ingas integrated gas powertrain m. müther, rwth 1 ingas sub project a3 „boosted lean burn gas...

INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain

1M. Müther, RWTHM. Müther, RWTH

INGAS Sub Project A3

„Boosted Lean Burn Gas Engine“

Review Meeting

07/04/2011 Brussels

RWTH, Martin Müther


2M. Müther, RWTHM. Müther, RWTH 2

Face to face meeting SP A3 – Brussels, 7 April 2011

Time Item Name (company)

14:30 Preamble with background

Motivations of face to face meeting

Coordinator Massimo Ferrera (CRF)

PM Stefania Zandiri (CRF)

14:40 FEV: executive summary of activities done in Period 1 and Period 2 versus effort planned and claimed (main engine project vs side engine project)

Christoph Bollig (FEV), Bertold Hüchtebrock (FEV), Michael Wittler (FEV)

15:00 OPEL: executive summary of activities done in Period 1 and Period 2 versus effort planned and claimed (main engine project vs side engine project)

Winfried Hartung (OPEL)

15:20 RWTH: executive summary of activities done in Period 1 and Period 2 versus effort planned and claimed

Martin Müther (RWTH), Philipp Simm (RWTH), Sandra Glück (RWTH)

15:40 Discussion All

16:30 End of reviewers meeting

17:30 Feedback of the reviewers & PO



Review meeting – Brussels, April 2011MM allocation RWTH

WP Task DescriptionStart [month]

Dur. [months]

End [month]

Plan Y1 Y2 Y3Open MM

Completion [%]

WP A3.1Concept phase and design specifications

WP A3.1 A3.1.1Definition of base engine and vehicle with fuel consumption and performance

0 4 4

WP A3.1 A3.1.2Design specifications of the power train and draft lay out

0 12 12

WP A3.1 A3.1.3 Support for gas storage system 5 31 36

WP A3.1 A3.1.4Draft packaging of power train and fuel system 3 10 13

WP A3.1 A3.1.5 Definition of the aftertreatment system 4 5 9

WP A3.1 A3.1.6 First lay out of the control strategy 0 12 12

WP A3.2Components, Engine Design and Procurement

WP A3.2 A3.2.1Modelling, design, procurement and rig test of the boosting device 7 9 16

WP A3.2 A3.2.2Modelling, design and rig testing of the aftertreatment system 7 6 13

WP A3.2 A3.2.3Modelling, design and rig testing of lean burn combustion 7 12 19

WP A3.2 A3.2.4Design of the power train and gas system packaging 7 9 16

1.6 1.6 0 0 100

9.6 9.6 0 0 100

0 0 0 0

0.8 0.8 0 0 100

0 0 0 0

2.4 2 0.5 -0.1 100

8 4 4 0 75

0 0 0 0

3.2 1 3 -0.8 100

0 0 0 0



Review meeting – Brussels, April 2011MM allocation RWTH

WP A3.3Component, Engine and Power Train Testing

WP A3.3 A3.3.1Testing and improvement of the boosting system on a test rig 13 8 21

WP A3.3 A3.3.2Testing and improvement of the aftertreatment system 13 12 25

WP A3.3 A3.3.3

Single cylinder testing of the lean burn combustion process for DI stratified charge and port fuelinjection w/o EGR, decision of the combustion chamber design

12 7 19

WP A3.3 A3.3.4

Multicylinder testing under steady state and transient conditions on a test bench and improvementof the engine

17 14 31

WP A3.3 A3.3.5Design of the power train control strategy 12 19 31

WP A3.3 A3.3.6Testing of the influence of NG / H2 mixture an combustion 28 7 35

WP A3.4Vehicle Testing and Potential Evaluation

WP A3.4 A3.4.1 Vehicle procurement 24 5 29WP A3.4 A3.4.2 Vehicle calibration and testing 29 5 34

WP A3.4 A3.4.3Potential evaluation and comparison with state of the art technology 33 4 37

0 0 0 0

0 0 0 0

0 0 0 0

12.6 0 9 3.6 75

0 0 0 0

0 0 0 0

0 0 0 02.4 0 0 2.4 0

0 0 0 0


Completion [%]


Dur. [months]

End [month]



Review meeting – Brussels, April 2011

Task-No. A3.1.1

Title Definition of base engine and vehicle with fuel consumption and performance

Main Activities Simulation work: Process calculation (engine decision focus on peak firing pressure)

Main Result A3 approach requires base diesel engine (pmax>150 bar!)

