Fuel efficient thermal management of diesel engine aftertreatment is a significant challenge, particularly during cold start, extended idle, urban driving, and vehicle operation in cold ambient conditions. Aftertreatment systems incorporating NO_x-mitigating selective catalytic reduction and diesel oxidation catalysts must reach ∼250 °C to be effective. The primary engine-out condition that affects the ability to keep the aftertreatment components hot is the turbine outlet temperature; however, it is a combination of exhaust flow rate and turbine outlet temperature that impact the warm-up of the aftertreatment components via convective heat transfer. This article demonstrates that cylinder deactivation improves exhaust thermal management during both loaded and lightly loaded idle conditions. Coupling cylinder deactivation with flexible valve motions results in additional benefits during lightly loaded idle operation. Specifically, this article illustrates that at loaded idle, valve motion and fuel injection deactivation in three of the six cylinders enables the following: (1) a turbine outlet temperature increases from ∼190 °C to 310 °C with only a 2% fuel economy penalty compared to the most efficient six-cylinder operation and (2) a 39% reduction in fuel consumption compared to six-cylinder operation achieving the same ∼310 °C turbine out temperature. Similarly, at lightly loaded idle, the combination of valve motion and fuel injection deactivation in three of the six cylinders, intake/exhaust valve throttling, and intake valve closure modulation enables the following: (1) a turbine outlet temperature increases from ∼120 °C to 200 °C with no fuel consumption penalty compared to the most efficient six-cylinder operation and (2) turbine outlet temperatures in excess of 250 °C when internal exhaust gas recirculation is also implemented. These variable valve actuation-based strategies also outperform six-cylinder operation for aftertreatment warm-up at all catalyst bed temperatures. These benefits are primarily realized by reducing the air flow through the engine, directly resulting in higher exhaust temperatures and lower pumping penalties compared to conventional six-cylinder operation. The elevated exhaust temperatures offset exhaust flow reductions, increasing exhaust gas-to-catalyst heat transfer rates, resulting in superior aftertreatment thermal management performance.

Approximately 30% of the fuel consumed during typical heavy-duty vehicle operation occurs at elevated speeds with low-to-moderate loads below 6.5 bar brake mean effective pressure. The fuel economy and aftertreatment thermal management of the engine at these conditions can be improved using conventional means as well as cylinder deactivation and intake valve closure modulation. Airflow reductions result in higher exhaust gas temperatures, which are beneficial for aftertreatment thermal management, and reduced pumping work, which improves fuel efficiency. Airflow reductions can be achieved through a reduction of displaced cylinder volume by using cylinder deactivation and through reduction of volumetric efficiency by using intake valve closure modulation. This paper shows that, depending on load, cylinder deactivation and intake valve closure modulation can be used to reduce the fuel consumption between 5% and 25%, increase the rate of warm-up of aftertreatment, maintain higher temperatures, or achieve active diesel particulate filter regeneration without requiring dosing of the diesel oxidation catalyst.

Homogeneous charge compression ignition (HCCI) is a novel combustion strategy for IC engines that exhibits dramatic decreases in fuel consumption and exhaust emissions. Originally conceived in 1979, the HCCI methodology has been revisited several times by industry but has yet to be implemented because the process is difficult to control. To help address these control challenges, the authors here outline the first generalizable, validated, and experimentally implemented physics-based control methodology for residual-affected HCCI engines. Specifically, the paper describes the formulation and validation of a two-input, two-state control-oriented system model of the residual-affected HCCI process occurring in a single engine cylinder. The combustion timing and peak pressure are the model states, while the inducted gas composition and effective compression ratio are the model inputs. The resulting model accurately captures the system dynamics and allows the simultaneous, coordinated control of both in-cylinder pressure and combustion timing. To demonstrate this, an $H2$ optimal controller is synthesized from a linearized version of the model and used to dictate step changes in both combustion timing and peak pressure within about four to five engine cycles on an experimental test bed. The application of control also results in reductions in the standard deviation for both combustion timing and peak pressure. The approach therefore provides accurate mean tracking, as well as a reduction in cyclic dispersion. Another benefit of the simultaneous coordination of both control inputs is a reduction in the control effort required to elicit the desired response. Instead of using a peak pressure controller that must compensate for the effects of a combustion timing controller, and vice versa, the coordinated approach optimizes the use of both control inputs to regulate both outputs.

