2014 DOE Annual Merit Review REGIS - Department of Energy€¦ · 2014 DOE Annual Merit Review...
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2014 DOE Annual Merit Review REGIS
Claus Schnabel (PI)
Award: DE-EE0005975 Sensors and Ignition Project ID: ACE091 Gasoline Systems, Robert Bosch LLC
2014 DOE Vehicle Technologies Program Review
Washington, D.C. June 19th, 2014
This presentation does not contain any proprietary, confidential, or otherwise restricted information 1
GS-SI/ENG2-NA | 6/19/2014 | © 2013 Robert Bosch LLC and affiliates. All rights reserved.
2014 DOE Annual Merit Review REGIS
Project Overview
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Partners
Timeline
US Department of Energy
Robert Bosch LLC
Clemson University
Oak Ridge National Lab
Target is to develop an Intake Air Oxygen (IAO2) sensor which directly and accurately measures the oxygen concentration in the intake manifold and demonstrate its potential.
Barriers are ! Inadequate data on requirements and risks
concerning sensing with IAO2 ! Control Strategies utilizing IAO2 sensing
$4,446,686 – Total Project Budget $2,750,000 – DOE Funding $1,696,686 – Partner Funding
$1,781,072 – Actual expenditure (as of 12/2013) $1,096,084 – DOE Funding $684,988 – Partner Funding
$2,665,614 – Remaining (as of 12/2013) $1,653,916 – DOE Funding $1,011,698 – Partner Funding
Project Overview
Sensor Development
Baseline Sensor Evaluation Design Development
Design Development Validation
Validation
System Evaluation
cEGR System Evaluation Requirements Sensor
Demonstration of potential
cEGR Control Strategy Control Algorithm Development Validation
2013-Phase I 2014 -Phase 2
Budget
Target & Barriers
2014 DOE Annual Merit Review REGIS
Objectives and Relevance Objectives Develop an Intake Air Oxygen (IAO2) sensor which directly and accurately
measures the oxygen concentration in the intake manifold
Demonstrate the potential of the sensor in combination with system adaptation and cEGR control strategies in a target engine application
Relevance of cEGR cEGR enables improved fuel economy in most driving conditions
(on and off cycle) supporting the mainstream trend of Downsizing
Improvement of up to 5% in engine peak thermal efficiency
Other future combustion technologies will utilize cEGR
Relevance of IAO2 IA02 aims at providing a significant improvement in control accuracy of
cEGR to maximize the fuel economy potential of the system
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2014 DOE Annual Merit Review REGIS
Collaborators and Partners
System level evaluation cEGR Control Development Proof of Potential
Funded by DOE 460 T USD Own Funding 115 T USD
Derivation of requirements Development and Validation Sensor Built of Sensor Prototypes Validation Control Strategy
Funded by DOE 2110 T USD Own Funding 1582 T USD
Advanced testing support Thermodynamics cEGR
Funded by DOE 180 T USD Own Funding 0 T USD
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2014 DOE Annual Merit Review REGIS
Milestones & Summary of Technical Accomplishments Sensor Development
Baseline sensor characterization
Improve sensor mounting and ECU connector design; build prototypes
Sensor development for functional robustness over lifetime; build prototypes
Concept for 2nd generation IAO2 element System Evaluation
Baseline system characterization (engine testing and simulation)
Assessment of system risks and requirements for sensor (intake conditions, controls)
Investigate impact of sensor location on sensor performance and requirements
Control Development
EGR estimation algorithm development
Control-oriented model for in-cylinder EGR prediction
Demonstration of sensing benefits
Engine simulation to demonstrate sensor benefits
Demonstration of improved sensor functionality and robustness
Demonstration of potential for fuel economy improvement and emissions performance
