The Role Of IC Engines In Future Energy Use · · 2014-03-04The Role Of IC Engines In Future...
Transcript of The Role Of IC Engines In Future Energy Use · · 2014-03-04The Role Of IC Engines In Future...
Confidential © MAHLE
Hugh Blaxill
MAHLE Powertrain
4th Oct 2011
The Role Of IC Engines In Future Energy Use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
The role of IC engines in future energy use
Confidential © MAHLE
Contents
Introduction
Market Trends and Forecast
MAHLE Powertrain Research
Downsizing Challenges
Range Extending Engines
Summary
2
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
The role of IC engines in future energy use
Confidential © MAHLE
Introduction
There is a role for IC engines for future energy use, why ..
– IC engine has high power to weight ratio
– Relatively low cost
– Flexible fuel use
– Established manufacturing investment
– Detailed pre existing knowledge
– Further development potential
The IC Engine is not addicted to fossil fuels …. WE ARE!
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
The role of IC engines in future energy use
Confidential © MAHLE
Where is the role?
Gas turbines will continue in at least aerospace applications
Heavy and medium duty and off highway applications using both SI and CI cycles
Emergency and remote power generation
Larger capacity residential equipment
Medium to long range and/or large capacity light duty applications …. in high efficiency form
What fuels?
Liquid biofuels and biofuel blends
Gaseous fuels
How do we get there?
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 5
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Short Term Forecast
Forecast Volumes of North America Manufactured Engines By Cylinder Number
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Year
Perc
enta
ge o
f Tot
al
3 Cyl 4 Cyl 5 Cyl 6 Cyl 8 Cyl 10 Cyl
Data taken from CSM WW Database Q1 2010
Gasoline Engine Technology Trends
0
3
6
9
12
15
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
Year
Fore
cast
US
Volu
mes
, Milli
ons
Boosted Engine Volumes Hybrid inc. Stop/Start Gasoline Direct Injection Variable Valve Train
Increasing volumes of 4 cylinder engines
Rapid ramp in direct injection and variable valvetrain technologies across all manufacturers
Start of an increase in downsized applications and hybrid powertrains
The role of IC engines in future energy use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 6 © MAHLE
Longer Term Forecast
ICE
0
140
Mill
ion
vehi
cles
bui
lt
Year
HEV with ICE
BEV
HEV with ICE range extender
50%
20%
10%
20%
ICE
Increasing 4 cylinder applications
Increasing 3 cylinder
applications
The role of IC engines in future energy use
Increasing Downsizing in both amount & application
Increasing Electrification
Bio & gaseous fuels
Now 2030
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 7
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 7
Confidential © MAHLE
Hybridization
Range extender engine, 30kW power
Combustion Process
Ultra lean combustion, Controlled auto ignition
1000 1500 2000 2500 30001.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
19
17
18
IMEP
net (
bar)
Engine Speed (rev/min)
12
16
20
14
% FE Improvement over Baseline SI (λ=1)
99.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.6
1000 1500 2000 2500 3000150
200
250
300
350
400
450
500
IMEP
net (
bar)
Engine Speed (rev/min)
99.7
99.8
99.5
% NOx Reduction over Baseline SI (λ=1)
Alternative Fuels
Downsizing
50% downsizing, up to 30% fuel economy
Friction Reduction
MAHLE low friction components, up to 4% fuel economy saving
Baseline Engine Comparison With MAHLE Engine Components
05
10152025303540455055606570
0 1000 2000 3000 4000 5000 6000 7000 8000
Engine Speed (rpm)
Torq
ue (N
m)
0510152025303540455055606570
Fric
tion
Red
uctio
n (%
)
Baseline engine PREDICTED MAHLE Components fitted % Predicted Benefit
De-Throttling
Valv
e Li
ft
BDCGE TDCGE BDCF
MAHLE CamInCam® Variable valvetrains
Optimized alcohol blends to suit downsizing applications
The role of IC engines in future energy use
So what is MAHLE Powertrain researching?
