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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME 494 SIMULATION AND OPTIMIZATION OF HSDI DIESEL ENGINE FOR SUV TO MEET BHARAT 4 EMISSION NORMS IN INDIA Pundlik R. Ghodke 1 , Dr. J. G. Suryawanshi 2 *(Research Scholar, VNIT Nagpur / DGM Mahindra Research Valley, Chennai, India) Email: [email protected]/[email protected] m) **(Associate Professor, Mechanical Engineering Department, VNIT, Nagpur, India) Email: [email protected] ) : ABSTRACT Direct injection diesel engine offers Performance and fuel economy benefit. Use of performance prediction software helps to reduce engine optimization time, reduces effort and cost of development. In the present work, base engine performance prediction was done by use AVL Boost software. This Model was validated by actual engine test results. This model is used for parametric study for further performance prediction. AVL Cruise software was used to predict 14 modes steady state speed-load point’s engine of Bharat stage 4 emission test cycle. These 14 modes were used for emission optimization on engine test bed. Design of experiment technique was used for emission optimization. INCA base CAMEO software is used for optimizing combustion parameters. Xcel base program was developed for comparing engine out hot emissions to chassis dynamometer vehicle hot emissions. This technique of emission development reduces engine and vehicle emission development time. Keywards : BSFC, BMEP, CO, DOC, EGR, SUV I. INTRODUCTION Diesel engine performance and emission development is need in current automobile industry due to future stringent emission norms, noise and CO2 norms. India has adapted partially European norms with emission limit same but modified test cycle with limited maximum speed from 120 kilometer per hour to 90 kilometer per hour. Bharat stage emission norms based on Indian road conditions. In present work, engine performance development and vehicle emission development were done for Bharat stage 4 norms which were introduced in metros and major cities of India from April 2010 onward .Rest of India still follows Bharat stage3 norms. To reduce emission development INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING AND TECHNOLOGY (IJMET) ISSN 0976 – 6340 (Print) ISSN 0976 – 6359 (Online) Volume 3, Issue 2, May-August (2012), pp. 494-510 © IAEME: www.iaeme.com/ijmet.html Journal Impact Factor (2012): 3.8071 (Calculated by GISI) www.jifactor.com IJMET © I A E M E

51 SIMULATION AND OPTIMIZATION OF HSDI DIESEL ENGINE … AND OPTIMI… · SIMULATION AND OPTIMIZATION OF HSDI DIESEL ENGINE FOR SUV TO MEET BHARAT 4 EMISSION NORMS IN INDIA Pundlik

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

494

SIMULATION AND OPTIMIZATION OF HSDI DIESEL ENGINE FOR

SUV TO MEET BHARAT 4 EMISSION NORMS IN INDIA

Pundlik R. Ghodke1 , Dr. J. G. Suryawanshi

2

*(Research Scholar, VNIT Nagpur / DGM Mahindra Research Valley, Chennai, India)

Email: [email protected]/[email protected]) **(Associate Professor, Mechanical Engineering Department, VNIT, Nagpur, India)

Email: [email protected] ):

ABSTRACT

Direct injection diesel engine offers Performance and fuel economy benefit. Use of performance

prediction software helps to reduce engine optimization time, reduces effort and cost of

development.

In the present work, base engine performance prediction was done by use AVL Boost software.

This Model was validated by actual engine test results. This model is used for parametric study

for further performance prediction. AVL Cruise software was used to predict 14 modes steady

state speed-load point’s engine of Bharat stage 4 emission test cycle. These 14 modes were used

for emission optimization on engine test bed. Design of experiment technique was used for

emission optimization. INCA base CAMEO software is used for optimizing combustion

parameters. Xcel base program was developed for comparing engine out hot emissions to chassis

dynamometer vehicle hot emissions. This technique of emission development reduces

engine and vehicle emission development time.

Keywards : BSFC, BMEP, CO, DOC, EGR, SUV

I. INTRODUCTION

Diesel engine performance and emission development is need in current automobile industry due

to future stringent emission norms, noise and CO2 norms. India has adapted partially European

norms with emission limit same but modified test cycle with limited maximum speed from 120

kilometer per hour to 90 kilometer per hour. Bharat stage emission norms based on Indian road

conditions.

