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The research work presented in this thesis is concerned with an investigation of fuel management of diesel engines for the purposes of developing control schemes to improve fuel consumption, exhaust emissions and engine controllability.

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The work presented in this thesis details a novel engine evaluation approach utilising real-time simulation and advanced engine testing systems for general applicability to new generations of air charging systems. A novel engine air charging system including a charge air handling unit (CAHU) has been developed which is connected to an engine to emulate advanced boosting system conditions. Significant analytical and development work has focused on generating a real-time turbocharger model such that the CAHU can be effectively controlled to emulate the turbocharger performance under both steady and pulsating conditions. Experimental work was carried out to evaluate this new engine air charge testing system against a production turbocharged baseline engine. The accuracies with respect to the boost pressure, turbocharger speed, mass air flow, and fuel consumption in the steady state tests are above 95%, and the level of confidence for the engine back pressure is approximately 90%. The difference of turbocharger speed between the steady turbocharger model and the pulsation model is also identified. In engine transient tests, the boost pressure and engine torque have shown fast response characteristics similar to that of the baseline engine. While general transient trends were achieved, some issues were identified with the high speed control of the CAHU interacting with the dSPACE real time turbocharger model. It is proposed that future improvement can be achieved via applying new control algorithms to improve the accuracy and tracking the CAHU control without increasing the system instabilities.

Este trabalho buscou estudar os efeitos do nível de Swirl e alteração da massa de combustível injetada nas emissões de poluentes de um motor Diesel. Foram selecionados 15 cabeçotes de uma população de 100 cabeçotes e agrupados pelo nível de Swirl. Como o motor testado utiliza 5 cabeçotes, 15 cabeçotes foram separados e classificados em 3 categorias pelo nível de Swirl. Em seguida, o motor foi montado com as 3 categorias de cabeçotes no dinamômetro com o objetivo de levantar os efeitos nas emissões de gases e parâmetros de desempenho do motor. Foram medidas as emissões de NOx, CO, THC, fuligem, fumaça e consumo de combustível nos 13 pontos do ciclo ESC, complementadas com medições de torque e potência à plena carga. Além disso, nas condições de plena carga foi explorado o efeito da alteração da massa de combustível injetado, pela mudança do ponto final de injeção, nos parâmetros de desempenho e emissões. / This work aimed at the investigation of the effects of the level of Swirl and the amount of fuel mass injected in the emissions of pollutants on a diesel engine. Cylinder heads were selected from a population of 100 cylinder heads and them grouped by Swirl level. As the engine used in the tests have 5 cylinder heads, 15 cylinder heads were separated into 3 categories by the Swirl level. The engine was mounted with the 3 Swirl level cylinder heads categories with the aim to investigate all effects on emissions and performance such as NOx, CO, THC, soot, smoke, fuel consumption, power and torque. The tests were performed following the ESC cycle and exploring the full load curve behavior with changes of the end of injection point, therefore altering the amount of fuel mass injected.

Este trabalho buscou estudar os efeitos do nível de Swirl e alteração da massa de combustível injetada nas emissões de poluentes de um motor Diesel. Foram selecionados 15 cabeçotes de uma população de 100 cabeçotes e agrupados pelo nível de Swirl. Como o motor testado utiliza 5 cabeçotes, 15 cabeçotes foram separados e classificados em 3 categorias pelo nível de Swirl. Em seguida, o motor foi montado com as 3 categorias de cabeçotes no dinamômetro com o objetivo de levantar os efeitos nas emissões de gases e parâmetros de desempenho do motor. Foram medidas as emissões de NOx, CO, THC, fuligem, fumaça e consumo de combustível nos 13 pontos do ciclo ESC, complementadas com medições de torque e potência à plena carga. Além disso, nas condições de plena carga foi explorado o efeito da alteração da massa de combustível injetado, pela mudança do ponto final de injeção, nos parâmetros de desempenho e emissões. / This work aimed at the investigation of the effects of the level of Swirl and the amount of fuel mass injected in the emissions of pollutants on a diesel engine. Cylinder heads were selected from a population of 100 cylinder heads and them grouped by Swirl level. As the engine used in the tests have 5 cylinder heads, 15 cylinder heads were separated into 3 categories by the Swirl level. The engine was mounted with the 3 Swirl level cylinder heads categories with the aim to investigate all effects on emissions and performance such as NOx, CO, THC, soot, smoke, fuel consumption, power and torque. The tests were performed following the ESC cycle and exploring the full load curve behavior with changes of the end of injection point, therefore altering the amount of fuel mass injected.

<p>To fulfil emission requirements specified by environment demands, such as Euro 4 and Euro 5, there is a need to utilize engines based on technologies such as Variable Turbine Geometry (VGT) and Exhaust Gas Recirculation (EGR). A model of an engine using VGT and EGR was created by Ph.D student Johan Wahlström at Linköping University. This thesis evaluates Wahlström's model and shows how it successfully describes the engine and its behaviour. The thesis also confirms theories about the occurrens of non.minimum phase behaviour in different transfer functions, e.g. from VGT signal to the mass flow through the compressor.</p><p>An interesting phenomenon when applying VGT and EGR is a nonlinearity leading to, for example, that the same pressure in the intake manifold can occur for two different VGT signals. Such phenomenon can cause problems when designing a control system. Furthermore, this nonlinearity also results in a replacement of the nonminimum phase behaviour with an overshoot when a large (above 80%) VGT control signal is used.</p><p>This thesis also provides a linearized model, which describes the engine satisfactory. The linearization results in transfer functions with two zeros and three poles, whose locations do not change much when varying engine speed and load (except at high load and low engine speed). This fact will most likely make it possible to utilize just a few different linearizations for all speeds and loads. However, altering VGT and EGR positions greatly affect the transfer functions. Thus, several linearizations are probably needed to cover all operating points.</p><p>When designing a future control system a good strategy is to utilize a decoupled system since the model has strong cross-connections. Another solution would be to apply multi dimensional control strategy, e.g. LQ-theory.</p>

Manufacturers face the challenge of enhancing fuel efficiency, engine performance, and reducing harmful emissions. Novel fuel injection technologies can assist in meeting such demands. This dissertation summarizes the stages in the design, prototyping and experimental analysis of a direct-acting piezoelectric fuel injector concept. In the proposed design, a piezoelectric stack actuator is used to directly control the injection of fuel in order to enhance the injection characteristics by utilizing the fast response time of the actuator. The direct-acting concept was implemented by developing a motion inverter in the form of a disc that reverses the direction of the input and allows the actuator to directly control injections. Tests with input signals similar to those used in diesel engines confirmed the theoretical calculations and verified the prototype’s performance. This design can control the quantity of injected fuel more precisely than currently available commercial injectors.