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Institute of Internal Combustion Engines 245

Institute of Internal Combustion Engines

Engine design and simulation, combustion technologies, and experimental evaluation

Prof. Dr.-Ing. Georg Wachtmeister

Combustion Technologies – CFD Simulation – Emission Reduction – Injection Technology

The reduction of engine emissions and fuel consumption are drivers for the improvement of combustion technology. Engines for gasoline, diesel, and natural gas are developed and built at the institute and are available for industrial or public funded research projects. A key com-petence for the realization of our engine concepts is the application of professional CFD simulation software, which is used to predict and optimize the gas exchange phase, in-cylinder swirl, tumble or turbu-lence, and the phases of fuel injection, mixture formation, and combustion. Simu-

n The focus of the Instiute of Internal Combustion Engines in 2015 was to connect theoretical and experimental methods of thermodynamic research on combustion processes. Optical measurement techniques are a powerful way of visualizing gas flow, fuel injection and combustion inside the cylinder of an engine. High temperatures and pressures are challenges for the construction of optically accessible engines.

A highlight was the completion and first operation of a new 5 l single cylinder re -search engine with full optical accessibility through the piston bowl. The engine offers insight to modern combustion systems for gas and industrial engines. The results are used to validate CFD calculations of gas flow, injection, and combustion in order to predict the in-cylinder processes. This helps to save time and costs for future developments.

[email protected] +49.89.289.24101

Contact

LVK 5 l optical single cylinder gas engine

lation results are used to design improved geometries of the combustion chamber or injector nozzles and are then validated on one of our 13 engine test benches. Engine out emissions are measured by means of up-to-date FTIR technology and a modern particle counting system. We use component test benches to evaluate hydraulic behaviour and spray parameters of fuel injectors. Simulative and experimental tools allow fast and effective optimization of both emission behaviour and engine efficiency. Test runs on the research engines are planned and evaluated with statistical methods (design of experiments, DOE) to reduce time and costs for the testing procedure.

Projectsn FNR project ‘CH4 Emissionen’n FVV project ‘THC Emissionen’n BMWi project ‘METHODIK’n Several projects funded by industry

partners

CFD calculation of prechamber engine

246 Institute of Internal Combustion Engines

Injection Systems – Spray Measurement – Optical Researches

In the past decades the injection pressure of modern diesel engines rose from 1000 bar up to 3000 bar. Our research activities includes all steps of injection system development. Key competences are vari-ous simulations containing 1-D hydraulic, 3-D multiphase flow as well as spray simulation. Furthermore, at several test benches hydraulic and optical measure-ments of injectors with various fuels could be carried out. One of the current projects is focusing on the hydraulic behavior of orifices in injection systems to validate simulation results. Part of the project is the development of a hydraulic test bench including measurement techniques to investigate the high dynamic fluid flow properties in combination with cavitation and thermal effects. The main target is to analyse hydraulic elements by using innovative measurement techniques and gain information about physical effects to

optimize the design of future injection sys-tems. Furthermore an open-loop control is under development in collaboration with the Institute of Applied Mechanics whose aim is to maintain an optimal injection rate throughout the entire lifetime of a common- rail injector subjected to coking, wear etc. For this purpose, different injector signals are evaluated in order to be able to determine the injection rate by an indirect signal in engine operation.

Projectsn BFS project ‘Messung und Berechnung

des Düsendurchflusses’n DFG project ‘Optimierung des Ein-

spritzverhaltens von Dieselinjektoren unter dem Einfluss von Alterungser-scheinungen des Injektors’

n Several projects funded by industry partners

Nozzle flow simulation

Mie-light measurement

Natural Gas Engines – Combustion – Emissions – Simulation

Engine of combined heat and power unit for biogas

Utilization of natural gas can be one step to cope with future energy demand. Surplus energy from renewable sources can be stored as hydrogen or methane. Further development is needed to fulfill future emission legislation with high efficiency combustion. Former research at the institute has dealt with phenomena modeling of the combus-tion for different ignition systems, like open-chamber, scavenged prechamber or diesel pilot-injection. Further research projects have the focus on emissions of unburned hydrocarbons like methane or formaldehyde. The goal is to understand the influence of engine parameters like valve timing, ignition, equivalence ratio and gas quality. Alternative combustion processes are another focus to overcome the trade-off between emissions and effi-ciency. Stratified or diesel-like combustion processes are promising techniques and could allow highest loads without restric-


tions from knocking while keeping lowest emission levels and highest efficiency with highly volatile gas qualities. To promote the development, the research engine with 5 l displacement has been modified with an optical access to the combustion chamber. Combined with CFD-Simulations a deep insight in the combustion process is now possible. Projectsn FVV project ‘Formaldehyd’n FVV project ‘Mitteldruck 30 bar bei