In present work, engine performance development and vehicle emission development were done

for Bharat stage 4 norms which were introduced in metros and major cities of India from April

2010 onward .Rest of India still follows Bharat stage3 norms. To reduce emission development

INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING AND

TECHNOLOGY (IJMET)

ISSN 0976 – 6340 (Print)

ISSN 0976 – 6359 (Online)

Volume 3, Issue 2, May-August (2012), pp. 494-510

© IAEME: www.iaeme.com/ijmet.html

Journal Impact Factor (2012): 3.8071 (Calculated by GISI)

www.jifactor.com

IJMET

© I A E M E

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

495

time, [3] AVL BOOST simulation software was used to predict the engine performance before

prototype was built. To reduce emission development time on chassis dynamometer, AVL Cruise

software [4] were used for generating 14 steady mode points of engine speed and load condition

which represents actual emission test cycle when vehicle was tested on chassis dynamometer for

emission.

After engine was optimized for emissions at 14 mode point’s further test work was done on

vehicle tested in chassis dynamometer.

This methodology of test reduces major emission development time of chassis dynamometer.

In emission test cycle, engine operates at different speed and load points based on transmission

ratio and axle ratio, tyre radius and reference mass of vehicle. It became more complex to

optimize engine as whole on vehicle and meet emission. Hence a systematic approach was

developed to convert emission cycle in to 14 steady state key points with time weightage factor

by use of AVL Cruise software.

Engine performance was predicted by use of AVL Boost software before engine in existence.

Boost Model engine gives fair confidence of reaching desired engine performance before actual

testing of engine on dynamometer. With this engine Boost model parametric study was done to

access the desired engine full load performance.

Major performance development work was done on test bed by optimizing injection parameters

of common rail and selection of suitable hardware like piston bowl shape, turbocharger and EGR

with cooler.

Engine part load optimization, 14 mode points and smoothening of injection parameters were

done on test bed. Major parameters like EGR rate, injection timing pilot injection and were done

on steady state test bench.

Once base is established engine was fitted on vehicle and further work started on vehicle on

chassis dynamometer. During chassis dynamometer test EGR rate and oxidation catalytic

convertor loading was optimized to reach to desired emissions.

With this method it is possible to reduce the engine emission development time and reduce the

cost of testing.

II. ENGINE AND VEHICLE SPECIFICATION USED FOR

EXPERIMENETATION

Table 1 shows base engine and vehicle specification. Full load performance targets for power

upgrade to 103 kW rating and Bharat stage 4 emission targets were kept for development.

Table1: Engine and vehicle specification for experimental setup.

Engine Type

Base Engine specifications Upgraded Engine

specifications

2.2L, Inline, 4 cylinders, DOHC,

HSDI Diesel

2.2L, Inline, 4 cylinders,

DOHC, HSDI Diesel

Compression

Ratio 18.5 : 1 16.5: 1

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

496

Rated Power 88 kW 103 kW

Rated Speed 4000 rpm 3750 rpm

Injection System Common Rail, Bosch Gen 2 Common Rail, Bosch Gen 2

Air System VGT Gen 2 Turbocharger Gen 3.5 ‘S’ vane VGT

Turbocharger

Emission Bharat stage 3 Bharat stage 4

Vehicle

specifications SUV SUV

Gearbox Manual Transmission with 5

forward+ 1 backward

Manual transmission with 5

speed + 1backward

Axle ratio 4.1 4.1

Rolling radius 0.331 m 0.331 m

III. METHODOLOGY

Following methodology was followed during performance and emission upgrade of engine and

vehicle to meet Bharat stage 4 emission norms.

3.1 Thermodynamic Engine model by use of AVL Boost software for simulation and

validating it with base engine.

