Southwest Research Institute (SwRI) is developing advanced combustion, aftertreatment and controls technology for light-duty vehicle engines for low emissions applications. With the recent changes in regulations, the transportation industry is expanding the portfolio of offerings to include new internal combustion engines and hybrids for light duty vehicles, creating a need for technologies that can increase total powertrain efficiency while minimizing emissions.

SwRI is conducting research using a wide range of advanced technologies including passive and active pre-chambers, cold-start emissions reduction strategies, advanced ignition systems and novel aftertreatment solutions. SwRI is also at the forefront of research and testing with low-carbon fuels such as renewable gasoline and diesel, methanol, ethanol and gaseous fuels including natural gas, propane and hydrogen.

Light-Duty Engine Development Expertise

SwRI offers a wide range of light duty engine development and testing services, including design and prototype work through calibration, certification and durability testing.

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Combustion system design and modeling.

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SwRI’s open engine controller integrates with OEM technology.

• Combustion System Development — SwRI utilizes advanced modeling tools to develop combustion systems optimized for high efficiency and low emissions. Designs support both spark ignited and compression ignited fuels.
• Design — SwRI’s hardware design services enable clean sheet engine designs and modifications to meet power, efficiency, and emissions goals.
• Calibration — Today’s engines require continuous monitoring of many sensors and simultaneous control of many actuators to operate. SwRI offers an open engine controller to enable rapid deployment or integrates with OEM controllers and automation tools.
• Engine Testing — Once an engine is designed, built and calibrated, SwRI offers testing services to support a full range of durability and 1065 and 1066-compliant certification testing for on and off-highway engines. SwRI also offers advanced inspection techniques to quantify engine wear, failure mode analysis and oil analysis to develop a holistic understanding of engine durability.

Core Technologies

SwRI leads the industry in the development of many key technologies which enable efficient engine designs. These core technologies can be applied across engine architecture and fuel type.

• Advanced Ignition Concepts — SwRI leads the industry in the development of novel ignition systems such as the Dual Coil Offset (DCO^™). This system uses two ignition coils to create a continuous spark of variable duration. The technology has proven extremely effective at igniting mixtures at high dilution ratios and/or with high ignition temperature fuels.
• Dedicated Exhaust Gas Recirculation (D-EGR^™) — While exhaust gas circulation (EGR) is not new, SwRI has developed a new method to generate and introduce EGR into engines. Conventional EGR systems collect EGR from the exhaust manifold, common to all cylinders and use the same calibration for all cylinders. While this method has benefits in reduction of pumping losses and emissions, it is also limited by combustion stability at high levels. In SwRI’s patented D-EGR^™ system, a single cylinder is “dedicated” to the production of EGR. The calibration for this cylinder is rich, and acts as a hydrogen reformer, producing exhaust gas that assists in participating in the combustion process. The full exhaust produced by this dedicated cylinder is then mixed with the intake charge and introduced to all four cylinders. This technology has enabled a 15% improvement in engine efficiency compared to the conventional baseline.
• Pre-Chamber Technology — SwRI has combined modeling and testing capabilities to design and demonstrate efficiency benefits of pre-chamber technology. In one experiment using a 1.2L gasoline engine, the burn duration was reduced by two-thirds, while the combustion efficiency was increased by 2%. Faster combustion is beneficial because it reduces the chances of autoignition and enables higher dilution.

Capabilities

SwRI’s testing facilities offer 60 test cells, capable of supporting engines across a wide power range. One project may utilize one or more testing resources. An example of a development project may include modeling to develop several combustion system designs, manufacture and testing of the best variants in a single cylinder engine, followed by expanded testing in a full multi-cylinder engine.

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Single-cylinder research engine.

• Single-Cylinder Research Engines — SwRI has developed flexible single cylinder engines, commonly used to screen combustion system concepts before they are scaled up to multi-cylinder designs. The flexible nature of single-cylinder engines enables engines ranging from 0.5 L per cylinder up to 2.2 L per cylinder. These engines are offered for sale and delivery to external facilities. SwRI also owns several that are available for customization to match your application.
• Multi-Cylinder Engines — The final proof of performance is demonstrated in multi-cylinder engine testing. Depending on the program requirements, testing can be conducted over a short duration for performance validation and/or certification, or extended duration for durability testing. In either case, SwRI can support testing needs. Additionally, SwRI offers specially outfitted test cells to replicate extreme environments, such as high-altitude and cold-air testing.

Why Partner with SwRI?

We deliver exceptional client service backed by decades of experience in engine design, calibration and testing. Our multidisciplinary experts span technical divisions and engineering disciplines, enabling us to support a wide range of project needs.

Whether it’s a standard application or a one-off, highly specialized test, we offer flexible, client-focused solutions tailored to each project’s unique requirements. Our highly skilled engineering and technical staff support are ready to support your hardware and development programs across all Technology Readiness Levels (TRL), from early-stage concepts to full-scale validation.

Related Services

• Automotive Vehicles, Engines & Drivelines