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Title: Demonstration of Air-Power-Assist Engine Technology for Clean Combustion and Direct Energy Recovery in Heavy Duty Application

The first phase of the project consists of four months of applied research, starting from September 1, 2005 and was completed by December 31, 2005. During this time, the project team heavily relied on highly detailed numerical modeling techniques to evaluate the feasibility of the APA technology. Specifically, (i) A GT-Power{sup TM}engine simulation model was constructed to predict engine efficiency at various operating conditions. Efficiency was defined based on the second-law thermodynamic availability. (ii) The engine efficiency map generated by the engine simulation was then fed into a simplified vehicle model, which was constructed in the Matlab/Simulink environment, to predict fuel consumption of a refuse truck on a simple collection cycle. (iii) Design and analysis work supporting the concept of retrofitting an existing Sturman Industries Hydraulic Valve Actuation (HVA) system with the modifications that are required to run the HVA system with Air Power Assist functionality. A Matlab/Simulink model was used to calculate the dynamic response of the HVA system. Computer aided design (CAD) was done in Solidworks for mechanical design and hydraulic layout. At the end of Phase I, 11% fuel economy improvement was predicted. During Phase II, the engine simulation group completed the engine mapping work. The airmore » handling group made substantial progress in identifying suppliers and conducting 3D modelling design. Sturman Industries completed design modification of the HVA system, which was reviewed and accepted by Volvo Powertrain. In Phase II, the possibility of 15% fuel economy improvement was shown with new EGR cooler design by reducing EGR cooler outlet temperature with APA engine technology from Air Handling Group. In addition, Vehicle Simulation with APA technology estimated 4 -21% fuel economy improvement over a wide range of driving cycles. During Phase III, the engine experimental setup was initiated at VPTNA, Hagerstown, MD. Air Handling system and HVA system were delivered to VPTNA and then assembly of APA engine was completed by June 2007. Functional testing of APA engine was performed and AC and AM modes testing were completed by October 2007. After completing testing, data analysis and post processing were performed. Especially, the models were instrumental in identifying some of the key issues with the experimental HVA system. Based upon the available engine test results during AC and AM modes, the projected fuel economy improvement over the NY composite cycle is 14.7%. This is close to but slightly lower than the originally estimated 18% from ADVISOR simulation. The APA project group demonstrated the concept of APA technology by using simulation and experimental testing. However, there are still exists of technical challenges to meet the original expectation of APA technology. The enabling technology of this concept, i.e. a fully flexible valve actuation system that can handle high back pressure from the exhaust manifold is identified as one of the major technical challenges for realizing the APA concept.« less
Publication Date:
OSTI Identifier:
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Resource Type:
Technical Report
Research Org:
Mack Trucks Incorporated
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Country of Publication:
United States