2001-01-0968 Air-Fuel Mixing in a Homogeneous Charge DI Gasoline Engine Martin Gold, John Stokes, Robert Morgan Ricardo Morgan Heikal, Guillaume de Sercey, Steve Begg University of Brighton Copyright © 2001 Society of Automotive Engineers, Inc. ABSTRACT For optimum efficiency, the direct injection (DI) gasoline engine requires two operating modes to cover the full load/speed map. For lower loads and speeds, stratified charge operation can be used, while homogeneous charge is required for high loads and speeds. This paper has focused its attention on the latter of these modes, where the performance is highly dependent on the quality of the fuel spray, evaporation and the air-fuel mixture preparation. Previous work by the authors and colleagues has examined in-cylinder air motion and fuel spray characteristics [6, 7, 8, 9]. The work described in this paper continued these studies to examine in-cylinder mixture formation under early injection conditions using optical visualisation and fluorescence techniques, including calibrated LIF measurements of air/fuel ratio. The results were related to engine performance by comparing with non-optical fired engine combustion data obtained under similar operating conditions. OBJECTIVES Results of quantitative and qualitative Laser Induced Fluorescence (LIF) measurements are presented, together with shadow-graph spray imaging, made within an optically accessed DI gasoline engine. These are compared with previously acquired air flow measurements, at various injection timings, and with engine performance and emissions data obtained in a fired single cylinder non-optical engine, having an identical cylinder head and piston crown geometry. INTRODUCTION The introduction of direct injection (DI) gasoline engines into the market place has been a consequence of continued pressure to improve fuel economy and reduce CO2 emissions, occurring firstly in Japan [1,2]∗ and more recently in Europe. The majority of published research on DI gasoline combustion systems has focused on understanding mixture preparation under late (compression stroke) injection, stratified operating conditions [3, 4, 5]. Equally important are the processes involved in producing a homogeneous charge with early (intake stroke) injection timing. Mixture quality under these conditions is important for low octane requirement, low smoke, low cyclic torque variation and high full load air utilisation. ∗ Numbers in [] denote references The objectives of the work described within this paper are to: • • • • Perform quantitative laser induced fluorescence measurements within a DI gasoline engine Measure and compare the in-cylinder fuel distribution for a series of injection timings Examine and assess the mixture formation processes by comparing the LIF fuel distribution results with previous air flow measurements Investigate the correlation between mixture formation processes and combustion data results TECHNICAL APPROACH ENGINE CONFIGURATION - The present analysis has focused on the homogeneous charge operating mode of a top-entry Ricardo DI gasoline engine (Table 1 and Figure 1). Previous investigations have centered on the experimental examination of the in-cylinder air flow using both the ‘dynamic flow visualisation rig’ (DFVR) and incylinder laser Doppler anemometry, within the present optical engine, plus comparisons and analysis of phase Doppler anemometry, spray imaging and qualitative LIF data. Subsequent comparison of the experimental data with the computational fluid dynamic software (VECTIS) has shown good correlation [8]. Engine speed 1500 rev/min Bore 74.0 mm Stroke 75.5 mm Intake valve opening 16° BTDC (intake) Intake valve closing 52° ABDC (intake) Exhaust valve opening 54° BBDC (exhaust) Exhaust valve closing 18° ATDC (intake) Max valve lift 8.1 mm Table 1: Engine parameters enhancing the intensity of fluorescence and recording only during its short lifetime, therefore eliminating a lot of ambient illumination. As the wavelength of the fluorescence image is Stokes shifted, it can be easily separated from the excitation energy by an appropriate band pass filter. Continuous measurement through one injection or engine cycle is precluded by a maximum repetition rate of the camera/intensifier and laser combination of 4 Hz. A picture of the air/fuel mixing process must therefore be built from several imaged cycles. Figure 2a : Photograph of experimental layout Laser sheet in Quartz annulus Figure 1: Schematic of engine configuration IN-CYLINDER