From Heavy-Duty Diesel to Spark-Ignited Gas

This 12L engine was converted from a modern on-highway diesel engine to a heavy-duty spark-ignited engine for electrical power generation and pumping applications. Control system is from Motive and utilizes a Woodward 70-pin controller with Motive control code, air-valve mixer with fuel trim valve for low-pressure fuel operation, direct-fire ignition, drive-by-wire throttle, proportional cooled EGR and three-way catalyst. Cooled EGR is used to limit in-cylinder and exhaust temperatures to that of the diesel engine, and also reduce engine out NOx. The engine is EPA certified for both prime and standby power on NG and LPG. Output is 315 kWe from 11.8L which is 274 psi BMEP, the highest specific output in its class.

Heavy-Duty On-Highway Engine Development

Heavy-duty diesel engines are routinely converted from diesel to natural gas fuel for use in on-highway markets. Fuels are typically CNG or LNG. Proprietary fuel systems have been developed for a variety of these engines. Calibration services and emissions development are provided on a contract basis. Shown here are two heavy-duty turbocharged, lean-burn, closed-loop, drive-by-wire natural gas engines under development and going thru successful transient emissions testing at a local emissions laboratory.

From Air to Land

This Thunder Engine, a high performance water-cooled twin-plug aircraft engine, was turbocharged and converted to a lean-burn natural gas engine for heavy-duty on-highway applications.

From Automotive Gasoline to Stationary Natural Gas

Automotive engines like this big block V8 and 13B rotary are low cost and readily available. These and others were converted to operate on natural gas, then performance and durability tested to ensure product life goals can be achieved. 20,000-hour useful life is targeted. Product improvements were made to achieve life goals. Turbocharged versions of the engines were also developed to increase power density.

The Translator

The Translator conversion system, developed by Motive’s owner, is an innovative, proven, and patented technology for converting modern fuel injected gasoline engines to run on an alternative fuel, such as natural gas or LPG. This concept was developed by a Motive employee while at SwRI and licensed to a commercial company for production. Motive engineers hold 10 patents for engine and fueling system related concepts.

Performance Development & Tuning

Motive has deep roots in drag racing and road racing. HP Tuners is used to maximize performance. Motive developed a port-injected methanol EFI system for a drag car in 1990, one of the first. Technical support has been provided to several NHRA Pro Stock and Pro Modified race teams through the years.

Enclosed Combustion Device (ECD)

ECD’s are used to destruct HC vapors that vent from processing, storage, and transfer of HC liquids at well sites and transfer facilities. Motive developed with air-assisted ECD for Total Destruction Products, LLC. The system passed all EPA test requirements on first test and is in production. Patents are pending on the novel design aspects of the ECD.

Venturi Mixers & Electronic Throttle Bodies

Motive developed a complete line of venturi mixers and electronic throttle bodies for small engine applications. Four mixer/throttle sizes from 24mm to 50mm fit engines from 1L to 7L. From concept to 3D design models to SLA models to rapid prototype castings to production intent components, Motive provided the engineering expertise to meet design, performance, and cost targets.

Product Validation & Design Validation (PVDV)

PVDV (product validation and design validation) testing is conducted to validate product performance and durability prior to production release. This test fixture was developed to durability test pressure regulators, gaseous-fuel mixers, electronic throttles, and fuel trim valves for a mobile industrial LPG fuel system. The entire assembly was placed in an environmental chamber and cycled between -40°C and 125°C as the components were cycled from minimum to maximum flow rates for 1000 hours.

Design & Modeling

Motive uses SolidWorks for product design and development. Partners aligned with Motive provide rapid prototyping and machining to reduce development time.

Water Injection System

Water injection is used to suppress knock on high compression and boosted engines, resulting in increased power output. This product was developed for a well-known aftermarket performance manufacturer.

The water injection nozzle with integral check valve provides finely atomized water mist to the intake air stream of an engine. The check valve prevents siphoning of water when the system is not in operation.

High-pressure regenerative water pump provides variable pressure and flow control to feed water injection nozzles in a boosted engine. Rapid prototyping was used to optimize the impeller design.

The final two two photos are conceptual designs for a high-pressure centrifugal water pump to be used in a water injection system on boosted engines. The solid models were developed in SolidWorks: a high-speed two-stage centrifugal pump and regenerative pump.

Dual Fuel (Diesel / Natural Gas) Control System for Stationary Gas Engines

This dual fuel control system uses low pressure natural gas from a pipeline or LNG source, only 8 in H2O fuel pressure is required. Mass flow rate of the fuel gas is controlled thru a throttle valve with a venturi flow tube. Generator output provides feedback for accurate fuel substitution rates up to 80%. The controller continually monitors engine conditions and controls to the desired substitution rate for optimum operation.

The dual fuel system includes mass flow measurement and control device, venturi mixers, balance valves, controller, and sensors.

The mass flow metering device consists of a venturi mass fuel flow rate measuring device and a throttle valve to give accurate and responsive fuel flow control of natural gas.

Engine ECM and Controller Design and Packaging

Mechanical packaging of custom electronic controllers can mean the difference between success and failure of the product. Motive has designed and developed PCB-level layouts for heat sinks, header connector systems, and mechanical packaging to meet the harsh underhood automotive environment. Key to these designs are connector systems, thermal management, and vibration resistance.

Fuel System Component Design and Development

A variety of fuel injection components have been developed for multipoint (MPI) and throttle body (TBI) systems. Fuels include gasoline, pipeline NG, CNG, LNG, LPG, and H2.

Photo 1: These natural gas metering valve assemblies use Bosch and Servojet PWM fuel injectors to meter fuel to the engine. They are equipped with integral fuel shutoff solenoid, fuel pressure sensor, and fuel temperature sensor. Both single point (TBI) and multi-point (MPI) configurations are available. The units shown are for single point fuel injection.

Photo 2: This gasoline TBI unit was developed for small industrial engines. It provides a fully integrated solution for gasoline injection and electronic air throttling. The system includes the electronic throttle, fuel injector, fuel pressure regulator, TMAP sensor, and cast bonnet.

Photo 3: This fuel metering block was developed for a low pressure MPI LPG vapor injection system. Each injector feeds a different cylinder thru it’s own fuel hose. This system can be adapted to MPI gasoline engines to provide an MPI fuel system on an alternative fuel, such as LPG or CNG. A patent was awarded for this design concept.

2-Stage LPG Vaporizing Pressure Regulator

Motive developed this 2-stage, positive-pressure, vaporizing LPG regulator for fuel-injected engines. The regulator was taken from concept thru PVDV testing. SolidWorks was used for 3D modeling. A working prototype regulator machined from billet is shown on the right. The regulator was developed for a prominent alternative-fuels vehicle component supplier.

On-Highway LPG Fumigation System for Diesel Engines

By adding a small amount of LPG (propane) to the intake air stream of a diesel engine, power output can be greatly enhanced. Motive developed this system to deliver proportional continuous-flow metering of LPG vapor to the engine when extra power is needed. The system is electronically controlled by an ECM and can be programmed to delivery a variety of power boost levels. It also significantly extends driving range of the vehicle. This product was awarded Runner-Up Best New Product at the SEMA show in 2004, and is manufactured and available from a popular aftermarket engine component company.