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Multi-parametric and multi-objective thermodynamic optimization of a spark-ignition range extender ICE

Toman R., Brankov I.

Journal of KONES

2018

Vol. 25, No. 3

459--466

The current legislation pushes for the increasing level of vehicle powertrain electrification. A series hybrid electric vehicle powertrain with a small Range Extender (REx) unit – comprised of an internal combustion engine and an electric generator – has the technical potential to overcome the main limitations of a pure battery electric vehicle: driving range, heating, and air-conditioning demands. A typical REx ICE operates only in one or few steady-states operating points, leading to different initial priorities for its design. These design priorities, compared to the conventional ICE, are mainly NVH, package, weight, and overall concept functional simplicity – hence the costeffectiveness. The design approach of the OEMs is usually rather conservative: parting from an already-existing ICE or components and adapting it for the REx application. The fuel efficiency potential of a one-point operation of the REx ICE is therefore not fully exploited. This article presents a multi-parametric and multi-objective optimization study of a REx ICE. The studied ICE concept uses a well-known and proven technology with a favourable production and development costs: it is a two-cylinder, natural aspirated, port injected, four-stroke SI engine. The goal of our study is to find its thermodynamic optimum and fuel efficiency potential for different feasible brake power outputs. Our optimization tool-chain combines a parametric GT-Suite ICE simulation model and modeFRONTIER optimization software with various optimization strategies, such as genetic algorithms, gradient based methods or various hybrid methods. The optimization results show a great fuel efficiency improvement potential by applying this multi-parametric and multi-objective method, converging to interesting short-stroke designs with Miller valve timings.