DIAGNOSTIC TECHNIQUES - In the present experiments, the techniques of shadow-graph spray imaging [10] and laser induced fluorescence (LIF) [11,12,13,14,15] have been employed to investigate the in-cylinder air/fuel mixing for the DI gasoline operating conditions under investigation. Figure 2a illustrates the arrangement used within the optical research engine for the LIF technique. The laser sheet is introduced along the engine mid-cylinder plane and is produced and optimised for the fourth harmonic of the pulsed Nd:YAG laser (266 nm, ultra-violet) by a series of cylindrical lenses. The result is a laser sheet of height 20 mm and thickness 1 mm, which is collimated within the test section, critical to the accuracy of any quantitative experiments. The laser has been tuned by the manufacturer to work with a repetition rate of 12.5 Hz, corresponding to an engine speed of 1500 rev/min. The resulting fluorescence signal is imaged onto a CCD camera (1268x1024) mounted in an orthogonal plane (Figure 2b) presenting a ‘2D’ slice of incylinder information frozen in time. Since the fluorescence is weak and short-lived, it is imaged on a gated intensified camera, having the advantage of Fluorescence and spray images out Figure 2b: Photograph of experimental optical access A fuel-tracer mixture was used for the LIF measurements and comprised 95% iso-octane with 5% acetone by volume; this mixture was calibrated prior to any quantitative in-cylinder mixture measurement. Acetone was used as the fluorescent tracer due to its low sensitivity to pressure and temperature quenching, hence minimising errors through cycle-to-cycle variations in these parameters, plus its high quantum yield and boiling point of 56 °C. Since the present experiments have been conducted within a motored engine, spray impingement will occur upon a relatively cold piston. The low boiling point of acetone will facilitate evaporation under these conditions, hence offering a closer simulation of fired engine mixture preparation conditions. Quantitative LIF requires extensive calibration of the correlation between the fluorescence signal and local fuel concentration, before in-cylinder air/fuel ratios can be derived. In the present application this calibration was performed within the optical engine, while motoring the engine and employing a unique closed-loop approach. The major benefits of the closed-loop in-cylinder LIF calibration are: • identical transmitting and receiving optical paths in calibration and experiment • precise matching of the in-cylinder physical conditions for each crank-angle • direct air/fuel ratio comparison for each crank-angle • variations in the laser sheet energy density, optical distortion and reflections can be filtered. (A more detailed description and discussion of this calibration technique will be presented in a future SAE paper). Start of Injection End of Injection Engine speed TDC 61° CA ATDC 1500 rev/min 30° CA ATDC 91° CA ATDC 1500 rev/min 60° CA ATDC 121° CA ATDC 1500 rev/min Table 2: Optical engine operating conditions for the shadow-graph spray imaging ENGINE COMBUSTION TESTS - Combustion testing was conducted in an engine geometry identical to the optical engine analysis, as part of an investigation into a lean boost DI gasoline concept [16]. The testing consisted of globally lean air/fuel ratios, rather than the rich air/fuel ratios used in the optical engine. However, the behaviour of the air and the fuel spray in both engines are comparable. Combustion data collected consisted of in-cylinder pressure, derived IMEP, coefficient of variation (CoV) of IMEP, mass fraction burned and smoke. The fired engine operating conditions are outlined in table 3. Engine load Start of Engine injection Full 4 bar IMEP speed (rev/min) (°CA ATDC) 0 X 1500 15 X 1500 30 X X 1500 45 X 1500 60 X X 1500 90 X 1500 Table 3: Fired engine operating conditions optical access Injector mounting RESULTS AND DISCUSSION MIXTURE FORMATION Figure 3: Photograph of optical cylinder head While a standard cylinder head in conjunction with a 20 mm fused silica annulus was used for the LIF work, a separate dedicated cylinder-head with pent-roof optical access was available for the shadow-graph imaging (Figure 3). This technique allows a quick fuel spray analysis as opposed to a laser sheet where several 2D plane data sets are required for a 3D analysis. A halogen lamp was placed diametrically opposite the camera, illuminating the combustion chamber. In this way, the injected spray obscures the