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2020-01-0788 Published 14 Apr 2020

Optical Characterization of the Combustion


Process inside a Large-Bore Dual-Fuel Two-Stroke
Marine Engine by Using Multiple High-Speed
Cameras
Johan Hult MAN Energy Solutions

Alexios Matamis Lund University

Eric Baudoin and Stefan Mayer MAN Energy Solutions

Mattias Richter Lund University

Citation: Hult, J., Matamis, A., Baudoin, E., Mayer, S. et al., “Optical Characterization of the Combustion Process inside a Large-Bore
Dual-Fuel Two-Stroke Marine Engine by Using Multiple High-Speed Cameras,” SAE Technical Paper 2020-01-0788, 2020,
doi:10.4271/2020-01-0788.

Abstract
high pressure, using separate injection systems. Optical access

D
ual-fuel engines for marine propulsion are gaining is obtained using borescope inserts, resulting in a minimum
in importance due to operational and environmental disturbance to the cylinder geometry. In this type of engine,
benefits. Here the combustion in a dual-fuel marine with fuel injection from positions at the rim of the cylinder,
engine operating on diesel and natural gas, is studied using a the flame morphology becomes asymmetric. The optical
multiple high-speed camera arrangement. By recording the spatial mapping and tracking method is demonstrated to
natural flame emission from three different directions the be well suited for the study of such an asymmetric combustion
flame position inside the engine cylinder can be spatially system. Spatial mapping and tracking of flame position is
mapped and tracked in time. Through space carving a rough applied to both engine operating modes; normal diesel opera-
estimate of the three-dimensional (3D) flame contour can tion and dual-fuel operation with diesel pilot ignition of the
be obtained. From this contour, properties like flame length gas. Similarities and differences between diesel and gas flame
and height, as well as ignition locations can be extracted. The shape and development can thus be visualised directly. The
multi-camera imaging is applied to a dual-fuel marine two- effects of changing charge density, gas injection pressure and
stroke engine, with a bore diameter of 0.5 m and a stroke of injection nozzle geometry on the flame geometry and develop-
2.2 m. Both liquid and gaseous fuels are directly injected at ment are also studied.

Introduction
CO2 emissions through the energy efficiency design index

A
round 90 percent of global trade is carried by sea. (EEDI) - which uses fuel carbon content as a calculation tool.
Large freight ships employ two-stroke diesel engines In the last couple of years more than 300 dual-fuel engines
for propulsion, owing to their high efficiency, capa- have been ordered and many also become operational. This
bility of direct propeller coupling, and reliability. The cost includes ships operating on LNG [2, 3, 4], methanol [5],
of fuel for operation within stricter shipping and environ- ethane [6] and LPG [7].
mental regulations in the marine market has led to increased The MAN dual-fuel marine engines use the diesel cycle
demand for dual-fuel two-stroke marine engines. These combustion process to burn the gas. The fuel gas is injected
enable vessels to run on alternative fuels, which offer at high-pressure close to top dead center (TDC) and ignited
enhanced environmental benefits at reduced cost [1]. This is with a liquid pilot injection from the main liquid fuel injection
particularly the case for LNG, ethane, LPG or methanol system [2]. The diesel combustion cycle offers stable combus-
carriers, which have a convenient and comparatively cheap tion and the high engine fuel efficiency, power density, load
fuel already on board. New and coming emission legislations acceptance and low emission of unburnt hydrocarbons are
have also contributed to the interest in dual-fuel engines, as preserved. Furthermore, gas or fuel quality requirements, such
an alternative to traditional heavy-fuel or diesel-oil burning as methane number, are not very stringent [3]. In this paper
engines. The emission legislation is both designed to protect the optical study of a LNG fueled MAN ME-GI engine
coastal areas from SOX and NOX emissions, but also to limit is reported.
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2 OPTICAL CHARACTERIZATION OF THE COMBUSTION PROCESS

