a combustion engine for a range extended hybrid electric...

A Combustion Engine for a Range Extended Hybrid Electric Vehicle

Steven Begg Experimental Fluid-Mechanics Group (EFMRG)

University of Brighton (acknowledgments for contributions: Elena Sazhina, Daniel Coren, Oyuna

Rybdylova, Nicolas Miché, Tiago Carvalho, Adil Karakayis)

CEREEV

EU INTERREG IVA Programme

• Priority 2 : Build partnerships for cross-border economic development and centres of excellence

• Specific Objective 3 : Identify and support common and complementary centres of business and research excellence

• To create a Cross Channel Centre of Excellence

INTERREG IVA Project Number 4224 ‘CEREEV’ A combustion engine for range-extended electric vehicle

High level aims:

• The CONCEPTION AND CONTROL STRATEGIES for an efficient internal combustion engine for a small, HYBRID ELECTRIC VEHICLE.

• CREATION OF A COLLABORATIVE CENTRE FOR HYBRID ELECTRIC VEHICLES, control strategies and complementary disciplines.

• SUSTAINABLE COLLABORATIVE RESEARCH, underpinning new projects in the renewable energy sector.

Motivation for the programme – Why hybrid electric vehicles?

http://www.theicct.org/blogs/staff/some-upcoming-changes-icct-global-passenger-vehicle-ghg-standard-comparison-charts (International Council for Clean Transportation)

http://www.theicct.org/blogs/staff/some-upcoming-changes-icct-global-passenger-vehicle-ghg-standard-comparison-charts






















Motivation for the programme – Why hybrid electric vehicles?

http://www.theicct.org/blogs/staff/some-upcoming-changes-icct-global-passenger-vehicle-ghg-standard-comparison-charts (International Council for Clean Transportation)

Corporate Average Fuel Economy (CAFE)























Motivation for the programme – Hybrid electric vehicles (HEV)

• Viable vehicle technology solutions for a compact city car • Highly optimised internal combustion (IC) engine • Auto stop-start • Series hybrid • Parallel hybrid • Full electric vehicle • Fuel cell

• Challenges for extended autonomy for extra-urban use • Match electrical power requirements to vehicle class • Advanced control strategies to manage optimal distribution of power • Fault tolerant diagnostic capability • Integration of small IC engine – what type of engine, operating point & control?

Hybrid electric vehicles (HEV) with Split-cycle Combustion Engine

Source: http://techon.nikkeibp.co.jp/english/NEWS_EN/20080418/150656/

http://www.scuderigroup.com/engine-development/

• Quasi-constant volume combustion requires rapid mixture preparation & combustion • Brighton team focus on rapid air filling and mechanical design of expander

http://techon.nikkeibp.co.jp/english/NEWS_EN/20080418/150656/

http://techon.nikkeibp.co.jp/english/NEWS_EN/20080418/150656/





Target Engine Specification • Rated Power: 10 kW • Capacity: 135 cc • Fuel: gasoline • Format: series hybrid

cf. Little-cars E.BOX

http://sites.esigelec.fr/Newsletter/ESIGELEC2/en/virtuose-the-car-of-the-future-co-developed-by-irseem.html

• Brighton Single cylinder research engine

Presentation Agenda

• Overview of Project and Work Packages

• Thermodynamics of a Split-Cycle Engine Concept

• Air-Filling Process in Split-Cycle Engines: A Parametric Study by CFD

• Mechanical Engineering Design of a Split-Cycle Combustor

• Modelling, Control and Observation of Electrohydraulic Valves

Overview project work packages at Brighton

• WP1 Implementation of a high pressure injection system

• Gas exchange, mixture preparation, engine architectures.

• Sensor requirements and identification of control parameters.

• WP2 Engine Modelling

• Thermodynamic models of the cycle. Combustion performance evaluation.

• WP3 Study of Electro-hydraulic Valves

• Hardware in the loop (HIL) control, test rig design and build, integration.

• WP4 Simulation

• Analytical and numerical (CFD) modelling.

• WP5 Validation and Optimisation

• Design and manufacture of prototype expander.

