Recent Developments in BMW's Diesel Technology · EA BMW Diesel History Recent Developments in...
Transcript of Recent Developments in BMW's Diesel Technology · EA BMW Diesel History Recent Developments in...
DEER Conference 2003 – Newport, USA August 2003
Recent Developments in BMW´s Diesel TechnologyEAEA
EAEA BMW Diesel History
Recent Developments in BMW´s Diesel Technology
3rd generation
2nd generation
1st generation
1985 1990 1995 2000 2005
DI-E
ngin
esID
I-Eng
ines
Spec
. Pow
er [k
W/d
m3 ]
35
42
55 revision
2.5 - R6 - DI - VNT
3.9 - V8 - DI - VNT
3.0 - R6 - DI - VNT
2.0 - R4 - DI - VNT
1.67 - R4 - ATL
2.5 - R6 - ATL
2.4 - R6NA-Engine
2.4 - R6 - ATL
revision
revision
EAEA Recent Developments in BMW´s Diesel Technology
350
300
250
200
150
100
50
0
Engi
nes
-100
0/ye
ar
83 84 85 86 87 88 89 90 91 92 93
Year of production
94 95 96 97 98 99 00 01 02
3rd generation2nd generation1st generation
Σ 1st generation:262.000
Σ 2nd generation:635.000
BMW Diesel Production
BMW Market Share 04/2003
Recent Developments in BMW´s Diesel Technology
World wide Europe
Petrol65%
Diesel35%
Petrol32%
Diesel68%
X5
EAEA BMW Diesel Engine Family
Recent Developments in BMW´s Diesel Technology
200
175
150
125
100
75
Pow
er [k
W]
1.5
Displacement [ I ]
2 2.5 3 3.5 4 4.5
4-cylinder2.0 l
6-cylinder2.5 / 3.0 l
8-cylinder3.9 l
EAEA BMW Diesel Product Range
Recent Developments in BMW´s Diesel Technology
3-Series
X5
Power Output
4 cylinder 6 cylinder 8 cylinder
85 kW 110 kW 150 kW
100 kW 120 kW 160 kW
160 kW
160 kW
190 kW
135 kW
MJ 03 MJ 04
5-Series
7-Series
Key Technologies
Recent Developments in BMW´s Diesel Technology
Core engineDurability for cylinder pressures up to 180 barHigh thermal resistanceLow friction
Combustion concept• Combustion chamber layout• Port design for efficient
swirl generation
Injection system• High hydraulic performance• Sophisticated application
strategy
Air management• VNT-Turbochargers• Optimised intake / exhaust
system with intercooling
Outstanding performanceLow consumption and emissions
BMW Diesel-Development
EAEA
Crank case• Material GGV-500• Cracked main bearing
walls• Two main bearing bolts
Core Engine Design
Recent Developments in BMW´s Diesel Technology
Cylinder head• Aluminium alloy with specific
thermal treatment• Design based on sophisticated
simulation methods- Mould filling- Residual stress simulation- Strength and fatigue analysis
Combustion Chamber and Port Design
Recent Developments in BMW´s Diesel Technology
8-Cylinder Engine• Inlet ports coming
from one side
6-Cylinder Engine• Swirl port from the top• Tangential port with swirl flap
from the side
EAEA Fuel Injection System
Recent Developments in BMW´s Diesel Technology
Common rail system 2nd Generation• 1600 bar• Fuel metering• Small pilot quantities• High flexible injection strategy• Reduced dispersion
spec
. Wor
k [k
J/dm
3 ]
2,5
2,0
1,5
02000 3000 40001000
Engine Speed [1/min]
0,5
1,0
PiI ... Pilot InjectionMI ... Main InjectionPoI ... Post Injection
PiI1+PiI2+MI+Pol
PiI1+MI
MIPiI1+MI+Pol
PiI1+PiI2+MI
Injection Strategy
Recent Developments in BMW´s Diesel Technology
Characteristics Diesel Electronic Control Units
Recent Developments in BMW´s Diesel Technology
Start of Production
* With Master / Slave ECU´s: 15600 Labels for Calibration
1989
bit
MIPS
Mio
kByte
730d740d
DDE5
32
40
7
1000
7800*
154
1993
DDE2
16
1
<1
64
1500
55
1998
DDE4
16
4
<1
256
4500
121
DDE1
8
<1
<1
33
500
55
2002
ECU-Type
