Enabling Improved Vehicle Fuel Economy and Emissions · Enabling Improved Vehicle Fuel Economy and...
Transcript of Enabling Improved Vehicle Fuel Economy and Emissions · Enabling Improved Vehicle Fuel Economy and...
© 2017 Eaton. All Rights Reserved.
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Enabling Improved Vehicle Fuel Economy and Emissions
James McCarthy, Jr.
Eaton
June 14th, 2017
2© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Agenda
• Introduction• Cylinder Deactivation (CDA)• Test Setup
• Engine Hardware
• Test Plan
• Results• Control Strategy
• Speed – Load (Torque) Sweeps
• Animation
• Full Engine CDA
• Conclusions
3© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Introduction
• NOx aftertreatment systems are temperature sensitive• High NOx conversion begins between 220 and 280C
depending on catalyst formulation
• Exhaust thermal management is key for Aftertreatment• Proposed ultra-low NOx standard on the order of 10% of
today’s standard
• 250C at the turbine exit was chosen as the target in this study for high NOx conversion efficiency
• Cylinder deactivation can provide high grade heat during low load operation while offering a fuel savings
4© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
IntroductionExhaust Temperature MapsMedium Duty Diesel Heavy Duty Diesel
Exhaust Too Cold
Peak Zone > 250C
• Medium and Heavy Duty Exhaust Maps are Scalable
Exhaust “too cold” below 3 to 4 bar BMEP for Efficient NOx Aftertreatment
5© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Agenda
• Introduction• Cylinder Deactivation (CDA)• Test Setup
• Engine Hardware
• Test Plan
• Results• Control Strategy
• Speed – Load (Torque) Sweeps
• Animation
• Full Engine CDA
• Conclusions
6© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Cylinder Deactivation (CDA) & Benefits
Fuel Economy
ExhaustTemperature
Fuel cut off
Intake and exhaust valves stop opening
Cylinder = Air Spring
How It Works
Charge trapped
Diesel Benefits
Fuel Economy
Gasoline Benefits
Half Engine CDA Options
7© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
CDA OptionsReference: All Valves Active
Half Engine CDA
Two Cylinder CDA Four Cylinder CDA
Today’s Focus:Half Engine CDA for Exhaust Temperature / Fuel Economy
Full Engine CDA for Friction / Breathing Reduction
Full Engine CDA
8© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Agenda
• Introduction• Cylinder Deactivation (CDA)• Test Setup
• Engine Hardware
• Test Plan
• Results• Control Strategy
• Speed – Load (Torque) Sweeps
• Animation
• Full Engine CDA
• Conclusions
9© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Proof of Concept Hardware
Production Mechanical Tappet
Production CDA
(gasoline)
CDA Concept EvaluationHardware
Modified Production Hardware for CDA Demonstration on a Medium Duty Diesel Engine
10© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
CDA Proof of Concept Hardware
OCV’sECM
CDA Controller
ECM
Dyno
Oil Control Valves (OCV)
…exha
ust
inta
ke
exha
ust
inta
ke
CDA
…
11© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Test Plan
• Tested all points with full and half engine operation
• Key Metrics:
• Turbine Out Temperature• Fuel Economy
• Reference points measured with camless engine
Camless Engine (Powered Remotely)
Evaluated CDA across speed map (800 to 2100 rpm) at engine loads having low exhaust temperatures (< 250C)
12© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Agenda
• Introduction• Cylinder Deactivation (CDA)• Test Setup
• Engine Hardware
• Test Plan
• Results• Control Strategy
• Speed – Load (Torque) Sweeps
• Animation
• Full Engine CDA
• Conclusions
13© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Control Strategy InfluenceCDA @ 800 rpm
A: ECM untouched
800
2100
1000
12001350
150018001650
Control Strategy A was used for investigation as results were negligible when using Strategies B & C
Varied Based On Cylinder Specific Loads & Air Flow
B:
C:
14© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Agenda
• Introduction• Cylinder Deactivation (CDA)• Test Setup
• Engine Hardware
• Test Plan
• Results• Control Strategy
• Speed – Load (Torque) Sweeps
• Animation
• Full Engine CDA
• Conclusions
15© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
ResultsCDA @ 800 rpm 800
2100
1000
12001350
150018001650
CDA Reaches 250C at lower load (130 Nm vs. 180 Nm)Saves 40% fuel at lowest load. Fuel neutral at 160 Nm.
16© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
ResultsCDA @ 1000 rpm 1000
800
2100
12001350
150018001650
CDA Reaches 250C at 90 Nm (vs. 180 Nm)Saves 49% fuel at lowest load. Fuel neutral at 180 Nm.
17© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
ResultsCDA @ 1200 rpm
1200
800
2100
1000
13501500
18001650
CDA Reaches 250C at 80 Nm (vs. 180 Nm)Saves 23% fuel at lowest load. Fuel neutral at 140 Nm.
18© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
ResultsCDA @ 1350 rpm
1350
800
2100
1000
1200
150018001650
CDA Reaches 250C at 75 Nm (vs. 190 Nm)Saves 31% fuel at lowest load. Fuel neutral at 180 Nm.
19© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
ResultsCDA @ 1500 rpm
1500
800
2100
1000
12001350
18001650
CDA Meets 250C at all loads (vs. 170 Nm)Fuel neutral as 1500 rpm was designed speed of the engine
20© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
ResultsCDA @ 1650 rpm
1650
800
2100
1000
12001350
18001500
CDA Reaches 250C at all loads (vs. 160 Nm)Saves 16% fuel at lowest load. Fuel neutral at 180 Nm.
21© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
ResultsCDA @ 1800 rpm
1800
800
2100
1000
12001350
15001650
CDA Reaches 250C at all loads (vs. 155 Nm)Saves 9% fuel at lowest load. Fuel neutral at 190 Nm.
22© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
ResultsCDA @ 2100 rpm
2100
8001000
12001350
150018001650
CDA Reaches 250C at all loads (vs. 130 Nm)Saves 15% fuel at lowest load. Fuel neutral at 170 Nm.
23© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Agenda
• Introduction• Cylinder Deactivation (CDA)• Test Setup
• Engine Hardware
• Test Plan
• Results• Control Strategy
• Speed – Load (Torque) Sweeps
• Animation
• Full Engine CDA
• Conclusions
24© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Peak Aftertreatment Efficiency Zone
Exhaust Too Cold
Exh
aust
Tem
pera
ture
[C]
Base EngineNeed for Exhaust Temperature Management
Exh. temp. is “too cold” below 3-4 bar for efficient NOx reduction
25© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Half Engine Cylinder Deactivation (CDA)Tested Low Load Conditions (Animation)
Base Engine CDA Test Region
CDA Result for Increase Low-Load Temperature
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2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Half Engine Cylinder Deactivation (CDA)Raises Exhaust Temperature at Low Load
CDA Raises Exh. Temp. in Majority of the Low Load Region
27© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Agenda
• Introduction• Cylinder Deactivation (CDA)• Test Setup
• Engine Hardware
• Test Plan
• Results• Control Strategy
• Speed – Load (Torque) Sweeps
• Animation
• Full Engine CDA
• Conclusions
28© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Full Engine CDA
Full engine CDA reduces friction / breathing by 78% at 2100 rpm
and removes convective heat transfer to keep the aftertreatment hot
All Cylinders Operating
29© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Agenda
• Introduction• Cylinder Deactivation (CDA)• Test Setup
• Engine Hardware
• Test Plan
• Results• Control Strategy
• Speed – Load (Torque) Sweeps
• Animation
• Full Engine CDA
• Conclusions
30© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Conclusions• Exhaust temperature management is needed to meet future emissions
• Half Engine CDA offers the following benefits
1. Increases exhaust temperature by approximately 100 C at all engine speed since AFR reduces; which can yield higher aftertreatment efficiencies
2. Improves engine fuel economy at low loads below 180 Nm (130 ft-lbs)
3. Reduces motoring torque (friction / breathing) by 62% at 2100 rpm
• Full Engine CDA
1. “Coast mode” benefit for reduced motoring torque by 78% at 2100 rpm
2. Keeps aftertreatment “hot” by eliminating convective heat transfer
• Recipe moving forward
• Use CDA at loads up to 180 Nm (130 ft-lbs) or up to 3 to 4 bar BMEP at all engine speeds to increase turbine outlet temperature while reducing fuel consumption
31© 2017 Eaton. All Rights Reserved..
2017 Symposium - Engine Research Center, June 14th, 2017, Madison, WI
Thank You
James McCarthy, Jr.Chief Engineer
Eaton Vehicle Group
James MichelsBusiness Communications
Eaton Vehicle Group