Gasmotoren’

n BFS project ‘Effizienzsteigerung von Dual-Fuel Motoren durch Optimierung der Zündung bei effektiven Mitteldrü-cken über 24 bar’

n BMWi project ‘Flex DI: Flexible direkt-einspritzende Motoren für die Schiff-fahrt’

n BStmW project ‘Optimierter Verbren-nungsmotor für landwirtschaftliche Biogas Mini-BHKW’

n EU project ‘HERCULES 2’n Several projects funded by industry

partners

Alternative Fuels – Emission Measurement – Energy Management

Fossil fuels are becoming more and more scarce and European CO2 saving policies have been introduced to fight global warming. Combustion engines can reduce their output of GHG emissions and contribute to the transition towards alter-native energy by enhancing the efficiency of energy conversion and by exploiting CO2 neutral primary energies. Sustainable biofuels and synthetic fuels can replace fossil fuels and offer the additional benefit of clean combustion. A detailed screening of various oxygen-containing synthetic fuels was carried out at the institute and oxymethylene ether (OME1) was found to burn without particle emissions in a diesel engine even under unfavourable operating conditions. Modern methods for the mea-surement of ultra-low particle emissions are needed for this and other advanced engine concepts. Cooperating closely with the industry, we help to improve such measurement techniques. Another field of our research is the utilisation of thermo-dynamic losses from coolant or exhaust. The thermodynamic Rankine cycle for instance allows to harvest enthalpy from hot exhaust gas and to produce electric power by means of a steam turbine.

Projectsn BMWi project ‘XME Diesel – (Bio-)

Methylether als alternative Kraftstoffe in bivalenten Dieselmotoren’

n FNR project ‘OME – Umweltfreundliche Dieselkraftstoffadditive’

n BMWi project ‘TruckER – Rankine Kreislauf für Nutzfahrzeuge mit ganz-heitlichem Energiemanagement’


Test bench with heavy-duty single cylinder engine


Friction Measurement – Tribology – Engine Mechanics

Reducing piston assembly friction is a central issue of improving the efficiency of modern internal combustion engines. Piston, piston rings, liner and lubricating oil form a complex tribological system operating in a field of constantly alterna-ting velocities, pressures, and tempera-tures. Therefore a special re search engine containing a measurement device using the floating liner method was developed at the institute. It allows measurement of the piston assembly friction with a highly accurate resolution up to 2 N under fired conditions. That enables the detection of optimization potential by experimental analysis. A second research engine was built up, containing several sensors to measure crank-angle resolved motions of the piston and the piston rings. Further-more the oil film thickness and oil trans-portation phenomena are measured during fired engine operation. The mea surement results of both engines establish a deeper understanding of the behavior and depen-dencies in the tribological system.

Projectsn FVV/AiF project ‘Kolbenring-Öltrans-

port I’n FVV project ‘Kolbenring-Öltransport II’n DFG project ‘Entwicklung eines kosten-

u. verbrauchsgünstigen Split-Verbren-nungsmotors’


Split-crankshaft engine reduces friction losses

Research Focusn Combustion technologiesn Gas enginesn Friction measurementn Fuel injection technologiesn Alternative fuels and biofuelsn Exhaust gas aftertreatment and

measurement

Competencen CAD constructionn CFD calculationn Thermodynamic simulationsn Hydraulic simulationsn Mechanical simulationsn Engine measurement techniques

Infrastructuren Engine test rigs (13)n Gasoline, diesel and gas engines (>15)n Injection test rigs (2)n Optical and laser diagnosticsn Mechanical workshopn Electronic workshop

Coursesn Combustion Enginesn Engine Thermodynamicsn Mechanics of Combustion Enginesn Methods of Engine Calibrationn Injection Technologyn Measurement Techniquesn Several practical courses


ManagementProf. Dr.-Ing. Georg WachtmeisterDr.-Ing. Maximillian PragerDipl.-Ing. Martin Härtl

Adjunct ProfessorsDr. Satoshi Kawauchi (since 04/14)

