The Role Of IC Engines In Future Energy Use · · 2014-03-04The Role Of IC Engines In Future...

Confidential © MAHLE

Hugh Blaxill

MAHLE Powertrain

4th Oct 2011

The Role Of IC Engines In Future Energy Use

1

MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011

The role of IC engines in future energy use


Contents

Introduction

Market Trends and Forecast

MAHLE Powertrain Research

Downsizing Challenges

Range Extending Engines

Summary

2




Introduction

There is a role for IC engines for future energy use, why ..

– IC engine has high power to weight ratio

– Relatively low cost

– Flexible fuel use

– Established manufacturing investment

– Detailed pre existing knowledge

– Further development potential

The IC Engine is not addicted to fossil fuels …. WE ARE!

3




Where is the role?

Gas turbines will continue in at least aerospace applications

Heavy and medium duty and off highway applications using both SI and CI cycles

Emergency and remote power generation

Larger capacity residential equipment

Medium to long range and/or large capacity light duty applications …. in high efficiency form

What fuels?

Liquid biofuels and biofuel blends

Gaseous fuels

How do we get there?

4

MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 5

MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 Confidential

© MAHLE

Short Term Forecast

Forecast Volumes of North America Manufactured Engines By Cylinder Number

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

Year

Perc

enta

ge o

f Tot

al

3 Cyl 4 Cyl 5 Cyl 6 Cyl 8 Cyl 10 Cyl

Data taken from CSM WW Database Q1 2010

Gasoline Engine Technology Trends

0

3

6

9

12

15

2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017

Year

Fore

cast

US

Volu

mes

, Milli

ons

Boosted Engine Volumes Hybrid inc. Stop/Start Gasoline Direct Injection Variable Valve Train

Increasing volumes of 4 cylinder engines

Rapid ramp in direct injection and variable valvetrain technologies across all manufacturers

Start of an increase in downsized applications and hybrid powertrains


5

MAHLE Powertrain LLC, MPT LLC, Hugh Blaxill, 03-September-2011 6 © MAHLE

Longer Term Forecast

ICE

0

140

Mill

ion

vehi

cles

bui

lt

Year

HEV with ICE

BEV

HEV with ICE range extender

50%

20%

10%

20%

ICE

Increasing 4 cylinder applications

Increasing 3 cylinder

applications


Increasing Downsizing in both amount & application

Increasing Electrification

Bio & gaseous fuels

Now 2030

6




Hybridization

Range extender engine, 30kW power

Combustion Process

Ultra lean combustion, Controlled auto ignition

1000 1500 2000 2500 30001.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

19

17

18

IMEP

net (

bar)

Engine Speed (rev/min)

12

16

20

14

% FE Improvement over Baseline SI (λ=1)

99.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.6

1000 1500 2000 2500 3000150

200

250

300

350

400

450

500

IMEP

net (

bar)


99.7

99.8

99.5

% NOx Reduction over Baseline SI (λ=1)

Alternative Fuels

Downsizing

50% downsizing, up to 30% fuel economy

Friction Reduction

MAHLE low friction components, up to 4% fuel economy saving

Baseline Engine Comparison With MAHLE Engine Components

05

10152025303540455055606570

0 1000 2000 3000 4000 5000 6000 7000 8000

Engine Speed (rpm)

Torq

ue (N

m)

0510152025303540455055606570

Fric

tion

Red

uctio

n (%

)

Baseline engine PREDICTED MAHLE Components fitted % Predicted Benefit

De-Throttling

Valv

e Li

ft

BDCGE TDCGE BDCF

MAHLE CamInCam® Variable valvetrains

Optimized alcohol blends to suit downsizing applications


So what is MAHLE Powertrain researching?

