Engine Design and Operation: Performance You Can Rely On

Performance you can rely on.
Engine Design and Operation

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1 © INFINEUM INTERNATIONAL LIMITED 2019. All Rights Reserved.
©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.
© 2020 Infineum International Limited. All rights reserved.
Discussion Topics
1 2 3 4
What is an internal Engine hardware Emissions Summary

combustion engine & configurations Control
▪ Four-stroke cycle engine – ▪ Pressure charging ▪ 3-way catalyst

gasoline, natural gas and diesel
▪ Valvetrain configurations ▪ Diesel After Treatment
▪ Two-stroke cycle engine
▪ Power cylinder
2
1. The Internal Combustion Engine
3
What is an Internal Combustion Engine?

The reciprocating internal combustion engine generates power by converting
chemically bound energy into work by the use of reciprocating motion
Ideal Conditions
Carbon Water Energy

Fuel Oxygen dioxide
Reality
Gasoline or Air CO2 SOx

Diesel or 78% Nitrogen NOx HC Water Energy
Natural Gas 21% Oxygen
PM VOC
4
Main Components of an Internal Combustion Engine

Rockers Camshaft
Valve springs
Valve
Piston
Piston rings
Cylinder block
Oil filter
Con rod
Journal bearings
Crankshaft
Oil pump
Oil
Sump
5
Standard Configurations
Inline 4 (I4)
V6
Horizontally-opposed
(Boxer)
6
Four-Stroke Cycle Engine

Intake Power
As piston moves down or toward crankcase, Ignition system fires spark plug to ignite
intake valve opens and partial vacuum is mixture just before piston reaches top of its
created in cylinder. Vaporized air-fuel mixture is travel. Expanding gases, which result from
forced into cylinder by atmospheric pressure. burning of fuel, force piston down to turn
crankshaft.
Compression Exhaust
Intake valve closes. As crankshaft rotates, After fuel charge is burned, exhaust valve
piston moves up and compresses air-fuel opens. Burned gases are forced out of cylinder
mixture. by upward movement of piston.
7
Additional Components of Gasoline and Diesel Engines
Spark plug Fuel injector

Gasoline
Liquid Fuel
Spark Ignition
Homogeneous Charge Diesel
Fuel pump Liquid Fuel
Natural Gas Compression Ignition
Stratified Charge
Gaseous Fuel
Spark Ignition
Homogeneous Charge
Distributor
Typical gasoline Typical diesel

engine engine
8
Comparison of Engine Ignition

Gasoline engine Diesel engine C.R. = Compression Ratio
C.R. 11:1 C.R. 16:1
Bore 1
Higher for
Stroke
Lower to avoid 16 compression
pre-ignition ignition
TDC BDC TDC BDC

Top Bottom
Dead Center Dead Center
Ratio of the volume of the combustion chamber and cylinder volume measured when the
piston is at the bottom of its stroke to the volume when the piston is at the top of its stroke.
9
Mixing of Air and Fuel

On Intake On Compression
Due to a tangential proponent to the flow As the piston reaches Top Dead Center a
of air into the cylinder on intake a vortex secondary flow is created by the piston
forms. bowl creating a barrel swirl.
10
Two-Stroke Cycle Engine: Small Engine

Piston  Piston 
▪ Compression ▪ Power ▪ Exhaust

▪ Creates suction to draw ▪ Pressurizes air: fuel in ▪ Intake
fuel: air into crankcase crankcase
11

2. Engine Hardware and Configurations
12
Engine Breathing Systems

Power output depends on quantity of fuel burned.
Which depends on the quantity of air “inhaled” (“breathing”)
Two types of engine breathing:

Naturally aspirated: Pressure charging:
▪ Uses suction from the engine ▪ Forcing air into the cylinder
(“intake stroke”)
▪ More air ➔ more fuel can be added ➔ more power
▪ Limited by atmospheric pressure
Two types of
pressure Supercharger Turbocharger
Driven by the Driven by
chargers engine or exhaust gases
external motor
13
2.1 Pressure Charging
14
Turbocharging and Supercharging

Turbocharger Supercharger
Compressed
by exhaust gas
Compressed
by motor/engine
15

Turbocharging
16

Supercharging
17

2.2 Valvetrain Configurations
18
Different Valve Configurations

Camshafts
Rocker
Tappets
Push Rod
Lifter
Camshaft Pushrod Double overhead cam
Rocker Camshaft
Bucket Tappet
Camshaft
19
Single overhead cam
Single overhead cam (direct acting)
Variable Valve Timing (VVT)

