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Experimental Measurement and Analysis of In-Cylinder Fuel-Air Mixing and Combustion Using an Optical Di Diesel Engine Under Realistic Operating Conditions

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Experimental Measurement and Analysis of In-Cylinder Fuel-Air Mixing and Combustion Using an Optical Di Diesel Engine Under Realistic Operating Conditions EXPERIMENTAL MEASUREMENT AND ANALYSIS OF IN-CYLINDER FUEL-AIR MIXING AND COMBUSTION USING AN OPTICAL DI DIESEL ENGINE UNDER REALISTIC OPERATING CONDITIONS By Cody Squibb A DISSERTATION Submitted to Michigan State University In partial fulfillment of the requirements for the degree of DOCTOR OF PHILOSOPHY Mechanical Engineering 2012 ABSTRACT EXPERIMENTAL MEASUREMENT AND ANALYSIS OF IN-CYLINDER FUEL-AIR MIXING AND COMBUSTION USING AN OPTICAL DI DIESEL ENGINE UNDER REALISTIC OPERATING CONDITIONS By Cody Squibb In order to improve engine-out emissions and performance of Diesel combustion systems, continued insight into the complex combustion and fuel spray processes must be gained. An optically accessible Diesel engine and modern diagnostic imaging methods can contribute to the understanding of the fuel spray, combustion, and soot formation phenomena that occur during the four-stroke engine cycle. This work will discuss nonintrusive methods of data acquisition used to gather in-cylinder information using an International VT275-based, optical DI Diesel engine with an electro-mechanical engine control system implemented for consistency of engine boundary conditions. Infrared, visible, and intensified OH imaging techniques are used to characterize fuel spray, combustion, and soot formation processes over a range of different operating conditions, including conventional and low-temperature combustion schemes. Probability maps of the in-cylinder occurrence of fuel, combustion, and soot volumes under low temperature combustion conditions are presented to analyze the effects that changes in engine load have on the process of combustion. The influence of the injector nozzle geometry on fuel spray characteristics and how these characteristics affect combustion is discussed. Comparisons between the combustion and soot production processes of oxygenated, bio-derived fuels and pump Diesel fuel are evaluated. General trends of in-cylinder soot formation are shown to compare well with engine-out filter smoke number emissions data across a range of loads, nozzle geometries, and fueling conditions. DEDICATION To Amanda. iii ACKNOWLEDGEMENTS I would like to take this time to thank and acknowledge the many people who have made this dissertation possible. I would like to thank Dr. Harold Schock for his belief in, and support of, me through the many years of working with him. The opportunities that have been afforded through his guidance have been much beyond what I might have imagined possible upon entering graduate school. Much gratitude is due to Dr. George Zhu who greatly aided in the setup of the engine controller and general overall understanding of data acquisition. Without Dr. Zhu’s many hours of guidance, support, and patience, the bulk of this work would not have been able to be accomplished. To the other members of my guidance committee, Dr. Giles Brereton and Dr. Dennis Miller, I owe many thanks for your support in this endeavor. Acknowledgement is also due to Dr. Tonghun Lee for his guidance and willingness to share equipment in support of this work. To all of the staff of the Engine and Automotive Research Laboratory, thank you for providing an enjoyable and entertaining work environment. In particular, Thomas Stuecken and Mulyanto Poort, should be recognized for their support. Without your great friendship and support, this work would not have been able to be completed. Tom was always available and willing to give support on the experimental setup; Muly was always willing to “turn knobs and click buttons” and provide guidance in image processing. Kyle Crayne and Andrew Nuttall should be recognized for their assistance. Much gratitude is owed to Zhen Ren, Xiaojian Yang, and Xuefei Chen for their help with implementing and programming of the engine controller. I would like to acknowledge the aid that Casey Allen provided in this work, as well. To Ed Timm and Andrew Huisjen, thank you for your great friendship through these past years. To Jeff Higel, Jen Higel, and Gary Keeney, sincere gratitude for all of the assistance you have given. iv To my family and friends, the support you have provided has been immense and unwavering, thank you. This work has been the culmination of a large amount of support from you. To Amanda, thank you, for everything. v TABLE OF CONTENTS LIST OF TABLES…………………………………………………………………………..….viii LIST OF FIGURES…………………………………………………………………………........ix LIST OF SYMBOLS AND ABBREVIATIONS……………………………………………...xviii CHAPTER 1 INTRODUCTION AND BACKGROUND…………………………………….……………...