3.2 Parametric study on Engine model by use of AVL Boost software to predict engine full

load performance

3.3 Generation of steady state 14 mode speed- load points and its weightage factor by using

AVL Cruise simulation software

3.4 Full load Performance development and testing of engine on steady state test bench

3.5 Hot emission development on engine for steady state test bench as per 14 mode speed

load- points.

3.6 Optimizing vehicle for hot emission on chassis dynamometer and verification with

engine dynamometer 14 mode point results.

After successful correlation of hot emission on engine and vehicle, cold correction were applied

and best practice in industry was followed for further vehicle calibration work. Like summer,

winter calibration and drivability and comfort functions etc which were not taken in the present

work scope of this paper.

3.1 Thermodynamic Engine simulation model by use of AVL BOOST software

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976

0976 – 6359(Online) Volume 3, Issue 2, May

Base engine simulation model was

Performance output of the model was compared and

This validated Boost model was

performance target of 103kW.

parametric study and full load performance prediction

Fig. 1: AVL Boost model for experimental engine

During developments of boost model,

to design and thermal boundary condition

155 bar. Maximum exhaust gas

material constraint. Engine Oil temperature

speed was allowed up to 2,10,0000 rpm.

Engine noise target were kept to

speed was constrained to 4750 rpm based on design and operating limit of engine valve train.

3.2 Parametric study on AVL Boost

Engine full load performance was

4000 rpm keeping boundary condition of cylinder pressure of 155 bar maximum.

Full load comparison of Boost simulated results with actual

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100

120

1000

Po

wer,

kW

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –

6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

497

was generated on computer by use of AVL Boost software

of the model was compared and validated with base engine performance.

used for parametric study to predict the desired

Figure 1 shows AVL Boost model of Engine model used for

parametric study and full load performance prediction.

AVL Boost model for experimental engine

developments of boost model, following practical boundary conditions were imposed

boundary conditions of engine. Engine cylinder pressure was

as temperature was limited to 760 deg C based on turbocharger

. Engine Oil temperature was allowed up to 130 deg C. Max

,0000 rpm. Pressure before turbocharger was limited

kept to 97 dBA at full load and full speed. Maximum

4750 rpm based on design and operating limit of engine valve train.

AVL Boost Engine Model

was predicted for entire speed- load condition from 1000 rpm to

keeping boundary condition of cylinder pressure of 155 bar maximum.

comparison of Boost simulated results with actual engine tested result of engine.

1500 2000 2500 3000 3500 4000

Engine speed, rpm

Actual

Tested

Simulated

– 6340(Print), ISSN

ter by use of AVL Boost software [3].

ine performance.

the desired engine full load

Figure 1 shows AVL Boost model of Engine model used for

following practical boundary conditions were imposed due

was limited up to

760 deg C based on turbocharger

to 130 deg C. Maximum Turbine

was limited 2300 mbar.

allowable engine

4750 rpm based on design and operating limit of engine valve train.

from 1000 rpm to

keeping boundary condition of cylinder pressure of 155 bar maximum. Figure 2 shows

tested result of engine.

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

498

Fig. 2: Engine Full load performance comparison of simulated and actual tested results.

.

Figure 3 shows Predicted engine torque and actual engine tested results which were matching

96% to actual tested results. Actual test results are slightly lower to the fact that turbocharger air

flow was observed lower in actual engine.

Fig. 3: Engine Torque comparison of Actual tested and simulated results.

Figure 4 shows Brake specific fuel consumption of actual tested engine and simulated results

from AVL Boost model. Simulated results were matching with actual test results. In all speed

actual results are slightly higher that predicted result due to simplified assumption made in boost

model.

Fig. 4: Engine power and BSFC Vs engine speed of actual tested and simulated results.

Figure 5 shows simulated results and actual tested results of engine at different engine full load

operating speed. Simulated results showing higher temperature than actual except at 4000 rpm.

This is possible due to fact that simplified assumptions done in boost combustion model. Hence

results were not closer to actual test results.

