Search Results (14)

Hydrogen combustion engine vehicles have the potential to rapidly enter the market and reduce greenhouse gas emissions (GHG) compared to conventional engines. The ability to provide a rapid market deployment is linked to the fact that the industry would take advantage of the existing internal combustion engine production chain. The aim of this paper is twofold. First, it aims to develop a methodology for applying life-cycle assessment (LCA) to internal combustion engines to estimate their life-cycle GHG emissions. Also, it aims to investigate the decarbonization potential of hydrogen engines produced by exploiting existing diesel engine technology and assuming diverse hydrogen production routes. The boundary of the LCA is cradle-to-grave, and the assessment is entirely based on primary data. The products under study are two monofuel engines: a hydrogen engine and a diesel engine. The hydrogen engine has been redesigned using the diesel engine as a base. The engines being studied are versatile and can be used for a wide range of uses such as automotive, cogeneration, maritime, off-road, and railway; however, this study focuses on their application in pickup trucks. As part of the redesign process, certain subsystems (e.g., combustion, injection, ignition, exhaust gas recirculation, and exhaust gas aftertreatment) have been modified to make the engine run on hydrogen. Results revealed that employing a hydrogen engine using green hydrogen (i.e., generated from water electrolysis using wind-based electricity) might reduce GHG emission by over 90% compared to the diesel engine This study showed that the benefits of the new hydrogen engine solution outweigh the increase of emissions related to the redesign process, making it a potentially beneficial solution also for reconditioning current and used internal combustion engines. Full article

This work presents a study of the performance of prime mover and hydraulic implement electrification in a backhoe loader. The results are validated through simulation and experimental tests. The construction and agriculture sector has grown in recent years with the aid of compact non-road mobile machines. However, as is common in fossil fuel-powered vehicles, they significantly contribute to increasing emissions. Previous research has primarily relied on powertrain electrification to address the low-efficiency drawbacks. Notably, compact off-road vehicles comprise implements less discussed in the literature. A hybrid series topology is employed, where the rear implement is driven by an electrical drive and the Diesel engine is coupled to a generator. A rule-based energy management strategy is applied. The operation of the Diesel engine and electrical machines in optimal points of the efficiency maps are the basis of the analysis. The design is validated using simulations and experimental tests in a commercial backhoe loader as a benchmark. Experimental and simulation results obtained from the hybrid series backhoe loader applied to the hydraulic implement show a 33% reduction in fuel consumption, demonstrating the effectiveness of electrification in reducing emissions and fuel consumption of compact non-road mobile machines. Full article

The environmental sustainability of agricultural and industrial vehicles, as well as of the transportation sector, represents one of the most critical challenges to the sustainable development of a nation. In recent decades, compression-ignition engines have been widely used in on-road and off-road vehicles due to their better fuel economy, autonomy, compactness, and mechanical performance (spec. the high torque values). Due to the consistent environmental impact of fossil fuels, scientists are searching for alternative energy sources while preserving the beneficial features of diesel engines. The utilization of blends of diesel fuel, biodiesel, and bioethanol fuel (referred to as “ternary blends”) is among the most promising solutions for replacing fossil fuels in the near term, allowing, at the same time, us to continue using existing vehicles until new technologies are developed, consolidated and adapted to the agricultural and industrial sector. These ternary blends can lower exhaust emissions without creating major problems for existing fuel-feeding systems, typically designed for low-viscosity fossil fuels. One of the concerns in using liquid biofuels, specifically biodiesel, is the high chemical affinity with conventional and bio-based lubricants, so the main parameters of lubricants can vary significantly after a long operation of the engine. The comprehensive literature review presented in this article delves into the technical challenges, the main research pathways, and the potential solutions associated with the utilization of biofuels. Additionally, it investigates the emerging application of nanoparticles as additives in lubricants and biofuels, highlighting their valuable potential. This study also discusses the potential implementation of bio-ethanol in ternary blends, offering a promising avenue for reducing reliance on fossil fuels while maintaining engine efficiency. Full article

