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Transcript of Deutz Diesel
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30.10.00 2000 GT-Suite User Conference / Deutz AG2000 GT-Suite Users ConferenceOctober 30, 2000 - Frankfurt, Germany
„Analysis of Alternative EGR Systems on the
DEUTZ BF6M 2013C Diesel Engine‘‘
„Analysis of Alternative EGR Systems on the
DEUTZ BF6M 2013C Diesel Engine‘‘
Dr. F. Schmitt
1) Deutz is an independent engine manufacturer. The engines are basically designed for industrial engine applications like agricultural and construction machinery, power generation as well as for transport applications in commercial vehicles like Volvo. One of these commercial vehicle engine is the engine 2013. My talk is about “Analysis ofAlternative EGR Systems on this DEUTZ BF6M 2013C Diesel Engine‘‘.
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30.10.00 2000 GT-Suite User Conference / Deutz AG
Contents
Introduction
- engine series 2013
- egr concept
Modelling of egr and injection system
Summary
- injection system
Simulation / Testing of egr
2) I will start my talk about some basics about the engine 2013, I haveto model in GTPower. Further technologies to consider are the injection systems and the egr concepts of this engine. For each of new the technologies I will also give some information about the modelling inGtpower. Further I will compare testing and simulation. Finally I will givea summary.
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30.10.00 2000 GT-Suite User Conference / Deutz AG
Engine family DEUTZ 2013
E n g i n e D a t a S e r i e s R e s e a r c hIn j ec t ion sys t em U P S , 6 - h o l e C R , 7 u n d 8 - h o l e
C o m b u s t i o n s y s t e m D I , w / o e g r w i t h e g r
T u r b o c h a r g e r A T L w i t h W G V G T
B o r e / S t r o k e d 9 8 m m / 1 2 6 m m
D i s p l a c e m e n t V h 5 , 7 d m 3
C o n n e c t i n g R o d l e n g t h l 1 9 4 m m
C o m p r e s s i o n r a t i o ε 1 8 , 5 1 8 , 1
M a x P o w e r P eff 1 9 0 k W @ 2 5 0 0 m i n -1
M e a n e f f . p r e ssu re 2 1 b a r @ 1 2 0 0 - 1 6 0 0 m i n -1
E m i s s i o n s t a n d a r d E U R O 3 E U R O 4 ( t a r g e t )
E n g i n e s p e c i f i c a t i o n
c o m p a c t n e s s
l o w f u e l c o n s u m p t i o n
4 -v a l v e, 4- a n d 6- c y l i n d e r
3 ) T h e e n g i n e f a m i l y D E U T Z 2 0 1 3 i s v e r y c o m p a c t , has l ow f ue l
c o n s u m p t i o n a n d i s a v a i l a b l e a s a 4 v a l v e, 4- a n d 6 - c y l i n d e r e n g i n e.
F u r t h e r E n g i n e D a t a i s g i v e n i n t h e t a b l e. The se r i es eng ine , that fu l f i l l s
t h e E U R O 3 E m i s s i o n s t a n d a r d , has a U n i t P u m p I n j e c t i o n s y s t e m
( U P S ) w i t h a 6- h o l e n o z z l e. T h e C o m b u s t i o n s y s t e m i s a DI s y s t e m
w i thou t eg r . A tu rbocha rge r o f 3 K w i th was te ga te i s used. Bore of 98
m m and St roke o f 1 2 6 m m l e a d s t o a d i sp lacemen t o f 5 , 7 li ter. W i t h a
compress ion ra t i o o f 1 8 . 5 a m a x i m u m p o w e r o f 1 9 0 k W @ 2 5 0 0 U / m i n
a n d a mean e f fec t i ve p ressu re o f 21 ba r i n the range o f 1 2 0 0 t o 1 6 0 0
r o u n d p e r m i n u t e c a n b e r e a c h e d.
F o r t h e r e s e a r c h e n g i n e a C o m m o n R a i l I n j e c t i o n S y s t e m wi th egr is
u s e d. A t u r b o c h a r g e r w i t h v a r i a b l e t u r b i n e g e o m e t r y i s u s e d i n s t e a d o f
w a s t e- gate at l . The a im o f t he i nves t i ga t i ons w a s t o r e a c h o r t o get
c l o s e t o E U R O 4 e m i s s i o n s t a n d a r d w i t h o u t e x h a u s t a f t e r t r e a t m e n t l i k e
par t ic le f i l te r or S C R s y s t e m
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
4)T h i s p i c t u r e s h o w s t h e e n g i n e 2 0 1 3 . C h a r g e a i r man i f o l d and exhaus t
p i p e s a r e o n t h e s a m e s i d e. B e t w e e n c y l i n d e r 1 a n d 2 a n d c y l i n d e r 5
a n d 6, y o u c a n s e e t w o f l a n g e s f o r e g r v a l v e s .