0

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1000 1500 2000 2500 3000 3500 4000

Engine speed, Rpm

TO

RQ

UE

Actual Tested

By Simulation

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170

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210

230

250

270

290

1000 1500 2000 2500 3000 3500 4000

Engine speed,rmp

BSFC

g/k

wh

r

Actual

testedSimulated,

BSFC

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

499

Fig. 5: Exhaust temperature Vs engine speed comparison of actual tested and simulated results

Figure 6 shows the combustion noise comparison of boost simulated results and actual tested

engine. Boost result were matching and lower engine speed and at higher speed above 2000 rpm

actual engine combustion noise was lower than boost simulated results by around 3 dBA.

Fig. 6: Combustion Noise comparison of actual tested engine and Boost simulated results.

Predicted cylinder pressure was compared with actual testing and is close agreement with actual

tested result based on optimized combustion parameters

Fig. 7: Combustion Noise comparison of actual tested engine and Boost simulated results.

3.3 Generation of 14 mode steady state points for hot emission development on Engine

dynamometer by use of AVL Cruise software

400

450

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1000 1500 2000 2500 3000 3500 4000Engine speed,rpm

Exh

uast

TEM

P ,

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g C

Actual Tested

By simulation

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1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750

NO

ISE

DB

A

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COMBUSTION NOISE ACTUAL VS SIMULATED

NOISE ACTUAL NOISE SIMULATED

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1000 1500 2000 2500 3000 3500 4000

Engine speed, rpm

Cyl

ind

er

Pre

ssu

re,B

ar

Actual Tested

By Simulation

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976

0976 – 6359(Online) Volume 3, Issue 2, May

New approach was suggested in this work .T

mode steady state speed-points with time

Excel base program was developed for conver

kilometer. Table 2 and figure 8

points generated by use of AVL cruise software.

Fig. 8: AVL Cruise prediction for

Table 2: Steady state 14 mode points

3.4. Full load Performance development of engine on test bed

Experiments were conducted on

equipped with Horiba 7100 D emission analyzers, Smart sampler, Cameo and INCA interface

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –

6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

500

in this work .Transient emission cycle was converted in

points with time weightage factor by use of AVL Cruise software

developed for conversion of engine out raw emission

shows engine speed, BMEP, percentage weightage of 14 mode

points generated by use of AVL cruise software.

prediction for 14 steady state mode speed-load points.

Table 2: Steady state 14 mode points for engine testing on test bed

l load Performance development of engine on test bed

Experiments were conducted on engine mounted on AVL make Hi Dynamic Test

equipped with Horiba 7100 D emission analyzers, Smart sampler, Cameo and INCA interface

– 6340(Print), ISSN

converted in to 14

weightage factor by use of AVL Cruise software [4].

PPM to gram per

age weightage of 14 mode

points.

for engine testing on test bed

Dynamic Test Bench

equipped with Horiba 7100 D emission analyzers, Smart sampler, Cameo and INCA interface

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

501

and hi speed data acquisition system for real time measurements all temperatures , pressures and

flows measurements. AVL Indi master for measurement of heat release and cylinder pressure

measurements. Figure 9 show test bed setup used for Experiment.

Fig. 9: Test bench setup for Experiment

Following design were modified in base engine to meet full load performance requirement. [1]

Piston with re-entrant bowl with new shape with more cavity volume and depth to modify

compression ratio from 18.5 to 16.5. To meet power demand, variable geometry turbocharger

(VGT) with straight vanes were replaced with ‘S’ shape vane, VGT turbocharger to meet higher

air flow requirement.[2] EGR cooler was used to cool exhaust gas and supply of cooled EGR to

ensure control NOX emissions and particulate trade off at part load condition without increase in

smoke and particulates. Bosch Generation 2 common rail fuel injection system is kept same.

Injector hydraulic through flow and spray cone angle is redesigned to suit new modified

combustion bowl. Injector protrusion is re-optimized to suit new combustion chamber design [5,

6]. Glow plugs were introduced compulsory as starting aid to minimize the effect of compression

ratio on start ability at cold conditions. Figure 9 shows comparison of engine power and Torque

achieved with respect to baseline performance.

