WP3 Presentation - Paregen
Transcript of WP3 Presentation - Paregen
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WP3 Presentation
Normann Freisinger/ Daimler, Jens Ewald / FEV, Helge Dageförde / BOSCH, Tobias Voßhall / RWTH, Francesco Endrici / UFI
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WP3: Stoichiometric small TC-VVA-DI water injection engine
12-13 November 2019 Joint Final Event PaREGEn & PEMs4Nano 2
Selection and optimization of the combustion system to reduce CO2 and to reach future emission demandsSet-up of a test vehicle with a research powertrain including
Rightsized engine and advanced components for stoichiometric Miller combustion system New Engine Control Unit with additional required functionsAdvanced turbocharger and aftertreatment system
Water injection as further enabler for increased compression ratioPort Water Injection (PWI) on demo vehicleDirect Water Injection (DWI) on testbench
Exhaust gas condensation for Water recovery and service free water supplyFinal evaluation of achievable CO2 reduction potential with investigated technology by cycle simulation
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WP3 Engine & vehicle investigation overview
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Hardware design & selectioncombustion process development
Comparison water direct & port
injection
Further investigations for additional CO2 reduction
Vehicle engine andcomponent calibration
Vehicle preparation for basis measurements
Vehicle set-up with PaREGEn powertrain & ECU
Vehicle calibration & chassis dyno
Basis measurements& target settings
Final vehicle assessment CO2 & emissions
results see WP5(assessment presentation)
Test
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design freeze vehicle powertrain
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Experimental matrix for hardware design, selection and combustion process dev’t
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6 intake camshafts ->1 sel.
3 exhaust camshafts ->1
3 turbochargers ->1
3 comp. ratios -> 2
3 intake manifolds-> 1
4 wastgate bodies -> 1
GDI injectors
PWI injectors
3 pistons -> 2
GDI injection pressure
PWI injection timing
PWI injection-Strategy
GDI multiple injection
Intake-phasing
Outlet-phasing
Function development
Knocking model
Boost pressure control
Water injection control
Camtronic control
Charge motion
Base exhaust system
Daimler PaREGEn exhaust system + GPF
JM prototype 1
JM prototype 2
JM exhaust system prototype 3
Emissions aftertreatment
GDI injection timing
CalibrationHardware
Hardware setting
Calibration setting
va
lve
lift
[%]
0%
25%
50%
75%
100%
crank angle [grdKW]
120 180 240 300 360 420 480 540
DWI Injectors
DWI injection timing
DWI injection-StrategyDaimlerBOSCHFEV
DaimlerJohnson Matthey
uncoated GPF
light-off TWC
TWC
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PaREGEn vehicle engine
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21
3 4 5
6 7 8
9
10 11
left: Machined protype crankcase with LDS coated liner (laser cladded, friction reduced surface)
right:Manufactured Cylinder Head with Port Water Injection, with Direct Water Injection and advanced inlet-port
1. Advanced cylinder head for GDI + PWI/DWI + Multi Spark Ignition
2. Variable valvetrain with 2 lifts on intaxe & exhaust side3. Miller valve timing and stroke4. Advanced gasoline injection system with increased injection
pressure5. Multi-hole solenid gasoline injector6. Port water injection (PWI)7. Advanced intake manifold with variable charge motion
meassures8. Advanced dual scroll turbocharger9. Advanced TWC+GPF aftertreatment10.Higher compression rate11.Higher stroke: bore ratio12.Direct water injection (DWI) (simulated)
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Optimization of water injection
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*Due to packaging restrictions no optimal mountingposition possible.
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Further investigations for additional CO2 reduction
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Base engine with CR=12:1, Miller and PWI was already close to thermodynamic optimum
Piston change to CR=13.5:1 as laid out by simulation activities for second campaign
DWI, going towards very high water/fuel shares to explore the limits
Valve timing was optimized for CR=12:1, for 13.5 valve timing re-adjustment required and partially realized
Test with exhaust condensate harvesting system
Tests with osmosis water and exhaust condensate: no significant difference in performance or emissions
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Exhaust gas water harvesting sytem
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Assembly for the engine test bed system
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Exhaust gas condensate purification: particulates and chemicals
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Particles removal was granted with a pre-filter + filter series that gives less than 20 mbar pressure drop and 95% efficiency for 10 microns particles at 0.45 l/min.
