Fiat 1.4L CNG performance - Presentation contents

INGAS - Integrated GAS Powertrain24 months Meeting, 27-28 October, 2010

Project number: 218447Project number: 218447 27-28 October 2010 27-28 October 2010

Fiat 1.4L CNG performance - Presentation contentsFiat 1.4L CNG performance - Presentation contents

• Engine tests at bench : 1st phase with base engine• Engine characterization with CR 9.8 (full load + Willans)

• Engine improvements : CR = 11:0 + Turbo matching

• Engine tests at bench : 2nd phase with new hardware• Engine characterization with CR 11 + VGT (full load + Willans)



Engine tests at bench : 1Engine tests at bench : 1stst phase with base engine phase with base engine

• Compression ratio : 9,8:1• Turbocharger : IHI 150 CV




• Partial load characterisation• Willans lines

0

2

4

6

8

10

12

14

16

18

20

22

24

0 20 40 60 80 100

Fuel flow (mg/cycle/L displacement)

BM

EP

(b

ar)

1000 rpm : WMEP = 1.78 bar and WSFC (eq. Gasoline) : 212.9 g/kW/h - R2 = 0.99992

2000 rpm WMEP = 2.05 bar and WSFC (eq. Gasoline) : 196.4 g/kW/h - R2 = 0.99995

3500 rpm WMEP = 2.29 bar and WSFC (eq. Gasoline) : 196.6 g/kW/h - R2 = 0.99990

5500 rpm : WMEP = 2.43 bar and WSFC (eq. Gasoline) : 210.4 g/kW/h - R2 = 0.99994




• Full load characterisation• Constraints : max temperature inlet turbine = 950 °C

max cylinder pressure (Pcyl max + 3) = 105 bars

0

50

100

150

200

250

1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000Engine speed (tr/min)

To

rqu

e (N

.m)

Torque Nm

CRF Torque curve

0

20

40

60

80

100

120

1000 2000 3000 4000 5000 6000Engine speed (tr/min)

Bra

ke p

ow

er (

kW)

Brake power kWCRF Power curve

Max torque :

IFP : 226 N.m @ 2500 rpm

CRF : 218 N.M @ 2040 rpm

Max power :

IFP : 90 kW @ 5000 rpm

CRF : 94 kW @ 5000 rpm



Engine improvements : CR = 11:0 + Turbo matchingEngine improvements : CR = 11:0 + Turbo matching

Turbo matching : Simulation of 4 turbocharger configurations :

Compressor Turbine

IHI 150 CV (conf 1) RHF3_BRL315_04 RHF3_TTW62P105NR

Garrett GT1238 (conf 2) C224(38) 60 Trim 0.38 A/R -

Garrett GT1446 (conf 3) C224(46) 55 Trim 0.46 A/R T202(43) 72 Trim 0.67 A/R

VGT Garrett GT1444 (conf 4) C224(44) 60 Trim 0.44 A/R T213(39)T84AR074vh65

y = 9E-07x2 - 9E-05x + 0.006

y = 3E-06x2 - 0.0003x + 0.0144

y = 2E-07x2 + 5E-05x - 0.0021

-0.05

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5

0 50 100 150 200 250 300 350 400 450

Gaz flow (kg/h)

Pre

ss

ure

lo

ss

es

(b

ar)

Air filter

Exaust line

Air cooler

Pressure loss models :



Turbo matchingTurbo matchingP

res

su

re R

ati

o (

t/t)

P2

c/P

1c

1.0

1.5

2.0

2.5

3.0

3.5

Corrected Air Flow (Kg/s)0.00 0.05 0.10 0.15 0.20

0.55

0.6

0.62

0.64

0.66

0.68

0.7

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


200000

220000

180000

160000

140000Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


Compressor IHI RHF3 BRL315 04(Base TC)

2000 rpm

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


0.55

0.6

0.62

0.64

0.66

0.68

0.7

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


280000

200000

260000

240000

220000

180000

160000140000

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


4750 rpmCompressor C224(38) 60 Trim 0.38 A/R

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


0.55

0.6

0.62

0.64

0.66

0.68

0.7

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


120000

160000

180000

100000

140000

200000

220000

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


> 3000 rpm

Compressor C224(46) 55Trim 0.46 A/R

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


0.55

0.6

0.62

0.64

0.66

0.68

0.7

0.72

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


120000 140000

160000

180000

200000

220000

240000

Pre

ss

ure

Ra

tio

(t/

t) P

2c

/P1

c

1.0

1.5

2.0

2.5

3.0

3.5


Compressor C224 (44) 60 Trim 0.44 AR (associated with VGT)

11

22

33

44



Turbo matchingTurbo matching

VGT turbocharger simulation :

0

5

10

15

20

25

30

500 1500 2500 3500 4500 5500

Engine speed (rpm)

BM

EP

(b

ar)

60 %

30 %

40 %

80%

100 %

Target

Allowed max. BMEP taking into account surge line

0

10

20

30

40

50

60

70

80

90

100

0 1000 2000 3000 4000 5000 6000

Engine speed (rpm)

VG

T p

osi

tio

n (

%)

?