transmission of the light to the camera and forms a shadow. A high speed intensified CCD camera (IMACON 468) having a spatial resolution per channel of 576x385 was employed to obtain the data. After an initial crank angle derived TTL trigger it was able to acquire up to eight consecutive images with inter-frame spacing down to 10 ns. The operating conditions for the shadow-graph spray imaging and the LIF tests are summarised in Table 2. In-Cylinder Spray Visualisation - Prior to the analysis of the fuel/air mixing processes with LIF, the in-cylinder spray structure was investigated for the full load condition of SOI at 60° CA ATDC and an engine speed of 1500 rev/min. Figure 4 shows a sequence of images illustrating the effects of the intake air motion on the injected spray during the early stages of injection, the mid-phase, corresponding to the injector’s steady state condition, and finally the closing stage. The DI injector spray can be initially seen to enter the cylinder at 65° CA ATDC with a narrow pencil structure having a high penetration velocity (approximately 120 m/s). Between the opening and closing transient injection flow periods, the mid-injection can be considered as a steady state flow condition. During this phase the injected spray can be seen to develop into a narrow angled hollow cone structure. Since the technique relies upon the obscuration of light passing through the liquid droplets, the hollow structure can be easily identified by the two darker regions representing the top and bottom surfaces of the cone. cylinder centre-line using the DFVR, it was shown that air velocities of greater than 20 m/s are present on the intake side during this period. The injector is positioned between and directly below the intake valves, where the two air-steams from each valve will meet, creating an area of high turbulence and flow fluctuation. This high velocity perturbating air flow will have a direct impact upon the injected fuel. Once the spray has become fully established, shown in the timings of 80° CA ATDC and 105° CA ATDC, the spray can be seen to be deflected, indicating reverse tumble influence on the small fuel droplets. A greater degree of break-up can be seen on the upper edge of the injected spray, since this is the intake air/spray interface. Evidence of this upper edge variability was previously noted in [6]. Further tests at the lower engine speeds of 1000 rev/min and 500 rev/min indicated reducing degrees of spray deflection and break-up due to the overall lower intake air velocities and consequential lower levels of turbulence. 65° CA ATDC 80° CA ATDC 105° CA ATDC At 125° CA ATDC the closing stages of the injection process are represented (Figure 5), with evidence of a more significant degree of spray structure break-up. The lower droplet velocities present during these latter stages will result in the air motion being the dominant driving force. High speed video taken under the same injection conditions showed similar highly variable injection spray, plus entrainment of smaller droplets which are carried into the cylinder centre. For homogeneous operation, interactions between the air and droplets can be favourable in the mixing process, although the high cycle-to-cycle variability could ultimately prove detrimental to the combustion stability, even at these early crank angles. Electronic pulse 125° CA ATDC Injection flow rate (approximation) 0 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 Crank angle (deg AT DC) Table 5: Example of typical injection electronic pulse and fuel flow rate profiles (SOI @ 60° CA ATDC) Figure 4: Visualisation of injected sprays (SOI @ 60° CA ATDC) During the studied injection period of 60 -121° CA ATDC, the two events of maximum piston speed and maximum valve lift will occur. The resulting intake air mass flow will consequently be at a maximum during the injection event. From the characterisation of the air motion on the Local Air/Fuel Ratio Measurements - In order to offer explanations for the mixture formation processes for various injection timings within the DI engine, the LIF data has been calibrated to provide the local air/fuel ratios across the cylinder centre-line. These results will compliment the explanations offered for the air / spray interactions in the previous results. Since the tracer LIF technique displays information on the fuel concentration, a very strong signal will be gathered in the presence of liquid fuel, which could damage the image intensifier. In the present