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3i n t a k e a n d e x h a u s t m a n i f o l d
V a l v e
c o v e r
R o c k e r a r m
h o u s i n g
S e a l i n g
C y l i n d e r
h e a d
C y l i n d e r h e a d
g a s k e t
C h a r g e a i r
m a n i f o l d
E x h a u s t
p i p e
5)A de ta i l ed desc r i p t i on o t t he i n t ake and exhaus t man i f o l d i s g i ven
h e r e. F o r t h e G T P o w e r M o d e l w e h a v e t o c o n s i d e r t h e s p e c i a l c h a r g e
a i r man i f o l d. A i r l e a v e s t h e c h a r g e a i r p i p e a n d e n t e r s t h e r o c k e r a rm
h o u s i n g . T h e n t h e a i r f l o w i s s e p a r a t e d i n t o a ma in sw i r l p i pe and a m a i n
f i l l ing pipe. T h e s e p i p e s a r e s e p a r a t e d a g a i n i n t o t h e t w o n e i g h b o u r i n g
cy l i nders .
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C h a r g e
a i r c o o l e r
T c h a r g e air
P charge a i r
V T G
E C U
e l e c t r . g o v e r n o r
m air
E G R - c o n t r o l
v a l v e
E G R - c o o l e r
R e e d
v a l v e s
E G R C o n c e p t : H i g h - P r e s s u r e E G Rp u l s e-E G R
6) N e x t p i c t u r e s h o w s a s c h e m a t i c d e s c r i p t i o n o f t h e e n g i n e 2 0 1 3 w i t h
c o m p r e s s o r , cha rge a i r coo le r , c y l i n d e r s a n d t u r b i n e. T h e h i g h p r e s s u r e
e g r s y s t e m c o n s o s t s o f t h e e g r- con t ro l va l ves , t he eg r -coo le r a n d t h e
r e e d v a l v e s .
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3h i g h p r e s s u r e E G R
7)T h e G T P o w e r M o d e l looks l i ke th i s . A i r e n t e r s t h r o u g h t h e
c o m p r e s s o r a n d t h e c h a r g e a i r coo le r i n t o t he cy l i nde rs . T h e i n t a k e
m a n i f o l d i s m o d e l e d a c c o r d i n g t o t h e e x p l a n a t i o n a l r e a d y g i v e n. Fu r the r
you can see t he exhaus t gas sys tem t i l l t he ou t l e t a f t e r t u rb i ne . T h e e g r
s y s t e m c o n s i s t s o f t h e e g r-c o n t r o l v a l v e s , the egr p ipes , t h e e g r-c o o l e r
a n d t h e r e e d v a l v e s . T h e M o d e l i n g o f t h e r e e d v a l v e s a n d t h e c o m m o n
ra i l i n jec t i on sys tem i s g i ven i n a m o r e d e t a i l e d w a y .
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
E G R c o n c e p t : r e e d v a l v e s
8)T h e r e e d v a l v e s l o o k l i k e i n t h e f o l l o w i n g e x a m p l e s . I n our
i n ves t i ga t i ons we used t he one on t he r i gh t s i de, m a d e b y P i e r b u r g.
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
E G R : c h a r g e a i r p r e s s u r e u n d b o o s t p r e s s u r e b e f o r e T u r b i n e
9) H e r e y o u c a n s e e t h e c h a r g e a i r p r e s s u r e a n d t h e b o o s t p r e s s u r e
b e f o r e t u r b i n e a s a func t i on o f c rank ang le . E a c h t i m e p r e s s u r e b e f o r e
t u rb i ne i s h i ghe r t han cha rge a i r p ressu re, e x h a u s t g a s f l o w s t h r o u g h
t h e o p e n r e e d v a l v e s i n t o t h e c h a r g e a i r p i p e. I n t h e o t h e r c a s e, t h e
r eed va l ves a re c l osed .
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3r e e d v a l v e s
10) I n G T P o w e r t h e V a l v e R e e d R e f e r e n c e i s u s e d. W i t h t h e E x c e l
M a c r o Chkva l50 . x ls the input w a s d e f i n e d . T o d e f i n e t h e p a r a m e t e r s f o r
t h e E x c e l -f i l e s o m e t e s t i n g s f o r t h e u s e d r e e d v a l v e h a v e b e e n d o n e t o
e s t i m a t e p r e s s u r e n e e d e d f o r o p e n i n g t h e v a l v e a n d t h e p r e s s u r e fo r
t h e c a s e, tha t va l ve i s f u l l open .
