Development and validation of a 5 stroke engine for range extenders application

A 5-stroke turbo-charged port-injection spark-ignition engine has been developed in the present study for use as a range extender or series-hybrid main power source. The development and the design of the engine are based on 0D/1D model and experimental results have been compared with the engine model. The 5-stroke engine is a three-cylinder in which two cylinders perform a four-stroke cycle and alternatively a second expansion of the burnt gases is performed in the third cylinder. The boost pressure delivered by the turbocharger is controlled by a particular innovative system called “smart wastegate”, different from a conventional wastegate, consisting in a variable valve timing of the two exhaust valves of the low pressure cylinder. The engine develops up to 40 kW for a speed range of 3500–4500 rpm. BSFC is 226 g/kW.h which corresponds to a fuel conversion efficiency of 36.1%. This efficiency can be achieved for an engine speed of 4000 rpm and a brake power of 32.5 kW, which are notable scores for an MPI two-valve per cylinder engine. Expected optimum should be below 217 g/kW.h BSFC and over 90 N.m torque. The engine has been tested over a wide range of conditions; model predictions and experimental results are compared and combustion efficiency increase discussed.