experiments the camera, intensifier and lens parameters have been optimised for analysis of fuel vapour, hence the earliest image acquisition is 15° CA after the end of the respective injection. The relationship between the LIF mixture measurements and the air flow data gathered using the DFVR has been analysed to lend support to the LIF data and the corresponding mixture formation mechanism analysis. Figure 6 shows the mixture distribution and the CoV of mixture distribution compared to air flow at 90° CA ATDC for SOI at TDC. In Figure 6a, a rich region with equivalence ratio values between 1.2 and 1.8 can be seen on the exhaust side of the chamber. It appears to have been deflected off the piston bowl and transported within the prevailing flow out of the piston bowl into the exhaust side re-circulation region. The high air velocity entering through the intake valves has resulted in a dilution of the mixture in the under valve area, down to equivalence ratio values of less than 0.5. There is a distinct division between this lean region and the rich region which correlates with the shear layer between the piston bowl jet and the intake air flow. From the spray data, the highly turbulent air flow was seen to cause spray break-up. The corresponding CoV in the mixture strength (Figure 6b) indicates a similarly high level of cycle-to-cycle variation. The lean mixture can be seen to have a CoV of up to 25% in this under valve region. The trajectory of the mixture jet from the bowl exit will additionally be influenced by the cycle-to-cycle variability of the intake air flow. This has also been captured by the region with a mixture strength CoV of up to 10% lying within the piston bowl jet velocity vectors. An injection timing swing was performed to aid the understanding of the different mixture formation processes present during the DI gasoline engine homogeneous charge operating mode. The initial series of images acquired 15° CA after the end of injection for each of the injection strategies are shown in Figure 7. Figure 7a compliments the result shown in Figure 6 with a rich region emanating from the lip of the piston bowl. However, the overall equivalence ratio levels are higher than in Figure 6 due to less mixture dilution by the intake air. At 105° CA ATDC, for an SOI of 30° CA ATDC, the mixture strength can be seen to be globally lean as a result of the reduced piston impingement for this injection timing, such that the injected fuel has passed through the measurement plane by this time. Conversely the SOI timing of 60° CA ATDC still has a strong mixture presence on the intake side of the combustion chamber; an equally rich region is also evident in the exhaust region. The explanation for the injection tail can be derived from the spray break-up evident in Figure 4, entraining liquid fuel droplets in the under valve region and hence the high liquid portion fluorescence signal. While the fuel presence on the exhaust side of the chamber was shown to come out of the bowl for the injection timing starting at TDC, with the strategy of SOI at 60° CA ATDC the piston will be too far down the bore to have a similar influence. Under these conditions it is proposed that the fuel spray has impinged upon the exhaust side cylinder wall, and rolled up into the upper part of the combustion chamber due to the bulk charge motion. Cycle-to-cycle variability in mixture strength is illustrated in Figure 8 by the CoV in the LIF measurements, where all three injection timings show regions of variability above 25%. Figure 8a illustrates the variability in transportation of fuel mixture out of the piston bowl, with evidence of the influence of the intake air flow perturbation in the under valve region. A similar under intake valve variability is seen in Figure 8b for the SOI timing of 30° CA ATDC. As the injection timing is retarded to 60° CA ATDC the level of spray break-up and entrainment has increased due to the increased intake air mass flow and variability. Cycle-to-cycle variation of over 25% on the exhaust side indicates the extent of injection roll-up into the upper regions of the chamber. Moving through the stroke, Figure 9 shows the mixture distribution for the three injection timings, at intake BDC, superimposed with the DFVR air-flow measurements. For the two earlier timings, a higher equivalence ratio can be seen in the central region of the upper cylinder due to the fuel/air mixture carried in the reverse tumble vortex out of the piston bowl. For the timing