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

502

Fig. 9: Full load power and torque curve comparison of base engine and upgraded engine

Figure 10 shows the pilot injection strategies used in optimization of full load performance of

engine at various speeds. Advantages of using pilot injection help in engine NVH characteristic

of engine and increase in power output of engine due to premixed combustion.

Fig.: 10: Main injection and Two pilot injection strategies for full load performance and emission

optimization.

3.5 Hot Emission development on Engine dynamometer

Engine was run-in and oil temperature was stabilized to 90 Deg C and coolant temperature to

97dec C. Engine is operated at each speed and load and row engine out emission were recorded.

These emissions were fed to excel sheet where program is developed to convert engine out

emission from ppm or g/hr to g/km and compared with the limit value of Bharat stage 4 emission

regulations. Design of experiments were conducted to optimize each point by varying the

0

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Upgraded toruebase torqueupgraded powerbase power

Torque

power

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

503

injection parameters like injection timing, injection pressure, pilot quantity, EGR rate, pilot

separation and different boost pressures to get optimized NOx-smoke trade-off and CO , HC

emission in control. AVL Cameo interfaced with common rail INCA software was used to run

engine with different operating points and optimum parameters were selected at each key points.

All optimized key points data was analyzed through excel base

program to check weather optimized results were close to legislation limits or not. By increasing

EGR rate PPM level of NOx was optimized. It was observed that smoke levels were drastically

increases when engine was optimized for Bharat stage 4 emission norms without EGR cooler.

EGR cooler was used with cooled EGR rate to control NOx and Smoke values to reach Bharat

stage 4 emission limits. Figure 10, 11, 12 and 13 shows engine out NOx, CO, HC and smoke at

14 mode points optimized from BS3 to BS4 emissions. Although CO and HC emissions were

more compared to BS3 were controlled by use of closed coupled DOC with higher platinum

loading and brought within the legislation limits.

Fig 10: Engine out NOx emission at 14 mode points

Fig 11: Engine out CO emissions at 14 mode points

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x,p

pm

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NOx,BSIV

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Mode

CO

,ppm

CO, BSIII

CO,BSIV

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

504

Fig 12 : Engine out HC emissions at 14 mode points

Fig 13: Engine out smoke at 14 mode points

Figure 14 and 15 shows various engine performance parameters for 14 mode points.

Fig 14: Cylinder pressure at 14 mode point

Fig 15: Exhaust temperature at 14 mode points

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C,p

pm

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oke

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BSIV

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p,

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C

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BSIV

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

505

Figure 16, 17, 18 and 19 shows main combustion and injection parameters.

Fig 16: Engine fueling at 14 mode points

Fig. 17: Pilot 1 and 2 quality at 14 mode points

Fig.18: Pilot 1 and 2 separation at 14 mode points

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pilot 2 BSIII

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976

0976 – 6359(Online) Volume 3, Issue 2, May

Fig. 19: Main injection timing at 14 mode points

Typically more pilot 2 quantity and separations

engine out NOx at these light load

engineering margins, optimized injection parameters of 14 key points are smoothened over entire

engine speed load condition to get smooth engine operation in terms of

points of view. After smoothening of injection parameters at entire engine speed load

again hot emission were taken to ensure that engine out emissions are still

targets. If not redo the optimization and smoothing till emissions reach within

targets. In actual conditions Bharat stage 4 emissions

cold start. This work were done by changing engine coolant and oil temperature at 40 Dec C on

test bed by applying cold corrections

3.6. Testing and optimizing hot emission on cha

dynamometer 14 key point results

Once Engine was optimized for 14 mode points and other part load points and smoothening of

injection parameters it was mounted on vehicle for

and hot emissions of chassis dynamometer

dynamometer with AVL make emission analyzers

Figure 20: Chassis dynamometer test

0

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1 2M

I, B

TD

C,

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –

6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

506

: Main injection timing at 14 mode points

and separations is required in mode 3 and more 8 to control the

light load points. After hot emissions are met with reasonable

, optimized injection parameters of 14 key points are smoothened over entire

engine speed load condition to get smooth engine operation in terms of noise and

After smoothening of injection parameters at entire engine speed load

again hot emission were taken to ensure that engine out emissions are still within the engineering

targets. If not redo the optimization and smoothing till emissions reach within

In actual conditions Bharat stage 4 emissions to be met when vehicle is at 20 deg C. at

cold start. This work were done by changing engine coolant and oil temperature at 40 Dec C on

test bed by applying cold corrections and get same engine out emissions.

