CRC Advanced Fuel and Engine Efficiency Workshop
Light-Duty DieselLight Duty Diesel Fuel Injection Systems
CRC Advanced Fuel and Engine Efficiency Workshop
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
Feb. 2014
1
CRC Advanced Fuel and Engine Efficiency Workshop
New Powertrains: Estimated world market volumes
113
94 EV HEV
PHEV3.1
EV2.5
HEV/PHEV
1.7
EV0.181
94HEV/PHEV
2.7
0.7HEV6.5
EVElectric vehicle
79.490.8
101.1PHEVPlug-in hybrid
HEVHybrid vehicle
Pure ICEInternal combustion engine
Sales PC & LCV<6t (millions of vehicles)
2012 2015 2020
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
Internal Combustion Engines will remain the predominant powertrain for the near future
2
CRC Advanced Fuel and Engine Efficiency Workshop
U.S. Passenger Car / Light-Duty Emissions Evolution
0.12
0.14
- 95%
0.08
0.10
g/m
i]
- 95%
Bin 10
- 88% - 90%
- 88%
Tier 1
Tier 2
0.04
0.06
PM [g
Bin 9
Bin 10
2006 vehicles1999 vehicles
- 88%
Bin 80.00
0.02Bin 8Bin 5 Bin 8Bin 8Bin 8Bin 8Bin 8
0.01Bin 8Bin 8
NOx [g/mi]
0 0.2 0.4 0.6 0.80.07 1.2 1.4Bin 2
Current Clean Diesel VehiclesBin 2Bin 2
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
More than 90% Reduction in Criteria Emissions in 10 Years
3
CRC Advanced Fuel and Engine Efficiency Workshop
Optimizing the Diesel System: Total System Approach
Powertrain
Air Management
Combustion Process
Reduction of compression ratio
Hybrid Technology
Swirl-/Throttle Valve
Turbo Charger/VGT*
Combustion strategies
Exhaust gas management
Fast Catalyst Light-Off (reduce thermal losses)
Diesel Particulate FilterFuel Injection System Tolerance Reduction
Diesel Particulate Filter
NOx storage catalyst
Catalyst temp control
New Generations Multiple Injections Reduced Tolerance Optimized Nozzle
Zero Fuel Calibration Fuel Balancing Control
Individual Cylinder Control
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
Optimized Nozzle Control*VGT= Variable Geometry Turbo
4
CRC Advanced Fuel and Engine Efficiency Workshop
Injection strategy – Multiple Events per Combustion Cycle
High -pressure cycle
sure
[bar
] 150
100Cylinder pressure
ylin
der p
ress
-180 0 180[ °CA ]
50
0
Cy 80 180[ CA ]
Precise control of
Exhaust-gas aftertreatment-
< 1mm3 3 ... 60mm3< 1mm3 � 1...3mm3 � 5...30mm3
injected fuel quantity
Verbrennungs-
optimierungAkustik-
maßnahmen
Acoustic-measures
Optimisation of combustion
gmanagement
Resultant system impact
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
5
CRC Advanced Fuel and Engine Efficiency Workshop
Fuel System CharacteristicsHistorical Trend of Fuel Injection Pressures Influence of injection pressure and EGR rate
Specific Fuel Consumption
Required pressure level depends on:• Desired power output
E i i d/ CO
Increasing Pressure, EGR rate
Consumption• Emission- and/or CO2-reduction potential
Source: 5th Intern. Exhaust Gas and Particulate Emission Forum 2008, MAN AG
Smoke number
Injection Rate Shape
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
Emissions Requirements Drive Need for Fuel System Flexibility
6
CRC Advanced Fuel and Engine Efficiency Workshop
Advanced Injection Strategies: Multiple Injections
1
Influence of injection strategy onfuel consumption and smoke
Influence of injection strategy on smoke and noise
Single Cylinder Research EngineSwept Vol.:≈ 540 cm³; 2000 rpm; 8 bar IMEP; Noise ≈ const.
Single Cylinder Testing0.5l/cyl, 2000 rpm, IMEP=8bar
0.7
0.8
0.9
1
Previous Focus
0.4
0.5
0.6
0.7
Soo
t [g/
kg] Conventional Injection
Strategy(1 or 2 x PI)
0 1
0.2
0.3
0.4S
Digital Rate Shaping I( 1 or 2 x ClosePI)
Digital Rate Shaping II(PI or ClosePI +
0.1 g/kg
0
0.1
80 82 84 86 88 90 92Noise [dB]
POI as Needed)New Focus
2 dB PI = Pilot InjectionPOI = Post Injection
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
Benefits of new injection patterns being evaluated
7
CRC Advanced Fuel and Engine Efficiency Workshop
Hydrocarbon Emissions: Minimized HC-Volume
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
Minimized nozzle HC-volume results in significant HC-reduction potential
8
CRC Advanced Fuel and Engine Efficiency Workshop
Advanced Fuel System Strategies: Control Algorithms Emissions and performance requirements are placing additional demands on fuel system
Fueling Accuracy Improved System Control Drift and Temperature Compensation Drift and Temperature Compensation
Example Corrective Functions for Improved System Behavior
Valve Closing Detection and Injector Temperature
Compensation
Fuel Balancing Control by Delta Rail Pressure
Quantity Wave Correction Adaptive Metering Unit and Pressure Control Valve Control
Compensation
Measure valve closing delay inorder to compensate for fuelviscosity as well as injector drift
Measures cylinder specificrail pressure drop caused by eachinjection and adjusts deviation
Reduces fuelling error caused bypressure oscillations in systemdue to injection pattern
Correction of controller deviationfor improved rail pressure control
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
Advanced Control Algorithms Available to Support System Requirements
9
CRC Advanced Fuel and Engine Efficiency Workshop
Advanced Fuel System Strategies: Fuel Quality Fuel quality and variation affects system performance
Functionality of system Exhaust emissions Performance requirements Performance requirements
Fuel Quality Detection by Engine Speed Component Robustness Measures
Example Countermeasures to Compensate for Fuel Effects
• Detection of fuel quality variation based on engine speed roughness
• Compensation of effectsfrom fuel quality variation
• Material choices• Material choices
• Design choices
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
Components and System Functions Available to Provide Limited Compensation for Fuel Quality
10
CRC Advanced Fuel and Engine Efficiency Workshop
Fuel Quality effects on fuel system componentsFuel Quality effects on fuel system components
Environmental effects Cleanliness particle erosive wear
Fuel Quality variation effects Low Lubricity premature wear
spray hole pump polygon Pump tappetspray hole pump polygon Pump tappet
Water content corrosion Low Oxidation Stability deposit formation
valve bodypump
DRV
Contaminants deposits (e.g. soap type) Kinematic Viscosity fuel metering
valve piston
DRV
Cetane Number sub-optimal combustion
valve piston
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
Consistent world-class Diesel fuel quality enables optimum performance and durability
11
CRC Advanced Fuel and Engine Efficiency Workshop
SummarySummary The internal combustion engine will remain the dominant transportation
engine for decades
Diesel performance and exhaust emission targets are achievable and require total engine control system integration
Advanced fuel injection systems and control techniques discussed for optimization of the combustion event: Injection rate shapingj p g Nozzle design Control algorithms
While some control techniques provide limited compensation for fuel quality variation; consistent state-of-the-art Diesel fuel quality assures vehicle performance and durability expectations are met
DS/ENS1-NA | 2/14/2014 | ENS_1481_018 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Diesel Systems
12