Development of Two-Step Exhaust Rebreathing for a Low-NOx Light-Duty Gasoline Compression Ignition Engine

The global automotive industry is undergoing a significant transition as battery electric vehicles enter the market and diesel sales decline. It is widely recognized that internal combustion engines (ICE) will be needed for transport for years to come; however, demands on ICE fuel efficiency, emissions, cost, and performance are extremely challenging. Gasoline compression ignition (GCI) is one approach for achieving the demanding efficiency and emissions targets. A key technology enabler for GCI is partially-premixed, compression ignition (PPCI) combustion, which involves two high-pressure, late fuel injections during the compression stroke. Both NOx and smoke emissions are greatly reduced relative to diesel, and this reduces the aftertreatment (AT) requirements significantly. For robust low-load and cold operation, a two-step valvetrain system is used for exhaust rebreathing (RB). Exhaust rebreathing involves the reinduction of hot exhaust gases into the cylinder during a second exhaust lift event during the intake stroke to help promote autoignition. The amount of exhaust rebreathing is controlled by exhaust backpressure, created by the vanes on the variable nozzle turbine (VNT) turbocharger. Because of the higher cycle temperatures during rebreathing, exhaust HC and CO may be significantly reduced, while combustion robustness and stability also improve. Importantly, exhaust rebreathing significantly increases exhaust temperatures in order to maintain active catalysis in the AT system for ultra-low tailpipe emissions. To achieve these benefits, it is important to optimize the rebreathe valve lift profile and develop an RB ON→OFF (mode switch) strategy that is easy to implement and control, without engine torque fluctuation. In this study, an engine model was developed using GT-Suite to conduct steady-state and transient engine simulations of the rebreathing process, followed by engine tests. The investigation was conducted in four parts. In part 1, various rebreathe lift profiles were simulated. The system performance was evaluated based on in-cylinder temperature, exhaust temperature, and pumping work. The results were compared with alternative variable valve actuation (VVA) strategies such as early exhaust valve closing (EEVC), negative valve overlap (NVO), positive valve overlap (PVO). In part 2, steady-state simulations were conducted to determine an appropriate engine load range for mode switching (exhaust rebreathing ON/OFF and vice-versa). The limits for both in-cylinder temperature and exhaust gas temperature, as well as the external exhaust gas recirculation (EGR) delivery potential were set as the criteria for load selection. In part 3, transient simulations were conducted to evaluate various mode switch strategies. For RB OFF, the cooled external EGR was utilized with the goal to maintain exhaust gas dilution during mode switches for low NOx emissions. The most promising mode-switch strategies produced negligible torque fluctuation during the mode switch. Finally, in part 4, engine tests were conducted, using the developed RB valve lift profile, at various low-load operating conditions. The mode switch experiments correlated well with the simulation results. The tests demonstrated the simplicity and robustness of the exhaust rebreathing approach. A robust engine response, low CNL, high exhaust gas temperature, and low engine out emissions were achieved in the low load region.