Tata_Motors_Rajendra_Petkar_Keynote_Integrated Powertrain Development and the Role of Simulation

© Copyright, Confidential, Tata Motors Ltd

Integrated Powertrain Development and the Role of Simulation

Rajendra Petkar

Head - Power Systems Engineering

Tata Motors –Engineering Research Centre


Index

S.No Topic

1 About Tata Motors

2 Drivers for Vehicle Technology

3 Integrated power train development

4 Diesel Technology drivers & trends

6 Gasoline Technology drivers & trends

7 Simulation- A key Enabler

8 Current Simulation Domains & New Focus Areas

10 Ricardo Software – Few examples & TML experience

11 Way forward


• Tata Motors is the country’s market leader in commercial vehicles and among the top

in passenger vehicles

• Over 8 million vehicles on Indian roads since inception

• 4th largest Manufacturer of buses globally

• 5th largest Truck Manufacturer in the world

• 62,000 + consolidated workforce

• Tata cars, buses and trucks are being marketed in several countries in Europe,

Africa, the Middle East, South Asia, South East Asia, South America, CIS and Russia

• 12 R & D centers across the globe

• Jaguar Land Rover, acquired in 2008, an industrial joint venture with Fiat in India

• Consolidated total Revenue in 2012 – 13 – Rs. 1,89,629 cr. (($ 35 billion)

• Operations in the UK, South Korea, Thailand, Spain, South Africa and Indonesia.

About Tata Motors


Product Range


Recent Launches


TATA Motors – Leadership in Powertrain Engineering

Rich Legacy of Powertrain Design & Development

Decades of Constantly Evolving Design & Engineering Experience

Widest Range of Engines & Applications

Best-in-class Performance, Refinement & Economy

Pioneers in Diesel & CNG Engine Technology

State-of-the-art R&D Facilities Comprising of Chassis Dynamometers, Transient Test Beds & Emission Systems

Millions of Engine Produced and Sold Across the Board


Customer

• Fuel Economy

• Low Cost

• Good NVH

• Performance

• Reliability

• Durability

• Comfort

• Serviceability

Manufacturers

must address

both demands

• Product Configuration

• Manufacturing

• After Sales Support

Legislative

• Emissions

• Performance

• Noise

• Safety

• Recyclability

• CO2 / Fuel Efficiency

( Future )

• Others ..

ERC –Engines

Drivers for Vehicle Technology


Integrated Powertrain Optimization Approach

Down sizing the engine

SCR

Smart thermal management & Auxiliary control

Waste heat recovery

Variable fuel, air and EGR management

Friction Optimization

Low Viscosity oils

Gear drive optimization

Six speed Gearbox

Automated Manual transmission

Continuously variable transmission (CVT)

Lower Gear hypoid offsets.

Lower rotational inertia

Final drive optimization

Low rolling resistance tires

Radials with low hysteresis tyre profile

Low friction hub bearing Constant velocity

joints

Weight reduction of 100kg on vehicle leads to 2-5% improvement in Cycle Co2


• In view of more and more stringent requirements on pollutants, CO2 emission and

drivability, it becomes increasingly important to optimize the performance of the

entire Powertrain.

• Synergy between engine, driveline and after treatment system has to be maximally

exploited, during all operating conditions.

•Therefore, a system approach is required for Integrated Powertrain Development.

Integrated Powertrain Development

Vehicle

Level

Targets

System

Level

Targets

Assembly

Level

Targets

Component

Level

Targets

Regulatory

Targets

Target Cascade – Outside in approach to integrated Powertrain development


Diesel Technology – Drivers & Trends


Further reduction of emission near to zero impact levels

Increased durability targets for emission compliance and requirement of robustness of control systems to compensate the deterioration of components

Stricter Pass by noise regulations on the anvil

On board diagnostics-In vehicle monitoring of emissions

Cycle CO2 targets and Corporate fleet average

Drivers for Diesel Technology


CO2 Emission Reduction: Passenger Cars - Diesel

Note: 100 units are taken as base in “Uncontrolled era”


10

20

30

40

50

60

70

80

Old Engines Current Engines Projected

En

gin

e P

ow

er

(PS

/ l

t)

65

70

75

80

85

90

Uncontrolled

era

1998 2003 2005 2010

Year

Pa

ss

-by N

ois

e (

db

A)

