Since 2004, a large part of our work, both professionally and as consultants, has been focused on the design and development of novel, high-efficiency engine concepts and the building of the required analytical and testing infrastructure from scratch.

Sample Project: ARPA-E GENSETS Program

  • Background: Department of Energy sponsored program to 
                         develop a high-efficiency, natural gas-powered 
                         residential CHP system (click 
    here for additional
                         information on ARPA-E GENSETS)

  • Role of NSES:  Co-principal investigator and technical lead for
    customer, Tour Engine, Inc. (click here for
                            additional information)

  • Project Duration/Funding:  5 yrs / $5.1M from private and government sources

  • Contributions by NSES
    • ​Grant application, project definition, SOW, schedule & budget
    • Specification of test cell, dyno, dyno driveline, instrumentation
    • Design, build and programming of test cell data acquisition system
    • Creation of all pre-/post-processing tools for dyno configuration and test data
    • Overseeing design & manufacturing of engine prototypes
    • Engine testing and performance evaluation
    • System model calibration and performance prediction (GT-Power)
    • Report generation for customer and ARPA-E

Engine R&D involving Analysis

  •  Engine Systems Simulations 
    • Optimization, DOE, model calibration, performance prediction
    • Software: GT-Power, Ricardo Wave, Optimus/Noesis
  • ​Structural Analysis
    • ​​Component level (crankshaft, conrod, pistons, etc.)
    • Engine dynamics (rotating & reciprocating masses using GT-Suite)
    • Resonance analysis (engine & dyno driveline using GT-Suite)
  • ​Thermal Analysis
    • ​Liquid cooling (pistons, cylinder, etc.)
  • Flow Analysis
    • ​Transient analysis of scavenging flow using ANSYS
    • Impingement jet cooling of pistons (experimentally and analytically)
    • Cylinder cooling (CHT) 

Engine R&D involving Testing

  • Testing Infrastructure
    • ​Defining/building/managing test cells
    • AC dynos and water brake dynos ranging from 5kW to 300kW
    • Instrumentation and sensors (Kistler, NI, Horiba, AVL, FTI, Meriam, etc.)
  • Data Acquisition & Processing
    • Development of complete data acquisition solutions using LabView
    • Development of pre-/post-processing software tools using Visual C++, VBA


​​​​Engine R&D