of SOI at TDC, the rich region has been drawn into the lower cylinder with the prevailing air motion. Conversely the upwardly moving injection roll up for SOI at 60° CA ATDC is still evident at BDC due to both its upward motion and the reduced time between end of injection and BDC when compared to SOI at TDC. Since the piston geometry interferes with the laser sheet for crank angles after 280° CA ATDC this timing is the latest in-cylinder mixture distribution presented, and is shown in Figure 10. The rich region carried into the lower part of the chamber for the SOI at TDC can be seen to re-appear on the exhaust side during compression (Figure 10a). A more even global mixture distribution is evident in Figure 10b for SOI at 30° CA ATDC. However the reduced evaporation and mixing time has resulted in exhaust side enrichment for SOI at 60° CA ATDC due to the initial injection roll-up region. Figure 11 illustrates the effect of reducing evaporation and mixing time available from the end of injection. The later start of injection (and hence end of injection due to fixed pulse width) shows an increasing level of cycle-tocycle variability in the in-cylinder mixture strength. These variability effects and the global mixture distribution processes will influence the combustion performance of the fired engine. The next section will address some of these effects. AFR(φ) CoV Rich High 1.8 25% 20% 1.2 15% 10% 0.6 5% 0 Lean 0% Low Figure 6 (a): Mixture distribution @ 90° CA ATDC for a SOI @ TDC; superimposed DFVR air-flow Figure 6 (b): CoV in the mixture distribution @ 90° CA ATDC for a SOI @ TDC; DFVR air-flow Figure 6: Comparison of in-cylinder mixture distribution and DFVR derived air-flow AFR (φ) Rich 2.5 2.0 1.5 1.0 Figure 7 (a): Mixture distribution @ 75° CA ATDC for a SOI @ TDC (φ range = 0 – 2.55) Figure 7 (b): Mixture distribution @ 105° CA ATDC for a SOI @ 30° CA ATDC (φ range = 0 – 2.55) 0.5 Figure 7 (c): Mixture distribution @ 135° CA ATDC for a SOI @ 60° CA ATDC (φ range = 0 – 2.55) 0 Lean Figure 7: In-cylinder mixture distribution 15° CA after the end of injection CoV in AFR (φ) 25% 20% 15% 10% 5% Figure 8 (a): CoV in the mixture distribution @ 75° CA ATDC for a SOI @ TDC Figure 8 (b): CoV in the mixture distribution @ 105° CA ATDC for a SOI @ 30° CA ATDC Figure 8(c): CoV in the mixture distribution @ 135° CA ATDC for a SOI @ 60° CA ATDC 0% Figure 8: CoV of in-cylinder mixture distribution 15° CA after the end of injection NB: Different scales have been used to maintain a visible contrast between the differing mixture strength regimes within the cylinder AFR (φ) Rich 2.5 2.0 1.5 1.0 0.5 0 Lean Figure 9 (a): Mixture distribution @ 180° CA ATDC for a SOI @ TDC with superimposed DFVR derived air-flow Figure 9 (b): Mixture distribution @ 180° Figure 9 (c): Mixture distribution @ 180° CA ATDC for a SOI @ 30° CA ATDC; with CA ATDC for a SOI @ 60° CA ATDC; with superimposed DFVR derived air-flow superimposed DFVR derived air-flow Figure 9: Mixture distribution @ 180° CA ATDC with superimposed DFVR derived air-flow AFR (φ) Rich 1.5 1.0 0.5 Figure 10 (a): Mixture distribution @ 280° CA ATDC for a SOI @ TDC (φ range = 0 - 1.5) Figure 10 (b): Mixture distribution @ 280° CA ATDC for a SOI @ 30° CA ATDC (φ range = 0 - 1.5) Figure 10 (c): Mixture distribution @ 280° CA ATDC for a SOI @ 60° CA ATDC (φ range = 0 - 1.5) 0 Lean Figure 10: Mixture distribution @ 280° CA ATDC CoV in AFR (φ) High 15% 10% Figure 11 (a): CoV in the mixture distribution @ 280° CA ATDC for a SOI @ TDC Figure 11 (b): CoV in the mixture distribution @ 280° CA ATDC for a SOI @ 30° CA ATDC Figure 11c): CoV in the mixture distribution @ 280° CA ATDC for a SOI @ 60° CA ATDC 5% Low Figure 11: CoV in the mixture distribution @ 280° CA ATDC NB: Different scales have been used to maintain a visible contrast between the differing mixture strength regimes within the cylinder FULL LOAD OCTANE REQUIREMENT - Figure 12 shows the knock-limited ignition advance versus start of injection timing at 1500 rev/min wide open throttle with a constant 22:1 air/fuel ratio. The changes in ignition advance reflect changes in octane requirement. Optimum start of injection for octane requirement was at 30° CA ATDC, with octane requirement increasing for more advanced or retarded injection timings. When operating at a mean air/fuel ratio of 22:1, fuel rich areas in the combustion chamber, particularly in the end-gas regions, would be detrimental to octane requirement. timing is retarded, less piston spray impingement