Exhaust gas recirculation (EGR) in internal combustion engines is an effective method of reducing NOx emissions while improving efficiency. However, insufficient mixing between fresh air and exhaust gas can lead to cycle-to-cycle and cylinder-to-cylinder non-uniform charge gas mixtures of a multi-cylinder engine, which can in turn reduce engine performance and efficiency. A sensor packaged into a compact probe was designed, built and applied to measure spatiotemporal EGR distributions in the intake manifold of an operating engine. The probe promotes the development of more efficient and higher-performance engines by resolving high-speed in situ CO2 concentration at various locations in the intake manifold. The study employed mid-infrared light sources tuned to an absorption band of CO2 near 4.3 μm, an industry standard species for determining EGR fraction. The calibrated probe was used to map spatial EGR distributions in an intake manifold with high accuracy and monitor cycle-resolved cylinder-specific EGR fluctuations at a rate of up to 1 kHz.
The need for more environmentally friendly and efficient energy conversion is of paramount importance in developing and designing next-generation internal combustion (IC) engines for transportation applications. One effective solution to reducing emissions of mono-nitrogen oxides (NOx) is exhaust gas recirculation (EGR), which has been widely implemented in modern vehicles. However, cylinder-to-cylinder and cycle-to-cycle variations in the charge-gas uniformity can be a major barrier to optimum EGR implementation on multi-cylinder engines, and can limit performance, stability, and efficiency. Precise knowledge and fine control over the EGR system is therefore crucial, particularly for optimizing advanced engine concepts such as reactivity controlled compression ignition (RCCI). An absorption-based laser diagnostic was developed to study spatiotemporal charge-gas distributions in an IC engine intake manifold in real-time. The laser was tuned to an absorption band of carbon dioxide (CO2), a standard exhaust-gas marker, near 2.7 µm. The sensor was capable of probing four separate measurement locations simultaneously, and independently analyzing EGR fraction at speeds of 5 kHz (1.2 crank-angle degree (CAD) at 1 k RPM) or faster with high accuracy. The probes were used to study spatiotemporal EGR non-uniformities in the intake manifold and ultimately promote the development of more efficient and higher performance engines.
The combustion-residual backflow into the intake ports of a commercial diesel engine (Cummins ISX series) was spatiotemporally mapped using a multiplexed multi-species absorption spectroscopy sensor system; the resulting cycle- and cylinder-resolved measurements are applicable for assessing cylinder charge uniformity, control strategies, and computational fluid dynamics tools. On-engine measurements were made using four compact (3/8 in Outside Diameter) stainless steel probes which enabled simultaneous multi-point measurements, required minimal engine hardware modification, and featured a novel tip design for measurement of gas flows parallel to the probe axis. Three sensor probes were used to perform simultaneous backflow measurements in intake runners corresponding to three of the six engine cylinders, and a fourth probe was installed in the intake manifold plenum for tracking dynamics introduced by an external exhaust gas recirculation mixer. Near-crank-angle resolved measurements (5 kHz, that is, 1.2 crank angle resolution at 1000 RPM) were performed during steady-state engine operation at various levels of external exhaust gas recirculation to measure the gas properties and penetration distance of the backflow into the intake runners on a cylinder- and cycle-basis. Validation of computational fluid dynamics model results is also presented to demonstrate the utility of such measurements in advancing engine research.
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