Off-road vehicles and transportation are vital for agricultural economics, yet the transition to green energies is challenging. To make this transition easier, a tool that enables the testing of heavy-duty off-road vehicles in various scenarios was created. Based on the methods of the World Harmonized Transient Cycle (WHTC), a new Hybrid Operational Cycle (HOC) that reflects the features of agricultural work was created and applied in a graphical model simulation. This was a newly developed methodology. The cycle and the model were based on gathered research data. A numerical model of a medium-power tractor with an internal combustion engine and a series-hybrid setup was created, and simulations were performed in Matlab and AVL Cruise. Both diesel and hybrid vehicles were compared in terms of their power production, fuel consumption, and efficiency in fieldwork and transportation scenarios. The results showed that a series-hybrid transmission can achieve an efficiency similar to that of a tractor with a continuously variable transmission (CVT), but because it uses an electric powertrain, it still provides the opportunity to exploit energy regeneration during transportation and under low-load conditions. The designed model may also be used to develop control algorithms for hybrid drives and improve their efficiency. Full article

The aim of the study was to determine impact of commercially available hydrotreated vegetable oil (HVO) and its mixture (HVO5, where 5% (v/v) HVO and 95% (v/v) FDD) with diesel fuel (FDD) on the power, torque, fuel consumption, and exhaust gas composition of an atmospheric internal combustion diesel engine used in off-road applications. Diesel fuel was used as the comparative fuel. Testing was realized in a full-load mode on the KOHLER KDI 1903 M 3-cylinder diesel engine on a SIERRA CP-Engineering engine test bench. The AVL SESAM FTIR exhaust gas analytical system was used to determine exhaust gas emissions, while the AVL KMA Mobile fuel consumption measuring device was used to measure fuel consumption. Research showed that the lowest power and torque readings were obtained with FDD, while HVO showed a slightly higher result compared to the fossil diesel fuel. At the same time, the highest hourly fuel consumption was observed running on HVO5, while the lowest was observed with FDD. Increases in carbon monoxide (CO), carbon dioxide (CO₂), and nitrogen oxide (NO_x) emissions were observed for HVO5 compared to those of FDD. The CO content in emissions increased by an average of 3.0% using HVO and by an average of 36% using HVO5, but the NO_x content in the emissions increased by an average of 3.0% using HVO and by an average of 8.8% using HVO5. The reduction by an average of 60% using HVO in emissions was found in the case of hydrocarbons (HC). Research confirmed that the physicochemical properties of HVO could leave an impact on the main engine performance parameters and exhaust emissions. Full article

The performance of modern, new generation-armored vehicles would greatly benefit from overall engineering, optimization, and integration techniques of advanced diesel engines-electrified transmissions. Modern axial flux electric motors and controllers are perfectly able to replace the classical automatic gearbox and complex steering system of traditional Main Battle Tanks. This study shows a possible design of a serial hybrid electric power pack for very heavy tanks with a weight well over 50 tons. The result is a hybrid power system that improves the overall performance of armored vehicles off-road and on-road, improving the acceleration and the smoothness of the ride. In addition, fuel consumption will be reduced because the internal combustion engine operates at fixed rpm. The electric motors will outperform the traditional engines due to their very high torque output even at “zero speed”. The weight of a hybrid system has also been calculated. In fact, in many cases, it is possible to use all off-the-shelf components. The on-board diagnosis of the subsystems in the hybrid powertrain makes it possible to achieve a Time Between Overhaul (TBO) of 4500 h with a failure probability inferior to one in 10,000. Full article