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30 .10 .00 2000 GT-Suite User Conference / Deutz AG
C o m m o n R a i l S y s t e m ( C R S )E lec t r i c un i t p u m p s y s t e m ( U P S )
I n j e c t i o n s y s t e m o f t h e e n g i n e f a m i l y 2 0 1 3
11)F o r o u r s e r i e s e n g i n e a U P S i s u s e d. T h i s i n j e c t i o n s y s t e m h a s b e e n
r e p l a c e d b y a C R s y s t e m i n t h e r e s e a r c h e n g i n e. U s i n g a C R s y s t e m ,
we have the poss ib i l i t y f o r m u l t i p l e in jec t i ons . I n o u r c a s e t h e i n f l u e n c e
of pre- and pos t -i n j e c t i o n w a s i n v e s t i g a t e d . T h e p i c t u r e s s h o w s t h e t w o
s y s t e m .
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3I n j e c t i o n s y s t e m
12) I n t h e G T P o w e r M o d e l o f t he eng ine 2013 , f o r m o d e l l i n g a c o m m o n
ra i l sys tem, the in jec t ion p ro f i le o f the need le l i f t i s g iven as a func t ion o f
c r a n k angle. For Un i t p u m p s y s t e m, w e u s e d t h e i n j e c t i o n p r e s s u r e.
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3un i t p u m p i n j e c t i o n s y s t e m ( U P S )
13)The p ro f i l es o f i n j ec t i on p ressu re, need le l i f t and cy l i nde r p ressu re
a re g i ven fo r a n e x a m p l e i n th i s p i c tu re.
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3c o m m o n r a i l i n j e c t i o n s y s t e m ( C R )
C R S w / o
p o s t i n j e c t i o n
b e : 2 1 6 . 7 g / k W h
N O x : 2 7 8 p p m
B S Z : 0 . 2 5
C R S w i t h
p o s t i n j e c t i o n
b e : 2 1 8 . 4 g / k W h
N O x : 2 6 3 p p m
B S Z : 0 . 1 1
I n f l u e n c e o f P o s t I n j e c t i o n o n E m i s s i o n s a n d S F C : E S C -tes t po in t 3 :1 8 4 5 r p m, 9 . 7 b a r
cylinder pressure needle lift heat release rate
14) C o n s i d e r i n g c o m m o n r a i l i n j e c t i o n w e h a v e t h e f o l l o w i n g p r o f i l e s of
c y l i nde r p ressu re, n e e d l e l i f t a n d h e a t r e l e a s e ra te . I n t h i s c a s e E S C
T e s t (E u r o p e a n S t a t i o n a r y C y c l e T e s t ) point 3 w i t h 1 8 4 5 r p m a n d 9.7
b a r i s i n v e s t i g a t e d. The i n f l uence o f pos t i n j ec t i on i s a l s o s h o w n .
P a r t i c l e c o n c e n t r a t i o n d e c r e a s e s v e r y m u c h w h i l e f u e l c o n s u m p t i o n and
N o x c o n c e n t r a t i o n s t a y a p p r o x i m a t e l y t h e s a m e. C a l c u l a t i o n i s s h o w n
for E S C T e s t (E u r o p e a n S t a t i o n a r y C y c l e ).
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
C o m p r e s s o r m a p E S C -T e s t w / o E G R
15)T h e E S C p o i n t s w i t h o u t e g r a r e s h o w n i n t h i s c o m p r e s s o r m a p . T h e
speeds o f 1 4 8 0 , 1 8 4 5 a n d 2 2 0 0 wi th fu l l l oad and severa l pa r t l oad
c a s e s a r e i n t h i s m a p .
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
C o m p r e s s o r m a p E S C -T e s t w i t h E G R
16)E g r l e a d s t o s m a l l e r m a s s f l o w r a t e s f o r t u r b i n e a n d c o m p r e s s o r s .
T h e E S C p o i n t l e a d a c c o r d i n g t o a s u m f o r m u l a t o t h e E S C T e s t v a l u e s .
