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Mixture Preparation in Automotive Spark-Ignition Engines

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Mixture Preparation in Automotive Spark-Ignition Engines MIXTURE PREPARATION IN AUTOMOTIVE SPARK-IGNITION ENGINES - with particular reference to multipoint fuel systems. by Mark J. Miller 1992 Submitted for the Degree of Doctor of Philosophy University College London Department of Mechanical Engineering ProQuest Number: 10610066 All rights reserved INFORMATION TO ALL USERS The quality of this reproduction is dependent upon the quality of the copy submitted. In the unlikely event that the author did not send a com plete manuscript and there are missing pages, these will be noted. Also, if material had to be removed, a note will indicate the deletion. uest ProQuest 10610066 Published by ProQuest LLC(2017). Copyright of the Dissertation is held by the Author. All rights reserved. This work is protected against unauthorized copying under Title 17, United States C ode Microform Edition © ProQuest LLC. ProQuest LLC. 789 East Eisenhower Parkway P.O. Box 1346 Ann Arbor, Ml 48106- 1346 ABSTRACT This thesis commences by reviewing current methods of fuel mixture preparation in automotive spark-ignition engines, identifying both desirable and adverse characteristics. Experimental techniques for measurement of fuel droplet spray size distributions are considered, before describing design and operation of novel test rigs incorporating a laser- diffraction drop sizing instrument. Such measurements were made upstream and downstream of the intake valve on representative multipoint fuel injected engine components. Comparisons are drawn between the mixture quality delivered by this modem form of fuel system and more traditional carburetted systems. Interpretation of such Malvern Particle Sizer results is considered critically. In-cylinder mixture preparation on one engine under test proved poor to the extent that a majority of the fuel entered the combustion chamber in liquid form. Excessive droplet size was postulated as a probable contributory factor. Motored rigs, based on two distinct types of cylinder head, were devised in order to quantify the wallfilm by measurement. A significant conclusion was that its prevalence (or otherwise) is indeed a direct function of the droplet size achieved upstream of the inlet valve. A computer model was constructed to predict in-cylinder droplet trajectories, and confirmed that relatively smaller droplets introduced at the valve seat would travel further within the cylinder before wall impaction, increasing the time available for evaporation. Rig experimentation and droplet trajectory theory is complemented by explanation of a cylinder pressure based technique for assessment of mixture preparation changes on the performance of a running engine. The benefits of a new type of port throttled fuel injection system, specifically designed to produce finer droplets at low load, are thereby demonstrated in terms of combustion stability. Reduced contamination of incoming charge by exhaust residuals, via a mechanism of port pressure recovery, is also held to be partially responsible for stability improvements and reduction in fuel consumption. TABLE OF CONTENTS Page General nomenclature 11 Acknowledgements 14 CHAPTER 1.0 LITERATURE SURVEY 1.1 INTRODUCTION 16 1.2 FUEL METERING METHODS AND TRENDS 1.2.1 Carburettors 17 1.2.2 Fuel injection systems 18 1.3 SIGNIFICANCE OF MIXTURE PREPARATION 1.3.1 Effects on fuel economy 20 1.3.2 Effects on emissions 21 1.4 INVESTIGATING MIXTURE PREPARATION 1.4.1 Possible approaches 22 1.4.2 Fuel droplet sprays 22 1.4.3 Fuel droplet sizing techniques 24 1.4.4 Manifold investigations 28 1.4.5 Inlet valve and cylinder flows 30 1.4.6 Topics for continuing investigation 31 CHAPTER 2.0 TEST ENVIRONMENT AND EQUIPMENT 2.1 FUEL SYSTEMS TEST FACILITY 37 2.2 FUEL AND AIRFLOW MEASUREMENT 38 2.3 DROPLET SIZE MEASUREMENT 2.3.1 Malvern Droplet and Particle Size Analyser principles 38 2.3.2 Malvern Analyser calculation methods 40 2.3.3 Interpretation of a Malvern measurement 42 -3- Page 2.3.4 Analyser validation 44 2.3.5 Effect of evaporation on laser diffraction droplet sizing 44 2.3.6 Use of Sauter mean diameter 45 Chapter 3.0 EXPERIMENTAL WORK - MIXTURE PREPARATION UPSTREAM OF INLET VALVE 3.1 MULTIPOINT INJECTOR SPRAYS INTO FREE AIR 3.1.1 Characteristics of injector mixture preparation 53 3.1.2 Arrangement of experiment 53 3.1.3 Typical free air spray results 55 3.1.4 Injector-to-injector variation 56 3.1.5 Spray photography 57 3.2 MULTIPOINT INJECTOR SPRAYS IN STEADY AIRFLOW 3.2.1 Experimental arrangement 58 3.2.2 Results at various air flow rates 59 3.2.3 Effect of fuel properties 61 3.3 