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 8
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 8
Confidential © MAHLE
Hybridization
Range extender engine, 30kW power
Combustion Process
Ultra lean combustion, Controlled auto ignition
1000 1500 2000 2500 30001.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
19
17
18
IMEP
net (
bar)
Engine Speed (rev/min)
12
16
20
14
% FE Improvement over Baseline SI (λ=1)
99.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.6
1000 1500 2000 2500 3000150
200
250
300
350
400
450
500
IMEP
net (
bar)
Engine Speed (rev/min)
99.7
99.8
99.5
% NOx Reduction over Baseline SI (λ=1)
Alternative Fuels
Downsizing
50% downsizing, up to 30% fuel economy
Friction Reduction
MAHLE low friction components, up to 4% fuel economy saving
Baseline Engine Comparison With MAHLE Engine Components
05
10152025303540455055606570
0 1000 2000 3000 4000 5000 6000 7000 8000
Engine Speed (rpm)
Torq
ue (N
m)
0510152025303540455055606570
Fric
tion
Red
uctio
n (%
)
Baseline engine PREDICTED MAHLE Components fitted % Predicted Benefit
De-Throttling
Valv
e Li
ft
BDCGE TDCGE BDCF
MAHLE CamInCam® Variable valvetrains
Optimized alcohol blends to suit downsizing applications
The role of IC engines in future energy use
So what is MAHLE Powertrain researching?
8
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
The role of IC engines in future energy use
Confidential © MAHLE
Contents
Introduction
Market Trends and Forecast
MAHLE Powertrain Research
Downsizing Challenges
Range Extending Engines
Summary
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Gasoline Engine Downsizing How low can you go?
Spec
ific
Pow
er O
utpu
t (kW
/l)
50
60
70
80
90
100
110
120
130
Peak BMEP (bar)10 15 20 25 30 35
MAHLE Downsize2-Stage Turbo
VW 1.4l SC / TC
Fiat 1.8 TGDI
Audi 1.8 TFSI
Audi 2l TFSI AVS
Audi 1.8T
Audi 2l TFSI
Ford 2.0l EcoBoost
Spec
ific
Pow
er O
utpu
t (kW
/l)
50
60
70
80
90
100
110
120
130
Peak BMEP (bar)10 15 20 25 30 35
MAHLE DownsizeSingle Turbo
MAHLE Downsize2-Stage Turbo
VW 1.4l SC / TC
Fiat 1.8 TGDI
Audi 1.8 TFSI
Audi 2l TFSI AVS
Audi 1.8T
Audi 2l TFSI
Ford 2.0l EcoBoost
Increasing Boost and Combustion Issues
The role of IC engines in future energy use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 11
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Downsizing: Unstable Combustion Issues
Combustion phasing can be retarded due to detonation, which leads to high exhaust valve opening pressures
Advancing combustion phasing allows higher boost and torque
To achieve this:
Turbocharger selection has a strong influence
Reduced duration exhaust cam has a positive effect
Optimized exhaust manifold design reduces trapped residuals
Careful fuel selection
Combustion chamber is shape-optimized
Oil consumption is minimized
Manifold Pressure [kPa Abs]
175
180
185
190
195
200
205
210
215
220
225
Spark Advance [CAD]0 2 4 6 8 10 12
17
19
21
16
18
20
BMEP [bar]
Preign
ition Lim
it
Detonation Limit
Advanced Combustion Phasing
Manifold Pressure [kPa Abs]
175
180
185
190
195
200
205
210
215
220
225
Spark Advance [CAD]0 2 4 6 8 10 12
17
19
21
16
18
20
BMEP [bar]
Preign
ition Lim
it
Detonation Limit
Advanced Combustion PhasingThe role of IC engines in future energy use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 12
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Boosting Systems
A) Single Turbocharger B) 2-Stage Turbocharger
C) Supercharger & Turbocharger D) Electric Supercharger & Turbocharger
BM
EP
[bar
]
12
14
16
18
20
22
24
26
28
30
32
34
Engine Speed [rpm]500 1500 2500 3500 4500 5500 6500
Target Curve 2-Stage Turbocharger LP Turbo Only VTES & LP Turbo
Steady State
Ave
rage
IME
P [b
ar]
0
5
10
15
20
25
Time [s]0.0 0.5 1.0 1.5 2.0 2.5 3.0
LP Turbo Only 2-Stage Turbocharging VTES + LP Turbo SC / TC
Transient Load Step at 1250rpm
The role of IC engines in future energy use
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 13
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Next Generation MAHLE Downsizing Engine
State-of-the-art clean-sheet design for 50% downsized concept DI-3 1.2 L
Up to 30% fuel economy improvement possible with similar performance levels
Excellent low speed torque and transient response with twin turbo configuration
Vehicle and engine demonstrators available Developed with MAHLE & Bosch advanced components
• 30 bar BMEP + • 100 kW/l Single Stage Turbo • 120kW/l Twin Turbo
150
200
250
300
1000 2000 3000 4000 5000 6000 7000 Engine Speed [rpm]
Torq
ue [N
m] .