Most optical imaging techniques routinely applied to  FIGURE 1   Cylinder pressure and heat release rates for
internal combustion engines are two-dimensional in nature. diesel and dual-fuel operating modes.
The flame morphology, however, is often asymmetric and
affected by in-cylinder flows, combustion chamber geometry,
or injection geometry. This is particularly true for asymmetric
combustion systems, such as the diesel diffusion flame in a
large bore marine engine as studied here. Two or three views
are therefore necessary to capture the transient flame shape
and even more views if precise three-dimensional data is
required. Furthermore, the spatial location and extent of the
flame is a useful property for validating CFD models. Previous
optical studies of large marine engines have been limited to
conventional two dimensional studies focused on character-
ising fuel jet structure [8, 9, 10, 11, 12, 13, 14, 15], ignition
location and dynamics [11, 15, 16, 17, 18], flame structure [11,

© SAE International.
12, 19, 6], charge flow [20], component temperatures [21], and
injector flows [22].
Multi-camera imaging of flame emission for spatial local-
isation or 3-dimensional (3D) reconstruction has been
reported in the past, both in open flames [23, 24, 25, 26, 27,
28,29] and in engines [30]. Those multi-camera or 3D combus- fuel injection and exhaust valve systems are electronically
tion studies have been performed in open flames or in systems controlled and hydraulically actuated.
with good optical access. Here borescope inserts with a The liquid fuel was marine gas oil, which has similar
minimal disturbance to the engine geometry are used [19, 31]. properties to diesel. Injection pressures from 800 to 900 bar
As window size is much smaller than engine size it makes the were used. LNG was used as the gaseous fuel. It was first pres-
test cylinder representative for the real engine, without any surised up to 300 bar and then vaporised [2]. The CH4 content
limitations or deviations from real boundary conditions posed of the LNG was around 97%.
by relatively large glass components normally encountered in For the optical tests presented here the test cylinder was
optical engines [32]. operated with only one injector for each fuel type in order to
The application of the multi-camera imaging method allow an unobstructed optical view of the flame. In Fig. 1 the
presented here to diesel operation on the two-stroke engine cylinder pressure and heat release rates corresponding to the
was recently presented [31]. Here the same technique is applied different operating modes are plotted. The diesel case corre-
for studying dual-fuel operation modes, with diesel and sponds to only liquid fuel injection. In the dual-fuel case gas
natural gas as fuels. Spatial mapping and tracking of flame is the main fuel, with a small diesel injection used as pilot for
position is demonstrated both during operation on diesel only, ignition. The operation corresponds to around 75% load.
and on gas with diesel pilot ignition. The usefulness of the
method as an engineering tool is also illustrated by studying
the effects of changing charge density, gas injection pressure Optical Set-Up
and injection nozzle geometry.
The diesel and gas flames were viewed using three high-speed
cameras, see Fig. 2. The use of multiple cameras makes spatial
flame localisation inside the cylinder possible [31]. As high-
Methods speed cameras are used, dynamics and variations within

 FIGURE 2   Arrangement for tri-camera flame imaging in a


Engine marine dual-fuel engine.
The dual-fuel engine studied was the MAN 4T50ME-X test
engine. It is a production sized turbocharged low-speed two-
stroke Diesel engine. It has four cylinders with a bore of 0.5 m
and a stroke of 2.2 m. At full load it produces 7 MW of power
at 123 rpm. The engine is of the uniflow scavenged type, with
air intake ports at the bottom of the cylinder and a centrally
located exhaust valve at the top. The in-cylinder flow is defined
by a strong swirling motion introduced with the scavenging
air. In standard configuration each cylinder is equipped with
two liquid fuel injectors and two gaseous fuel injectors. The
© SAE International.

liquid injectors can be used both as pilots for igniting the gas,
and for full operation on diesel. The injectors are placed
around the rim of the cylinder and injecting tangentially along
the swirl direction. Each injector has four nozzle holes. The
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OPTICAL CHARACTERIZATION OF THE COMBUSTION PROCESS 3

 FIGURE 3   The three high-speed cameras mounted on the centre. The average projection error for the fit in the camera
cylinder top. calibration was 0.27 pixels, which corresponds to an uncer-
tainty of around 0.4 mm in a triangulation of a point in the
region around the fuel injectors.
For visualisation of the flame location a space carving
method was used [34,31]. The process is illustrated in Fig 4
for a diesel flame case. First flame emission images from the
three cameras are segmented into burnt and unburnt regions,
using an adaptive intensity threshold method (Fig. 4 a).The
method relies on first identifying the valley in the intensity
histogram, which separates the background pixels from the
luminous flame pixels, for each individual image. At each
recording time the average threshold value, over the multiple
cycles recorded for an experimental condition, is then calcu-
lated. A polynomial fit to those average threshold values, as
a function of recording time, is then performed. For each
© SAE International.