Pass-by Noise

Reduction:

Passenger Car -

Diesel

Engine Power:

Passenger Car -

Diesel

Improvements in Diesel Engine Performance


VGT, Two stage

charging

After treatment systems:-

SCR, DPF, POC

High pressure

(2000-2500 bar) fuel

injection system

4V per cylinder

High power

density and down

sizing

Mild, medium, full

Hybridization

Smart and

Intelligent control

systems

Design for FE-

weight and friction

reduction

Diesel Technology Trends

Intelligent cooling

and Lubrication

Advanced EGR

systems , HP,

HP + LP


Resurgence of Gasoline Powertrains Gasoline Technology – Drivers & Trends


Strategic Drivers for Gasoline Technology

Increasing cost of Diesel Fuel & Diesel Emission Control technologies

Continuous evolving technologies for gasoline engines to deliver Performance, Refinement & Economy such as downsizing, GDI, VVT etc.

Variable fuel quality of Diesel in market

Increasing attractiveness of Gasoline engines in sub compact car segment due to lighter weight & low cost

Fuel Economy

Co

st


Turbo Charging/

E-boosting

Waste heat

recovery

GDI

VVT

High power

density and down

sizing, red. Cyl.

count

Mild, medium, full

Hybridization

Smart and

Intelligent control

systems

Design for FE -

weight and friction

reduction

After treatment

TWC, LNT

Electric / Mech

supercharger

Gasoline Engine – Technology Trends


• Simulation has become a key enabling factor in the development of power train systems.

• Simulation plays a vital role in evaluating and finalizing new power train concepts

• Enables the implementation of optimal solutions to aggressively tight timescales.

• Helps to achieve key product aspirations for weight package size and lifecycle cost.

• It reduces development cost due to decreased dependence on testing.

• Software in Loop testing helps to debug control problems in early stage of development.

• Offline hardware-in-the-loop testing together with vehicle and transmission simulation on the

test bed helps to optimize vehicle fuel consumption, emissions and drivability.

Simulation – A key Enabler


Current simulation domains


Gear train

analysis

Valve train analysis

Crank train analysis

Gas side thermal

analysis

High cycle fatigue

Thermo mechanical

fatigue analysis

Coolant side CFD

Engine Design Simulation


Thermodynamic

Simulation

Vehicle Simulation

Challenge is to integrate

simulation software on same

time domain & simulate real

time behavior of engine in

vehicle environment

Combustion

Simulation Flow Simulation Automated test cell

Development Simulation


Clutch Housing Air

Flow Simulator

Casing deflection

analysis

Gear Shift Linkage parts

Vibration analysis

Axle Housing

Mounting Deflection Axle Carrier

Housing deflection

Transmission Shaft & gear

deflection analysis

Driveline Simulation


Role of simulation in ECU Software development process

• First time right approach demands ECU software development to follow ‘V’ Cycle methodology

• ‘V’ cycle methodology is used for rapid development and validation of new control strategies


New Focus Areas for Simulation


Advantages:

• Increased Efficiency/Reduced fuel combustion

• Reduced NOx & PM emissions

• Stratified Direct Injection leads to reduced throttling

losses.

• Reduced thermal losses due to low temperature

Challenges:

• Auto-ignition at wide operating ranges

• Maintaining combustible mixture ratios

• Sustenance & controlling the combustion

• Higher tendency of HC residuals

Low Temperature Combustion methods

Premixed Charge Compression Ignition (PCCI)

Homogeneous Charged Compression Ignition (HCCI)

Reactivity Controlled Compression Ignition (RCCI)

Partially Premixed Compression Ignition (PPC/PPCI)

Lean Gasoline Direct Injection (LGDI)

Stoichiometric Gasoline Direct Injection (SGDI)

Stratified Charged Engines

Advanced combustion technologies

Role of Simulation :

In cylinder combustion analysis using CFD

http://bioage.typepad.com/.a/6a00d8341c4fbe53ef01538e9a4b58970b-popup


Multistage supercharging/ turbocharger parallel/sequential

Supercharger-Turbocharge compounding

Gasoline supercharging/turbocharging

VGT turbines, engine/motor assisted

VGT compressors

Advantages:

Improved efficiency and reduced HC, CO emissions

Power/Weight ratio improvement

High EGR feasibility.