Ammonia removal is granted with a ion exchange resins bed that allows more than 97% efficiency
Other chemical are present in quantities that were not recognized as dangerous for the system
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Comparision water direct & port injection
Potential of water injection @ high load conditions
Blue diagrams:Best DWI spray (W4) compared to operation w/o water injection
Green diagrams:Best PWI spray (E-Type) compared to operation w/o water injection
Findings:
Low engine speed (LET):DWI shows higher mfb50 advancing potential than PWI
High engine speed (rated power):DWI and PWI show similar mfb50 advancing potential
mfb50 advancing [°CA]1 mfb50 advancing [°CA]1
water rate [%]2 water rate [%]2
DWIW4
DWIW4
PWIE-type
PWIE-type
1.compared to engine map without water injection 2.Water rate lowest ISFC
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Final PaREGEn vehicle
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In-vehicle engine status display
Engine bay package with electrical wiring
Demo vehicle on dyno
Measurement technology in the trunk Schematic diagram of the vehicle exhaust aftertreatment system
Water tank
uncoated GPF
light-off TWC
TWC
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* Reduction of 15% based on the WLTC results of the baseline vehicle
* Additionally: reduction of 15% based on the 2015 BIC
WP3 vehicle results
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CO2 Standard emissions PN
Complicane with Euro 6 (d)limits
RDEFinal Conformity Factor of 1.5 incase of NOx (*)
Reduction of sub-23 nm to at least 10 nm
RDEFinal Conformity Factor of 1.5 incase of PN
Vehicle-test THC(mg/km)
NOx(mg/km)
CO(mg/km)
CO2
(g/km)PM
(mg/km)PN ≥ 10nm(pk/km)
Mercedes DemonstratorWLTC Low
100 60 1000 Base Vehicle → -15 % 4.5 6.0E +11
Mercedes Demonstrator WLTC High
100 60 1000 Base Vehicle → -15 % 4.5 6.0E +11
Mercedes Demonstrator RDE
--- 90 --- --- --- 9.0E +11
Targets on vehicle dyno. and test bench fulfilled
Targ
ets
(*) New Reg 1.43 (2020)
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CO2 emissions reduction potential with investigated technology: WLTP-H Cycle
95%
0%
85%
90%
100%
Vehicle SimulationCR12 PWI
with improved shift strategy
CO2 / (g/km)
Vehicle Simulationscaled engine mapCR14.5 with DWI
Vehicle TestMercedes E180Baseline Vehicle
Vehicle TestCR12 PWI
Demonstrator
Vehicle Simulationwith engine map from test benchCR13.5 with DWI
Target -15%
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• Copyright ©, all rights reserved. This document or any part thereof may not be made public or disclosed, copied or otherwise reproduced or used in any form or by any means, without prior permission in writing from the PaREGEn Consortium. All the material included in this document is based on: 1) data/information gathered from various sources, 2) certain assumptions and 3) forward-looking information and statements that are subject to risks and uncertainties. Although, due care and diligence has been taken to compile this document, the contained information may vary due to any change in any of the concerned factors and the actual results may differ substantially from the presented information. Further, there can be no assurances that results will prove accurate and, therefore, readers are advised to rely on their own evaluation of such uncertainties. Readers are encouraged to carry out their own due diligence and gather any information to be considered necessary for making an informed decision.
• Neither the PaREGEn Consortium nor any of its members, their officers, employees or agents shall be liable or responsible, in negligence or otherwise, for any loss, damage or expense whatever sustained by any person as a result of the use, in any manner or form, of any knowledge, information or data contained in this document, or due to any inaccuracy, omission or error therein contained.
• All Intellectual Property Rights, know-how and information provided by and/or arising from this document, such as designs, documentation, as well as preparatory material in that regard, is and shall remain the exclusive property of the PaREGEn Consortium and any of its members or its licensors. Nothing contained in this document shall give, or shall be construed as giving, any right, title, ownership, interest, license or any other right in or to any IP, know-how and information.
• This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 723954. The information and views set out in this publication does not necessarily reflect the official opinion of the European Commission. Neither the European Union institutions and bodies nor any person acting on their behalf, may be held responsible for the use which may be made of the information contained therein.
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