recording time the value from this fit is used as the threshold
value for each individual image in a series. For most times
the luminous non-premixed flames are quite distinct, with
good separation against the dark background, and the
segmentation method is robust and agrees well with
visual perception.
individual engine cycles can be captured. Camera 1 provided
The cylinder is then filled with voxels representing poten-
a front view of the flame, camera 2 a side view and camera 3
tial flame locations. For each camera one then carves away all
a view slightly from behind.
the voxels falling outside the observed flame contour, which
Optical access was achieved using borescopes, inserted
are projected into the cylinder as the red, blue and green cones,
into optical inserts with a sapphire window at the tip, which
Fig. 4 b). The voxels where the cones cross correspond to a
extends into the combustion chamber. The inserts were
possible flame location, as indicated by the red contour in
mounted in ports otherwise used for fuel injectors at the top
Fig. 4 c).
of the cylinder cover [19], see Fig. 3. The inserts were tilted 15°
from the vertical and the borescope direction of view was 70°,
resulting in a side view into the combustion chamber. The  FIGURE 4   Illustration of the space carving concept for
diameter of the sapphire window limits the effective viewing
flame visualisation. Borescope tips shown in green and fuel
angle to around 55°. A mirror and camera objective lens were
injectors in yellow, thin blue and red lines indicate nozzle hole
used for optical coupling between borescope and camera. This
directions. a) Flame emission images from the three cameras,
detection system captures light in the visible spectral region,
with the flame contour outlined. b) Carving cones from the
where the flame emission is dominated by soot luminosity,
for both diesel and natural-gas flames. The use of borescopes three cameras. c) overlapping regions corresponding to
with front lenses of a diameter of only a few mm, leads to very flame location.
large focal depths. This ensures that the entire flame is in focus
(focal depth extends from around 25 mm to beyond the engine
cylinder wall. The cameras uses were two Photron SA-Z
(cameras 1&2) and one was a Photron SA-X2 (camera 3). All
cameras were operated at a constant frame rate of 10000
frames per second and with exposure times from 6.25 μs to
25 μs.

Data Processing
The camera views and the effective camera positions were
determined using a calibration method relying on imaging a
checker-board target positioned at various locations inside
the combustion chamber [33]. The calibration method also
accounts for imaging system distortions (for example the
radial barrel distortions of the borescopes). The overlapping
region of camera views, where flames can be spatially located
© SAE International.

based on all three cameras, is located around and in front of


the fuel injectors - which is the space where the flame will
propagate for the first few crank-angles. This coverage is about
7% of the total combustion chamber volume at top dead
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4 OPTICAL CHARACTERIZATION OF THE COMBUSTION PROCESS

 FIGURE 5   Left: single-shot space carved flame. Right: PDF surfaces corresponding to 25% (red), 50% (blue) and 75% (green)

