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Model-Based Investigation of Lean Gasoline PM and Nox Control

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Model-Based Investigation of Lean Gasoline PM and Nox Control Model-Based Investigation of Lean Gasoline PM and NOx Control THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Shreyas Shivaprasad Graduate Program in Mechanical Engineering The Ohio State University 2014 Master's Examination Committee: Dr. Shawn Midlam-Mohler Professor Yann Guezennec Copyright by Shreyas Shivaprasad 2014 Abstract A flexible model-based vehicle platform was developed with all the appropriate aftertreatment components and sensors for a GDI engine having the ability to perform diagnostic analysis. This model was developed by integrating aftertreatment and sensor models available in the public domain to develop a platform capable of running different drive cycles and scaling across different vehicle platforms with minor changes. Faults were identified for each system and the model was added with the capability to inject those faults to analyze the ability of the sensor set to diagnose those faults. Results have been presented representing the working of the model when the faults are injected. A Design of Experiments (DOE) study was conducted to explore the design space of the GPF and understand the impact of the design parameters on the performance of the filter. It was concluded from the study that smaller filters can be used due to low soot loading and soot can be regenerated passively without any need for external heating. It was observed that ash loading in the filter may be a critical issue during the long run. In addition, the scalable model was provided to an industrial research consortium as a tool for future precompetitive research. ii Acknowledgements I would like to thank Center for Automotive Research for providing me with an excellent environment to work towards my Master’s degree. I would like to extend my gratitude to my advisor, Dr. Shawn Midlam-Mohler, for giving me the opportunity to be a part of such a detailed and demanding endeavor and believing in my abilities for the entire duration of the work. I also owe a debt of gratitude to my parents, friends for the emotional and mental support who all on a daily basis unwaveringly listened to never-ending stories about the progress of the work. All in all, I had a very rewarding experience as a graduate student. CAR is a special place which nurtured my individuality and constantly kept me motivated to explore new avenues. iii Dedication Dedicated to loving parents and Ananya iv Vita 2008 – 2012 ................................................... B.Tech. Production Engineering, . NIT, Trichy 2012 - 2014 .................................................... Graduate Research Associate, Center for Automotive Research, The Ohio State University Fields of Study Major Field: Mechanical Engineering v Table of Contents Abstract ............................................................................................................................... ii Acknowledgements ............................................................................................................ iii Vita ...................................................................................................................................... v Table of Contents ............................................................................................................... vi Table of Figures ................................................................................................................. ix Chapter 1 Introduction ........................................................................................................ 1 Section 1.1 Scope of Work .............................................................................................. 2 Section 1.2 Document Layout ......................................................................................... 3 Chapter 2 Background and State of Art .............................................................................. 5 Section 2.1 Gasoline Engine Technologies ..................................................................... 5 2.1.1 Variable Valve Timing ....................................................................................... 5 2.1.3 Exhaust Gas Recirculation.................................................................................. 6 2.1.4 Injection Strategy Modification .......................................................................... 7 2.1.5 Gasoline Direct Injection .................................................................................... 8 Section 2.2 Emission Control Devices – An overview ................................................. 11 2.2.1 Three Way Catalytic Convertors ...................................................................... 11 vi 2.2.2 Lean NOx Trap ................................................................................................. 13 2.2.3 Selective Catalytic Reduction (SCR) ............................................................... 16 2.2.4 Particulate Filters .............................................................................................. 18 Section 2.3 Engine Emissions Modelling ..................................................................... 21 Section 2.4 On Board Diagnosis of Emission Control Devices .................................... 22 2.4.1 OBD in Vehicles – Brief History and State of Art ........................................... 22 2.4.2 On Board Diagnostic Regulations (Federal and California) ............................ 25 2.4.3 Faults Diagnostic Methods in Emission Systems ............................................. 30 2.4.4 Sensors for Lean Burn Engines ........................................................................ 33 Chapter 3 Model Development of a Flexible Vehicle Platform ....................................... 37 Section 3.1 Introduction ................................................................................................ 37 Section 3.2 Driver Model .............................................................................................. 38 Section 3.3 Powertrain Model ....................................................................................... 39 Section 3.4 Vehicle Model ............................................................................................ 40 Section 3.5 Aftertreatment Model ................................................................................. 41 3.5.1 Engine Emissions Model .................................................................................. 43 3.5.2 Aftertreatment Components ............................................................................. 49 3.5.3 Modelling and Calibration of AFR controller for LNT Regeneration ............. 62 3.5.4 Model Application - Fault Modelling Approach .............................................. 63 Chapter 4 Design of experiments for GPF and Results of Fault Injection ....................... 67 vii Section 4.1 Model analysis – GPF design of experiments ............................................ 67 4.1.1 Change in Cell density/Wall thickness ............................................................. 68 4.1.2 Change in Length of the Filter .......................................................................... 69 4.1.3 Change in Trap Diameter ................................................................................. 72 4.1.4 Change in Porosity............................................................................................ 74 4.1.5 Passive Regeneration ........................................................................................ 75 Section 4.2 Sample Model Results ................................................................................ 76 4.2.1 Engine Actuator Fault ....................................................................................... 79 4.2.2 Multiplicative Sensor Fault in a AFR Sensor ................................................... 80 Chapter 5 Conclusions and Future work ........................................................................... 82 Section 5.1 Conclusions ................................................................................................ 82 Section 5.2 Future Work ............................................................................................... 85 References ......................................................................................................................... 86 viii Table of Figures Figure 1 : Dependence of Concentration of Emission Species on Valve Timing ............. 6 Figure 2: Dependence of Injection Timing on PM Emissions ............................................ 7 Figure 3: Effect of AFR on Operation of TWC .................................................................. 9 Figure 4: Particulate Number Emissions of Different Engines ........................................ 10 Figure 5: Particulate Mass Emissions (g/mile) from 9 Different Vehicles With GDI Engines ........................................................................................................................................... 10 Figure 6: Impact of Catalyst Conversion Efficiency Due to Change in Exhaust Gas Temperature ..................................................................................................................... 12 Figure 7: Phases Of Operation of Lean NOx Trap ........................................................... 14 Figure 8: LNT Efficiency as a Function of Sulfur Concentration ...................................
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