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A Crank Angle Resolved Cidi Engine Combustion Model with Arbitrary Fuel Injection for Control Purpose

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A Crank Angle Resolved Cidi Engine Combustion Model with Arbitrary Fuel Injection for Control Purpose A CRANK ANGLE RESOLVED CIDI ENGINE COMBUSTION MODEL WITH ARBITRARY FUEL INJECTION FOR CONTROL PURPOSE DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Chung-Gong Kim, B.S., M.S. * * * * * The Ohio State University 2004 Dissertation Committee: Approved by Dr. Yann G. Guezennec, Adviser Dr. Giorgio Rizzoni Adviser Dr. Andrea Serrani Department of Mechanical Engineering Dr. Ahmed Soliman ABSTRACT With the introduction of new generation common rail system Diesel engines capable of multiple injections per stroke, and in the context of ever more stringent pollutant emission standards, the optimization and calibration of modern compression ignition direct injection (CIDI) engines is more and more complex. On one hand, the additional degrees of freedom provide additional opportunities to optimize the engines. On the other hand, the additional flexibility does not permit the exhaustive engine mapping approach used in the past any more, and necessitate the advent of new modeling tools for rapid optimization and calibration. Those tools must be sufficiently accurate to capture all the relevant physical phenomena, yet simple enough to be computationally cheap and permit the exhaustive exploration of a large multi-dimensional design and control space. In particular, one of the missing such model today is a simple and efficient tool for CIDI combustion simulation with arbitrary fuel injection profile. Thus in this study, a crank-angle resolved CIDI engine combustion model was developed and validated. This model uses a single-zone approach and is limited to the closed-valve part of cycle of a single cylinder for computational efficiency. All these sub-models were suitably parameterized in terms of externally controllable variables. To perform these ii parameterizations and sub-model validations, extensive experiments were conducted using a fuel injection rig and a multi-cylinder engine on a dynamometer. With this combustion model, the crank-angle resolved history of the in-cylinder parameters was calculated. Based on these results, the NOx emissions were predicted using the extended Zeldovich mechanism, and applying the concept of local equivalence ratio to calculate the temperature of each burned gas element. To validate the overall combustion and NOx estimation models, a series of engine tests were performed over a range of operating conditions. The calibrated models allow to accurately predict in-cylinder pressure, torque and NOx emissions and also allow to perform a virtual dynamometer mapping, hence demonstrating the proposed methodology. Furthermore, the results from these virtual engine mappings can be used to calibrate the black-box models of the combustion process which are typically used in control-oriented, dynamic Mean Value Models. iii Dedicated to my Parents in Heaven, my precious family who supported and endured me, and Cho. iv ACKNOWLEDGMENTS I would like to express my gratitude toward my advisor, Dr. Yann Guezennec for the assistance and advice throughout my research. I also would like to thank Dr. Giorgio Rizzoni for his guidance in my thesis work and for being on my candidacy examination committee member. I am very grateful that Hyundai Motor Company has given me a great opportunity in exploring the deeper world of automotive engineering. Both vice president Hyun-soon Lee and director Jung-kook Park were the most important individual who proposed and provided me another academic life. Also, I would like to thank all those students and staff members who have worked with me at CAR. Particularly I thank Avra Brahma, Shawn Midlam-Mohler, and Manik Narula for their cooperation during the CIDI engine and fuel injection rig tests. I also want to express my thanks to excellent Korean students, Byungho Lee and Ta-Young Gabriel Choi for their spiritual cheer-up and academic communication during my entire hard and long work. My small accomplishment would not be possible if it was not for the endless patience of my beloved family, Young-Ghil, Young-Sung, and my wife, Jung-Mi. Thank you all whom I did not mentioned here. v VITA July 13, 1960 Born – Ulsan, South Korea 1980-1984 B.S. Mechanical Engineering, Seoul National University, Seoul, South Korea 1985-2004 Hyundai Motor Company, South Korea 1990-1992 Master of Science Mechanical Engineering, Korea Advanced Institute of Science and Technology, Daejon, South Korea 2001-2004 Graduate Research Assistant, Center for Automotive Research, OSU FIELDS OF STUDY Major Field: Mechanical Engineering vi TABLE OF CONTENTS Page Abstract…………………….………..……………………………………………..……. ii Dedication………………….………..…………………………………………………....iv Acknowledgments………………………………………………………………….……...v Vita ………………………………………………………………………………....…….vi List of Figures ……………………………………………………………………..……..xi List of Tables ……………………………………………………………………..……..xv Nomenclature ……………………………………………………………………….…xxiv Chapters: 1. Introduction .................................................................................................................. 1 1.1 The diesel engine and research background ............................................................. 1 1.2 Mean value model in diesel engines......................................................................... 6 1.3 A crank angle resolved CIDI engine combustion model.......................................... 9 1.3.1 Motivation of the research ................................................................................. 9 1.3.2 Crank-angle resolved combustion model by a single-zone approach.............. 10 1.3.3 Research objective ........................................................................................... 10 vii 2. Literature review ....................................................................................................... 12 2.1 CIDI engine combustion modeling......................................................................... 12 2.2 Single zone combustion model approach ............................................................... 13 2.3 Fuel injection in diesel engines............................................................................... 16 2.4 Emission modeling ................................................................................................. 22 2.5 Combustion and NOx modeling.............................................................................. 24 2.6 A mean value engine model.................................................................................... 27 2.7 After treatment system for diesel engines............................................................... 27 2.8 Summary of literature review and research motivation.......................................... 31 3. CIDI engine combustion model by a single-zone approach ................................... 32 3.1 Introduction............................................................................................................. 32 3.1.1 Governing equation formulation...................................................................... 32 3.2 Sub models.............................................................................................................. 34 3.2.1 Heat release rate model.................................................................................... 34 3.2.2 Ignition model.................................................................................................. 37 3.2.3 Heat transfer model.......................................................................................... 40 3.2.4 Fuel injection rate model ................................................................................. 41 3.2.5 EGR gas mass estimation................................................................................. 43 3.2.6 Other sub models ............................................................................................. 45 3.3 Numerical solver for the ordinary differential equations........................................ 46 3.4 NOx modeling ........................................................................................................ 47 3.4.1 Extended Zeldovich NO formation mechanism .............................................. 47 3.4.2 Temperature calculation for the rate constant.................................................. 50 3.4.3 Total NO concentration calculation................................................................. 52 viii 4. Validation test .............................................................................................................54 4.1 Introduction............................................................................................................. 54 4.2 Validation test set-up .............................................................................................. 54 4.2.1 Test engine and dynamometer ......................................................................... 54 4.2.2 Fuel injection test rig ....................................................................................... 56 4.3 Instrumentation ....................................................................................................... 57 4.3.1 Instrumentation of the fuel injection rig .......................................................... 57 4.3.2 Instrumentation for the engine tests................................................................. 63 4.4 Test result...............................................................................................................
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