Utilize experimental engine maps as inputs to drive cycle simulation software to estimate the real-world fuel economy and emissions impact. Fiscal Year (FY) 2011 Objectives Release ORNL VCR engine design Complete crankcase castings Complete crankcase machining Procure 90 percent of engine hardware Complete buildup of ORNL engine test facility for VCR engine evaluation Accomplishments A custom, four cylinder crankcase block, designed by Envera LLC, was casted and machined. This custom block was designed to allow installation of a mass production gasoline direct-injection cylinder head cylinder head and permit the integration of the VCR mechanism to be fully contained within the crankcase. Figure 1 shows picture of completed crankcase block. Figure 1. Finished crankcase block Engine block bedplate and crankshaft support cradle were designed and casted. Below are pictures of casted engine block bedplate and crank cradle. Figure 2 and 3 shows picture of casted block and crankshaft cradle, respectively. Figure 2. Engine block bedplate casting Figure 3. Crankshaft cradle housing casting Completed purchase of 90% of engine hardware ORNL test site preparations for the VCR engine were completed. The test facility incorporates state of the art common fueling system, cooling system, air handling system, emissions bench, and data acquisition system that are fully functional.
Utilize experimental engine maps as inputs to drive cycle simulation software to estimate the real-world fuel economy and emissions impact. Fiscal Year (FY) 2011 Objectives Release ORNL VCR engine design Complete crankcase castings Complete crankcase machining Procure 90 percent of engine hardware Complete buildup of ORNL engine test facility for VCR engine evaluation Accomplishments A custom, four cylinder crankcase block, designed by Envera LLC, was casted and machined. This custom block was designed to allow installation of a mass production gasoline direct-injection cylinder head cylinder head and permit the integration of the VCR mechanism to be fully contained within the crankcase. Figure 1 shows picture of completed crankcase block. Figure 1. Finished crankcase block Engine block bedplate and crankshaft support cradle were designed and casted. Below are pictures of casted engine block bedplate and crank cradle. Figure 2 and 3 shows picture of casted block and crankshaft cradle, respectively. Figure 2. Engine block bedplate casting Figure 3. Crankshaft cradle housing casting Completed purchase of 90% of engine hardware ORNL test site preparations for the VCR engine were completed. The test facility incorporates state of the art common fueling system, cooling system, air handling system, emissions bench, and data acquisition system that are fully functional.
Pub33709.docx