with IAO2 compared to a model-based EGR control strategy using rapid prototyping
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Engine Speed [RPM]
BMEP
[bar
]
LTG LP-EGR Relative BSFC Delta [%]
1500 2000 2500 3000
5
10
15
20
-3
-2
-1
0
Cooled EGR Relative BSFC Delta [%]
2014 DOE Annual Merit Review REGIS
IAO2 Motivation
IAO2 is a key enabler for maximizing the benefits of LP cooled EGR
IAO2 ∆p
Accuracy (long term)
HW Robustness
Dynamic
Cost
Risk
Calibration effort
Near unity pressure ratio over EGR valve in region with greatest impact on fuel economy
Near unity pressure ratio with LP-EGR is challenging for flow modeling and controls with differential pressures sensor
Region with small pressure differential across EGR valve (pressure ratio is near unity)
Sensing Alternatives for EGR Determination
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2014 DOE Annual Merit Review REGIS
IAO2 Control Development
0
2.5
5
7.5
10
14 16 18 20 22
Mas
s Flo
w [k
g/hr
]
Time [s]Measured EGR Mass Flow Modeled EGR Mass Flow Requested EGR Mass Flow
EGR % Known Here!Air-to-fuel ratio
transients require modeling of Transport
Delay #1
Physics-based control models
Real-time validation
GT-Power
Transport delays
Low ∆p challenge for system
model
IAO2 able to close model
gap
Long term accuracy
major challenge
0.85
0.85
0.9
0.9
0.9
0.9
0.95
0.95
0.95
0.95
0.97
0.97
0.97
0.99
0.99
0.99
1
0.85
0.85
0.9
0.9
0.9
0.9
0.95
0.95
0.95
0.95
0.97
0.97
0.97
0.99
0.99
0.99
1
Speed [RPM]
BM
EP
[bar
]
1
0.99
0.99
0.99
0.97
0.97
0.97
0.95
0.95
0.95
0.95
0.9
0.9
0.9
0.9
0.85
0.85
1000 2000 3000 4000 5000
5
10
15
20
0.7
0.8
0.8
0.9
0.9
1
Significant part of the map shows a pressure ratio > 0.95
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2013 2014 2015High Pressure EGR Low Pressure EGR
2014 DOE Annual Merit Review REGIS
IAO2 Accuracy
0.0%
0.5%
1.0%
1.5%
2.0%
2.5%
3.0%
0 2.5 5 7.5 10 12.5 15 17.5
Devi
atio
n in
Sen
sed
Mol
ar
Conc
entr
atio
n [%
]
Concentration of Water [%]
21% Oxygen 7% Oxygen
Range of Water in Ambient Air
Range of Waterfrom EGR
0
2
4
6
8
10
12
14
16
18
20
20% 30% 40% 50% 60% 70% 80% 90%
EGR
Erro
r [%
]
Relative Humidity [%]
Error in EGR calculation by neglecting humidity
T=40 F
T=50 F
T=60 F
T=70 F
T=80 F
T=90 F
T=100 F
T=110 F
40%
50%
60%
70%
80%
90%
100%
110%
120%
130%
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Chan
ge in
Sen
sor S
igna
l [%
]
Absolute Pressure at Sensor [mBar]
Exhaust
Target ±1% ∆O2/O2
Multi-faceted approach needed to meet desired accuracy targets.
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2014 DOE Annual Merit Review REGIS
IAO2 Mounting Position
IAO2 mounting post-compressor is the best solution for durability, functionality and power consumption
Sensor Location
2000/2 3000/10
V8 5.0 NA
6000/9
2000/2
I4 2.0 GTDI
2000/15
Response Time [ms]
2420
16
12 2420
16
1212
16
2024
massflow [kg/h]di
amet
er [m
m]
Heater Power [W]
200 400 600 800 100040
60
80
100
0
5
10
15
20
Overlapping regions where response time
and heater power requirements are met
5000/20 4000/16
2000/8
Gas Velocity
Res
pons
e Ti
me
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2014 DOE Annual Merit Review REGIS
Technical Risk Assessment
Technical / technology
1 Sensor not robust for intake
2 Other methods for controlling EGR are better
3 Sensor can lead to ignition of intake gas
Development risk
4 Sensor accuracy not sufficient
5 Sensor costs higher than estimated
Competencies / Know-how
6 Unable to package sensor for intake
max
min
min max
prob
abili
ty
Potential risk
1 4
2
5
6
3
6
1 4
5 3
2
Ignition of intake gas is key remaining risk after Phase 1
Start of Project today
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30
40
50
60
70
80
Initi
al G
as T
empe
ratu
re (C
)
Derived Sensor Temperature (C) Circles = E0 Gasoline Square = 100% non-denatured ethanol Blue, empty = no ignition (<10C Delta Gas T) Red, filled = ignition (>10C Delta Gas T) Temperature range of new sensor
