early stage of product development. At first, full vehicle comprising of skid, sheet metals and Intake-exhaust systems modelled has been built using Finite Element (FE) Preprocessor. In this methodology, reverse acoustic modelling approach has been used to

gunasekaran, pandiyanayagam, Chavan, Amit, K, Somasundaram

Experimental Analysis of Heavy Duty CNG Engine based on its Aspiration and Fuel System

2021-26-011709/22/2021

Engine calibration involves the interaction of Electronic components with various engine systems like intake system, exhaust system, ignition system, etc. Emissions are the byproducts of combustion of fuel and air inside the combustion chamber. After-treatment systems generally take up the responsibility to scrape out harmful emissions from the engines. However, a good engine calibration will focus on emission reduction at source i.e. during the combustion itself. Thus, the intake of air and fuel in proper amount at each engine operating point is crucial for optimized engine performance and minimal emissions. The Intake system is an integral part of any internal combustion engine and it plays an important role to improve its performance and emission. Generally, for an SI engine, maintaining the stoichiometric A/F ratio is a challenging endeavor from an operational standpoint. Engine power, BSFC, torque and harmful emissions are much influenced by geometric aspect of intake manifold and

bandyopadhyay, Debjyoti, Sutar, Prasanna S, Sonawane, Shailesh Balkrishna, Rairikar, S D, Kavathekar, Kishorkumar, Thipse, Sukrut S, Kshirsagar, Chinmay, Kale, Samir

The Diesel Particulate Filter Calibration- Challenges & Counter measures targeting Indian Scenario

2021-26-018909/22/2021

As vehicle emission norms are becoming stringent worldwide, the application of Diesel Particulate Filter to trap particulate matter is becoming widespread in diesel engine powered vehicles and equipment. A Calibration transfer from the well established emission technology from Europe to India is not a feasible approach because of challenges in typical Indian driving cycles and Common Rail System limitation due to cost sensitive market requirement . This paper explains techniques used to overcome the challenges with respect to Indian conditions. With catalyst protection integrated in the technique and a robust model based exhaust temperature control, a complete closed loop technique of DPF regeneration is achieved. This technique combined with model based soot load calibration has proven as an effective countermeasure for DPF calibration improving DPF regeneration efficiency, good repeatability of temperature control, higher average DPF temperatures, and shorter regeneration durations

Chaudhari, Kuldeepak, Kumar, Raman, Madhukar, Prahlad, Wolter, Marcus

ESTIMATION OF DIESEL SOOT PARTICLES IN EXHAUST GAS EMISSION AND ITS ACCUMULATION IN DIESEL PARTICULATE FILTER USING GRAPHICAL CALCULATION MODEL

2021-26-019509/22/2021

To avoid frequent regeneration intervals leading to expeditious ageing of the catalyst and substantial fuel penalty for the driver, it is always desired to estimate the soot coming from diesel exhaust emission and the soot accumulated and burnt in the diesel particulate filter. Certain applications and vehicle duty cycle cannot make use of the Delta pressure sensor for estimating the soot loading in the DPF because of the limitations of the sensor tolerance and measurement accuracy. The Physical soot model is always active and hence a precise and more accurate model is preferred to calibrate & optimize the regeneration interval. This paper presents the approach to estimate the engine out soot and the accumulated soot in the DPF using a graphical calculation model. The tool reduces the effort of driving different duty cycles multiple times on the testbed and recurrent vehicle trips for data collection while calibrating the soot models, hence saving testbed cost, diesel cost and manpower

Gaur, Kunal, parashar, Shalabh, vos, Bas, Kusumba, Manoj

Rational design of Cu-SSZ-13 catalyst for the selective catalytic reduction of NOx to meet BS-VI emission standards

2021-26-018109/22/2021

To achieve healthier and sustainable air quality and to protect human life, worldwide emission standards are being tightened for harmful vehicular air pollutants such as CO, hydrocarbon, NOx and particulate matters. Among selective catalytic reduction catalysts for NOx control in automotive after treatment system, Cu-SSZ-13 (Chabazite structure) is one of the most promising SCR catalyst, mainly used in light and heavy duty diesel vehicles. This article focuses on the development of Cu-SSZ-13 with desired properties such crystallinity, morphology, surface area and Cu loading in the catalyst. With the help of sophisticated catalyst characterization tools such as NH3-Temperature Programmed Desorption (TPD), Temperature Programmed Reduction (TPR), BET surface area, X-ray diffraction (XRD) and Scanning Electron Microscopy (SEM), novel and highly active formulations of Cu-SSZ-13 are reported here. Furthermore a correlation between the physico-chemical properties and catalytic performance of