With the increasingly stringent regulations on air quality and the consequent emission limits for internal combustion engines, researchers are concentrating on studying new solutions for improving efficiency and energy saving even in off-road mobile machines. To achieve this task, pump-controlled or displacement-controlled systems have inspired interest for applications in off-road working machines. Generally, these systems are derived from the union of a hydraulic machine coupled to an electric one to create compact components that could be installed near the actuator. The object of study of this work is a 9-ton excavator, whose hydraulic circuit is grounded on load sensing logic. The validated mathematical model, created previously in the Simcenter Amesim© environment, represents the starting point for developing electro-hydraulic solutions. Electric components have been inserted to create different architectures, both with open- and closed-circuit layouts, in order to compare the energy efficiency of the different configurations with respect to the traditional load sensing system. The simulations of a typical working cycle show the energy benefits of electro-hydraulic solutions that allow for drastically reducing the mechanical energy required by the diesel engine and, consequently, the fuel consumption. This is mainly possible because of the elimination of directional valves and pressure compensators, which are necessary in a load sensing circuit, but are also a source of great energy dissipations. The results show that closed-circuit solutions produce the greatest benefits, with higher energy efficiencies than the open-circuit solution. Furthermore, closed-circuit configurations require fewer components, allowing for more compact and lighter solutions, as well as being cheaper. Full article

A common challenge among internal combustion engine (ICE) manufacturers is shortening the development time while facing requirements and specifications that are becoming more complex and border in scope. Virtual simulation and calibration are effective instruments in the face of these demands. This article presents the development of zero-dimensional (0D)—real-time engine and exhaust after-treatment system (EAS) models and their deployment on a Virtual test bench (VTB). The models are created using a series of measurements acquired in a real test bench, carefully performed in view of ensuring the highest reliability of the models themselves. A zero-dimensional approach was chosen to guarantee that models could be run in real-time and interfaced to the real engine Electronic Control Unit (ECU). Being physically based models, they react to changes in the ECU calibration parameters. Once the models are validated, they are then integrated into a Simulink^® based architecture with all the Inputs/Outputs connections to the ECU. This Simulink^® model is then deployed on a Hardware in the Loop (HiL) machine for ECU testing and calibration. The results for engine and EAS performance and emissions align with both steady-state and transient measurements. Finally, two different applications of the HiL system are presented to explain the opportunities and advantages of this tool integrated within the standard engine development. Examples cited refer to altitude calibration activities and soot loading investigation on vehicle duty cycles. The cases described in this work are part of the actual development of one of the latest engines developed by Kohler Engines: the KDI 1903 TCR Stage V. The application of this methodology reveals a great potential for engine development and may become an essential tool for calibration engineers. Full article

The fuel qualities of several biodiesels containing highly saturated, mono, and poly unsaturated fatty acids, as well as their combustion and exhaust emission characteristics, were studied. Six biodiesel samples were divided into two groups based on their fatty acid composition, including group 1 (coconut, castor, and jatropha) and group II (palm, karanja, and waste cooking oil biodiesel). All fuels (in both groups) were tested in a single-cylinder off-road diesel engine. Castor and karanja biodiesel, both rich in mono-unsaturation level, have a high viscosity of about 14.5 and 5.04 mm²/s, respectively. The coconut and palm biodiesels are rich in saturation level with cetane numbers of 62 and 60, respectively. In both groups, highly saturated and poly-unsaturated methyl esters presented better combustion efficiency and less formation of polluted emissions than mono-unsaturation. At full load, coconut and palm biodiesel displayed 38% and 10% advanced start of combustion, respectively, which reduced ignition delay by approximately 10% and 3%, respectively. Mono-unsaturated methyl esters exhibited a higher cylinder pressure and heat release rate, which results in higher NOx gas emissions. The group II biodiesels showed about 10–15% lower exhaust emissions owing to an optimum level of fatty acid composition. Our study concluded that highly saturated and poly-unsaturated fatty acid performed better than mono-unsaturated biodiesels for off-road engine application. Full article

