Michigan State University

College of Engineering
Fall 2007 - ME 444

THE AUTOMOTIVE DIESEL ENGINE

Roger B. Krieger
Powertrain Systems Research Laboratory
GM R&D CENTER
(Retired)
Adjunct Professor Engine Research Center
University of Wisconsin

Roger Krieger, GM R&D Center

Diesel History

Roger Krieger, GM R&D Center

 Lecture Outline
• Overview
• Combustion systems
• Fuel injection systems
• Fuel characteristics
• Performance issues
• Emissions control
• Summary & future trends
Roger Krieger, GM R&D Center
 The Diesel Engine

“.... an internal combustion engine in

which air is compressed to a temperature
sufficiently high to ignite fuel injected
into the cylinder where the combustion
actuates a piston.”
Webster’s Dictionary

Roger Krieger, GM R&D Center

 Diesel Combustion
• Fuel sprayed in cylinder near TDC
• Atomization, vaporization & mixing delay
ignition
• Ignition occurs wherever conditions right
• Combustion rate controlled by injection
characteristics (injection rate, spray angle,
injection pressure, nozzle size and shape),
chamber shape, mixture motion, & turbulence
• Glow plug may be used to aid cold starting
• Power output controlled only by amount of fuel
injected
Roger Krieger, GM R&D Center
Roger Krieger, GM R&D Center
Roger Krieger, GM R&D Center
Roger Krieger, GM R&D Center
 Lecture Outline

• Overview
• Combustion systems
• Fuel injection systems
• Fuel characteristics
• Performance issues
• Emissions control
• Summary & future trends
Roger Krieger, GM R&D Center
 Typical DI Chambers

Spray Outline

Heavy duty - 4-valve,

central injector, low swirl,
Light duty - 4-valves, central
wide shallow bowl
vertical injector, high swirl,
deep narrow bowl
Roger Krieger, GM R&D Center
 Lecture Outline
• Overview
• Combustion systems
• Fuel injection systems
• Fuel characteristics
• Performance issues
• Pressure-volume comparisons
• Emissions control
• Summary & future trends
Roger Krieger, GM R&D Center
 Fuel Injection Systems

• Electronic distributor pump

• Electronic unit injector (EUI)
• High-pressure common rail

Roger Krieger, GM R&D Center

Electronic Distributor Pump

Roger Krieger, GM R&D Center

Electronic Unit Injector (EUI)

Roger Krieger, GM R&D Center

 High-Pressure Common Rail
Common Rail

Spill
Control
Valve

Injectors
Fuel
Return to
Tank
ECU
High-Pressure Pump

Roger Krieger, GM R&D Center

 Lecture Outline
• Overview
• Combustion systems
• Fuel injection systems
• Fuel characteristics
• Performance issues
• Emissions control
• Summary & future trends

Roger Krieger, GM R&D Center

 Fuel Characteristics
Fuel
Diesel Gasoline Effect
Property
Cetane High Low Self ignitability
Non self
Octane Low High
ignitability
Volatility Low High Vapor emissions

Energy/Gal 1.12xBase Base Miles per gallon

~350 Particulates,
Sulfur (now) ~350 ppm
ppm catalyst poisoning

Sulfur
<15 ppm <30 ppm
(future) Roger Krieger, GM R&D Center
 Lecture Outline
• Overview
• Combustion systems
• Fuel injection systems
• Fuel characteristics
• Performance issues
• Emissions control
• Summary & future trends
Roger Krieger, GM R&D Center
 MAXIMUM SPECIFIC POWER & BMEP
COMPARISON
50 GASOLINE vs DIESEL
45

40

35
POWER, kW/L &

30 BMEP-GAS
BMEP, bar

25 POWER-GAS
POWER-DIESEL
20
BMEP-DIESEL
15

10

0
0 1000 2000 3000 4000 5000 6000 7000
SPEED, r/min

Roger Krieger, GM R&D Center

 COMPARISON OF FUEL CONSUMPTION
DIESEL & GASOLINE @ 2500 r/min
BSFC vs BMEP
600

550

500
Gasoline
450
BSFC, g/kWh

400 DI-Diesel

350

300

250

200

150
0 2 4 6 8 10 12 14 16
BMEP, bar

Roger Krieger, GM R&D Center

P-V Diagrams

Roger Krieger, GM R&D Center

 Boosting

• Most diesels boosted (i.e., turbocharged)

