increased engine efficiency via advancements in engine

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DDC NZ-50 and Super Truck Team

Increased Engine Efficiency via Advancements in Engine Combustion Systems

September 29, 2010Kevin Sisken, Marc Allain, Rakesh Aneja, Jason Barton

Public Information

Public InformationDTNA / DDC Super Truck Team 2

Cold

Altitude DPF Regen.

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Altitude DPF Regen.

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Altitude DPF Regen.

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Altitude DPF Regen.

Transient

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Altitude DPF Regen.

Transient

Cold

Altitude DPF Regen.

Transient

AirCold

Altitude DPF Regen.

Transient

Cold

Altitude DPF Regen.

Transient

EGR

Inj. rate

Inj. timing

Inj. pressure

Exh. Temp.

Urea dosing

HC dosing

Setpoints

Cold

Altitude DPF Regen.

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Altitude DPF Regen.

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Cold

Altitude DPF Regen.

TransientCold

Altitude DPF Regen.

Transient

Cold

Altitude DPF Regen.

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Altitude DPF Regen.

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Altitude DPF Regen.

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Altitude DPF Regen.

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Altitude DPF Regen.

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Altitude DPF Regen.

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Altitude DPF Regen.

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Altitude DPF Regen.

Transient

AirCold

Altitude DPF Regen.

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Altitude DPF Regen.

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Cold

Altitude DPF Regen.

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Altitude DPF Regen.

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EGR

Inj. rate

Inj. timing

Inj. pressure

Exh. Temp.

Urea dosing

HC dosing

SetpointsNZ-50 and SuperTruck

NZ-50 Recent Efforts• Advanced Combustion System• Advanced Flexible Fuel Injection• Air/ EGR Handling System• Next Generation Controls

SuperTruck Takes NZ-50 Advancements Plus:• Waste Heat Recovery• Engine Down Sizing• Parasitic Loss Reduction• Hybrids


Advanced Combustion -- PCCI

Simulation Studies• Evaluated Over a Design Matrix• At A25; Up to 3% ISFC Improvement• At B50; ISFC Suffers

Fuel Injector Development• Dual Mode Injector Functional• 2nd Generation Hardware Required

Real Time Combustion Feedback• Evaluated Two Pressure Feedback Devices • Each Had Unique Challenges• With Significant Effort, Could Work

0

50

100

150

200

-180 -120 -60 0 60 120 180Pres

sure

[bar

]

Crank Angle [deg. aTDC]

Piez…Cont…

5 10 15 20 25 30198

200

202

204

206

208

210

212

214

1 2

3

4 56

gisf

c (g

/kw-

hr)

NOx (g/kgf)

High Speed & Load

4 5 6 7 8 9 10 11 12190

192

194

196

198

200

1

2

34

5

gisf

c (g

/kw-

hr)

NOx (g/kgf)

Low Speed & Load


Advanced Combustion – Conventional Approach

Improvements Being Seen • Expectation is 2% to 3%

Alternative Bowl Shapes

High Pressure Fuel System

Integration with High Efficiency Aftertreatment

2 4 6 8 10 12 14 16 18 20 22

B a se lin e B o w l-S te p B o w l

EGR

%

SM

OKE

FSN

BSFC

L

ambd

a

NO

x [g

/hph

r]

BMEP [bar]

Baseline BowlV2Bowl


Air/ EGR Advancements

Significant Air System Improvements• Rematch/ Optimization• Flow Improvements

Moving Forward• Interface with Vehicle Aero• Waste Heat Recovery• Turbo Compounding• Aftertreatment

BTR

Q [N

-m]

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

RPM [rpm]1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

-1.00-1.00

-1.00

-1.00

-1.00

-1.50-1.50

-1.25

-1.25

-1.25

-1.25

-0.75

-0.75

-0.75

-0.75

-0.75

-1.75

-0.77

-1.22

-1.45

-1.03-1.19-1.28-1.20

∼1% BSCF Improvement


Transition to SuperTruck

Advance Current State-of-the-Art Engine Technology To Yield 50% Engine Thermal Efficiency On A Dyno• Optimized For Speed and Load Representing 65,000 lbs GVW @ 65 mph

Analytical Roadmap to 55% Engine Thermal Efficiency

Engine Features Identified

Program Moving ForwardThermal Efficiency vs BSFC

0.140

0.150

0.160

0.170

0.180

0.190

0.200

0.210

0.220

0.230

35.0 40.0 45.0 50.0 55.0 60.0

Engine Thermal Efficiency (%)

BS

FC

(kg

/kw

hr) 50% eff = 0.167 kg/kWhr

55% eff = 0.152 kg/kWhr


Waste Heat Recovery

Approximately 55% of Fuel Energy is “Waste Heat”

Waste Heat Recovery• Turbocompound – In Production on DD15• Rankine Bottoming Cycle – Recover Energy From

EGR and/ or Exhaust Gases• Works Well With Hybrid System• 5% BSFC Improvement Expected• Significant Technical Challenges

• Heat Exchangers, Expander, Compressor, Packaging, Engine Integration, etc

generator

boiler

Power

expander

condenserpump

turbo

EGR


Engine Down Sizing

In the Early 1990’s, 11-13L Engines Dominated

Today, 13-15L Displacements Dominate• Power Increase As Well• Some Reasons Technical, Some User Based

Where is Engine Size Headed?• Drivability• CO2/ Fuel Economy• Weight• Cost• Hybrids

0

2

4

6

8

10

12

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r Tru

ck (2

)EG

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Frei

ght E

ffici

ency

Ben

efit


Parasitic Reduction – Dual Approach

Reduction Of Baseline Parasitic Losses

Smarter Use Accessories and Pumps• Increased Flexibility in Component Outputs• Feedback in Control System to Allow

Optimization


Hybrids for Heavy Duty Trucks

Can Hybrids Improve Engine Performance In Long Haul Application?

• Conventional Wisdom is Hybrid For Urban Cycle Only?

• Recover Braking Losses

Drive Cycle Data Shows Load Varies Significantly• Hybrid Will Dampen Load Swings• Potential Benefit For Engine Downsizing E-Machine on

Engine Output

E-Machine on Transmission Input

E-Machine on Transmission Output

E-Machine on separate axle or PTO


Acknowledgements

• Department of Energy Headquarters• Gurpreet Singh• Roland Gravel

• National Energy Technology Laboratory• Carl Maronde• Jeffrey Kooser

This material is based upon work supported by the Department of Energy National Energy Technology Lab under Award Numbers 409000-A-N8, DE-FC26-00-OR22805, and DE-EE-0003348.

Disclaimer: This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

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