This research paper studied the environmental impact of using methane fuels for supplying internal combustion engines. Methane fuel types and the methods of their use in internal combustion engines were systematized. The knowledge regarding the environmental impact of using methane fuels for supplying internal combustion engines was analyzed. The authors studied the properties of various internal combustion engines used for different applications (specialized engines of power generators—Liebherr G9512 and MAN E3262 LE212, powered by biogas, engine for road and off-road vehicles—Cummins 6C8.3, in self-ignition, original version powered by diesel fuel, and its modified version—a spark-ignition engine powered by methane fuel) under various operating conditions in approval tests. The sensitivity of the engine properties, especially pollutant emissions, to its operating states were studied. In the case of a Cummins 6C8.3 modified engine, a significant reduction in the pollutant emission owing to the use of methane fuel, relative to the original self-ignition engine, was found. The emission of carbon oxide decreased by approximately 30%, hydrocarbons by approximately 70% and nitrogen oxide by approximately 50%, as well as a particulate matter emission was also eliminated. Specific brake emission of carbon oxide is the most sensitive to the operating states of the engine: 0.324 for a self-ignition engine and 0.264 for a spark-ignition engine, with the least sensitive being specific brake emission of nitrogen oxide: 0.121 for a self-ignition engine and 0.097 for a spark-ignition engine. The specific brake emission of carbon monoxide and hydrocarbons for stationary engines was higher in comparison with both versions of Cummins 6C8.3 engine. However, the emission of nitrogen oxide for stationary engines was lower than for Cummins engines. Full article

Notwithstanding the policies that move towards electrified powertrains, the transportation sector mainly employs internal combustion engines as the primary propulsion system. In this regard, for medium- to heavy-duty applications, as well as for on- and off-road applications, diesel engines are preferred because of the better efficiency, lower CO₂, and greater robustness compared to spark-ignition engines. Due to its use at a large scale, the internal combustion engines as a source of energy depletion and pollutant emissions must further improved. In this sense, the adoption of alternative combustion concepts using cleaner fuels than diesel (e.g., natural gas, ethanol and methanol) presents a viable solution for improving the efficiency and emissions of the future powertrains. Particularly, the methane–diesel dual-fuel concept represents a possible solution for compression ignition engines because the use of the low-carbon methane fuel, a main constituent of natural gas, as primary fuel significantly reduces the CO₂ emissions compared to conventional liquid fuels. Nonetheless, other issues concerning higher total hydrocarbon (THC) and CO emissions, mainly at low load conditions, are found. To minimize this issue, this research paper evaluates, through a new and alternative approach, the effects of different engine control parameters, such as rail pressure, pilot quantity, start of injection and premixed ratio in terms of efficiency and emissions, and compared to the conventional diesel combustion mode. Indeed, for a deeper understanding of the results, a 1-Dimensional spray model is used to model the air-fuel mixing phenomenon in response to the variations of the calibration parameters that condition the subsequent dual-fuel combustion evolution. Specific variation settings, in terms of premixed ratio, injection pressure, pilot quantity and combustion phasing are proposed for further efficiency improvements. Full article

With the rising demand for energy efficiency, displacement-controlled or so-called pump-controlled systems have become an attractive research topic for applications in construction machinery and other off-road vehicles. Pump-controlled systems can be implemented with electro-hydrostatic actuators as electro-hydraulic zones, which are located next to the end actuator as a replacement for the traditional valve-controlled hydraulic actuation systems. In this paper a 9-tonne class excavator is utilized as a study case. A mathematical model of the conventional machine, validated with tests carried out on both the excavator and the single hydraulic components, was previously developed within the Simcenter AMESim^© environment. This mathematical model was modified with electric components for simulating a zonal hydraulics excavator and compared with a conventional load sensing (LS) machine. The energy efficiencies of both the LS circuit and the new solution were evaluated for typical duty cycles, pointing out the obtainable energy efficiency improvements, which were mainly due to the absence of the directional valves and pressure compensators. The results also point out the effect of the pipe losses when the circuit layout requires the pipe for connecting the pump with the actuator; moreover, the effect of a diesel engine downsizing on the energy saving was evaluated. Full article