Phase 1 air jet

chamber

Phase 1 2-ACE cylinder head

Fuel injection and ignition

control

Prototype Engine

performance

CFD

Phase 2 fuel spray chamber

CFD

EHV test rig and control

Model of engine for hybrid vehicle optimisation

Engine model

Hybrid Simulator

Thermodynamic model

CFD

Research strategy

Phase 1a air jet in

crossflow

Phase 2 new cylinder head

and combustion chamber design

Overview technical programmes • Thermodynamic model

• Fuel injection system

• Air delivery requirements

• Electro-hydraulic valve air induction • Piezoelectric air injector • Numerical simulations

• Ignition and combustion

• Mechanical design

1. Flat Fan DI 2. Hollow Cone PFI 3. Multi-hole (10) DI 4. Pressure Swirl DI 5. Hollow Cone DI

Fan images courtesy of collaborative project with Uni. Of Cardiff and Ricardo

1 Nouri et al., 2007, 2 (Fansler et al., (2006))

1

2

Fuel injection system – evaluation of injector and spray

Criteria

• fuel mass flow rate

• time to steady fuel delivery at short fuel pulse widths/ multiple injections

• spray geometry (cone shape) consistent with concept

• flexible spatial scales (penetration/impingement) – rate shaping

• flow range for homogenous / stratified concepts

• droplet size range <10 µm diameter

• injection duration range from 0.08 to 4 ms

• high shot-to-shot repeatability

• favourable structures – e.g. fuel vortex ring stratification

• available historical empirical data for PRF:

• characteristic break-up scales in high-speed airflows

• droplet probability size distributions from SOI

• droplet evaporation (modelled for PRF and multi-components)

Fuel injection system – evaluation of injector and spray

• Injector 5: Bosch HDEV Hollow Cone

• DI piezoelectric

• 140-200 bar fuel pressure

• Flow rate 42 mg/ms at 200 bar

• Variable multiple injections

Fuel injection system




• Electro-hydraulic valve air induction • Piezoelectric Air injector • Numerical simulations



Air induction – flexible two staged approach

Electro-hydraulic valve air induction • Devise EHV hydraulic test rig

• Develop advanced valve control models at IRSEEM

• Implement and validate models on test bench at Brighton with HIL before move to engine

Bosch HDEV fuel injector • Experimental characterisation of air injection in quiescent,

ambient powder chamber

• Characterisation of air injection in cross flow using aeronautical wind tunnel and smoke seeding

Air delivery requirements

Electro-hydraulic valve air actuation – hydraulic test rig

• Design and build of hydraulic test rig • Matlab/Simulink models with experimental monitor of valve performance • HIL operation/XPC target closed loop observer control • Mechanical design and physical integration of displacement and pressure

sensors

Electro-hydraulic valve air actuation

Preliminary experimental results – pressure manifold

Target Valve Lift Profile against LVDT Signal

-0.3

-0.2

-0.1

0

0.1

0.2

0.3

0

2

4

6

8

10

12

0 0.01 0.02 0.03 0.04

Cu

rren

t (A

)

Lift

(m

m)

- En

gin

e Sp

eed

(x1

00

0rp

m)

Time (s)

Desired Lift (mm) Simulation Lift (mm)

LVDT(mm) Current Monitoring (A)

-40

-30

-20

-10

0

10

20

30

40

50

0

1

2

3

4

5

6

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8

9

10

0 0.01 0.02 0.03 0.04 0.05

Pre

ssu

re (

Bar

)

Lift

(m

m)

Time (s)

LVDT(mm) Bottom Pressure (bar) Top Pressure (bar)Instantaneous

pressure

Bosch HDEV4 (Piezo, 200 bar, 40 cc/s)

Piezoelectric air injection - Ambient Rig Experiments

Air motion study

Quiescent environment; seeded air (powder suspended in chamber a priori to injection)

Injector clamp Spray chamber (MK1) with injector

Ambient Rig Experiments (air injector concept)

Vortex ring-like structures observed in gas phase after

air injection impulse

Flow direction

Piezoelectric air injection into crossflow

Simulation - Numerical modelling (CFD)

