FINAL EVENT - project-reward.eu...Tasks: •Implementation and optimisation of controls...

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FINAL EVENTTRA – Vienna, Austria

Engine Downsizing Approach for a Passenger Car

Stefan Bohatsch, Håkan Persson, Marie Stenfeldt, Markus Ekström – Volvo Car Corporation, Sweden

Ludwig Bürgler, Alexander Machold, Edwin Mücke, Richard Penn – AVL List GmbH, Austria

Jeremy Gidney , Valerie Houel – Johnson Matthey, UK

Prof. Louise Olsson, PhD - Competence Center for Catalysis, Chalmers University of Technology, Sweden

http://www.ecochamps-project.eu/

General Objectives

18-APRIL-2018REWARD – Final Event @ TRA Conference, Vienna 2018Slide 2

• Down sizing Performance > 100 kW/l

• 5% FC improvements compared to MY2015

• Develop Quiescent Combustion system

• Manage Euro 7 RDE (0.5 x Euro6c w CF 1.5)

Boosting system development

Development targets:


0

100

200

300

400

500

600

0 1000 2000 3000 4000 5000 6000

Bra

ke T

orq

ue

[N

m]

Engine Speed [rpm]

VED HP 2015: 170 kW / 480 Nm

Increased PRHigh Flow Capability

Wide operating range

Fast

res

po

nse

• Permanent 2-stage turbocharging system with intermediatecooling

• 48V E-Booster to achieve low end torqueand response

Boosting system development

Development methodology:


1-D simulationCFD-optimiation

DesignPackaging

Mulit-Cylinder Verification

Goal: Quiescent Combustion systemBenefits:• Increased port flow capacity increasing volumetric

efficiency, reducing pressure drop• Potential for reducing combustion chamber surfaces with high

heat transfer

Challenges:• Combustion duration• Part load emissions

Late cycle oxidation with less in-cylinder generated mixing

Enablers:• Capable FIE system• Balanced requirements engine out emissions vs EATS

conversion efficiency• Highly effective cylinder head cooling concept• High temperature capable exhaust side

Combustion system development

REWARD – Final Event @ TRA Conference, Vienna 2018Slide 5 18-APRIL-2018

Flo

w C

oef

fici

en

t [C

f]

Valve lift [mm]

Quiescent

Swirling

Heat transfer

Oxidationrate




Rapid prototypes for verification

3D CFD simulationsFlow Box1D simulations

Single cylinder evaluation

Mulit-Cylinder Application

0.1

0.09

0.08

0.07

0.06

Mea

nfl

ow

coef

fice

nt

Red. Swirl Number0 0.2 0.3 0.4 0.5


Port Development:

• Flow boxes designed and manufactured via a 3D rapid prototyping printer.

• Flow boxes are equipped with seat rings, valve guides and valve dummies.

• Design evaluation in stationary flow test rig; AVL standard valve lift curve with a maximum valve lift of 9mm derived from the inner seat diameter; both valves opened, neglecting dynamical effects.

Two port concepts, Zero-Swirl & Low Swirl as backup


Zero-Swirl port concept;Green = final design


CFD-study:


6 parameters in full factorial DoE 972 cases / bowl

D1

D2

H1

H1

H1

R1

R2

R3

Equivalence Ratio [-]

Soot [-] HIGHLOW

Optimised utilization of air

Reduced soot formation


Verification in Single Cylinder Engine:


1280

Aftertreatment system development

Targets:

Real driving emissions:

• Conformity factor 1.5 in Real Driving

• PEMS measurement on VCC RDE certification cycle on road

• 2x 30 min test sequences derived from road driving (AVL / VCC)


Legislation CO [g/km]

HC + NOx

[g/km]NOx

[g/km]PM

[g/km]Pn

[#/km]

Euro 6 0,50 0,170 0.08 0.005 6.0x1011

ReWArd 0,25 0,085 0,04 0,0025 3.0x1011




Screening tests in gas standVerification on donor engine

Vehicle & EATS simulations (WP2)