▪ Valves open and close at different
times in the cycle and to varying
amounts of lift depending on the
engine speed and load
▪ Engines perform well across wide range

of engine speeds and loads
▪ Less compromise between efficiency

and performance
▪ Many different mechanical, hydraulic,

and electronic options have been
developed for VVT
20

2.3 Power Cylinder
21
Engine Lubrication Regimes

CONFORMING SURFACES
▪ Hydrodynamic – moving surfaces completely separated by a film of lubricant
– Piston rings, bearings
Stribeck Curve
▪ Mixed – surfaces are still separated but asperities occasionally interact
– Piston rings, gears
▪ Boundary – surfaces come into closer contact, asperities start to break off,
intense localized heat begins to activate anti-wear additives in the lubricant
to form protective films
– Piston rings, gears
NON-CONFORMING SURFACES
▪ Elasto-hydrodynamic – rolling contact surfaces are separated but undergo
elastic deformation
– Valvetrain, cam and followers
22

Piston Ring and Cylinder Lubrication Mode

50% of engine friction is
between piston rings and liner
23

Piston Ring Action

Intake Stroke Compression and Exhaust Strokes
Cylinder Scrapes surplus Ring rides on film of oil;

oil from walls absolute viscosity of
lubricant influences film
thickness
Enlarged view showing how

ring tips and presents
Piston lower edge to cylinder wall. Cylinder wall
24

Piston Ring Action

Firing Stroke
Head
Fired fuel mix
Firing pressure pushes ring

down until entire ring face
engages cylinder wall
Piston
Cylinder wall
25

Pressures in an Engine Cylinder

Max cylinder pressure
800
Intake
Intake
Compression
Compression
600 Power
Power
Exhaust
Exhaust
Pressure, PSI
400
Ignition point
200
Advance Retard
14.7
0° 90° 180° 270° 360° 450° 540° 630° 720°
Degrees of Crankshaft Rotation and Piston Strokes

26

Effect of air/fuel ratio on combustion gas composition

Stoichiometric = 14.7 parts air to 1 part fuel
Concentration (Approximate Ranges – Not to 100 Stoichiometric
90 NOx – caused by high in-cylinder

Engine efficiency
temperatures experienced under moderate
CO, NOx and HC Emissions
80
to heavy load
70
60 NOx
HC – unburned hydrocarbons (fuel)
scale)
50
40 HC CO – carbon monoxide results from
30 incomplete combustion of fuel in a low
oxygen environment
20 CO
10
10 12 14 16 18 20 22
Rich Air-Fuel Ratio Lean
More fuel More air

27

Temperature Distribution of Pistons

Median distribution temperature of light alloy pistons
▪ Structural and functional characteristics influence temperatures
Temperature, Fahrenheit
100 200 300 400 500 600 700 800 900
Gasoline Diesel
engine engine Natural
Gas engine
0 100 200 300 400 500

28 Temperature, Celsius
3. Emissions Control
29
Emissions Control – Gasoline and Natural Gas

Gasoline and natural gas engine Emission control mechanisms
major emissions are: ▪ TWC = Three-Way Catalyst
▪ CO Carbon monoxide
▪ NOX Nitrogen oxides

Reduction Oxidation
Pt, Rh Pt, Pd
▪ HC Hydrocarbons N2
NOx HC CO2
+ + + O2 +
O2 O2 CO H2O
30

Exhaust Gas Recirculation (EGR) for NOx Control

▪ NOx are formed at Turbocharger
high combustion temperatures
EGR cooler
▪ Exhaust gas has a high heat capacity Exhaust manifold
▪ EGR consequences:
Charge Air Cooler

• reduces engine efficiency
(CAC)
• increases soot production
▪ EGR used to meet NOx emission limits

• 2002 Light EGR (10-20%) EGR crossover pipe EGR valve Inlet manifold
• 2007 Heavy EGR (20-35%)

EGR routed from exhaust manifold to intake manifold
NOTE: In use since 2002

31 Reprinted with Permission from Volvo Group Trucks Technology

Diesel Particulate Filter (DPF) Reduces Exhaust Soot

▪ Filter service is required to remove ash build-up
90+% Efficiency
▪ Filter Regeneration
• Passive
• Active Filter
• Organic matter is burned off leaving small
amount of incombustible ash
Oxidation catalyst
▪ As filter fills with soot back pressure builds Fuel

Injector
▪ Particulate matter ‘soot’ enters the filter
32 Reprinted with Permission from Volvo Group Trucks Technology NOTE: In use since 2007
Selective Catalytic Reduction (SCR) for NOx Control

