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Article history: Many studies of renewable energy have shown hydrogen is one of the major green energy
Received 19 June 2009 in the future. This has lead to the development of many automotive application of using
Received in revised form hydrogen as a fuel especially in internal combustion engine. Nonetheless, there has been
21 January 2010 a slow growth and less knowledge details in building up the prototype and control meth-
Accepted 12 March 2010 odology of the hydrogen internal combustion engine [1]. In this paper, The Toyota Corolla 4
Available online 21 April 2010 cylinder, 1.8l engine running on petrol was systematically modified in such a way that it
could be operated on either gasoline or hydrogen at the choice of the driver. Within the
Keywords: scope of this project, several ancillary instruments such as a new inlet manifold, hydrogen
Hydrogen powered car fuel injection, storage system and leak detection safety system were implemented.
Engine characteristics prediction Attention is directed towards special characteristics related to the basic tuning of hydrogen
Artificial neural networks engine such as: air to fuel ratio operating conditions, ignition timing and injection timing in
Tuning of hydrogen engine terms of different engine speed and throttle position. Based on the experimental data,
a suite of neural network models were tested to accurately predict the effect of different
engine operating conditions (speed and throttle position) on the hydrogen powered car
engine characteristics. Predictions were found to be 3% to the experimental values for all
of case studies. This work provided better understanding of the effect of hydrogen engine
characteristic parameters on different engine operating conditions.
Crown Copyright ª 2010 Published by Elsevier Ltd on behalf of Professor T. Nejat Veziroglu. All
rights reserved.
* Corresponding author.
E-mail addresses: ntho@utas.edu.au (T. Ho), v.karri@ack.edu.kw (V. Karri).
0360-3199/$ e see front matter Crown Copyright ª 2010 Published by Elsevier Ltd on behalf of Professor T. Nejat Veziroglu. All rights reserved.
doi:10.1016/j.ijhydene.2010.03.054
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 3 5 ( 2 0 1 0 ) 1 0 0 0 4 e1 0 0 1 2 10005
from which was then wired into the Motec Engine Control Unit
Table 2 e Engine parameters and appropriate source of
(ECU) M400 as well as was connected to the Motec ADL. The measurement sensors [1,3,6].
manifold air pressure was measured by an aftermarket Bosch
Parameter Designation Sensor/Source
Manifold Air Pressure (MAP) sensor. The output from this was
directly wired into the Motec ECU. The ignition timing or igni- 1. Engine RPM RPM Stock ECU
tion advance was the value of angle (degree before top death 2. Throttle Position TP Stock ECU
3. Mass Air Flow Amass MAF Sensor via stock ECU
centre, oBTDC) to start to ignite the hydrogen fuel while the
4. Manifold MAP MAP Sensor via stock ECU
injection timing which was included end of injection angle and
Air Pressure
injection duration (hydrogen fuel injector pulse width). These 5. Fuel Actual Pulse FAPW Motec ECU lookup table
parameters can be utilised and controlled by the Motec ECU width
and were stored by the ADL for later analysis. The hydrogen 6. Ignition advance ladv Motec ECU lookup table
pressure within the fuel rail was measured using a pressure 7. Exhaust Gas EGT1 EOT sensor via Motec ECU
gauge. The flow rate of hydrogen was calculated using the Temperature
8. Lambda La1 Lambda sensor via PLM
pressure differential across the hydrogen fuel injectors
9. Intake Air AT Stock ECU
(between the hydrogen fuel rail pressure and the inlet manifold
Temperature
pressure) and the injector pulse width time [1,3] Table 2 shows 10. Engine ET Stock ECU
the engine parameters and appropriate source of measure- Temperature
ment sensors. 11. Output Power PWR Dynamometer
Engine parameters were logged at a rate of 2 Hz through
a MoTeC ADL Unit. Results were found to be adequate at that
rate and increasing the logging rate did not further improve following procedures at different desired engine’s speed and
accuracy of recorded data. The ADL has a total of 1 MB of load points as shown below:
memory with logging time being dependant on the number of
parameters being logged as well as logging frequency. The 1. Firstly, the engine’s fuel requirements were adjusted by
vehicle was then placed on a dynamometer while a 5-way gas tuning injection pulse width in order to bring them into line
analyser was installed on the exhaust port. The gas analyser with the desired air to fuel ratio values.
was a commercial unit from OTX-SPC. The set up for the gas 2. Secondly, the engine’s ignition timing was adjusted in
analyser is similar to that for a normal vehicle with the order to achieve minimum ignition advance for maximum
exception of additional moisture traps required due to the high brake torque (MBT).
water vapour content in the exhaust stream [1e3]. Data logging 3. Thirdly, the engine’s injection timing (injection start angle)
was set up for the device with a frequency of 2 Hz to match the was tuned and the procedure as in step 2. However, this
input frequency. The catalytic converter was removed from the control parameter only needs to be tuned for engine speed
exhaust system of the vehicle in order to measure the true site.
