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The automotive industry is experiencing radical changes under the pressure of institutions that are increasingly reducing the limits on CO2 and pollutant emissions from road vehicles powered by internal combustion engines (ICEs). A way to decarbonize the transport sector without disrupting current automotive production is the adoption of alternative fuels for internal combustion engines (ICEs). Hydrogen is very attractive, thanks to the zero-carbon content and very high laminar flame speed, allowing for extending the lean burn limit. Other alternative fuels are methanol and ethanol. This work deals with the conversion of a small-sized passenger car powered by a three-cylinder spark ignition (SI) engine for the use of alternative fuels. In particular, the spark timing has been optimized to improve the fuel economy under every operating condition. The optimization procedure is based on the MATLAB/Simulink® R2024a-GT-Power co-simulation analysis and minimizes the fuel consumption by varying the spark timing independently for each cylinder. In particular, at full load, the algorithm reduces the spark timing only for the cylinder in which knock is detected, reducing fuel consumption by about 2% compared to the base calibration. This approach will be adopted in future activities to understand how the use of alternative fuels affects the ignition control strategy. [ABSTRACT FROM AUTHOR]

The H2-ICE project aims at developing, through numerical simulation, a new generation of hybrid powertrains featuring a hydrogen-fueled Internal Combustion Engine (ICE) suitable for 12 m urban buses in order to provide a reliable and cost-effective solution for the abatement of both CO2 and criteria pollutant emissions. The full exploitation of the potential of such a traction system requires a substantial enhancement of the state of the art since several issues have to be addressed. In particular, the choice of a more suitable fuel injection system and the control of the combustion process are extremely challenging. Firstly, a high-fidelity 3D-CFD model will be exploited to analyze the in-cylinder H2 fuel injection through supersonic flows. Then, after the optimization of the injection and combustion process, a 1D model of the whole engine system will be built and calibrated, allowing the identification of a "sweet spot" in the ultra-lean combustion region, characterized by extremely low NOx emissions and, at the same time, high combustion efficiencies. Moreover, to further enhance the engine efficiency well above 40%, different Waste Heat Recovery (WHR) systems will be carefully scrutinized, including both Organic Rankine Cycle (ORC)-based recovery units as well as electric turbo-compounding. A Selective Catalytic Reduction (SCR) aftertreatment system will be developed to further reduce NOx emissions to near-zero levels. Finally, a dedicated torque-based control strategy for the ICE coupled with the Energy Management Systems (EMSs) of the hybrid powertrain, both optimized by exploiting Vehicle-To-Everything (V2X) connection, allows targeting H2 consumption of 0.1 kg/km. Technologies developed in the H2-ICE project will enhance the know-how necessary to design and build engines and aftertreatment systems for the efficient exploitation of H2 as a fuel, as well as for their integration into hybrid powertrains. [ABSTRACT FROM AUTHOR]

The thermal management of lithium-ion batteries in hybrid electric vehicles is a key issue, since operating temperatures can greatly affect their performance and life. A hybrid energy storage system, composed by the integration of a battery pack with a metal hydride-based hydrogen storage system, might be a promising solution, since it allows to efficiently exploit the endothermic desorption process of hydrogen in metal hydrides to perform the thermal management of the battery pack. In this work, starting from a battery electric scooter, a new fuel cell/battery hybrid powertrain is designed, based on the simulation results of a vehicle dynamic model that evaluates power and energy requirements on a standard driving cycle. Thus, the design of an original hybrid energy storage system for a plug-in fuel cell electric scooter is proposed, and its prototype development is presented. To this aim, the battery pack thermal power profile is retrieved from vehicle simulation, and the integrated metal hydride tank is sized in such a way to ensure a suitable thermal management. The conceived storage solution replaces the conventional battery pack of the vehicle. This leads to a significant enhancement of the on-board gravimetric and volumetric energy densities, with clear advantages on the achievable driving range. The working principle of the novel storage system and its integration within the powertrain of the vehicle are also discussed.

In the last few years, car manufacturers are moving toward electrified powertrains, like Battery Electric Vehicles (BEV) and Hybrid Electric Vehicles (HEV), to reduce the levels of CO2 in the atmosphere. A promising alternative to BEVs to reduce CO2 emissions, while maintaining an existing and well-developed technology, could be the use of hydrogen for internal combustion engines (ICEs). Particularly, the zero-carbon content of hydrogen allows for guaranteeing very clean combustion and near-zero carbon footprint. Within this context, the present study aims to deeply investigate the effects of pure hydrogen fueling of Spark Ignition (SI) engines, especially on specific fuel consumption and NOx emissions. Particularly, the benefits of pure hydrogen fueling were assessed in a production small Direct Injection (DI) SI engine. The engine is intended to operate in steady state conditions as an Auxiliary Power Unit (APU) for a series hybrid powertrain. The effects of pure hydrogen fueling were investigated at two engine speeds, namely 2000 and 3000 rpm. All tests were carried out at unthrottled conditions and lean mixture. A 1-D engine model was developed within a commercial software. Combustion, heat transfer, and NOx emissions embedded sub-models were tuned based on the experimental data, to accurately reproduce the engine behavior in a wide range of operating conditions. Both experimental and simulation results demonstrated that hydrogen fueling, together with lean mixture operation, allow for significantly improving engine thermal efficiency. The results of 1-D model simulations supported the energy management strategies of the hybrid powertrain in selecting the most suitable ICE operating condition. Particularly, the best engine operating conditions in terms of fuel consumption are achieved at 2500 rpm, with λ = 2.0, while the lowest NOx emissions are reached when λ is increased up to 2.4. [ABSTRACT FROM AUTHOR]

In the last years, emissions standards for internal combustion engines are becoming more and more restrictive, particularly for NOx and soot emissions from Diesel engines. In order to comply with these requirements, OEMs have to face with innovative combustion concepts and/or sophisticate after-treatment devices. In both cases, the role of the Engine Management System (EMS) is increasingly essential, following the large number of actuators and sensors introduced and the need to meet customer expectations on performance and comfort. On the other hand, the large number of control variables to be tuned imposes a massive recourse to the experimental testing which is poorly sustainable in terms of time and money. In order to reduce the experimental effort and the time to market, the application of simulation models for EMS calibration has become fundamental. Predictive models, validated against a limited amount of experimental data, allow performing detailed analysis on the influence of engine control variables on pollutants, comfort and performance. In this paper, a simulation analysis on the impact of injection pattern and Exhaust Gas Recirculation (EGR) rate on fuel consumption, combustion noise, NO and soot emissions is presented for an automotive Common-Rail Diesel engine. Simulations are accomplished by means of a quasi-dimensional multi-zone model of in-cylinder processes. Furthermore a methodology for in-cylinder pressure processing is presented to estimate combustion noise contribution to radiated noise. Model validation is carried out by comparing simulated in-cylinder pressure traces and exhaust emissions with experimental data measured at the test bench in steady-state conditions. Effects of control variables on engine performance, noise and pollutants are analyzed by imposing significant deviation of EGR rate and injection pattern (i.e. rail pressure, start-of-injection, number of injections). The results evidence that quasi-dimensional in-cylinder models can be effective in supporting the engine control design toward the optimal tuning of EMS with significant saving of time and money.