Spark-Assisted HCCI

Residential CHP

Wisconsin Engine Research Consultants

(WERC), LLC

Briggs & Stratton Corp.

University of Wisconsin – Madison

Adiabatics, Inc.

PI Dr. Rolf D. Reitz

Team• Rolf Reitz, Chris Rutland, Chris Wright, Dave Wickman

• Leading company in IC engine consulting, specialized in

computer modeling

• Project lead and administration / engine modeling

• Doug Shears, Dave Procknow, Jacob Zuehl

• One of the largest manufacturers of small engines for outdoor

power equipment

• Funding / base engine design / engine testing / technology to

market

• Sage Kokjohn, Mike Andrie

• World-class research and educational institution dedicated to

investigating the fundamental thermo-physical processes that

control combustion in internal combustion engines

• Advanced combustion and controls development / boosting

system development

• Lloyd Kamo

• Leading company in the development and

application of surface coatings for IC engines

• Thermal barrier coatings (TBC) development

/ testing / application

Technology• Transform small internal combustion (IC)

engine efficiency by creating a cost effective

large IC engine thermodynamic cycle in a

small engine

• Systematically address the underlying losses

inherent to small engines

Advanced

combustionReduced

heat loss

Reduced

friction loss

Technology• Advanced combustion

– SA-HCCI

– Optimized heat release

– High combustion efficiency

• Low heat rejection – Thermal barrier coatings

• Advanced boosting – Comprex supercharging

• Low friction – Off-set crankshaft

– Roller bearings

– Low friction seals

– Roller cams

– Low loss oil systems

– Low friction surface coatings

Technical Progress• Model based design study completed

• Determined optimum design parameters for initial design concepts

• Initial engine concepts designed• Concept 1 uses mostly production engine components to accelerate

testing with an engine close to the design study specifications

• Concepts 2 and 3 are clean sheet engine designs based on the

design study

• Concepts are currently being evaluated using CFD models

Concept 1

Concept 2wide valve angle

Concept 3narrow valve angle

Technical Progress• Fully instrumented test laboratory design and

fabrication completed

• Cylinder pressure feedback control with

Woodward® ECU

• Fully instrumented pressure wave

supercharger (PWS) development laboratory

designed and fabricated• Decoupled PWS from test engine to

characterize independent boosting

performance

• PWS instrumented with temperature, pressure

and mass air flow sensors reading into high

speed data acquisition system

3D Design and Analysis Prototype Fabrication System Level Testing

Technical Progress• Base thermal barrier coating (TBC)

durability testing in a production NG

fueled engine completed

• Development of improved TBCs in

progress

• Key is minimizing heat conductivity

and heat capacity (to maximize

temperature swing), while

maintaining durability

• Accelerated TBC durability testing

laboratory designed, fabricated and

functional

NG engine base TBC durability testing

Lessons Learned• TBC performance affects air and combustion system

performance requirements

• Target 38.5% BTE line shown on all graphs

• Note different X and Y axis values for Current coating

compared to Development and Stretch Goal coatings

• Current coating requires ~35+% EGR and 1.5bar Pintake

• Development coating can achieve 38.5% BTE with 1.5bar

Pintake and ~25% EGR

• Stretch Goal coating only requires ~16-18% EGR with Pintake

as low as 1.3bar

Current

Coating

Development

Coating

Stretch Goal

Coating

Lessons Learned• Original TBC accelerated durability test results did not agree with

engine durability test results

• Improved TBC accelerated durability test

• New test has better agreement with engine test results

• New test uses oxygen – acetylene flame in place of natural gas –

air flame

• Failure of baseline TBC using O-A torch is strikingly similar to initial “flaking” of

coating in durability test engine

• Higher heat immediately screened out older TBCs

• Improved test contributed to new technological advancement with refractory

additives and binder system compatibility

• New variation TBCs are much more robust, passing both O-A and NG torch

thermal shock tests

Next Steps - 2017• Testing of concept engines

• Engine data will be used to improve Phase I prototype design

• Engine data will be used to refine the GT-power and CFD models

• Bench testing of 3 boosting concepts• Identify best method to achieve required intake conditions

• Complete Phase I prototype engine design and build 2 engines

• Testing of Phase I prototype engine• Engine data will be used to refine GT-power and CFD models

• Demonstrate that Phase I engine is meeting interim performance targets

• Validate Phase I prototype GT-power engine model

• Re-optimize engine design using Phase I prototype GT-power model

• Validation and durability testing of new coatings

• Commence:

• CFD model validation of Phase I prototype engine

• Design of Phase II prototypes

• Model based optimization of boost system

• Durability testing of Phase I prototype

• Manufacturing and cost study of TBCs

• Commercialization assessment

• On-going T2M and techno-economic analysis