Administrativ StaffMarita Weiler Sonja Zeilhofer

Research ScientistsDipl.-Ing. Fabian BackesDipl.-Ing. Laura BaumgartnerDipl.-Phys. Vinicius Berger (since 07/15)Dipl.-Ing. Yves ComperaStephanie Frankl, M.Sc. (since 02/15)Kai Gaukel, M.Sc. (since 04/15)Stephan Gleis, M.Sc.Dipl.-Ing. Stefan GrafDipl.-Ing. Johannes Halbhuber Stefan Held, M.Sc. (since 10/15)Dipl.-Ing. Benedikt von Imhoff (until 04/15)Stefan Karmann, M.Sc. (since 05/15)Dipl.-Ing. Claus KirnerDipl.-Ing. Christian Daniel KochDipl.-Ing. Benjamin KorbDipl.-Ing. Qixong Li (until 06/15)Dipl.-Phys. Thomas MaierMarkus Mühlthaler, M.Sc. (since 05/15)Dipl.-Ing. Alexander Oliva (until 06/15)Dipl.-Ing. Johann PeerDominik Pélerin, M.Sc.Dipl.-Ing. Christian Pötsch (until 04/15)Dipl.-Ing. Sebastian RöslerCarsten Schneider, M.Sc.Dipl.-Ing. Alexander SchröderDipl.-Ing. Sebastian SchuckertDipl.-Ing. Fabian SchweizerAndreas Stadler, M.Sc. (since 10/15)Dipl.-Ing. Richard StegmannDipl.-Ing. Benedict UhligMaximilian Weber, M.Sc. (since 12/15)Dipl.-Ing. Stefan WeberDipl.-Ing. Thomas Zimmer (until 06/15)Sebastian Zirngibl, M.Sc.

Technical StaffDipl.-Ing. Frank Bär Martin DanielDipl.-Ing. Christian Hödl Alex Link, M.Sc. (since 11/15)Kai Möbius (since 11/15)Patrick OttigerJohann Schuster Ferdinand Springer Werner Straßer Edgar ThieleDipl.-Ing. Ulrich TetznerMarkus Weiß

TraineesPhilipp HellFabiano Palfner da Paz


Publications 2015

n Kuratorium für Technik und Bauwesen in der Landwirtschaft e.V. (KTBL): Emissionen beim flexiblen Betrieb von Biogas-BHKW. 978-3-945088-07-4. Kuratorium für Technik und Bauwesen in der Landwirtschaft e.V. (KTBL)

n Baumgartner, L.S.; Wohlgemuth, S.; Zirngibl, S.; Wachtmeister, G.: Investigation of a Methane Scavenged Prechamber for Increased Efficiency of a Lean-Burn Natural Gas Engine for Automotive Applications. SAE Int. J. Engines 8 (2) 2015 and SAE Technical Paper 2015-01-0866

n Benjamin Korb, Kalyan Kuppa, Friedrich Dinkel-acker, Georg Wachtmeister: THC-Emissions in Gas Engines – Experimental and Numerical Studies. 15. Tagung “Der Arbeitsprozess des Verbrennungs-motors”

n Härtl, Martin; Seidenspinner, Philipp; Jacob, Eber-hard; Wachtmeister, Georg: Oxygenate screening on a heavy-duty diesel engine and emission characteristics of highly oxygenated oxymethylene ether fuel OME1. Fuel 153, 2015, 328-335

n von Imhoff, B.; Zweck, J.; Wachtmeister, G.,: Detection of Stationary Operating States of Internal Combustion Engines. SAE Technical Paper 2015

n Johann Peer, Fabian Backes, Georg Wachtmeister: Engine Thermodynamics Research Hitachi & LVK; Project Year 03/2014 – 03/2015. Hitachi Europe GmbH

n Kawauchi, S.; Korb, B.; Wachtmeister, G.: Einfluss des H2 Gehalts auf Betriebsverhalten, Wirkungs-grad und Emissionen von Erdgasmotoren mit Magerbrennverfahren bei hohen spezifischen Lasten. 12te Tagung: Motorische Verbrennung – Aktuelle Probleme und moderne Lösungsansätze, 2015

n Kirner, C.; Uhlig, B.; Wachtmeister, G.; Behn, A.; Feindt, M.; Matz, G.: Abschlussbericht Kolben-ring-Öltransport 1. AiF/FVV

n Kirner, C.; Uhlig, B.; Wachtmeister, G.: 6. Projektbe-gleitender Ausschuss – Kolbenring-Öltransport 1. AiF/FVV

n Kirner, C.; Uhlig, B.; Wachtmeister, G.: 1. Projektbe-gleitender Ausschuss – Kolbenring-Öltransport 2. AiF/FVV

n Korb B.: 3. FNR-Zwischenbericht – Ursachen und Reduzierung der CH4-Emissionen in Biogasmoto-ren. Fachagentur Nachwachsende Rohstoffe, 2015