0
50
100
150
Pow
er [k
W]
The role of IC engines in future energy use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
The role of IC engines in future energy use
Confidential © MAHLE
NEDC
Increasing Technology
100% 91.0% 74.0% 71.0% 65.0% 59.0%
9.0% 26.0% 29.0% 35.0% 41.0%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
2.4 L NA
2.0 L Turbo GDI
MAHLE 1.2 L Turbo GDI
MAHLE 1.2 L Turbo GDI
+ Idle-stop
MAHLE 1.2 L Turbo GDI
+ Mild-
hybrid
Concept 0.8 L Turbo GDI
+ Mild-hybrid
NED
C C
O₂ [
Perc
enta
ge c
ompa
red
to 2
.4 L
NA]
Downsizing Electrification Path
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
The role of IC engines in future energy use
Confidential © MAHLE
Increasing Technology
100% 84.4% 83.8% 80.5% 78.8% 78.8%
15.6% 16.2% 19.5% 21.2% 21.2%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
MAHLE 1.2 L
Turbo GDI
MAHLE 1.2 L
Turbo GDI
+ Idle-stop
MAHLE 1.2 L
Turbo GDI
+ Mild-
hybrid
ARTEMIS
2.4 L NA
2.0 L Turbo GDI
Concept 0.8 L Turbo GDI
+ Mild-hybrid
NED
C C
O₂ [
Perc
enta
ge c
ompa
red
to 2
.4 L
NA]
Downsizing Electrification Path
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
The role of IC engines in future energy use
Confidential © MAHLE
Increasing Technology
US06
100% 88.2% 88.0% 86.8% 84.6% 85.3%
11.8% 12.0% 13.2% 15.4% 14.7%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
MAHLE 1.2 L Turbo GDI
+ Idle-stop
2.4 L NA
2.0 L Turbo GDI
MAHLE 1.2 L Turbo GDI
MAHLE 1.2 L Turbo GDI
+ Mild-
hybrid
Concept 0.8 L Turbo GDI
+ Mild-hybrid
NED
C C
O₂ [
Perc
enta
ge c
ompa
red
to 2
.4 L
NA]
Downsizing Electrification Path
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE Average Drive Cycle Load Increase
Fuel Effects: 1.2l Downsizing + Mild Hybrid
Average Drive Cycle Load Increase
Fuel H/C & O/C Ratio
MPT 1.2l DI3 ICE + Hybrid
Average Drive Cycle Load Increase
V4
Fuel Lower Heating Value Rating
The role of IC engines in future energy use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
The role of IC engines in future energy use
Confidential © MAHLE
Contents
Introduction
Market Trends and Forecast
MAHLE Powertrain Research
Downsizing Challenges
Range Extending Engines
Summary
18
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Introduction - E-REV Concept Description
Extended-Range Electric Vehicle (E-REV) – Vehicle propelled purely by electric motors with small battery pack (c.f. EV)
Typical range of 20 to 100 km using only battery power
Battery pack can be charged from residential electrical outlet
– On-board electrical generator (IC Engine or Fuel Cell) can also be used to re-charge battery on the move
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
Electric range
RE
Pow
er /
Tail-
pipe
CO
2 Optimum is a function of vehicle performance targets
Full sized engine and no electric range capability
No RE and very large battery
Vehi
cle
wei
ght a
nd c
ost
The role of IC engines in future energy use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Range Extender - Conflicting Targets - Range / Cost / Weight
Baseline – Short Range Electric Vehicle (EV)
– Compact Class
– Range 80 km
– Battery Capacity 15 kWh
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
EV #2
EV #1
RE
Baseline EV
WeightRangeCost
+3000 EUR
* Battery cost: 500 EUR/kWh
+3000 EUR
+52000 EUR
+550 km