. Testing and optimizing hot emission on chassis dynamometer and matching with engine

dynamometer 14 key point results.

optimized for 14 mode points and other part load points and smoothening of

injection parameters it was mounted on vehicle for establishing correlation engine our e

dynamometer tested results. Figure 20 shows the

make emission analyzers for test purpose.

Chassis dynamometer test setup for vehicle Emissions

3 4 5 6 7 8 9 10 11 12 13 14

Mode

BSIII

BSIV

– 6340(Print), ISSN

is required in mode 3 and more 8 to control the

emissions are met with reasonable

, optimized injection parameters of 14 key points are smoothened over entire

noise and drivability

After smoothening of injection parameters at entire engine speed load condition

within the engineering

targets. If not redo the optimization and smoothing till emissions reach within engineering

to be met when vehicle is at 20 deg C. at

cold start. This work were done by changing engine coolant and oil temperature at 40 Dec C on

ssis dynamometer and matching with engine

optimized for 14 mode points and other part load points and smoothening of

engine our emission

shows the Horiba chassis

Emissions

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

507

Before taking emission test, vehicle was wormed up on chassis dynamometer by running it with

three EUDC cycle. Hot emission test was conducted on chassis dynamometer as per test cycle

defined in Bharat stage 4 emission norms. Figure 21, 22, 23 and 24 shows online traces of CO,

NOx, HC and smoke emissions plotted in real time scale during the test cycle.

Fig. 21: Online Traces of Dilute CO Emission during Hot Emission Test Cycle

Fig 22: Online traces of Dilute NOx Emission during hot emission test cycle

Fig. 23: Online traces of Dilute HC Emission during hot emission test cycle

Online CO Emission tracess

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Online HC Emission tracess

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Online Nox Emission tracess

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

508

Fig. 24: Online Traces of Dilute Smoke Emission during Hot Emission Test Cycle

IV RESULTS AND DISCUSSSIONS

4.1 Co-relation of AVL Boost simulation and actual test results

Boost simulation was done and parametric study showed that to lower compression ratio from

18.5 to 16.5 is necessary maintain peak firing cylinder pressure of 155 bar . Actual engine test

results were matching with simulation results .Figure 25 and 26 shows the comparison of

simulation boost pressure and actual test results at full load 3750 rpm and 1500 rpm.

Fig 25: Cylinder Pressure comparison at Full load @ 3750 rpm for actual and simulated results

Figure 26: Cylinder Pressure comparison at Full load @ 1500 rpm for actual and simulated

results

Online Smoke Emission tracess

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18

20

0 200 400 600 800 1000 1200Time Sec

Dilu

te_S

moke in %

0

20

40

60

80

100

Vehic

le s

peed,k

mph

Smoke %Bharat stage 4 test cycle

Combustion pressure 100 % Load @1500 rpm

0

20

40

60

80

100

120

140

160

0 90 180 270 360 450 540 630 720Crank angle

Cylin

der Pre

ssure

,Bar

Actual Tested

Simulated

Combustion Pressure 100% Full load@ 3750 rpm

0 200 400 600

Crank angle,Degree

Pre

ssure

,bar

0

20

40

60

80

100

120

140

160

180Actual Tested

Simulated

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

509

4.2 Engine 14 mode hot emission and vehicle hot emission of chassis dynamometer results.

14 mode emission tests results of engine dynamometer and chassis dynamometers were

compared for HC+NOX and PM for Bharat stage 4 emission norms and hot engine out targets.