(uncontrolled) emissions data from the vehicle. 4. Finally, the ignition timing was checked in order to ensure
that no changes were required.
2. Brief description of experimental Note that the methodology proposed here could be a generic
methodology and neural network model application for all hydrogen internal combustion engines
involving basic tuning control parameters utilise electronic fuel
The basic tuning of hydrogen powered car has been conducted injected vehicle.
within the investigation purposes of this paper with the With the complexity of the configuration and tuning tech-
niques of an aftermarket ECU for a new fuel such as hydrogen,
the work to make the engine to start properly is a very difficult
Table 1 e Specifications of the conversion vehicle [1,2]. task. Meanwhile in the basic terms, the providing of the correct
Manufacturer Toyota amount of hydrogen at the right time with appropriate ignition
timing needs all of ECU functions to work correctly. Idle
Model Corolla
condition was seemed to be the most difficult task for tuning
Series Ascent
Body Type Hatchback for hydrogen engine which requires load to be placed on.
Year of Manufacture 2002 Moreover, the mixture of air/fuel ratio or fuel quality needs to
Type Inline, 4 Cylinders, DOHC, VVTi be measured to keep the mixture is neither too rich nor too lean
Total Displacement 1794 cm3 which are the main reason of exhaust gas excessive heat or
Compression Ratio 10.0:1 severe engine damage and increasing NOx emission gases [4].
Fuel Type Unlead Petrol RON 91 or Higher
A best tuning engine will show the best performance for any
Maximum Power Output 100 kw @ 6000 RPM
Maximum Torque 171 Nm @ 4200 RPM
given conditions including rich mixture at high power, lean or
Length 4385 mm stoichiometric when idle or slow speed. Beside that, hydrogen
Width 1695 mm injection systems should be tuned correctly to precisely control
Height 1475 mm the mixture air/fuel ratio to suit different operating conditions.
Wheelbase 2600 mm Therefore, this has online instrumentation to measure the
Driven wheels Front wheel drive
input parameters were all installed for subsequent data
Transmission 5 speed manual
acquisition and modelling.
10006 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 3 5 ( 2 0 1 0 ) 1 0 0 0 4 e1 0 0 1 2
network from the output layer to the input layer. The weights yj ðpÞ ¼ sigmoid xi ðpÞwij ðpÞ qj
i¼1
are modified using delta rule as the error is propagated to
improve the network performance. Fig. 2 depicts the map of Where n is the number of inputs of neuron j in the hidden
three layer back-propagation neural network as a virtual layer and sigmoid is the sigmoid activation function.
sensor for prediction of hydrogen car engine characteristics. (b) Calculate the actual outputs of the neurons in the
The general training algorithm of the back-propagation output layer:
2 3
neural networks can be defined as following [8]. Xm
yk ðpÞ ¼ sigmoid4 xjk ðpÞwjk ðpÞ qk 5
j¼1
2.1. Step 1: Initialisation
Where m is the number of inputs of neuron k in the output
Set all the weights and threshold levels of the network to layer.
random numbers uniformly distributed inside a small range:
temperature and NOx emissions as a function of various engine ISO 15550:2002 [5]. This ensured that the obtained results
speed and load. would suitable for subsequent scientific analysis and testing.
The effect of hydrogen as a fuel compare with gasoline engine
3. Results and discussion parameters (such as: brake power, brake torque, brake mean
effective pressure, brake specific fuel consumption, brake
The engine testing procedures outlined were in compliance thermal efficiency) and the effect of hydrogen as a fuel
with the requirements of the relevant International Standard, compare with gasoline on emission characteristics have been
Injecting Timing
450.0
400.0
350.0
End of injection (Degree BTDC)
300.0
250.0
200.0
150.0
100.0
50.0
0.0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Engine speed (RPM)
°BTDC
30 100
28 95
90
26
24
80
22 75
20 70
65
18
60
16
Actual 55 Actual
Predicted Predicted
14 50
0 5 10 15 20 25 30 35 40 45 50 0 5 10 15 20 25 30 35 40 45 50
Number of Testing data Number of Testing data
11 260
Actual Actual
Predicted Predicted
10 240
E x haus t gas tem perature (D eg. C)
F uel A c tual P uls e W idth (m s )
220
9
200
8
180
7
160
6
140
5 120
0 5 10 15 20 25 30 35 40 45 50 0 5 10 15 20 25 30 35 40 45 50
Number of Testing data Number of Testing data
90 2000
Actual
Actual
1800 Predicted
Predicted
89
1600
E ngine tem perature (D eg. C )
1400
88
1200
N O x (ppm )
87 1000
800
86
600
400
85
200
84 0
0 5 10 15 20 25 30 35 40 45 50 0 5 10 15 20 25 30 35 40 45 50
Number of Testing data Number of Testing data
Fig. 6 e Comparison of actual and prediction performance results for hydrogen powered car engine’s characteristics.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 3 5 ( 2 0 1 0 ) 1 0 0 0 4 e1 0 0 1 2 10011
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