Mulit-Cylinder VerificationVehicle application


3 basic systems for evaluation:


Close-coupled LNT+ SCR/SCRF + Under-floor SCR

EATS Recommendation

Backup System Reason

LNT+SCRF+ u/f SCR

LNT+cDPF+ u/f SCR

Better highway phase NOX

control than LNT+SCRF system

Better urban phase NOX

control than LNT+ u/f SCR system with lower fuel consumption penalty from exhaust heating

Engine testing and calibration

Tasks:

• Implementation and optimisation of controls

• Evaluation of charging and combustion system

• partload mapping optimised for engine out emissions

• Improved heating with balanced fuel consumption

• SCR characterisation



Tasks:

• Implementation and optimisation of controls

• Evaluation of charging and combustion system

• partload mapping optimised for engine out emissions

• Improved heating with balanced fuel consumption

• SCR characterisation



Part Load Calibration


DoEmap / operating points

variation parametersDefinition model space

model qualitytrends

target functions optimization map smoothing

Model verification

Calibration maps for variation parameters


Part Load Calibration

Goal: Optimised Engine Out Emissions balanced with Fuel Consumption



”Keep-warm”-strategy:

Goal:

Keep SCR system in operating temperature window

Internal EGR and adjusted injection timing to achieve increased exhaust temperature by acceptable fuel consumption penalty



Full Load Evaluation:

Max. Torque:

550 Nm @ 2000 – 3250 rpm

Peak Power:

200 kW / 270 PS @3750 –4250 rpm


Vehicle Verification:

Emission Test cycles:

• WLTC

• 30 min RDE cycles derivedfrom RDE driving cyclesfrom AVL (Graz) and VCC certification cycle

• PEMS driving on VCC ceritification cycle


-30

-25

-20

-15

-10

-5

0

5

10

0

25

50

75

100

125

150

175

200

0 200 400 600 800 1000 1200 1400 1600 1800

Gra

die

nt

[%]

Ve

hic

le S

pe

ed

[km

/h]

Time [s]

Cycle 1 -Velocity [km/h]

Cycle 2 - Velocity [km/h]

Cycle 1 - Gradient [%]

Cycle 2 - Gradient [%]

Vehicle Verification:

Status:

• First test run done to evaluate basicstatus

• Expedition to TRA and back

• Analyse and optimise

• Final evaluation scheduled for week 21, supervised by Dr. Blasenegger, TU Graz


Summary

”Quiesent” Zero Swirl combustion concept for high performance engine & permanent 2-stage charging with 48V E-Booster support for lowe end torque and response

High Performance Diesel engine for D/E-class passenger cars, 200 kW / 550 Nm

Close Coupled LNT + SCR/SCRF with additional UF-SCR to achieve future emission legislation levels in WLTC and real driving

Engine and vehicle for demonstration and further development of clean and efficientdiesel technology


Demonstrator Vehicle


Engine: Reward

TypeIn-line 4-cyl. twin turbo

+ 48 V E-Boost

Displacement 1969 cm³

Bore 82,0 mm

Stroke 93,2 mm

Compression ratio 14:1

Engine idling speed 825 rpm ± 150

Max engine speed 5000 rpm

Max output 200 kW (270 hp) / 4000 rpm

Max torque 550 Nm @ 1750

Base Vehicle: XC60 gen II, D5 AWD; VED gen II HP; 173 kW / 235 PS; 480 Nm; EU6 Emissions

Official information: https://www.media.volvocars.com/global/en-gb/models/new-xc60/2018

Major Changes: Reward Engine & EATS system; 48V E-KERS prototype system; improved Charge Air Cooling system

https://www.media.volvocars.com/global/en-gb/models/new-xc60/2018

Research and Higher Education

Suppliers

Vehicle Manufacturers

Thank you

www.project-reward.eu

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380Slide 24

http://www.project-reward.eu/

FINAL EVENT - project-reward.eu...Tasks: •Implementation and optimisation of controls...

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