+30 km
+550 km
+130 kg
+1375 kg
+75 kg
The role of IC engines in future energy use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
Near Term Spark Ignition Engine Technologies
Confidential © MAHLE
Range Extender - Conflicting Targets - Range / Cost / Weight
Baseline – Short Range Electric Vehicle (EV)
– Compact Class
– Range 80 km
– Battery Capacity 15 kWh
Range Extender (RE) (inc. Generator, 40 l Tank, Controller, …)
– Weight: +130 kg
– Cost: +3000 EUR
– Range: +550 km
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
EV #2
EV #1
RE
Baseline EV
WeightRangeCost
+3000 EUR
* Battery cost: 500 EUR/kWh
+3000 EUR
+52000 EUR
+550 km
+30 km
+550 km
+130 kg
+1375 kg
+75 kg
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Range Extender - Conflicting Targets - Range / Cost / Weight
Baseline – Short Range Electric Vehicle (EV)
– Compact Class
– Range 80 km
– Battery Capacity 15 kWh
Range Extender (RE) (inc. Generator, 40 l Tank, Controller, …)
– Weight: +130 kg
– Cost: +3000 EUR
– Range: +550 km
Electric Vehicle #1 (identical additional cost)
– Weight: +75 kg
– Range: +30 km
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
EV #2
EV #1
RE
Baseline EV
WeightRangeCost
+3000 EUR
* Battery cost: 500 EUR/kWh
+3000 EUR
+52000 EUR
+550 km
+30 km
+550 km
+130 kg
+1375 kg
+75 kg
The role of IC engines in future energy use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Range Extender - Conflicting Targets - Range / Cost / Weight
Baseline – Short Range Electric Vehicle (EV)
– Compact Class
– Range 80 km
– Battery Capacity 15 kWh
Range Extender (RE) (inc. Generator, 40 l Tank, Controller, …)
– Weight: +130 kg
– Cost: +3000 EUR
– Range: +550 km
Electric Vehicle #1 (identical additional cost)
– Weight: +75 kg
– Range: +30 km
Electric Vehicle #2 (identical range)
– Weight: +1375 kg
– Cost: +52000 EUR
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
EV #2
EV #1
RE
Baseline EV
WeightRangeCost
+3000 EUR
* Battery cost: 500 EUR/kWh
+3000 EUR
+52000 EUR
+550 km
+30 km
+550 km
+130 kg
+1375 kg
+75 kg
The role of IC engines in future energy use
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MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
MAHLE Range Extender Concept
MAHLE Range Extender Two-cylinder Inline, 4-Stroke Gasoline
900 cm3 Swept Volume
30 kW Peak Power at 4000rpm
Port-fuel Injection (λ = 1)
180°/540° Firing Order
Flexible Installation
481
mm
Wei
ght [
kg]
020406080
100120
Power [kW]0 10 20 30 40 50
AB
C
D
MAHLE
Specific Power Power 30 kW
Weight (incl. Generator) 70 kg
Power to Weight Ratio 2.3 kg/kW (Competitors: 2.75 to 4.3 kg/kW)
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011
The role of IC engines in future energy use
24
MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential
© MAHLE
Summary
There is a role for IC engines in future energy use!
We will see an increase in downsizing and electrification in light duty applications
Downsizing needs further technology development, especially in combustion and boosting systems
Higher alcohol content fuels will support the trend in downsizing via increased octane levels
Range extenders are very effective energy providers, further efficiency steps can be taken, but cost is a more significant factor
The role of IC engines in future energy use
25