INJECTOR AND CARBURETTOR SPRAY QUALITY COMPARED 3.3.1 Carburettor spray measurements 63 3.3.2 Comparison of carburettor and injector results 64 CHAPTER 4.0 EXPERIMENTAL WORK- MIXTURE PREPARATION DOWNSTREAM OF INLET VALVE 4.1 STEADY FLOW SIMULATIONS 4.1.1 Steady flow 'blown' rig 80 4.1.2 Typical results with steady flow blown rig 81 4.1.3 Photographs and confirmation of evaporation effect 82 4.1.4 Importance of injector orientation 83 4.1.5 Steady flow 'suction' rig 85 4.1.6 Typical results with steady flow suction rig 86 4.2 CYLINDER WALLFILM MEASUREMENT 4.2.1 Requirement for a wallfilm measurement technique 87 -4- Page 4.2.2 Possible approaches to wallfilm measurement 88 4.3 PULSATING FLOW RIGS FOR WALLFILM MEASUREMENT 4.3.1 Rig based on Ford V 6 engine 89 4.3.2 Rig based on Ford Zeta four-valve engine 90 4.4 WALLFILM RIG RESULTS 4.4.1 Ford V 6 engine results 91 4.4.2 Ford Zeta engine results 93 4.4.3 Inference from wallfilm rig results 95 CHAPTER 5.0 THEORETICAL PREDICTION OF DROPLET TRAJECTORY 5.1 INTRODUCTION 112 5.2 EQUATIONS OF MOTION 5.2.1 Radial direction 112 5.2.2 Tangential direction (to > 8 ) 113 5.2.3 Tangential direction (co < 0) 113 5.3 DIFFERENTIAL EQUATION SOLUTIONS 5.3.1 Radial direction 113 5.3.2 Tangential direction (co >0) 114 5.3.3 Tangential direction (co < 0) 116 5.4 DRAG COEFFICIENT 116 5.5 EVAPORATION MODEL 116 5.5.1 Fuel properties for evaporation model 118 5.6 COMPUTER PROGRAM 118 5.6.1 Program validation 119 5.7 PARAMETRIC STUDIES 120 5.7.1 Choice of input values 120 5.7.2 Simulation results 122 -5- Page CHAPTER 6.0 TESTS OF PORT THROTTLED ENGINE 6.1 INTRODUCTION 130 6.2 PORT THROTTLING 6.2.1 Theoretical benefits of port throttles 131 6.2.2 Design of port throttle unit for test bed engine 132 6.2.3 Test bed installation 133 6.2.4 Engine management system 134 6.2.5 Commissioning and operation of port throttled engine 134 6.3 DATA ACQUISITION AND ANALYSIS METHODS 6.3.1 Mixture quality assessment 135 6.3.2 Data acquisition with LabVIEW 136 6.3.3 Cylinder pressure transducer selection 138 6.3.4 Data acquisition triggering 138 6.4 ENGINE TESTING 6.4.1 Objectives 138 6.4.2 Notes on presentation of results 139 6.4.3 Baseline results - standard engine 140 6.4.4 Pressure drop across port throttles 140 6.4.5 Optimisation of fuel injection timing 142 6.4.6 Optimisation of ignition timing 143 6.4.7 50° valve overlap 144 6.4.8 Implications of port throttle tests 145 OVERALL CONCLUSIONS 146 FIGURES Fig. 1.1 The simple carburettor: schematic to show basic principle 32 Fig. 1.2 Response of carburettor droplet size to manifold depression 32 Fig. 1.3 Equivalence ratio requirements at various conditions 33 -6- Page Fig. 1.4 Multipoint fuel injection system (Bosch LE-Jetronic) 33 Fig. 1.5 Single-point fuel injection system (Bosch Mono-Jetronic) 34 Fig. 1.6 Cross-section through Bosch multipoint fuel injector 34 Fig. 1.7 Typical response of exhaust emissions to equivalence ratio (X) 35 Fig. 2.1 General arrangement of Fuel Systems Test Facility 47 Fig. 2.2 Malvern Analyser: schematic of optical arrangement 48 Fig. 2.3 Fourier Transform lens 48 Fig. 2.4 Geometry of semi-circular detector 48 Fig. 2.5 Diffracted light energy distribution in the focal plane 49 Fig. 2.6 Intersection between spray cone and laser beam (schematic) 49 Fig. 2.7 Estimated number of droplets in sampling volume 49 Fig. 2.8 Effect of fuel volatility on Malvern Analyser histograms 50 Fig. 2.9 Sensitivity of Sauter mean diameter to small droplets 50 Fig. 3.1 Multipoint injector sprays into free air: size distributions 66 Fig. 3.2 Free air spray size distributions with involatile fuel 67 Fig. 3.3 Injector-to-injector variation: 10 ms measurement delay 68 Fig. 3.4 Injector-to-injector variation: 14 ms measurement delay 69 Fig. 3.5 Viewing passage for Malvern Particle Size Analyser 70 Fig. 3.6 Injector spray size distributions at various air flowrates 70 Fig. 3.7 Effect of port vacuum on injector spray size distribution 71 Fig. 3.8 Injector sprays with various fuels (free air) 71 Fig. 3.9 Injector sprays with various fuels (900 rev/m in idle) 72 Fig. 3.10 Injector sprays with various fuels (1500 rev/m in road load) 73 Fig. 3.11 Injector sprays with various fuels (2000 rev/min WOT) 74 Fig. 3.12 Carburettor droplet size distributions for Conditions 1-6 75 Fig. 3.13 Comparison of carburettor and multipoint injector droplet sizes 76 Fig. 4.1 Particle Sizer and flashgun triggering circuit 97 Fig. 4.2 Laser beam path over valves in blowing simulation 98 Fig. 4.3 Typical in-cylinder droplet sizes measured on 'blown' rig 98 Fig. 4.4 Normalised air velocity around inlet valve periphery 98 Fig. 4.5 Spurious Analyser indications due to refraction by fuel vapour 99 Fig.
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