7




Hybridization

Range extender engine, 30kW power

Combustion Process

Ultra lean combustion, Controlled auto ignition

1000 1500 2000 2500 30001.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

19

17

18

IMEP

net (

bar)


12

16

20

14

% FE Improvement over Baseline SI (λ=1)

99.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.699.6

1000 1500 2000 2500 3000150

200

250

300

350

400

450

500

IMEP

net (

bar)


99.7

99.8

99.5

% NOx Reduction over Baseline SI (λ=1)

Alternative Fuels

Downsizing

50% downsizing, up to 30% fuel economy

Friction Reduction

MAHLE low friction components, up to 4% fuel economy saving

Baseline Engine Comparison With MAHLE Engine Components

05

10152025303540455055606570

0 1000 2000 3000 4000 5000 6000 7000 8000

Engine Speed (rpm)

Torq

ue (N

m)

0510152025303540455055606570

Fric

tion

Red

uctio

n (%

)

Baseline engine PREDICTED MAHLE Components fitted % Predicted Benefit

De-Throttling

Valv

e Li

ft

BDCGE TDCGE BDCF

MAHLE CamInCam® Variable valvetrains

Optimized alcohol blends to suit downsizing applications


So what is MAHLE Powertrain researching?

8




Contents

Introduction





Summary

9


© MAHLE

Gasoline Engine Downsizing How low can you go?

Spec

ific

Pow

er O

utpu

t (kW

/l)

50

60

70

80

90

100

110

120

130

Peak BMEP (bar)10 15 20 25 30 35

MAHLE Downsize2-Stage Turbo

VW 1.4l SC / TC

Fiat 1.8 TGDI

Audi 1.8 TFSI

Audi 2l TFSI AVS

Audi 1.8T

Audi 2l TFSI

Ford 2.0l EcoBoost

Spec

ific

Pow

er O

utpu

t (kW

/l)

50

60

70

80

90

100

110

120

130

Peak BMEP (bar)10 15 20 25 30 35

MAHLE DownsizeSingle Turbo

MAHLE Downsize2-Stage Turbo

VW 1.4l SC / TC

Fiat 1.8 TGDI

Audi 1.8 TFSI

Audi 2l TFSI AVS

Audi 1.8T

Audi 2l TFSI

Ford 2.0l EcoBoost

Increasing Boost and Combustion Issues


10



© MAHLE

Downsizing: Unstable Combustion Issues

Combustion phasing can be retarded due to detonation, which leads to high exhaust valve opening pressures

Advancing combustion phasing allows higher boost and torque

To achieve this:

Turbocharger selection has a strong influence

Reduced duration exhaust cam has a positive effect

Optimized exhaust manifold design reduces trapped residuals

Careful fuel selection

Combustion chamber is shape-optimized

Oil consumption is minimized

Manifold Pressure [kPa Abs]

175

180

185

190

195

200

205

210

215

220

225

Spark Advance [CAD]0 2 4 6 8 10 12

17

19

21

16

18

20

BMEP [bar]

Preign

ition Lim

it

Detonation Limit

Advanced Combustion Phasing

Manifold Pressure [kPa Abs]

175

180

185

190

195

200

205

210

215

220

225

Spark Advance [CAD]0 2 4 6 8 10 12

17

19

21

16

18

20

BMEP [bar]

Preign

ition Lim

it

Detonation Limit

Advanced Combustion PhasingThe role of IC engines in future energy use

11



© MAHLE

Boosting Systems

A) Single Turbocharger B) 2-Stage Turbocharger

C) Supercharger & Turbocharger D) Electric Supercharger & Turbocharger

BM

EP

[bar

]

12

14

16

18

20

22

24

26

28

30

32

34

Engine Speed [rpm]500 1500 2500 3500 4500 5500 6500

Target Curve 2-Stage Turbocharger LP Turbo Only VTES & LP Turbo

Steady State

Ave

rage

IME

P [b

ar]