© SAE International.
The space carved volume slightly overestimates the flame dif ference bet ween engine operating conditions
volume, however, as it corresponds to the convex hull of the or configurations.
flame. The back of the flame, towards the cylinder wall, is also
overestimated - as there is limited camera coverage there.
However, certain features are reasonably well captured by the
carving, such as the location and time of the first ignition Results
point. The flame tip position is also captured, from which the
furthest distance from the fuel injector to the front of the
flame can be calculated, as an estimate of flame length. The Fuel Mode Variations
height of the flame can also be estimated, as both the highest Two examples of high-speed movies recorded by the three
and lowest points on the flame are captured well by the cameras are shown in Fig. 6. An example of conventional
carving. Finally, the distance from flame to exhaust valve and diesel operation is shown on the left, and of dual-fuel opera-
piston can also be reasonably estimated. tion to the right. The spacing between frames is 100 μs, which
The number of cycles captured by the high-speed cameras corresponds to 0.067 crank angle degrees (CAD) at 112 rpm,
varied from 11 to 22 for the cases analysed here. In the left but only every 13th frame is shown here. The cylinder condi-
part of Fig. 5 an example of a single-shot space carved flame tions at start of fuel injection corresponds to 75% load, with
is shown. To the right the corresponding PDFs calculated from a cylinder pressure of around 125 bar at top dead centre
22 cycles are shown. The three semi-transparent contours (TDC). The first light is visible around 10 frames (-0.8 CAD
correspond to 25% (red), 50% (blue) and 75% (green) proba- ATDC) before the first frame shown in Fig. 6 and the flame
bilities of locating the flame within the contours. The relatively leaves the field of view of camera 3 around 12 frames (2.5 CAD
small difference between the spatial extent of the 25% and ATDC) after the last frame shown here. The flame luminosity
75% shells demonstrates that cycle-to-cycle variations in flame visible in Fig. 6 is dominated by soot incandescence for both
position and shape are quite small, once the flame has devel- fuels. For the dual-fuel case one can observe that the flame
oped. Direct inspection of the individual high-speed movies emission from the natural-gas flame (the right part of the joint
confirms the relatively small cycle-to-cycle variations in flame flame in the views from cameras 1 and 2) is similar in magni-
location. For the remainder of the paper it is the 50% PDF tude to that of the diesel pilot flame (left parts of the same
contours that will be  displayed, in order to visualise the flame). In previous studies in the MAN ME-GI dual-fuel

 FIGURE 6   Flame evolution in single cycles captured using the three high-speed cameras. Left: Diesel operation, right: dual-fuel
operation. Every 13th frame from the full sequence is shown here, corresponding to 1.3 ms or 0.87 CAD.
© SAE International.
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OPTICAL CHARACTERIZATION OF THE COMBUSTION PROCESS 5

engine the same strong soot dominated flame luminosity from In Fig. 8 the front view of the same two operating cases
the directly-injected natural-gas flame has been observed [35]. is shown. From this view one can even more clearly see that
From spectral analysis of the flame emission it appears that the gas flame is a bit flatter than the diesel flame, and follows
soot luminescence clearly dominates over any chemilumines- the nozzle hole directions more closely in the initial stages of
cence within the visible spectral region, also for the natural- flame development. An obvious difference between the two
gas flame burning in a diesel process. operating modes in the initial flame development stage is the
The corresponding space carved flame development for larger flame volume of the dual-fuel case. Furthermore, the
the two operating modes is illustrated in Fig. 7, with the diesel gas flame in the dual-duel case clearly propagates closer to
flame shown in red in the top row and the dual-fuel flame the piston.
shown in blue in the bottom row. The diesel flame appears a Several flame characteristics can be deduced from the
bit rounder in shape than the gas flame, which appears a bit space carved contours. In Fig. 9 a) the evolution of the flame
flatter. One can also see that the diesel pilot flame and the gas length is plotted for the diesel flame and for the gas flame,
flame quickly form a merged flame in the dual-fuel case. An corresponding to the two operating cases illustrated in Fig. 6-8.
obvious limitation is the difficulty to differentiate diesel and Flame length was calculated as the furthest distance from any
natural gas flames once they have merged, as the visual lumi- point on the individual carved contours to the fuel injector
nosity is similar. nozzle. For the dual-fuel case the furthest distance within a
cone around the nozzle hole directions of the gas injector was

 FIGURE 7   Overview of flame propagation in the two different operating modes: diesel (top row), gas with diesel pilot (bottom
row). Every 13th frame from the full sequence is shown here, corresponding to 1.3 ms or 0.87 CAD. The contours correspond to
50% PDF
© SAE International.

 FIGURE 8   Diesel (red) and dual-fuel (blue) flames viewed from the front. The frames correspond to those in Fig. 7.
© SAE International.

