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The objective of current research on internal combustion engines
is to further reduce exhaust emissions while simultaneously
reducing fuel consumption. The resulting measures often mean
an increase in complexity of internal combustion engines, which
on one hand increases production cost and on the other hand
increases the susceptibility of the overall system to defects. It is
therefore necessary to develop technologies which can generate
an advantage for the consumer despite increasing complexity.
Within the scope of the project “High Efficiency Diesel Engine
Concept” (“Hocheffizientes Diesel-Motoren-Konzept” HDMK),
funded by the Federal Ministry of Economic Affairs and Energy
with TÜV Rheinland as project management organization
(funding code: 19U15003A), two engine concepts were
investigated and combined on a John Deere four-cylinder inline
engine.
On the one hand, a new cylinder activation concept ("3/4-
cylinder concept") was implemented with the aim of reducing
fuel consumption. On the other hand, a fully variable valve train
was developed for this engine, which both improves the
functionality of the 3/4-cylinder concept and can have a positive
influence on exhaust emissions through internal exhaust gas
recirculation.
A comparison of this engine concept with its series reference
based on measurement data showed a fuel economy advantage
of up to 5.2% in the low load field cycles of the DLG PowerMix.
The maximum fuel consumption benefit in the low load engine
regime exceeded 15% in some of the operating points.
As a final step, the engine was modified for the integration into
an existing and working tractor, maintaining the available
installation space of the powertrain.
A detailed study of a cylinder activation concept by efficiency loss analysis and 1D simulation
(2020)
Cylinder deactivation is a well-known measure for reducing fuel consumption, especially when applied to gasoline engines. Mostly, such systems are designed to deactivate half of the number of cylinders of the engine. In this study, a new concept is investigated for deactivating only one out of four cylinders of a commercial vehicle diesel engine (“3/4-cylinder concept”). For this purpose, cylinders 2–4 of the engine are operated in “real” 3-cylinder mode, thus with the firing order and ignition distance of a regular 3-cylinder engine, while the first cylinder is only activated near full load, running in parallel to the fourth cylinder. This concept was integrated into a test engine and evaluated on an engine test bench. As the investigations revealed significant improvements for the low-to-medium load region as well as disadvantages for high load, an extensive numerical analysis was carried out based on the experimental results. This included both 1D simulation runs and a detailed cylinder-specific efficiency loss analysis. Based on the results of this analysis, further steps for optimizing the concept were derived and studied by numerical calculations. As a result, it can be concluded that the 3/4-cylinder concept may provide significant improvements of real-world fuel economy when integrated as a drive unit into a tractor.