• Air filling parametric study

• Conventional poppet valve into combustion chamber geometry • Air jet injection into quiescent chamber

• Vortex ring study (promote turbulent mixing). Injection into quiescent chamber


• Air filling parametric study • Conventional poppet valve into combustion chamber geometry

Velocity vectors

Example at 6.0 bar inlet pressure

Pressure contours


• Air filling parametric study • Air jet injection into quiescent chamber – ‘large nozzle’ • Mixing study – vortex rings

• Examples at inlet boundary condition: injection nozzle – straight narrow jet

• Inlet gas pressure: 10 bar / chamber region: 1 bar

M = 1

Sonic flow at ‘throat’

Inlet diameter = 200 microns; Length = 5.5 mm

Turbulent premixed and partially premixed combustion regimes

• Split cycle concept necessitates rapid mixture preparation and combustion • Turbulent flame speed dependent on local flow conditions/mixture composition

Borghi diagram for flame regime • Requires

characteristics of turbulent flow field

• Determined from historical data from GDI and HCCI studies

• Estimates of Da number:

Turbulent premixed and partially premixed combustion regimes

• Lean combustion

• Slow and incomplete away from stoichiometric optimum • Therefore requirement to increase overall combustion rate • Accurate measurement of turbulence and chemical scales required • Borghi diagram first estimate of required turnover/chemical reaction scales

• Conceptual combustion in 2-stages: • Initiate local flame in stoichiometric pre-chamber • Flame jet from chamber to ignite overall lean mixture in main chamber • Suitable for split cycle concept • Combustion pocket in piston crown • High compression ratio lends itself to HCCI

Mechanical design overview

• Brainstorming concepts • Specification of test stand • Donor engine carry-over • Sensors, instrumentation, synchronisation and control hardware • CAD models • Prototype modular cylinder head for combustor • Integration of fuel / air injectors and spark ignition within high CR geometry • Preservation of convective mean flow /augmentation of turbulence intensity • Design and manufacture of prototype parts • Commissioning and dry build • Control and data acquisition • Integration of 4 independent EHV units

Research Engine Facility

Hydra single-cylinder research Engine

3WH Research Cylinder Head

Concept combustion system for HEV SC-SI engine

Academic, research and technical staff at UOB

Steven Begg, Sharon Gunde,

David Mason, Elena Sazhina, Daniel Coren,

Miltos Petridis, Morgan Heikal, Nicolas Miché,

Aidan Delaney, Andrew Fish,

Oyuna Rybdylova, Guillaume De Sercey,

Peter Rayner, Brian Maggs, Ken Maris,

Jon Armory, Mario Palermo, Tony Brown

Graduate students at UOB

Post-doc/MSc/MEng/BEng/exchange/STEM Nuffield students

Patrick Chakanyuka, David Harrison,

Larissa Taylor, Donato Pirozzi

Dimitrios Papathanasiou, Sam Callaghan,

CJ Karun, Mark Mawhinney,

Adrien Oger, Tiago Carvalho,

Adil Karakayis, Arnaud Christen,

Marina del Panta, Tasos Karmas,

Omar Jarrar, Khaled Alhajeri

INTERREG IVA Programme

CEREEV partners

EPSRC

University of Cardiff (Prof. P. Bowen, Dr M. Alonso and Dr P. Kay)

Ricardo UK, Suzuki, Toyota, Honda

DTI/TSB 2/4 SIGHT and 2/4 CAR programmes

Staff and students of the School of Computing, Engineering and Mathematics, School

of Pharmacy and Applied Biological Sciences

A Combustion Engine for a Range Extended Hybrid Electric Vehicle

Steven Begg Experimental Fluid Mechanics Group (EFMRG)

University of Brighton

Presentation Agenda

• Overview of Project and Work Packages

• Thermodynamics of a Split-Cycle Engine Concept

• Air-Filling Process in Split-Cycle Engines: A Parametric Study by CFD

• Mechanical Engineering Design of a Split-Cycle Combustor

• Modelling, Control and Observation of Electrohydraulic Valves

a combustion engine for a range extended hybrid electric...

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