 FIGURE 9   Comparison of a) flame length, b) flame tip speed and c) lift-off length development between diesel and gas flames.
© SAE International.
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6 OPTICAL CHARACTERIZATION OF THE COMBUSTION PROCESS

identified. The error bars correspond to cycle-to-cycle varia- the difference between flame regions marked by OH chemi-
tions. The same flame characteristics could also be calculated luminescence and soot luminescence has been observed to
directly from CFD simulation results, and could thus be used be very small [36]. The deviation in these measurements to
for numerical model validation. The flame length can lift-off as conventionally determined from OH* chemilumi-
be followed until it leaves the view of the cameras, at around nescence is thus not expected to be  large for this type of
200 mm flame length. The flame length development is quite engine. For the natural gas the velocity close to the nozzle is
similar for the two flames. This is not unexpected, as the gas expected to be higher than for the liquid phase, as well as being
injection system has been tuned to achieve a similar combus- colder - which could explain the longer lift-off length.
tion rate in dual-fuel mode as in conventional diesel mode.
From the time-resolved flame length data the flame tip speed
was calculated, see Fig. 9 b). For the diesel flame it initially
Charge Density
increases to around 100 m/s, after which it drops and stabilises The multiple camera approach can also be used to directly
around 40 m/s. Gas flame velocity is more stable, with a value visualise the effect of parameter variations. The first variation
of around 50-60 m/s. The observed velocities appear to be a presented here is charge density (representing a difference in
combination of jet propagation and flame propagation along load) for operation on diesel. In Fig. 10 the higher density case
the fuel jets, as it is well above the velocity of the swirling (identical to that in Fig. 6-9) is shown in red, whereas the lower
in-cylinder flow (which is around 10-15 m/s [20]). density case is shown in blue. At TDC the charge densities of
Another property which can be extracted is the lift-off the two cases are around 47 kg/m3 and 37 kg/m3, respectively.
distance, which is plotted in Fig. 9 c). The difference between For the lower charge density case the engine is operated at
the flames is here much larger, with the diesel flame stabilising 78 rpm instead of 112 rpm. In the first frame of Fig. 10 in the
close to the fuel injector (4-8 mm). The gas flame first moves high density case the diesel jets have ignited both on the top
away from the injector, and then stabilises at a distance of and bottom. In the lower density case only the top diesel jet
around 30 mm (at least during the initial part of the injection has ignited and the ignition is at a slightly larger distance from
studied here). The lift-off presented here represents the the injector. The lower charge density case flame is then seen
smallest distance from the injector to where soot starts to to grow and propagate a bit faster.
form. For a large nozzle hole diesel injector the behaviour is The faster flame spread is also evident from the plot of
quite different to that of a modern car or truck sized injector. flame lengths in Fig. 11 a). Note that the flame length is plotted
For a marine diesel injector the liquid penetration is greater as a function of time after start of injection (SOI), to allow a
than the lift-off and fuel is injected into a burning flame direct comparison despite differences in rpm between the two
envelope surrounding the fuel jet [11]. For this type of injector cases. At lower charge density the fuel jet is expected to

 FIGURE 10   Comparison between diesel injection at two different charge densities (red: 47 kg/m3, blue: 37 kg/m3). Every 9th
frame from the full sequence is shown here, corresponding to 0.9 ms or 0.6 CAD for the high density case and 0.42 CAD for the
low density case.

© SAE International.

 FIGURE 11   Comparison of a) flame length and b) lift-off length development between high and low charge densities, when
operating on diesel.
© SAE International.
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OPTICAL CHARACTERIZATION OF THE COMBUSTION PROCESS 7

propagate faster [11] as it has a higher exit velocity and encoun- injector configuration 10 °C higher piston temperatures were
ters a less dense medium, thus leading to faster apparent flame measured, further supporting the visible change in flame
development. In Fig. 11 b) the lift-off distance is plotted. The geometry. For a marine two-stroke engine small adjustments
lift-off is seen to be around 5 mm longer for the lower charge to nozzle hole directions are part of the engine tuning for a
density case, which could be a combined effect of higher diesel new engine model, in order to find a good compromise between
jet velocity and colder charge air temperatures (about 30 performance and component heat-loads.
degrees colder). The second variation studied was that of nozzle hole
diameters. In Fig. 13 the red flame is identical to the low
Fuel Injector Design density case in Fig. 10, whereas the blue flame is the result of
injection from a fuel injector with a nozzle hole diameter of
Another type of variation that was studied is that of nozzle hole 1.3 mm (instead of 1.05 mm). The nozzle hole directions for
directions. In Fig. 12 the flames from two 4-hole diesel injectors the two injectors were identical. The change due to the 50%
with different nozzle hole directions are plotted. The red flame increase in nozzle hole areas is not very drastic. The large holes
is identical to that in Fig. 7 and Fig. 10. The blue flame, however, give a slightly faster propagation, see Fig. 14 a), as expected as
was the result of a diesel injector with all nozzle holes pointing jet penetration approximately scales with the square root of
8° further down into the cylinder. One can clearly see that the nozzle hole diameter. The larger holes also result in a slightly
flame then propagates further down into the combustion higher flame, in the direction perpendicular to the nozzle hole
chamber. This brings it closer to the piston surface. In this directions, see Fig. 14b).