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
t e s t i n g / c a l c u l a t i o n : R e s u l t s f o r E S C - T e s th i g h p r e s s u r e / p u l s e e g r
0 1 2 3 4 5 6 7 8 9 100.00
0.02
0.04
0.06
0.08
0.10
0.12
CR-injection systemwith postinjection,ATL with WG
CR, VTG
UPS-injection system, CR-injectionsystem w/o preinjection,ATL with WG
tes t ing h igh p ressure egr
s imu la t ion h igh p ressure egrP
artic
les
[g/k
Wh]
NOx [g / kWh ]
EURO4
EURO3
17) I n t h i s m a p i n c l u d i n g t h e E U R O 3 a n d E U R O 4 e m i i s i o n s t a n d a r d s ,
t he t r ade - o f f s f o r p a r t i c l e s a n d N o x a r e s h o w n. T h e s e r i e s e n g i n e w i t h
U P S a n d w a s t e- g a t e t u r b o c h a r g e r, we fu l f i l l the E U R O 3 e m i s s i o n
s t a n d a r d . T h e C R sys tem w i t hou t p re i n j ec t i on l eads t o s im i l a r r esu l t s .
The resu l t s w i t h p re i n j ec t i on a re show by the second t rade o f f . T u r b i n e
w i t h v a r i a b l e t u r b i n e g e o m e t r y l e a d s t o the th i rd t rade o f f . F o r t h i s c a s e
tes t i ng ( b lack) a n d s i m u l a t i o n ( r e d ) a r e s h o w n . W i th r a the r sma l l eg r
ra tes o f about 10 pe r cent , a r e d u c t i o n o f N o x f r o m 6 to 4 .5 g /kWh c a n
b e r e a c h e d. A g r e e m e n t b e t w e e n t e s t i n g a n d s i m u l a t i o n i s v e r y g o o d .
F u e l c o n s u m p t i o n s t a y s c o n s t a n t . Fo r h igher e rg ra tes the resu l t s a re
r a t h e r p o o r r e g a r d i n g r e d u c t i o n p o t e n t i a l s a n d a g r e e m e n t .
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
0
20
4060
80
100
120140
160
180
200
220
gem. Motorleistung ber. Motorleistung ohne AGR
en
gin
e p
ow
er
[KW
]
40
60
80
100
120
140
160
180
200
exp.erm. Zünddruck mit GTPower ber. Zünddruck ohne AGRm
ax.
cylin
der
pres
sure
[ba
r]
0 2 4 6 8 10 12 14
1.0
1 .5
2 .0
2 .5
3 .0
3 .5
4 .0
4 .5
5 .0
gem. Ladedruck ber. Ladedruck ohne AGR
Nr. [-]
char
ge a
ir p
ress
ure
[bar
]
t e s t i n g / c a l c u l a t i o n : E S C-T e s t
G o o d A g r e e m e n t b e t w e e n m e a s u r e m e n t a n d c a l c u l a t i o n f o r :
e n g i n e p o w e rm a x . c y l i n d e r p r e s s u r ec h a r g e a i r p r e s s u r e
18)The resu l t s fo r each tes t po in t o f E S C tes t w i thou t eg r a re g i ven
h e r e. T h e r e i s g o o d a g r e e m e n t b e t w e e n t e s t i n g a n d c a l c u l a t i o n f o r
e n g i n e p o w e r, c y l i n d e r p r e s s u r e a n d c h a r g e a i r p r e s s u r e f o r e x a m p l e.
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
0
20
4060
80
100
120140
160
180
200
220 gem. Motorleistung ber. Motorleistung ohne AGR ber. Motorleistung mitAGR
Mo
torl
eis
tun
g [
KW
]
40
60
80
100
120
140
160
180
200
gem. Zünddruck ber. Zünddruck ohne AGR ber. Zünddruck mit AGR
Zü
nd
dru
ck [
ba
r]
0 2 4 6 8 10 12 14
1.0
1 .5
2 .0
2 .5
3 .0
3 .5
4 .0
4 .5
5 .0
gem. Ladedruck ber. Ladedruck ohne AGR ber. Ladedruck mit AGR
Nr. [-]
La
de
dru
ck [b
ar]
t e s t i n g / c a l c u l a t i o n : E S C-T e s t w i t h e g r
E G R : R e g u l a t i o n of c h a r g e a i rp r e s s u r e by V G T con t ro le r
i n n e r a i r-fu le ra t io λ V c a l c u l a t e d f r o m f resh a i r f low and a i r ( o x y g e n ) in b o o s t :
0 2 4 6 8 10 12 14
0
1
2
3
4
5
Nr. [-]
ber. λ V ohne AGR ber. λ
V mit HD-AGR
"inn
eres
" V
erbr
ennu
ngsl
uft-
Kra
ftst
off-
Ver
hält
nis
λ V[-
]
19) Wi th eg r t he resu l t s a re st i l l v e r y g o o d. Fo r eg r ca l cu la t i on and
tes t i ng, t he cha rge a i r p ressu re i s con t r o l ed by V G T con t ro l l e r . T o h a v e
s a m e e m i s s i o n l e v e l s , the inner a i r -f u e l r a t i o, ca l cu laed f r om f resh a i r
a n d o x y g e n i n b o o s t , i s s im i la r l y cons tan t .