0

5

10

15

20

25

Time [s]0.0 0.5 1.0 1.5 2.0 2.5 3.0

LP Turbo Only 2-Stage Turbocharging VTES + LP Turbo SC / TC

Transient Load Step at 1250rpm




© MAHLE

Next Generation MAHLE Downsizing Engine

State-of-the-art clean-sheet design for 50% downsized concept DI-3 1.2 L

Up to 30% fuel economy improvement possible with similar performance levels

Excellent low speed torque and transient response with twin turbo configuration

Vehicle and engine demonstrators available Developed with MAHLE & Bosch advanced components

• 30 bar BMEP + • 100 kW/l Single Stage Turbo • 120kW/l Twin Turbo

150

200

250

300

1000 2000 3000 4000 5000 6000 7000 Engine Speed [rpm]

Torq

ue [N

m] .

0

50

100

150

Pow

er [k

W]


13




NEDC

Increasing Technology

100% 91.0% 74.0% 71.0% 65.0% 59.0%

9.0% 26.0% 29.0% 35.0% 41.0%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2.4 L NA

2.0 L Turbo GDI

MAHLE 1.2 L Turbo GDI


+ Idle-stop


+ Mild-

hybrid

Concept 0.8 L Turbo GDI

+ Mild-hybrid

NED

C C

O₂ [

Perc

enta

ge c

ompa

red

to 2

.4 L

NA]

Downsizing Electrification Path

14





100% 84.4% 83.8% 80.5% 78.8% 78.8%

15.6% 16.2% 19.5% 21.2% 21.2%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

MAHLE 1.2 L

Turbo GDI

MAHLE 1.2 L

Turbo GDI

+ Idle-stop

MAHLE 1.2 L

Turbo GDI

+ Mild-

hybrid

ARTEMIS

2.4 L NA

2.0 L Turbo GDI


+ Mild-hybrid

NED

C C

O₂ [

Perc

enta

ge c

ompa

red

to 2

.4 L

NA]


15





US06

100% 88.2% 88.0% 86.8% 84.6% 85.3%

11.8% 12.0% 13.2% 15.4% 14.7%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%


+ Idle-stop

2.4 L NA

2.0 L Turbo GDI



+ Mild-

hybrid


+ Mild-hybrid

NED

C C

O₂ [

Perc

enta

ge c

ompa

red

to 2

.4 L

NA]


16


© MAHLE Average Drive Cycle Load Increase

Fuel Effects: 1.2l Downsizing + Mild Hybrid

Average Drive Cycle Load Increase

Fuel H/C & O/C Ratio

MPT 1.2l DI3 ICE + Hybrid

Average Drive Cycle Load Increase

V4

Fuel Lower Heating Value Rating


17




Contents

Introduction





Summary

18


© MAHLE

Introduction - E-REV Concept Description

Extended-Range Electric Vehicle (E-REV) – Vehicle propelled purely by electric motors with small battery pack (c.f. EV)

Typical range of 20 to 100 km using only battery power

Battery pack can be charged from residential electrical outlet

– On-board electrical generator (IC Engine or Fuel Cell) can also be used to re-charge battery on the move


Electric range

RE

Pow

er /

Tail-

pipe

CO

2 Optimum is a function of vehicle performance targets

Full sized engine and no electric range capability

No RE and very large battery

Vehi

cle

wei

ght a

nd c

ost


19

http://www.google.co.uk/imgres?imgurl=http://www.shinkobe-denki.co.jp/10.products/10.10.sbattery/10.10.40.battery/images/10.10.40.20.jpg&imgrefurl=http://www.shinkobe-denki.co.jp/100.en/100.10.products/100.10.10.sbattery/100.10.10.10.html&usg=__rJJC3xUo_4nqRA0RpT-yWYCN1Nc=&h=130&w=160&sz=8&hl=en&start=42&zoom=1&um=1&itbs=1&tbnid=-nZncdJotu34gM:&tbnh=80&tbnw=98&prev=/images?q=HEV+traction+battery&start=40&um=1&hl=en&sa=N&rls=com.microsoft:*:IE-SearchBox&rlz=1I7EGLC_en&ndsp=20&tbs=isch:1