Advanced combustion strategies including premixed charge compression ignition, homogeneous charge compression ignition, and lifted flame combustion are promising approaches for meeting increasingly stringent emissions regulations and improving fuel efficiency in next generation powertrains. Variable valve actuation and closed-loop control promise to play a key role in the promotion and control of these advanced combustion modes. For example, modulation of intake valve closure timing dictates the effective compression ratio and influences the total amount of charge trapped inside the cylinder, and in so doing allows manipulation of the in-cylinder reactant concentrations and temperature prior to and during the combustion process. The effort described here uses data from, and an experimentally-validated simulation model for, a multi-cylinder engine with variable geometry turbocharging, cooled exhaust gas recirculation, and fully flexible variable valve actuation. This effort’s intent is to determine the control authority over the gas exchange process and effective compression ratio when intake valve closure timing modulation is included on a modern turbocharged diesel engine, as well as to lay the groundwork for closed-loop control design for the promotion and control of advanced combustion modes. The engine testbed at Purdue provides a unique opportunity to pursue these objectives for turbocharged engines with exhaust gas recirculation, as it is the only such engine system in academia outfitted with multi-cylinder fully-flexible valve actuation. A method to estimate in-cylinder temperature at top dead centre is also described. Candidate control architectures for both steady state and transient operation are introduced.

Modern on-road diesel engine systems incorporate flexible fuel injection, variable geometry turbocharging, high pressure exhaust gas recirculation, oxidation catalysts, particulate filters and selective catalytic reduction systems in order to comply with strict tailpipe-out NOx and soot limits. Fuel consuming strategies, including late injections and turbine-based engine exhaust throttling are typically used to increase turbine outlet temperature and flow rate in order to reach the aftertreatment component temperatures required for efficient reduction of NOx and soot. The same strategies are used at low load operating conditions to maintain aftertreatment temperatures. This paper demonstrates that cylinder deactivation (CDA) can be used to maintain aftertreatment temperatures in a more fuel efficient manner through reductions in airflow and pumping work. The incorporation of CDA to maintain desired aftertreatment temperatures during idle conditions is experimentally demonstrated to result in fuel savings of 3.0% over the HD-FTP drive cycle. Implementation of CDA at non-idle portions of the HD-FTP where BMEP is below 3 bar is demonstrated to reduce fuel consumption further by an additional 0.4%, thereby resulting in 3.4% fuel savings over the drive cycle.

Most diesel engines meet today’s strict NOx and particulate matter emission regulations using after-treatment systems. A major drawback of these after-treatment systems is that they are efficient in reducing emissions only when their catalyst temperature is within a certain range (typically between 250 °C and 450 °C). At lower engine loads this is a major problem as the exhaust temperatures are usually below 250 °C. The primary objective of this study was to analyze “cylinder throttling” via both delayed and advanced intake valve closure timing. The effect of cylinder throttling on exhaust gas temperatures, fuel consumption, in-cylinder combustion and emissions is outlined. A significant increase in turbine outlet temperature accompanied by a decrease in fuel consumption, NOx, and particulate matter emissions was observed. Both delayed and advanced intake valve closure timings were equally effective. The increase in exhaust gas temperatures was attributed to a drop in air flow through the engine, which resulted from a reduction in the volumetric efficiency via cylinder throttling. The increase in fuel efficiency resulted from a decrease in the pumping work through a reduction in air flow through the engine. Reductions in NOx are attributed to the combined effect of a lower in-cylinder temperature due to a reduction in piston-motion-induced compression and a shift to a more premixed combustion mode. Particulate matter emissions were also reduced as a result of additional premixing. At the 1200 RPM and 2.5 bar brake mean effective pressure (BMEP) operating point, both delayed and advanced intake valve closure timings resulted in a turbine outlet temperature increase from 195 °C to 255 °C accompanied by an increase in brake thermal efficiency of 1.5% (absolute) and a reduction in brake-specific NOx and particulate matter emissions by 40% and 30%, respectively.