HC+NOx results are within 6 % as compared to chassis dynamometer results. Particulate (soot)

emissions are within 10 % with test bed and chassis dynamometer vehicle emissions. CO and HC

emissions are within the engineering test bed targets. There is big difference in CO and HC

emission margins and can be optimized on vehicle by use of suitable oxidation catalyst on

chassis dynamometer. Further refinements of injection parameters, EGR rate and playing with

catalytic converter loading on vehicle were done as per normal practice.

Table No 3: Hot emission results comparison of 14 mode and vehicle tested on chassis

dynamometer

Hot Emissions [ g/km]

Engine /vehicle Nox HC+Nox

Soot

(PM) CO HC

14 mode Emission

results 0.343 0.396 0.044 0.375 0.053

Vehicle Emission

results 0.333 0.391 0.042 0.402 0.058

% difference 2.915 1.279 4.762 6.716 9.434

Engine out target 0.360 0.420 0.050 0.550 0.060

Bharat stage 4

limits 0.390 0.460 0.060 0.740 -

Table 3 and figure 27 shows the hot emission test of 14 mode and chassis dynamometer. Results

were comparable and give the confidence of selected hardware and combustion parameters to

proceed further for work on chassis dynamometer.

Fig. 27: HC+NOx verses particulate hot emission results

V.CONCLUSIONS

0.00

0.01

0.02

0.03

0.04

0.05

0.06

0.0 0.1 0.2 0.3 0.4 0.5

HC+NOx,g/km

PM

, g

/km

14 Mode Engine results

Vehicle emission results

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 – 6340(Print), ISSN

0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

510

Engine design and developments is complex process. There is no short cut in development to meet future

ultra low emission norms due to complexity of engine features like common rail, EGR cooler, new

generation boosting system, etc.

Based on this developments following are conclusions.

5.1 Use of simulation tool helps early prediction of engine performance and selection of critical engine

hardware’s before engine goes in test bed.

5.2 Considerable development time of vehicle emission development time on chassis dynamometers can

be reduced by optimizing engine on steady points on test bench.

5.3 This method is very useful if one engine goes on different vehicles or having more vehicle variant to

meet same emission legislation.

5.4 Considerable development cost saving and crunch on overloading on infrastructure can be avoided.

5.5 Possible to do single engine development and use it on many vehicle variants with same emission

norms.

5.6 Very good correlation was seen for NOx and soot emissions between steady state and hot chassis

dynamometer.

5.7 For HC and CO correlations are not seen. This is mainly due to conversion efficiency and light of

temperature of catalyst.

5.8 Detection of wrong hardware at final stage of vehicle emission development testing becomes costly

affair in terms of time and cost.

VI. ACKNOWELGMENTS

Author would like to thank to Mr. Rajan Wadhera, Chief of TPDS (Technology production Development

and Sourcing), Mahindra and Mahindra Ltd for use of test facility at R&D Center Nasik, India and Mr. R

Velusamy, Sr. General Manager, R&D for his valuable suggestions and guidance

VII. REFERENCES [1] HEYWOOD,J.B,Internal combustion Engines Fundamentals,Mc Graw-Hill,Inc.,1988

[2] WATSON,N.and JANOTA,M.S,Turbocharging the internal combustion engine-wiley-interscience,

1982

[3] AVL Boost V5.5 User Manual

[4] AVL CRUISE V 5.4 User Manual

[5] JUNMIN,WANG and et.al.:2008-01-1198: Development of High Performance Diesel Engine

Compliant with Euro V Norms, 2008 World Congress, Detroit ,Michigan April 2008

[6] Ramdasi SS and Etal : 2011-26-0033, SIAT2011, ‘Design and Development of 3 Cylinder 75

kW/Litre High Power Density Engine for Passenger Car Application to Meet EIV /E V Norms

DEFINITIONS, ACRONYMS, ABREVIATIONS BMEP : Brake Mean Effective pressure

EGR : Exhaust Gas Recirculation

FSN : Filter Smoke Number

BSFC : Brake specific fuel consumption

NVH : Noise vibration and harshness

DOC : Diesel oxidation catayst

CO : Carbon Monoxide

HC : Hydrocarbon

NOx : Oxides of Nitrogen

SUV : Sport Utility Vehicle