Key Components
• Hot Exhaust gas
• Diesel Exhaust Fluid (DEF)
• Catalyst
DEF injected after DPF

• DEF vaporizes and decomposes into
Ammonia
Ammonia + NOx pass over catalyst and

form N2 and water vapor DOC – Diesel Oxidation Catalyst
DPF – Diesel Particulate Filter
SCR - key advantage OEMs could re- DEF – Diesel Exhaust Fluid (Urea)
advance injection timing SCR – Select Catalytic Reduction
ASC – Ammonia “Slip” Catalyst
33 Reprinted with Permission from Volvo Group Trucks Technology NOTE: In use since 2010
Next Generation Exhaust After Treatment

▪ First major redesign of emission after treatment system
▪ 1 box solution weighs significantly less and takes up less space
▪ New copper-zeolite coating improves low temperature NOx

conversion for improved emissions control
▪ Mack – CleartechTM one

▪ Cummins – Single ModuleTM
▪ Detroit Diesel – 1-box aftertreatment
Mack CleartechTM one 2017+
34 Reprinted with Permission from Volvo Group Trucks Technology

Continuing Hardware Changes will Affect Future Formulations
Design change Resulted in change
Higher top rings Higher upper piston temperatures
Exhaust gas recirculation Higher oil temperatures
Increased BMEP Need for better oxidation stability
Higher fuel injector pressures Greater stress on oil in crankcase
Retarded timing Increased soot loading of oil
Lower oil consumption Less fresh make-up oil
Exhaust after treatment devices Chemical limits on oil formulation
Engine downsizing + Turbocharging + GDI Higher Oxidation, LSPI
35

4. Summary
36
Summary
Internal combustion engines convert
1 chemical energy into work
▪ 4 stroke process:
Intake, Compression, Power, Exhaust
Engine oil has many responsibilities
4 (bearings, ring & liner, valvetrain, turbo, etc.) a
balance of viscometric properties and additive
Modern gasoline and diesel engines have many chemistry is required to provide satisfactory
2 common parts but differ in ignition source, lubrication in all phases of engine operation
engine temperatures and pressures, plus
combustion chemistry, making the diesel
lubricating environment more severe Engine design and operating conditions are
5 constantly evolving, placing ever more
stringent demands on the crankcase lubricant
Heavy-duty diesel emissions requirements
3 are having a significant impact on engine
design and lubricant formulation
37

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©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved. 38

Engine Design and Operation: Performance You Can Rely On

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Performance you can rely on.

Engine Design and Operation

Performance you can rely on.

What is an internal Engine hardware Emissions Summary

▪ Four-stroke cycle engine – ▪ Pressure charging ▪ 3-way catalyst

1. The Internal Combustion Engine

What is an Internal Combustion Engine?

Carbon Water Energy

Gasoline or Air CO2 SOx

Main Components of an Internal Combustion Engine

Four-Stroke Cycle Engine

Additional Components of Gasoline and Diesel Engines

Spark plug Fuel injector

Typical gasoline Typical diesel

Comparison of Engine Ignition

TDC BDC TDC BDC

Mixing of Air and Fuel

Two-Stroke Cycle Engine: Small Engine

▪ Compression ▪ Power ▪ Exhaust

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

2. Engine Hardware and Configurations

Engine Breathing Systems

Two types of engine breathing:

2.1 Pressure Charging

Turbocharging and Supercharging

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

2.2 Valvetrain Configurations

Different Valve Configurations

Camshaft Pushrod Double overhead cam

Variable Valve Timing (VVT)

▪ Engines perform well across wide range

▪ Less compromise between efficiency

▪ Many different mechanical, hydraulic,

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

2.3 Power Cylinder

Engine Lubrication Regimes

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

Piston Ring and Cylinder Lubrication Mode

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

Piston Ring Action

Cylinder Scrapes surplus Ring rides on film of oil;

Enlarged view showing how

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

Piston Ring Action

Fired fuel mix

Firing pressure pushes ring

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

Pressures in an Engine Cylinder

Degrees of Crankshaft Rotation and Piston Strokes

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

Effect of air/fuel ratio on combustion gas composition

90 NOx – caused by high in-cylinder

More fuel More air

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

Temperature Distribution of Pistons

0 100 200 300 400 500

Emissions Control – Gasoline and Natural Gas

▪ NOX Nitrogen oxides

©INFINEUM INTERNATIONAL LIMITED 2020. All Rights Reserved.

Exhaust Gas Recirculation (EGR) for NOx Control

▪ Exhaust gas has a high heat capacity Exhaust manifold