2014 DOE Annual Merit Review REGIS
Result Ignition can occur at elevated gas
temperatures and with aged sensor Next Steps FMEA Study to understand ignition risk for
failure modes identified by FMEA Identify measures in sensor
design to arrest flame kernels Propagate engine design
with purge entry upstream of sensor for critical operation points
Ignition Study at Oak Ridge National Lab
50 C
85050
70
90
110
130
150
0 30 60 90 120 150 180 210
Der
ived
Sen
sor T
emp
(C)
Gas
Tem
p (C
)
Time (sec)
Gas Temp (C)Sensor Temp (C)
Fuel flow started at 60 sec. (Stoichiometric, E0 Gasoline)
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2014 DOE Annual Merit Review REGIS
Choice of Sensor Concept
ProductionProcesses
Develop Product Requirements
Design All Elements
Search for Solution Principles
Derive Functions
Analyze and Adjust Design(Cause Effect Relationships
Design to Function)
Derive Process Chain
Prozesse analysieren, abgleichen (WzH. Design/Prozess)
Evaluate
Decide
Subdivide into Modules and Design Elements
Analyze and Adjust Processes(Cause Effect Relationships
Process to Design)
Use single cell wideband element
Change to direct connector
Find high commonality to existing production
Optimize protection tube for intake application
Contacting 25
Housing 10
Mounting 3
Protection Tube 4
Number of concepts evaluated
Sensor Concept:
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GS-SI/ENG2-NA | 6/19/2014 | © 2013 Robert Bosch LLC and affiliates. All rights reserved.
2014 DOE Annual Merit Review REGIS
Choice of Sensing Element High water load robustness Stable in lean conditions Low pressure dependency High soot robustness (optimized for Diesel engines) Strong heater optimized for Diesel engines Stabilized sensor temperature at high, cold flow rates Flexibility regarding protection tube design Single cell sensor : Compact 4 wire sensor concept
Free choice of sensor connector
Coating for thermal
shock protection
Inner ElectrodeDiffusion Barrier
ZrO2
O--
Pumping Voltage
AirReferenceElectrode
ExhaustGas
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2014 DOE Annual Merit Review REGIS
First Build Thermal Management
Development goal for first build robustness of plastic connector/ housing achieved
Thermal mapping at rated power conditions
Results from thermal mapping of component Component temperatures are in acceptable range Recommendation for calibration derived
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2014 DOE Annual Merit Review REGIS
Validation Results of First Build
Sealing of plastic connector to metal housing after thermal aging achieved
B1S
B2S
B3S
B4S
B5S
C1S
C2S
C3S
C4S
C5S
Leak
Rat
e
LSU IM1 Connector Housing Thermal Aging Leak Test Results
1000 Cycles / Hours
Unsealed Sealed
No leakage insealed parts
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2014 DOE Annual Merit Review REGIS
Protection Tube Optimization - Tool Box
cEGRrate,des cEGR Valve Control
cEGRPressure
Model
cEGRCoordinator
Engine Speed
Engine Load
Operating Mode
Exhaust Pressure/
Temperature Model
Texh
Pexh
EGR Valve Position
Pint
cEGRAging Model
Intake Air Flow
eEGR Valve Flow Model
EGR Valve Set Position
LSU IM Intake O2Sensing
Intake Oxygen Concentration
Requirements
Response Time Heater Power Demand
Thermal Shock Contamination
3-d CFD
DFFS Flow bench
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Hea
ter P
ower
(W)
Switch Time (ms)
BoschExisting
DirectionalA1.0
DirectionalB1.0
DirectionalB1.2
BechmarkPatent
2014 DOE Annual Merit Review REGIS
Protection Tube (PT) Optimization
Hea
ter P
ower
(W)
Low flow / part load conditions
Bosch Existing Directional A1.0
Directional B1.0 Directional B1.2 Benchmark Patent
Results from protection tube optimization PT performance has increased from
optimization of feature parameters. 100 ms
1 W
Ther
mal
Sho
ck R
obus
tnes
s
Target to exceed performance of benchmark patent was achieved.
