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Regulated emissions (THC, CO, NOx, and PM) and particulate SOF and sulfate fractions were determined for a 1995 Detroit Diesel Series 50 urban bus engine at varying fuel sulfur levels, with and without catalytic converters. When tested on EPA certification fuel without an oxidation catalyst this engine does not appear to meet the 1994 emissions standards for heavy duty trucks, when operating at high altitude. An ultra-low (5 ppm) sulfur diesel base stock with 23% aromatics and 42.4 cetane number was used to examine the effect of fuel sulfur. Sulfur was adjusted above the 5 ppm level to 50, 100, 200, 315 and 500 ppm using tert-butyl disulfide. Current EPA regulations limit the sulfur content to 500 ppm for on highway fuel. A low Pt diesel oxidation catalyst (DOC) was tested with all fuels and a high Pt diesel oxidation catalyst was tested with the 5 and 50 ppm sulfur fuels.

In order to reduce PM (Particulate Matter) emitted from diesel vehicles, we have been developing the particulate trap system using a burner since 1993. This AEFR system (Active Exhaust Feeding Regeneration System) shows considerably low peak temperatures and temperature gradients in the filter during the regeneration process. The AEFR system used the engine exhaust gas partially for the regeneration of the ceramic wall flow filter. It controlled the bypass flow rate of the engine exhaust gas actively for the combustion rate control of filtrated PM. The temperature distributions and temperature gradients in the filter during the regeneration process varied widely according to the regeneration control schemes. Scheme III has shown the most desirable peak temperatures and temperature gradients in the filter during the regeneration processes with AEFR system.

The main purpose of this study was to investigate the influence of diesel engine conditions on the mutagenic activity of the exhaust. Special emphasis was put on investigation of the influence of nitrogen oxides content. Experiments with a diesel engine have been carried out in the laboratory and the emissions of carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NOx) and particulate matter (PM) have been measured at different engine conditions. The particulate matter was extracted in order to obtain the soluble organic fraction (SOF), and this fraction was analyzed for mutagenic activity in the Salmonella/microsome assay (AMES test). It was found that the mutagenic activity evidently depended on the PAH content (PAH = Polycyclic Aromatic Hydrocarbons) of the exhaust gas rather than the NOx content. However, the percentage of the direct mutagenic activity of the total mutagenic activity increased as the NOx content in the exhaust gas increased.

Comparative emission measurements were made in two dynamometer-based diesel engines using protocol specified by the U.S. Environmental Protection Agency (EPA) and the California Air Resources Board (CARB). A single JP-8 fuel with a sulfur level of 0.06 weight percent (wt%) was adjusted to sulfur levels of 0.11 and 0.26 wt%. The emission characteristics of the three fuels were compared to the 1994 EPA certification low-sulfur diesel fuel (sulfur level equal to 0.035 wt%) in the Detroit Diesel Corporation (DDC) 1991 prototype Series 60 diesel engine and in the General Motors (GM) 6.2L diesel engine. Comparisons were made using the hot-start transient portion of the heavy-duty diesel engine Federal Test Procedure. Results from the Army study show that the gaseous emissions for the DDC Series 60 engine using kerosene-based JP-8 fuel are equivalent to values obtained with the 0.035 wt% sulfur EPA certification diesel fuel.

Particle emissions from vehicles are currently under close scrutiny with respect to their contribution to ambient air quality relative to other sources. Small particles, less than 10 μm, referred to as PM10, have been linked to various health issues. In this study, tests have been performed on European diesel light duty vehicles using a range of production diesel fuels. Tests were also performed on two gasoline passenger cars for comparison. Measurements were made of exhaust particle size distribution and number, as well as mass emissions using the legislated filter paper method. The results showed that most of the particles emitted were very small, with median size of the order 100 nanometres (nm). The median particle size was insensitive to changes in fuel, vehicle or operating condition. Measurements of particle number broadly correlated with particle mass emissions, and ranked fuels and vehicle types in the same order.