Fuel economy efficiency is one of the most important parameters for vehicle powertrains, which is of particular interest for heavy-duty powertrain calibration. Conventionally, this work relies heavily on road tests, which cost more and may lead to long duration product development cycles. The paper proposes a novel hardware-in-loop modeling and calibration method to work it out. A dSPACE hardware-based test bench was successfully established and validated, which is valuable for a more efficient and easier shift schedule in calibration. Meanwhile, a real-time dynamic powertrain model, including a diesel engine, torque converter, gear box and driver model was built. Typical driving cycles that both velocity and slope information were constructed for different road conditions. A basic economic shift schedule was initially calculated and then optimal calibrated by the test bench. The results show that there is an optimal relationship between an economic shift schedule and speed regulation. By matching the best economic shift schedule regulation to different road conditions; the fuel economy of vehicles can be improved. In a smooth driving cycle; when the powertrain applies a larger speed regulation such as 12% and the corresponding shift schedule; the fuel consumption is smaller and is reduced by 13%. In a complex driving cycle, when the powertrain applies a smaller speed regulation such as 5% along with the corresponding shift schedule; the fuel consumption is smaller and is reduced by 5%. The method thus can provide guidance for economic calibration experiments of off-road heavy-duty vehicles. Full article

The U.S. Army TACOM-TARDEC developed and validated a high-fidelity six-degree-of-freedom model to use in a trade study for the development of a prototype autonomous vehicle. The model captures realistic dynamics of the six-wheeled, skid-steered vehicle along with the electrical, thermal, and mechanical response of a detailed series hybrid-electric power system with in-hub drive motors, lithium-ion battery, and generator linked to a diesel engine. These components were modeled and integrated via extensive power and energy component libraries developed for use with a high-fidelity software tool for dynamics modeling. Further, the vehicle model’s entire complement of components was integrated in a flexible configuration that allowed them to be readily adjusted or swapped out so the user could use the model to ascertain the relative effects of modifying the vehicle’s structural or power system components on specific vehicle evaluation criteria. Such criteria include the vehicle’s performance with high-speed stability, skid steering stability, body pitch/roll/dive/squat characteristics, braking capability, road/soft-soil traversal, and steering maneuverability.
The model captures both the on- and off-road mobility for the vehicle via use of an extensive library of various terrains including hard surface, sand, sandy loam, clay soil, and snow. Further, detailed waypointbased path navigation routines automate the vehicle’s traversal over a number of user-selectable courses including some established military courses such as Churchville-B, Perryman 1, 3, and A, and Munson with user-defined vehicle velocities. The model functions as an executable file run independent of any proprietary or close-source software; the user utilizes a simplified interface to vary any of the variables associated with the vehicle’s geometry, power system, course and speed to navigate, and terrain type applied to the course. The graphical view for the vehicle traversing the selected terrain is shown with an open source 3D graphics tool. The model was validated by applying the specifications in the model for the prototype vehicle of the first-generation of autonomous six-wheeled skid-steered vehicle, simulating the model in maneuvers identical to those the prototype vehicle performed, and comparing the simulated and actual results; the data matched and the model was successfully validated.
The vehicle model was designed primarily for the trade study for the design of a specific vehicle, but was created with sufficient flexibility and capability for modeling future vehicles as well. The interchangeability of the vehicle models’ components and environments allow a user to modify or replace the vehicle’s power system components, chassis masses, tires, transmission, duty cycles, courses to traverse, and many other aspects of the vehicle. Thus the user can essentially model any vehicle with similar types of components or structures and use that model to determine the impact of those elements upon many vehicle design considerations such as mass requirements, volume constraints, power system requirements, wheels design, suspension characteristics, and controls. Several new vehicle models are already being developed using this model’s flexibility and capability. Full article