…1 CHAPTER 2 LITERATURE REVIEW................................................................................................................5 2.1 Soot Formation in Diesel Engines.................................................................................5 2.2 Optical diagnostic Techniques.......................................................................................9 2.3 In-Cylinder Variability.................................................................................................12 CHAPTER 3 EXPERIMENTAL SETUP……………………………………………………..……............…..13 3.1 Engine Specifications………………………………………………..…….................13 3.2 Optical Piston Design…………………………………………………......................16 3.3 Data Acquisition System………………………………………………....…..............17 3.4 Dynamometer………………………………………………………….…..................17 3.5 Fuel Delivery System …………………………………………………..…................17 3.6 Intake Charge System…………………………………………………..…................19 3.7 Coolant System………………………………………………………………............22 3.8 Engine Control System……………………………………………………................22 3.9 Testing of Engine Control System.…………………………………….….................27 3.10 Safety of Engine Test Cell.........................................................................................29 3.11 Cameras…………………………………………………………………..................31 3.12 Camera Setup………………………………………………………….…................32 3.13 Smoke Meter..............................................................................................................33 3.14 Source of Uncertainty and Error................................................................................37 3.15 Probability Map Study Experimental Setup..............................................................42 3.16 Injector Nozzle Comparison Study Experimental Setup…………………...............43 3.17 Biodiesel Study Experimental Setup…………………………………….................45 CHAPTER 4 IMAGE PROCESSING..…………………………………………………………............….......49 4.1 Fuel Spray Image Processing.......................................................................................49 4.2 Combustion Image Processing.....................................................................................52 4.3 Probability Maps Image Processing.............................................................................54 CHAPTER 5 PROBABILITY MAP STUDY RESULTS...................................................................................56 5.1 Mass Fraction Burned..................................................................................................56 vi 5.2 Engine Speed Variations..............................................................................................57 5.3 Soot Deposition Effects...............................................................................................58 5.4 Sample Probability Maps.............................................................................................59 5.5 Projected Areas of Fuel Spray ....................................................................................60 5.6 Projected Exothermic Areas from Combustion ..........................................................63 5.7 Projected Areas of Soot ..............................................................................................65 5.8 Fractional Areas of Projected Exothermic Areas from Combustion...........................67 5.9 Radial Distance of Projected Exothermic Areas from Combustion............................73 5.10 Engine-Out Soot Emissions.......................................................................................79 CHAPTER 6 NOZZLE GEOMETRY STUDY RESULTS………………………...………..…….…..............81 6.1 Nozzle Study Fuel Spray Results.................................................................................81 6.2 Nozzle Study Combustion Results...............................................................................99 CHAPTER 7 BIODIESEL STUDY RESULTS..………………………………………..….....…............…...137 7.1 Composite Cycle Sample Images..............................................................................137 7.2 Pressure and MFB......................................................................................................140 7.3 Liquid Fuel Penetration Lengths................................................................................148 7.4 Projected Area of Combustion Gases with IR Imaging.............................................149 7.5 Average Pixel Intensity of Combustion Gases with IR Imaging...............................153 7.6 Projected Area of Soot with Visible Imaging............................................................158 7.7 Projected Area of OH with Intensified Imaging........................................................161 7.8 Average Pixel Intensity of OH..................................................................................164 7.9 Combustion, Soot, and OH Lengths from Injector....................................................167
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