Advancements in natural gas engine control technology can result in natural gas engines which are more efficient, powerful, responsive, and durable than those currently available. The vast majority of hardware required to make these advancements exists or can be modified for application on natural gas engines. Given this, an investigation to develop and incorporate advanced natural gas engine control technology was completed. Advanced control techniques for equivalence ratio control, knock detection and control, misfire detection and control, and turbocharger transient surge supression are detailed in this paper. Control strategies were developed and applied to a heavy-duty on-highway natural gas engine using a personal computer-based prototyping control system. The engine control system advancements resulted in a natural gas engine with increased efficiency, power density, and response, along with reduced emissions over the current state-of-the-art in natural gas engines.

A multiplex communication system has been developed for the Ford Alternative Fuel Qualified Vehicle Modifier (QVM) program, linking the vehicle's powertrain control module (PCM) to the alternative fuel (natural gas or propane) control module (AFCM). The system allows precalibrated diagnostic routines (OBD and non-OBD) to be selectively modified and disabled which otherwise would be affected by alternative fuel operation. The system enables the broadcasting of selected information from the PCM for use by the AFCM. An additional benefit is smoother transition between alternative fuel and gasoline operation when the gaseous fuel is depleted. Also, improved emissions on the alternative fuel have been noted due to the link. System development and function are detailed in this paper.

A novel piezo-fluidic gaseous fuel injector system designed for natural gas engines is described in this paper The system consists mainly of no-moving-part fluidic devices and piezo electro-fluidic interfaces The steady state and dynamic characteristics of the system were tested on a laboratory experimental rig The results show that the system can handle the large gas volume flow rate required by natural gas engines and is capable of operating via pulse width modulation. A few typical commercial solenoid type gas injectors were also tested and the results were compared with those from the piezo-fluidic injector system. It was found that the piezo-fluidic gaseous fuel injector system has faster switching responses and smaller injection cycle-to-cycle variations

Throttle tip-in and tip-out tests on a 2.0 litre passenger car engine were performed using four different natural gas fuelling systems an air-valve or variable restriction type mixer, a venturi type mixer, central fuel injection, and port fuel injection. The in-cylinder fuel-air equivalence ratio, ϕ, was measured using a fast response flame ionization detector sampling about 7 mm from the spark plug gap. The data reveal characteristics of each fuel system's in-cylinder fuel-air ratio response and torque response.

This paper describes experimental studies carried out as part of a program to develop a neat methanol (M100) version of a GM 4-cylinder light truck engine. The engine was originally intended for variable fuel applications with fuels containing up to 80% ethanol. To permit M100 operation, a variable energy ignition circuit and special recessed surface gap ignitors have replaced the standard ignition components. This is referred to as a “plasma jet” ignition system, and is employed both to overcome the cold starting difficulties inherent with neat alcohol fuel and to permit less enrichment to be used during start-up in the interest of reduced hydrocarbon emissions. The plasma jet ignition systems used in previous related studies suffered from excessively high ignition energy requirements which would be detrimental to ignitor durability.

Tins report describes the experimental procedure used to evaluate the effect of selected fuel components (butane, propane and propene) of liquefied petroleum gas (LPG) on both regulated and speciated exhaust emissions. A total of seven LPG fuels were tested on three different vehicles. FTP-75 emission tests were conducted on each fuel blend for all three vehicles. Full hydrocarbon and carbonyl speciation were included for at least one test on each fuel. In general, fuel composition effects on post catalyst emissions were overwhelmed by vehicle to vehicle differences. There was no clear indication that one fuel showed best emissions in all vehicles. Results also suggest some dependence upon initial LPG fuel system calibration. Data presented here may lend itself to further statistical analysis which is beyond the scope of this paper. These mixed results suggest that more research is needed to provide greater insight on the effect of LPG fuel components on vehicle emissions.