• VGT is the best competitor to improve the full load engine performances. • VGT offers the potential to improve the low speed engine performance, in spite of the surge line of the compressor from 1000 to 1500 rpm• For engine speed higher that 2500 rpm, the VGT turbine also offers an higher efficiency than a fixed geometry turbine with an opened waste gate.



Engine tests at bench : 2Engine tests at bench : 2ndnd phase with new hardware phase with new hardware

• Compression ratio : 11:1• Turbocharger : VGT Garrett GT1444



• Partial load characterisation• Willans lines


0

2

4

6

8

10

12

14

16

18

20

22

24

0 20 40 60 80 100

Fuel flow (mg/cycle/L displacement)

BM

EP

(b

ar)

1000 rpm : WMEP = 2,18 bar and WSFC (eq. Gasoline) : 209,8 g/kW/h - R2 = 0,99965

2000 rpm WMEP = 1,98 bar and WSFC (eq. Gasoline) : 208,6 g/kW/h - R2 = 0,99965






CR 9.8 CR11 + VGT

WMEP (bar)

WSFC (g/kW.h)

WMEP (bar)

WSFC (g/kW.h)

1000 rpm 1.78 212.9 2.18 209.8

2000 rpm 2.05 196.4 1.98 208.6

3500 rpm 2.29 196.6 2.22 202.9

5500 rpm 2.43 210.4 2.59 213.9

Differences observed at partial load could be due to :

• New compression ratio

• New turbine permeability

• New engine parts (piston rings, crankshaft bearings, …)



• Full load characterisation : Torque• Constraints : max temperature inlet turbine = 850 °C



Max torque :

• IFP CR 9.8:1 :

226 N.m @ 2500 rpm

• IFP CR 11:1 + TGV

227 N.m @ 2250 rpm

(limited by Tin turb = 850 °C)

Max torque at lower rev

40

60

80

100

120

140

160

180

200

220

240

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000Engine speed (tr/min)

To

rqu

e (N

.m)

0.9

1

1.1

1.2

1.3

1.4

1.5

Lam

bd

a (

-)

CR 9.8:1 CR 9.8:1 CRF Curve

CR = 11:1 + VGT - Lambda = 1 CR = 11:1 + VGT - Lambda opti



• Full load characterisation : Power• Constraints : max temperature inlet turbine = 850 °C



Max power :

• IFP CR 9.8:1 :

90 kW @ 5000 rpm

• IFP CR 11:1 + TGV (=1)

76 kW @ 4500 rpm !!

strongly limited by

Tin turb 850 °C, not WOT

• IFP CR 11:1 + TGV ( opti)

92 kW @ 5000 rpm

limited by Tin turb = 850 °C 0

20

40

60

80

100

120

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000

Engine speed (tr/min)

Bra

ke p

ow

er (

kW)

0.9

1

1.1

1.2

1.3

1.4

1.5

Lam

bd

a (-

)

CR 9.8:1 CRF Curve CR 9.8:1

CR = 11:1 + VGT - Lambda = 1 CR = 11:1 + VGT - Lambda opti



• Full load characterisation : Thermomechanical constraints


400

500

600

700

800

900

1000

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000


Te

mp

era

ture

inle

t tu

rbin

e (

°C)

CR 9.8:1 CRF Curve

CR 9.8:1

CR = 11:1 + VGT - Lambda = 1

CR = 11:1 + VGT - Lambda opti

Pressure maximum in Cylinder 4 (Bar)

45

55

65

75

85

95

105

115

500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000


PC

yl m

ax

(b

ar)

CR 9.8:1

CR = 11:1 + VGT - Lambda = 1

CR = 11:1 + VGT - Lambda opti

Turbine inlet temperature Pcyl4 + 3

Performation limitation due to turbine inlet inlet temperature



• Full load characterisation : Turbochargers duty zones


IHI 150 CV

Pre

ssure

Ratio (t/t) P

2c/P

1c

1.0

1.5

2.0

2.5

3.0


0.55

0.6

0.62

0.64

0.66

0.68

0.7

Pre

ssure

Ratio (t/t) P

2c/P

1c

1.0

1.5

2.0

2.5

3.0


200000

220000

180000

160000

140000

VGT Garrett GT1444

Compressor of Garrett TC presents better efficiency than IHI oneIn return, surge limit is dramatically reduced



• New hardware configuration (VGT + CR 11:0)• offers similar performances regarding maximum torque and power.

No improvement was obtained because the lower maximum

turbine inlet temperature (850°C vs. 950°C)• reduces maximum torque engine speed (VGT effect)• does not reduce the fuel consumption because the turbine is

undersized• GT 1444 compressor works with a better efficiency …• … but the safety margin regarding surge is not sufficient with the

GT1444

ConclusionsConclusions

Fiat 1.4L CNG performance - Presentation contents

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