 FIGURE 12   Comparison between two diesel fuel injectors with different nozzle hole directions (red: reference, blue: lowered
by 8°). Every 10th frame from the full sequence is shown here, corresponding to 1.0 ms or 0.67 CAD.
© SAE International.

 FIGURE 13   Comparison between two diesel fuel injectors with different nozzle hole diameters (red: 1.05 mm, blue: 1.3 mm).
Every 12th frame from the full sequence is shown here, corresponding to 1.2 ms or 0.56 CAD.
© SAE International.

 FIGURE 14   Comparison of a) flame length and b) flame height development between two different nozzle hole diameters when
operating on diesel.
© SAE International.
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8 OPTICAL CHARACTERIZATION OF THE COMBUSTION PROCESS

 FIGURE 15   Comparison of gas injection pressures in dual-fuel mode (green: 300 bar, red: 250 bar, blue: 200 bar). The spacing
is 6 frames, corresponding to 0.6 ms or 0.4 CAD.

© SAE International.
 FIGURE 16   Comparison of a) flame length and b) lift-off development between three different gas injection pressures when
operating on gas.

© SAE International.

Gas Pressure longer lift-off at higher injection pressure would be expected


as the f lame has to stabilise against a higher incoming
The final parameter studied is gas-injection pressure, when gas velocity.
operating in dual-fuel mode. In Fig. 15 the flames corre-
sponding to gas injection pressures of 200 bar (blue), 250 bar
(red) and 300 bar (green) are visualised. The diesel pilot
employed here is a smaller injection, compared to the main Summary/Conclusions
diesel injection in the previous figures. The diesel pilot flame
can be seen in the back of the view. The gas flames are seen Large marine two-stroke engines do not have a single
in the front of the view. One can clearly see that a higher symmetric fuel injector located at the centre of the cylinder,
gas-injection pressure leads to a faster flame propagation, as but instead multiple asymmetric injectors along the periphery.
the green (300 bar) flame stretches further along the nozzle The resulting flames are thus also asymmetric. Here, multiple
hole directions than the blue (200 bar). It is also clearly seen high-speed cameras have been applied to allow the spatial
in the plot of flame propagation in Fig. 16a). This is expected location and shape of flames to be  studied. For dual-fuel
as the increased pressure leads to an increased nozzle exit engines, as the one studied here, flame geometry is even more
velocity, resulting in a faster jet propagation and thus more complicated as there are both flames, from the directly
rapid spread of the flame in the downstream direction. There injected liquid pilot and from the directly injected gaseous
seems to be no visible effect on flame extent in the other fuels. For a production type engine, the multiple-camera
direction (perpendicular to propagation direction). The approach allows parameter changes to be studied directly,
higher gas injection pressure also leads to a slight increase both in terms of spatial and temporal changes. Here the effects
in lift-off. It is a bit difficult to see from the space carved of changing injection pressure, nozzle hole size and direction,
contours, but is clear from the plot of lift-off in Fig. 16 b). This as well as charge density were studied.
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OPTICAL CHARACTERIZATION OF THE COMBUSTION PROCESS 9

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Acknowledgments
Three-Dimensional High-Speed Combustion Diagnostics in This project has received funding from the European Union’s
Internal Combustion Engines,” SAE Technical Paper 2006- Horizon 2020 research and innovation program under grant
01-3315, 2006, https://doi.org/10.4271/2006-01-3315. agreement no. 634135 HERCULES-2

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