A range of gasoline/alcohol blends containing methanol, ethanol, iso-propanol and n-propanol, up to 5% oxygen content by mass, was tested in a multi-valve production engine to quantify the raw exhaust emissions, performance and burn-rate. A heat-release model was developed to facilitate the quantification of burn-rate. The engine was operated with various control strategies to enable the results to represent the response of different engine types. With standard open-loop engine calibration the alcohols reduced the equivalence ratio which resulted in increased combustion duration and reduced regulated emissions, while there was no difference between the effects of the different alcohols.

A new Electronic Gantry Applied Drilling System has been developed and demonstrated which provides a CNC controlled, multi-axis drilling system to replace hand drilling and countersinking operations at Assembly Jig Stations. Therefore improving hole quality while reducing touch labor and tooling costs. The system has statistical process control capabilities which confirm position accuracy for tooling details, parts holes.

Under Contract No. N00019-93-C-0006 EMD with the Department of the Navy, Bell Helicopter Textron Inc. (BHTI) conducted a Manufacturing Process Verification Test as part of the V-22 Engineering Manufacturing Development process. The objective of this test was to develop a “One Step” drilling solution for peck drilling close tolerance holes in V-22 major assemblies. These assemblies consist of Titanium / Graphite / Titanium and Aluminum / Graphite compositions. The V-22 is a graphite / epoxy composite structure that has metal detail parts mechanically attached to the basic structure. Attachment of these detail parts is accomplished with two piece titanium fasteners that require a close tolerance of .003″ per hole. To achieve this tolerance a drill / ream process is currently used.

A new wing panel riveting cell capable of replacing tack fasteners and performing small repair jobs has been developed. Using two mobile scissor lift platforms with electromagnetic riveters mounted on each, the operators can access every portion of the wing panel without the use of ladders or platforms. This method minimizes fatigue, allows workers to carry all tools and supplies with them, meets current safety standards and minimizes coldworking of the components.

This technical paper will address the advancements made in the area of automatically riveting complex double-contour 180 degree fuselage panels. Detailed is an automatic fastening system that accomplishes the aforementioned task in a single workframe mounted panel/fixture sequence. Through the use of innovative machine motions and enhanced adaptive controls, increased production throughput for difficult to rivet panel assemblies has been realized.

A new control architecture has been utilized to control an “anti-wink” automatic slug riveting process which improves fastening accuracy, reliability and cycle time. Cycle rates are equal to or better than that of conventional slug riveting. This technique of fastening provides for virtually no work piece movement during the forming process allowing for the use of rigid fixturing.

Two new concept of flexible fixture subsystem (FFS) for aircraft wing spar assembly are introduced in this paper. The advantages and characteristics of FFS are discussed and compared with the current assembly method and fixtures. The objective of FFS is to replace the dedicated tooling and be able to quickly reconfigure itself for new types of spars. The fixture enables a family of spars to be mounted and assembled in the same tooling. Left- and right-hand side spars, varying lofts(spar cap angles), height, and depths are all accommodated on the same tool, within its envelop.

McDonnell Douglas Aircraft in St. Louis, MO manufacturers various transport and fighter military aircraft such as the C-17 and the F/A-18. With shrinking military budgets and increased competition, market forces demand high quality parts at lower cost and shorter lead times. Currently, a large number of different fastener types which include both solid rivets and interference bolts are used to fasten these assemblies. The majority of these fasteners are installed by hand or by using manually operated C-Frame riveters. MDA engineers recognized that in order to reach their goals they would be required to rethink all phases of the assembly system, which includes fastener selection, part fixturing and fastener installation methods. Phase 1 of this program is to identify and to develop fastener installation processes which will provide the required flexibility. The EMR fastening process provides this flexibility.

Many of the large CNC controlled riveting systems that were purchased in the late 1970s and 1980s are beginning to show signs of dated technology. To protect the original investment in this equipment, aerospace companies are looking into refurbishing these machines. Issues such as pre-planning, teaming concepts, communications, and a thorough understanding of the equipment are essential to a successful project. This paper is based on the case history of one such refurbishment project.