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2014 DOE Annual Merit Review REGIS
Future Directions REGIS Sensor Development
Develop and demonstrate sensor functional robustness over lifetime Build production intent prototypes Investigate concept for 2nd generation IAO2 element
System Evaluation Understand risk in vehicle for ignition Understand signal off-set caused by HC’s found in intake during vehicle operation
Control Development Control-oriented model for in-cylinder EGR prediction
Demonstration of sensing benefits Demonstration of improved sensor functionality and robustness Demonstration of potential for fuel economy improvement and emissions
performance achieved with IAO2 compared to a model-based EGR control strategy using rapid prototyping
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2014 DOE Annual Merit Review REGIS
Summary REGIS Relevance of Intake Air Oxygen (IAO2) sensing Directly and accurately measures the oxygen concentration in the intake manifold Enables accurate and robust EGR control for future engine concepts utilizing cEGR Approach Develop requirements Design sensor solutions Develop robust cEGR controls Technical Accomplishments Developed and demonstrated improved sensor mounting and ECU connector design Identified sensor design for improved thermal shock robustness and response time Assessed system risks and requirements for sensor (intake conditions, controls) Identified sensor location for best sensor performance and cEGR control Developed cEGR estimation algorithm Future Work Develop and demonstrate sensor functional robustness over lifetime Investigate concept for 2nd generation IAO2 element Develop control-oriented model for in-cylinder EGR prediction Demonstrate sensing benefits
Tools Targeted engines Flow benches Simulation studies
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GS-SI/ENG2-NA | 6/19/2014 | © 2013 Robert Bosch LLC and affiliates. All rights reserved.
2014 DOE Annual Merit Review REGIS
Technical Back Up slides
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2014 DOE Annual Merit Review REGIS
LSU IM Accuracy
-0.80%
-0.60%
-0.40%
-0.20%
0.00%
0.20%
0.40%
0.60%
15.00%
16.00%
17.00%
18.00%
19.00%
20.00%
21.00%
16.00% 17.00% 18.00% 19.00% 20.00% 21.00%
Rela
tive
Erro
r in
O2
[%]
Mea
sure
d O
2 Co
ncen
trat
ion
[%]
Absolute O2 Concentration [%]Reference O2 Values LSU IM Values Relative error in O2 from LSU IM
High Accuracy Potential Predictable Cross-Sensitivity
Ability to tolerate large errors in system metering Production part tolerance Aging of components Modeling errors in calibration
Long term adaptation possible over lifetime
-2.0%
-1.5%
-1.0%
-0.5%
0.0%
0.5%
0 200 400 600 800 1000
Devi
atio
n in
Sen
sed
Mol
ar
Conc
entr
atio
n [%
]
Concentration [ppm]
NO (ppm) C3H6 (ppm) NH3 (ppm)
0
2.5
5
7.5
10
14 16 18 20 22
Mas
s Flo
w [k
g/hr
]
Time [s]Measured EGR Mass Flow Modeled EGR Mass Flow Requested EGR Mass Flow
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2014 DOE Annual Merit Review REGIS
Ignition Study Introduce aerosolized fuel/air mixture to REGIS sensor
Fixed gas velocity (slow) ~1 m/s Fixed air/fuel ratio (stoichiometric) Fixed mixture temperature (50 -80 °C) Two fuels: E10 gasoline blend plus E85 blend
Vary sensor element temperature Detect ignition with thermocouple measurement of gas temperature downstream of REGIS sensor
Realization
Use of air assisted atomizer nozzle w/ preheated air Air flow control using a mass flow controller Fuel flow control using a syringe pump Heating of air and surfaces around the injector to
maximize fuel vaporization minimize condensation on surfaces
Thermocouple
Test Sensor
Air assisted nozzle
Preheated air inlet
Device body (3/4 inch stainless tube w/ insulation)
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Hea
ter P
ower
(W)
2014 DOE Annual Merit Review REGIS
Protection Tube Optimization Low Flow - part load conditions
100 ms
Hea
ter P
ower
(W)
1 W
1 W
50 ms
High Flow
Bosch Existing Directional A1.0
Directional B1.0 Directional B1.2 Benchmark Patent
Protection tube optimization achieved targets for sensor performance in engine part and medium load conditions
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Engine off
2014 DOE Annual Merit Review REGIS
First Build Thermal Management
Thermal mapping for hot soak showed component temperature in acceptable range
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2014 DOE Annual Merit Review REGIS
First Build and Validation First build completed in December 2013
Environmental Testing: Hot Soak Cold Soak Thermal Cycling Salt Water Submergence High Pressure Water Spray
Mechanical Testing: Sine Vibration Wideband Vibration Vibrational Resonance Mechanical Shock Drop Pendulum Swing
Purpose: Ensure sealing of components Mechanical robustness of external and internal connections Pre- and post- functionality of sensor
First build validation completed in April 2014
Results: No design related failures
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