Narkhede, Vijay, Patel, Rajesh, Tinwala, Tanzeem, Sabde, Dhananjay, Kumar, Dinesh, Sidiquie, Touquire A

Regulatory Norms and effect on transmission component validation

2021-26-046009/22/2021

With the advent of BS VI regulations, automotive manufacturers are required to innovate the powertrains, fuel systems, exhaust and its after treatment systems to meet the regulatory requirements. The exhaust regulations can be met either by reducing the exhaust gases being generated by the engine (attacking the source) or by treating the exhaust gases in after treatment devices. The choice of the opted system varies with the manufacturer. The after-treatment devices such as catalytic converters are generally mounted in the engine compartment to take advantage of high temperature of exhaust gases to yield the reactions. Such an arrangement imposes a lot of thermal load on the peripheral components such as gearshift cables, bearings, oil seals, driveshafts etc. Thermal shields or thermal sleeve are used to address thermal issue and to protect transmission components. System level validation test requirement of transmission need to be re-visited to considering change in environmental

Tongaonkar, Yogesh Manohar, Patel, Hiral, Tendulkar, Vishveshvar, Bhosale, Vikas, halingale, Amol

Tailpipe emission study of aged after treatment system on Medium duty commercial vehicle

2021-26-021509/22/2021

As the emission norms are getting stringent in BSVI and regulations like OBD-II on vehicle. It is essential to define the life of exhaust after treatment along with the vehicle. The After treatment mainly consist DOC+DPF+SCR. Lubricating oil consumption is always be there with engine running condition and these additive oils contains phosphorus or zinc which gives an adverse effect on DOC and there is unburnt hydrocarbon (UNHBC), SOF in tail pipe that get accumulated in DPF which further require regeneration means a higher temperatures in exhaust after treatment (EATS ) and as the regeneration count increases there is ash accumulation in DPF that reduces its capability for soot accumulation. The tail pipe emission also consist Sulphur which has a negative impact on SCR for Nox conversion. So in present study we analyze the effect of (1) Chemical aging (2) Thermal aging on 3.77 liter diesel engine after treatment. A test cycle was prepared to run durability for EATS which consist total

Tiwari, Amit, Durve, Anurag, Srinivasan, Pradhan, Barman, Jyotirmoy

Development of Compression Spring Variable Valve for Exhaust Mufflers

2021-26-028909/22/2021

The main function of the muffler is to reduce noise from the internal combustion engine without affecting its performance due to the impact of higher backpressure. The backpressure of the exhaust system is directly related to the fuel efficiency of the engine. BS VI and the forthcoming RDE emission control systems (hot end) use combination technologies such as DOC, DPF,SCR and multiple SCR. In BS IV application, emission control system (hot end) contributes about 30% of the total allowable exhaust backpressure, whereas in BS VI regulation the contribution of hot end system is about 70% of exhaust backpressure. The addition of hot end internals (DOC, DPF, SCR) in BS VI system increases backpressure abnormally and hence the engine performance decreases. So,there is a mandatory requirement to control backpressure of the exhaust system.Although these hot end components contribute additional value for acoustic tuning, the upcoming NVH targets demand precise optimization. Noise and back

Rajadurai, Dr. Sivanandi, K J, Rajakumar

Adopting the features of Digital Rate Shaping (DRS) with Multiple injections strategy on small 2 Cylinder Common Rail BSVI engine to improve FE

2021-26-006109/22/2021

The Common Rail Fuel Injection System (CRS) has completely changed the whole diesel engine combustion cloud dynamics and enhanced the applicability of diesel engines further with a motto of providing a more cleaner sky and greener earth. The most cutting-edge technological developments made in CRS and EGT system enables OEMs to achieve further more stringent emission norms and adopt the environmental protection compliances. Today’s CRS systems are the most advanced generation fuel injection systems providing further high injection pressures, wide multiple injections capability with shorter dwell periods enabling real smoother Digital Rate Shaping (DRS) benefits and Smart thermal management of exhaust systems while meeting stringent emission compliances and achieving future CO2 reductions goal. Initial DRS I system developments were tried with a dwell period up to 500us-800us due to injector durability life limitations. DRS II system is such an advanced system developed in recent years

Yarsam, Pravin, Athawale, abhijit, kapadnis, Vaibhav

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