VGT reduces turbo-lag.

Improves performance over the operating range

Challenges

Advanced control mechanism

Combustion characteristics refinement

Durability/ PM clogging the vanes

Tendency of increased NOx emissions

Advanced boosting technology


Advanced thermodynamic Simulation

SIL simulation integrated with engine plant model at design stage


About 10% of available mechanical energy is lost to overcome internal friction. Expected benefits are in the

order of 2 -5% improvement in BTE

Following advancements are happening to reduce the losses.

Advance lubricants and blending agents

Advancement materials for piston rings, liners, valve-train, bearings, belts and gears

Nano particle coatings

Downsizing turbocharged/supercharged

Down speeding

Free piston engines as HFPE (Hydraulic free piston engine)

Advanced engine architecture beyond slider-crank mechanism.

Friction Reducing Technology


Friction simulation tools ( like PISDYN & RINGPACK for Piston, Rings & Liner friction)


Advanced Fuel Injection Technologies

Variable nozzle geometry Injectors: e.g. two row injectors:

one row of nozzles used for part load, two rows full load

Multistage, pulsating type Injectors

Variable lift injectors.

Individualized spray hole designs

Advanced common rail technologies operating at higher pressure ranges.

Advantages:

• Controlled atomization

• Improved Homogeneous mixing if desired

• Improved stratification if desired

• Proper combustion with reduced emissions

• Reduced wall wetting

• Improved fuel economy

Challenges

• Complex Spray & Combustion characteristics.

• Complex control mechanism

• Cost of Injection system


• CFD for Spray (targeting , interference,

pattern) and wall-impingement

optimization to improve mixing


Emission reduction technologies

EGR ( HP, LP , LP + HP)

Cooled/ Super cooled EGR

SCR

DPF/DOC

LNT

Challenges

Diesel oxidising catalyst (DOC): Ageing.

Urea injection: NH3 uniformity index

SCR: Ageing and Efficiency

Long-term stability / thermal aging

Transient control of boost and EGR

Durability improvements for high EGR

EGR technology configuration.

SCR technology configuration.

Advanced EGR and after treatment systems


• CFD for SCR mixing efficiency, urea consumption, Nox reduction, Pressure drop .

• Virtual System optimization of engine with after treatment

• EGR distribution using CFD


Parallel Hybrid: Mild / Full hybrid, torque addition, single- / double-shaft

Power Split Hybrid

Series Hybrid

Advantages

• Increase in driving dynamics through boost function

• Torque Vectoring / enhanced heavy terrain drivability

• Improved in fuel efficiency, NVH, reduced CO2 emissions

• Active support in stability control systems (electric braking, torque vectoring)

Challenges

• Increases the powertrain complexity

• Complex control functions for energy management and traction optimization

Hybrid Powertrain technologies


• Simulation of vehicle with power plant model

to optimize complex control functions for energy

management


Ricardo Simulation Software – Few examples

& Tata Motors Experience


ENGDYN and FEARCE

F E Analysis of cylinder Head &

Block compound Stress

Distortion

Head lift

Thermo Mechanical Fatigue


Main Bearing Wall

Analysis

ENGDYN & FEARCE

Bore-Distortion

Factor-of-safety

Bearing Contact Pressure distribution


CFD Analysis of head and

block water jacket

VECTIS

Flow Velocities & distribution

Pressure-drop across system

Heat-Transfer Coefficient &

Temperature distribution


1D engine simulation with CFD analysis of exhaust manifold

WAVE and VECTIS Coupling

EGR Mixing

EGR Mixing

Balancing EGR flow in cylinders


Valve train kinematics and dynamic analysis

VALDYN

Hertzian stress.

System resonances

Velocity, Accn. & Jerk


• Simulation is going to play a central role as we move towards near zero impact

emission levels

• An outside in approach ie coming from regulatory targets & market requirement

to vehicle system, assembly and components optimization will be required.

• If the challenging CO2 requirements at 95 gms / km have to be achieved and

integrated approach to power train development will gain currency.

• As simulation techniques improve, there will be an increasing trends towards

coupling multiple analysis tool to do multi physics simulation

Way Forward


Thank You

Tata_Motors_Rajendra_Petkar_Keynote_Integrated Powertrain Development and the Role of Simulation

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