Data Length
Computer Performance
Number of Transistors
Memory
Number Labels for Calibration
Number of ECU - Pins
Spontaneous Glow System
Recent Developments in BMW´s Diesel Technology
• Pre Glow Phase < 3 sec• Reduction Power Consumption• ECU Mounted to the Engine
Previous Engine12V Glow Plug
New Engine6V Glow Plug
Spontaneous Glow System
Recent Developments in BMW´s Diesel Technology
1200
1000
800
600
400
200
0
Tem
pera
ture
[°C
]
0 5 10 15Time [s]
New Engine Previous Engine
-25 -15 -5 5Temperature [°C]
Temperature Glow Plugs Pre Glow Time
10
8
6
4
2
0Ti
me
[s]
EAEA Air Management
Recent Developments in BMW´s Diesel Technology
EAEA Air Management
Recent Developments in BMW´s Diesel Technology
Base Engine: Cylinder pressure bar 160 180
Compression Ratio 18:1 17:1
Injection System: Rail pressure bar 1350 1600
Number of Injection 3 4
Min. Pilot quantity mm3/cyc 1.6 1.0
Fuel metering without with
Turbocharging: Max. Boost pressure bar 2.1 2.3
Pressure ratio 2.48 2.72
Max. Turbine Eff. % 64 70
Max. Compressor Eff. % 59 63
Improvements DI 1st to 2nd Generation
Recent Developments in BMW´s Diesel Technology
1st gen. 2nd gen.
Engine Performance 6-Cylinder in X5
Recent Developments in BMW´s Diesel Technology
2000 3000 40001000
Engine Speed [1/min]
Pow
er [k
W]
180
160
140
20
40
120
5000
Torq
ue [N
m]
540
500
460
260
380
420100
60300
34080
Torque Power
Diesel MJ 03135 kW Engine
Diesel MJ 04160 kW Engine
X5 MJ 04 X5 MJ03
Fuel ConsumptionAcceleration0-100 km/h
Maximum speed
Performance / Fuel Consumption - X5 AT
Recent Developments in BMW´s Diesel Technology
Acceleration 0-100 [sec]
Fuel Consumption in X5 AT – Comparison Diesel / Petrol
Petrol Diesel
Recent Developments in BMW´s Diesel Technology
8
FC [m
ile/g
al]
8.5 9 9.5 10 10.5 11
26
24
22
20
30
28
X5 with 3.0 6-cylinder engines
Diesel MJ 03135 kW Engine
Diesel MJ 04160 kW Engine
Petrol
CO2 Reduction20 percent
NOx- and PM-Reduction for BMW 5 Series Diesel cars
Recent Developments in BMW´s Diesel Technology
0
Particulate Matter [g/km]
NO
x [g
/km
]
0.02 0.04 0.08 0.10 0.14
0.8
0.6
0.4
0
1.2
1.0
0.2
0.06 0.12
525tds1992
Potential with DPF
EU 1 1992
525tds1996
EU 2 1996
EU 2 2000
EU 4 2005530d2000
530d2005
Recent Developments in BMW´s Diesel Technology
0
Particulate Matter [g/mi]
NO
x [g
/mi]
0.02 0.04 0.08 0.10 0.14
0.8
0.6
0.4
0
1.2
1.0
0.2
0.06 0.12EPA BIN 5 MJ09= CARB LEV 2 MJ07
EPA BIN 8 MJ09
EPA BIN 10 MJ04 to MJ08
EPA till MJ03
X5 3.0 dA with specific US-tuneadditional DPF
With DPF andDeNOx-System
X5 situation
CARB LEV 1 MJ04 to MJ06
Emission Legislation in USA
Biggest challenge(technology and time)
Recent Developments in BMW´s Diesel Technology
Conclusion
• Modern BMW Diesel technology offers powerful, cleanand economic engines for the new decade
• Improved combustion systems combined with filtertechnologies can virtually remove PM-emissions
• The 2007 US NOx-limits are the biggest challenge Technology for highly efficient NOx-aftertreatment Time scale for 2007 very demanding
• The introduction of diesels with durable and enablingemission control technologies should be supported by:
Better fuel quality similar to ECE 2005+Slightly legislation adaptations to take account of the specific diesel advantages (long term emission stability, CO2)
Diesel engines could play a major role in saving crude oil and reducing CO2-emissions in USA too
Recent Developments in BMW´s Diesel Technology
DEER Conference 2003 - Newport USA