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
C h a r g e
a i r c o o l e r
E g r - c o o l e rE g r c o n t r o l v a l v e
m a i r
C h a r g e a i r
V G T
D i e s e l p a r t i c l e f i l t e r
T charge air
E l e c t r .
g o v e r n o r
E G R C o n c e p t : L o w -P r e s s u r e E G R
E C U
20)T h e s e c o n d s y s t e m , t h a t h a s b e e n i n v e s t i g a t e d i s t h e l o w p r e s s u r e e g r. A part of
t h e e x h a u s t g a s h a s t o b e c l e a n e d i n a part ic le f i l ter , a n d f l o w s t h e n t h r o u g h a n e g r-
c o o l e r a n d a n e g r -c o n t r o l v a l v e.
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3l o w p r e s s u r e E G R
21)T h e G T P o w e r m o d e l l o o k s l i k e f o l l o w s. The mode l i s s im i l a r t o t h e h igh p r e s s u r e
e g r m o d e l .
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22
3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
0 1 2 3 4 5 6 7 8 9 1 00.00
0.02
0.04
0.06
0.08
0.10
0.12
CR-injection systemwith postinjection,ATL w i th WG
CR, VTG
UPS-inject ion system, CR-inject ionsystem w/o preinjection,ATL w i th WG
t e s t i n g l o w p r e s s u r e e g r
s i m u l a t i o n l o w p r e s s u r e e g rP
artic
les
[g/k
Wh]
N O x [ g / k W h ]
E U R O 4
E U R O 3
t e s t i n g / c a l c u l a t i o n : R e s u l t s f o r E S C - T e s tl o w p r e s s u r e e g r
22)T h e r e s u l t s a r e a l s o s h o w n i n the par t ic les - n o x m a p . T h e r e f e r e n c e p o i n t i s d i f f e ren t
t o the resu l t s f o r h i gh p r e s s u r e e g r. Fo r eg r ra tes o f abou t 11 pe r cent , a r e d u c t i o n f o r
n o x i s o b t a i n e d f r o m 9 to 6 .5 g /kWh. B u t t h e p a r t i c l e s i n c r e a s e s v e r y m u c h i n t h i s c a s e.
T h e r e s u l t s a r e e v e n w o r s e r t h a n m o v i n g o n t h e t r a d e o f f w i t h o u t egr.
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3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G
S u m m a r y
Fulf i l l ing of E U R O 4 : f u r t he r op t im i za t i ons (i n j e c t i o n p r e s s u r e,c h a r g e a i r p r e s s u r e, E G R ) E T C : a f t e r t r e a t m e n t D iese l par t ic le f i l ter or S C R
Inves t i ga t i on o f d i f fe rent e g r s y s t e m s
Deta i l ed Mode l l i ng o f
G o o d a g r e e m e n t b e t w e e n t e s t i n g a n d s i m u l a t i o n r e s u l t s
- E G R -s y s t e m
- C R i n j e c t i o n s y s t e m
- i m p l e m e n t a t i o n o f V T G
23) L e t m e s u m m a r i z e t h e r e s u l t s. W e i n v e s t i g a t e d H I G H P R E S S U R E a n d L O W
P R E S S U R E e g r s y s t e m s f o r t h e D E U T Z d i e s e l e n g i n e 2 0 1 3 . The de ta i l ed mode l i ng o f
e g r a n d i n j e c t i o n s y s t e m h a s b e e n d i s c u s s e d . T h e r e s u l t s s h o w s g o o d a g r e e m e n t
b e t w e e n t e s t i n g a n d s i m u l a t i o n. For fu l f i l l ing E U R 4 e m i s s i o n s t a n d a r d i n s ta t i ona ry t es t ,
f u r t h e r o p t i m i z a t i o n s h a v e t o b e i n v e s t i g a t e d . Fo r t r ans ien t t es t E T C e x h a u s t g a s
a f te r t rea tment l i ke par t i c le f i l t e r o r S C R a r e n e e d e d .
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... k n o w i n g i t ‘ s D E U T Z