occurs and less fuel is carried over to the exhaust side combustion chamber wall. 2 1.5 FSN COMBUSTION AND LIF COMPARISON 1 0.5 0 30 20 10 0 0 15 30 45 60 SOI (degATDC) 75 90 Figure 12: Knock limited ignition timing (°CA ATDC) correlated to SOI (Full load 1500 rev/min) Turning to the LIF results shown in Figure 10, a start of injection timing of 30° CA ATDC appears to be optimum for mixture homogeneity. With start of injection at TDC or 60° CA ATDC there is a rich area on the exhaust side of the combustion chamber, more so for TDC start of injection. This would explain the increased octane requirement at these injection timings. The increase in coefficient of variation of AFR with start of injection 60° CA ATDC would also have a detrimental effect on octane requirement. In a fired engine operating at 22:1 air/fuel ratio, cycles containing locally fuel rich areas would be more likely to knock. FULL LOAD SMOKE - Figure 13 shows smoke versus start of injection timing at 1500 rev/min wide open throttle with a constant 22:1 air/fuel ratio. For more information on the lean boost DI gasoline concept, please refer to [16]. Start of injection at TDC produces the highest smoke emissions, with smoke reducing as injection timing is retarded. The LIF results provide an explanation for these observations. With start of injection at TDC, fuel impinges on the wall of the bowl and is carried by its own momentum and the strong air motion over to the exhaust side of the combustion chamber, where some probably impinges on the cylinder wall. Any fuel which does not evaporate from the piston surface and cylinder walls will be ignited by the pre-mixed flame and burn by diffusion, producing smoke. As injection 15 30 45 60 75 90 SOI Figure 13: Engine out smoke (FSN) correlated to SOI (Full load 1500 rev/min) PART LOAD CYCLIC COMBUSTION STABILITY Figure 14 shows cycle to cycle combustion stability, measured as coefficient of variation of IMEP, versus start of injection timing at 1500 rev/min 4 bar IMEP. In this case the air/fuel ratio was 14.5 and 10% external EGR was applied. Later injection timings produced an increase in cycle to cycle combustion variation, with a more rapid deterioration beyond 45° CA ATDC. This correlates with the increase in coefficient of variation of AFR observed in the LIF results, shown in Figure 11. It would appear that, although impingement on the bowl at early start of injection results in some mixture inhomogeneity, the reliability of this mode of fuel transport and evaporation results in low cycle to cycle AFR variation. As injection timing is retarded, less fuel impingement occurs and more reliance is placed on air motion for fuel transport and evaporation. This results in improved fuel evaporation rate and mixing. However, the cycle to cycle variation in air motion, combined with reduced SOI-to-ignition interval, leads to increased cycle to cycle AFR variation. 3 CoV IMEP (%) Ign (deg BTDC) 40 Octane requirement Improvement 0 2.5 2 1.5 1 0.5 0 0 15 30 45 60 SOI (degATDC) Figure 14: CoV in IMEP (%) correlated to SOI (Part load 1500 rev/min) CONCLUSION The use of in-cylinder diagnostic techniques in a singlecylinder DI gasoline engine has revealed strong correlation between data from different optical techniques and combustion performance. The following conclusions can be drawn from the observations: • • • • • • • The high velocity spray from a DI injector will be deflected by intake air during the homogeneous operating mode. Different injection timings result in different mixture formation processes. Fuel vapour is carried out of the piston bowl by the reverse tumble air motion for early injection timings There is evidence of fuel spray impingement and ’rolling-up’ on the exhaust side cylinder wall for later timings. Vaporised fuel is carried in the prevailing reverse tumble air motion out of the piston bowl towards the spark-plug. This process is evident at 180° CA ATDC for all injection timings. A start of injection of 30° CA ATDC offers optimum mixture conditions for engine octane requirement. This can be explained by the areas of enrichment evident at 280° CA ATDC for the SOI timings of TDC and 60° CA ATDC. As the time between injection and ignition increases, the variability in combustion stability improves, a direct consequence of increased time for fuel evaporation and air/fuel vapour mixing. ACKNOWLEDGMENTS The authors would like to thank the University of Brighton and Mr. R. 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