• Boosting helps power & torque
• Boosting helps fuel consumption
• Boosting facilitates torque curve shaping
• Boosting helps relative package size
• Boosting increases cost but is good value

Roger Krieger, GM R&D Center

 Boosting Systems

Current Technologies
• Waste-gate turbocharger
• Variable nozzle turbine turbocharger
Future Technologies
• Two-stage turbocharging systems
• Electric motor driven compressor,
turbine, or both
• Dual range compressors with one
turbine
Roger Krieger, GM R&D Center
 Lecture Outline
• Overview
• Combustion systems
• Fuel injection systems
• Fuel characteristics
• Performance issues
• Emissions control
• Summary & future trends
Roger Krieger, GM R&D Center
 Progression in European Passenger
Car Diesel Emissions Standards

0.16
EURO I (1992)
Particulates (g/km)

0.14

0.12
EURO II -- DI (1996) Efficiency
0.1
Power
0.08
Density
0.06 EURO III (2000) Driveability
0.04
EURO IV (2005)
0.02
EURO V (2009)
0
0 0.2 0.4 0.6 0.8 1 1.2
HC + NOx (g/km)

Roger Krieger, GM R&D Center

 Exhaust Emission Control
• HC (challenging)
– Nozzle design
– Catalyst (HC & exhaust odor)
• CO (less challenging)
• NOx (most challenging)
– Injection timing
– EGR
– Injection rate shaping
– Lean NOx catalyst
– Combustion chamber shape optimization
Roger Krieger, GM R&D Center
 Exhaust Emission Control
• Particulates (very challenging)
– Chamber symmetry and shape
– Injection characteristics (mixing rates)
– Oil control
– Catalyst (soluble fraction)
– Particulate trap

• Odor (oxidation catalyst)

• Co2 (global warming)

Roger Krieger, GM R&D Center

 Combustion Development
• Optimize piston bowl shape to control
spray/airflow interaction
• Increase combustion rate

FUEL SPRAY FUEL VAPOR REVERSE SQUISH

SPRAY ON BOWL LIP

SOOT CLOUD
FUEL FILM ON WALL
SWIRL DIRECTION

Roger Krieger, GM R&D Center

 Low-Temperature Combustion
Low NOx/Soot
6 Region
6

5 Conventional
5

Combustion
Equivalence Ratio

4
4

Toward LTC

3
3

2
2

1
1

HC/CO

01000 1400 1800 2200 2600 3000

0

1000 1400 1800 2200 2600 3000

Temperature, K
Roger Krieger, GM R&D Center
Exhaust Aftertreatment
ECU

EGR AIR FLOW

VALVE METER
THROTTLE

DOC

NOx PARTICLE
DOC DEVICE FILTER

VAPORIZER

TEMPERATURE PRESSURE DROP

SENSORS SENSOR
Roger Krieger, GM R&D Center
 Lecture Outline
• Overview
• Combustion systems
• Fuel injection systems
• Fuel characteristics
• Performance issues
• Emissions control
• Summary & future trends
Roger Krieger, GM R&D Center
 Summary Diesel Engines

Advantages:
• Efficiency (most efficient prime mover)
• Emissions (low CO, CO2, good durability)
• Very high torque and performance

Disadvantages:
• Emissions (more challenging to control
NOx, particulates)
• Higher cost
• Heavier
• Noise (more challenging to make quiet)
Roger Krieger, GM R&D Center
 Future Trends
• Factors
– Global warming (favors diesel)
– Energy resources (favors diesel)
– Government policy (low fuel tax unfavorable for diesel)
• USA
– Truck use increasing
– Car use discouraged by low fuel tax
– Higher recent fuel prices and higher CAFE threat driving
some introduction
• Europe
– New technology (4-valve DI, common-rail injection,
particulate traps)
– Diesel car sales up dramatically (currently 50% of new car
market)
– Being marketed as performance engine
Roger Krieger, GM R&D Center