n Korb, B.: 6. FVV-Arbeitskreistreffen – Ursachen und Reduktionsmaßnahmen der THC-Emissionen in Gasmotoren. FVV-Arbeitskreistreffen

n Korb, B.: 5. FVV-Arbeitskreistreffen – Ursachen und Reduktionsmaßnahmen der THC-Emissionen in Gasmotoren. FVV-Arbeitskreistreffen

n Korb, B.; Gleis, S.: Auslegung und Entwicklung eines volloptischen Einzylinder-Großmotors mittels Ansys Workbench und einer vereinfachten FKM-Richtlinie. Ansys Conference & 33. CADFEM Users’ Meeting

n Korb, B.; Kawauchi, S.; Wachtmeister G.: Einfluss des H2 Gehalts auf das Brennverfahren von magerbetriebenen Erdgasmotoren im Hinblick auf heutige und zukünftige Emissionsgrenzwerte. 9th Dessau Gas Engine Conference

n Korb, Benjamin; Kawauchi, Satoshi; Wachtmeister, Georg: Influence of hydrogen addition on the operating range, emissions and efficiency in lean burn natural gas engines at high specific loads. Fuel 164, 2015, 410-418

n Li Q., Backes F., Wachtmeister G.,: Application of canola oil operation in a diesel engine with common rail system. Fuel 159

n Oliva, A.: Entwicklung einer Simulationsmethode zur Berechnung der auftretenden Phänomene im Ölsumpf. 8. Arbeitskreis Fuel in Oil

n Oliva, A., Held, S., Herdt, A., Wachtmeister, G.: Numerical simulation of the gas flow in the piston ring pack of an internal combustion engine. SAE Technical Paper

n Oliva, A., Wachtmeister, G.: Abschlussbericht Fuel in Oil – Teilprojekt S2: Entwicklung einer Simula-tionsmethode zur Berechnung der auftretenden Phänomene im Ölsumpf. FVV Frühjahrstagung

n Prager, M.; Korb, B.; Wachtmeister, G.: Emissionen beim flexiblen Einsatz von Biogas-BHKW. Biogas in der Landwirtschaft – Stand und Perspektiven

n Qixiong Li: Erfassung der grundlegenden Ablage-rungsbildungsmechanismen im rapsölbetriebenen Forschungsmotor mit anschließender Übertragung der Ergebnisse auf einen Vollmotor. Projektab-schlusstreffen

n Qixiong Li: FNR-Schlussbericht: Erfassung der grundlegenden Ablagerungsbildungsmechanis-men im rapsölbetriebenen Forschungsmotor mit anschließender Übertragung der Ergebnisse auf einen Vollmotor. Fachagentur Nachwachsende Rohstoffe, 2015

n Schneider, C.; Wachtmeister, G.; Klumpp, P., Halbhuber, J.: Improve Simulation of Plain Bearings in Dry and Mixed Lubrication Regime by Defining Locally Resolved Dry Friction Coefficients. Tribology in industry (37), 2015

n Schröder, A.; Wachtmeister, G.; Prager, M.: Poten-tiale in Brennverfahren und Abgasnachbehandlung zur Reduzierung der Formaldehydemissionen bei Magergasmotoren. 1. FVV-Arbeitskreis Formal-dehyd

n Seidenspinner, Philipp; Härtl, Martin; Wilharm, Thomas; Wachtmeister, Georg: Cetane Number Determination by Advanced Fuel Ignition Delay Analysis in a New Constant Volume Combustion Chamber. SAE Technical Paper

n Stegmann, R., Wachtmeister, G.: Messung und Berechnung des realistischen Düsen- und Drosseldurchflusses und der Temperaturen in engen Spalten – 1. Jahreszwischenbericht. Bayrische Forschungsstiftung, 2015

n Yves Compera: Projekttreffen 5 zum Förderprojekt METHODIK. LVK, TUM

n Yves Compera: 4. Projekttreffen zum Förderprojekt METHODIK – Entwicklung einer Simulationsme-thode zur Vorausberechnung des Brennverlaufs. LVK, TUM

n Zirngibl, S.; Wachtmeister, G.; Prager, M.: 2. Arbeitskreis – Optimierter Verbrennungsmotor für landwirtschaftliche Biogas Mini-BHKW. Bay.-StM-WI-Arbeitskreistreffen

n Zirngibl, S.; Wachtmeister, G.; Prager, M.: 3. Arbeitskreis – Optimierter Verbrennungsmotor für landwirtschaftliche Biogas Mini-BHKW. Bay.-StM-WI-Arbeitskreistreffen

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