http://www.google.co.uk/imgres?imgurl=http://www.shinkobe-denki.co.jp/10.products/10.10.sbattery/10.10.40.battery/images/10.10.40.20.jpg&imgrefurl=http://www.shinkobe-denki.co.jp/100.en/100.10.products/100.10.10.sbattery/100.10.10.10.html&usg=__rJJC3xUo_4nqRA0RpT-yWYCN1Nc=&h=130&w=160&sz=8&hl=en&start=42&zoom=1&um=1&itbs=1&tbnid=-nZncdJotu34gM:&tbnh=80&tbnw=98&prev=/images?q=HEV+traction+battery&start=40&um=1&hl=en&sa=N&rls=com.microsoft:*:IE-SearchBox&rlz=1I7EGLC_en&ndsp=20&tbs=isch:1


© MAHLE

Range Extender - Conflicting Targets - Range / Cost / Weight

Baseline – Short Range Electric Vehicle (EV)

– Compact Class

– Range 80 km

– Battery Capacity 15 kWh


EV #2

EV #1

RE

Baseline EV

WeightRangeCost

+3000 EUR

* Battery cost: 500 EUR/kWh

+3000 EUR

+52000 EUR

+550 km

+30 km

+550 km

+130 kg

+1375 kg

+75 kg


20


Near Term Spark Ignition Engine Technologies




– Compact Class

– Range 80 km


Range Extender (RE) (inc. Generator, 40 l Tank, Controller, …)

– Weight: +130 kg

– Cost: +3000 EUR

– Range: +550 km


EV #2

EV #1

RE

Baseline EV

WeightRangeCost

+3000 EUR


+3000 EUR

+52000 EUR

+550 km

+30 km

+550 km

+130 kg

+1375 kg

+75 kg

21


© MAHLE



– Compact Class

– Range 80 km



– Weight: +130 kg

– Cost: +3000 EUR

– Range: +550 km

Electric Vehicle #1 (identical additional cost)

– Weight: +75 kg

– Range: +30 km


EV #2

EV #1

RE

Baseline EV

WeightRangeCost

+3000 EUR


+3000 EUR

+52000 EUR

+550 km

+30 km

+550 km

+130 kg

+1375 kg

+75 kg


22


© MAHLE



– Compact Class

– Range 80 km



– Weight: +130 kg

– Cost: +3000 EUR

– Range: +550 km

Electric Vehicle #1 (identical additional cost)

– Weight: +75 kg

– Range: +30 km

Electric Vehicle #2 (identical range)

– Weight: +1375 kg

– Cost: +52000 EUR


EV #2

EV #1

RE

Baseline EV

WeightRangeCost

+3000 EUR


+3000 EUR

+52000 EUR

+550 km

+30 km

+550 km

+130 kg

+1375 kg

+75 kg


23


© MAHLE

MAHLE Range Extender Concept

MAHLE Range Extender Two-cylinder Inline, 4-Stroke Gasoline

900 cm3 Swept Volume

30 kW Peak Power at 4000rpm

Port-fuel Injection (λ = 1)

180°/540° Firing Order

Flexible Installation

481

mm

Wei

ght [

kg]

020406080

100120

Power [kW]0 10 20 30 40 50

AB

C

D

MAHLE

Specific Power Power 30 kW

Weight (incl. Generator) 70 kg

Power to Weight Ratio 2.3 kg/kW (Competitors: 2.75 to 4.3 kg/kW)



24


© MAHLE

Summary

There is a role for IC engines in future energy use!

We will see an increase in downsizing and electrification in light duty applications

Downsizing needs further technology development, especially in combustion and boosting systems

Higher alcohol content fuels will support the trend in downsizing via increased octane levels

Range extenders are very effective energy providers, further efficiency steps can be taken, but cost is a more significant factor


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The Role Of IC Engines In Future Energy Use · · 2014-03-04The Role Of IC Engines In Future...

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