Engine: OPEL Z19DTH (diesel)

Vehicle: OPEL ZAFIRA


Dur. [months]

End [month]

WP A3.1 A3.1.1Definition of base engine and vehicle with fuel consumption and performance

0 4 4


Completion [%]

1.6 1.6 0 0 100



0

20

40

60

80

100

120

140

160

0 60 120 180 240 300 360Crank Angle [°]

Cyl

. P

ress

ure

[b

ar]

Cyl. Pressure

Intake Valve

Exhaust Valve

Ign. Timing

Compression

0

0.2

0.4

0.6

0.8

1

120 150 180 210 240 270Crank Angle [°]

Mas

s F

ract

ion

Bu

rned

[-]

Engine Speed 4000 rpm

Rel. Air-Fuel Ratio 1,60

BMEP 17 bar

Efficiency (eff.) 37,1 %

Pmax @ CA 139 bar @ 191°CA

Ignition Timing 157 °CA

Ignition Delay (0%-5%) 14,5 °CA

Combustion Duration (5%-95%) 31,5°CA

Combustion Centre (50%) 187 °CA


Performance prediction referenced to 1.9 l (Z19DTH)




Task-No. A3.1.2

Title Design specifications of the power train and draft lay out

Main Activities Spark plug application using manufacturer CAD data and investigation of base hardware. Spark plug dimensioning. Layout of the fuel metering system and intake manifold modification. Specific conversion work (dieselNG). Determination of CR and piston design. Application of cylinder pressure indication device. Definition and adaption of throttle. Definition of ignition system.

Main Result Initially CR of 13. Squish height 0.8 mm. Spark plugs M12x1.25 (mm). Fuel injectors close coupled to intake ports via „spacer“-construction. Pressure indication with KISTLER 6041 (8 mm). Throttle from OPEL GT (2 l Turbo). Twin-coil ignition system (BOSCH).


Dur. [months]

End [month]


Completion [%]

9.6 9.6 0 0 100WP A3.1 A3.1.2

Design specifications of the power train and draft lay out

0 12 12



Basic Diesel engine (Z19DTH): CAD-Data Spark plug application

Analysis of CAD-Data




Task-No. A3.1.4

Title Draft packaging of power train and fuel system

Main Activities Constructional data exchange with OPEL.

P1: Integration of PFI system („spacer“).

Main Result Definition of spacer-length. Integration of PFI is feasible considering a spacer-length below 40 mm.


Dur. [months]

End [month]


Completion [%]

WP A3.1 A3.1.4Draft packaging of power train and fuel system 3 10 13 0.8 0.8 0 0 100




Task-No. A3.1.6

Title First lay out of the control strategy

Main Activities Definition of EMS. Definition of required sensors and actuators. Definition of necessary functionalities (-control (lean!); EGR; SCR; …).Study (recherche) on possible SCR strategies (NH3 dosing NH3 storage modelling).P1: 2 MM‘s; P2: 0.5 MM.

Main Result Input for EMS documentation supervised by FEV.


Dur. [months]

End [month]


Completion [%]

WP A3.1 A3.1.6 First lay out of the control strategy 0 12 12 2.4 2 0.5 -0.1 100




Task-No. A3.2.1

Title Modelling, design, procurement and rig test of the boosting device

Main Activities Setup and matching (measurementcalculation) of GT Power engine model for 1.9 l diesel based NG engine. Performance calculation using TC maps from rig testing delivered by FEV.

Main Result High power/torque-targets linked with high air excess (efficiency target) requires 2-stage TC in A3 approach.


Dur. [months]

End [month]


Completion [%]

WP A3.2 A3.2.1Modelling, design, procurement and rig test of the boosting device 7 9 16 8 4 4 0 75



HPC-BPHPT-BP

LPT-WG

serial / serial

System specific actuators

• High-Pressure-Turbine bypass– low speeds -> controlled wastegate

function for High Pressure Turbine – from mid speed on complete mass

flow bypassed toward Low Pressure Turbine

• High-Pressure-Compressor bypass– back pressure valve– on/off bypass (not active)

• Low-Pressure-Turbine wastegate– conventional function of turbine control





Task-No. A3.2.3

Title Modelling, design and rig testing of lean burn combustion

Main Activities close linked to Task A3.1.2 (design specifications)

Generation of CAD files regarding spark plug application, 1st piston modification on base diesel piston (=13), intake manifold upgrading („spacer“) and other specific conversion aspects (i.e. removal of diesel HP pump). Layout of 2nd CR and corresponding piston design (1312).

Main Result Transfer of CAD data FEV regarding hardware machining.


Dur. [months]

End [month]


Completion [%]

WP A3.2 A3.2.3Modelling, design and rig testing of lean burn combustion 7 12 19 3.2 1 3 -0.8 100



Piston design (CR=13CR=12 (Final))IMG_2592.jpgK:\B_Technical_Status\04_Engine\044_Kolben\Fotos\20090605IMG_0004.jpgK:\B_Technical_Status\04_Engine\044_Kolben\Fotos\20100601CR=13.0 CR=12.0

Increased bowl-diameter (‚open bowl‘) Increased pocket-width Unchanged Squish Height: 0.83 mm

Reduced squish area share

Machining at FEV




Task-No. A3.3.4

Title Multicylinder testing under steady state and transient conditions on a test bench and improvement of the engine

Main Activities Definition of NEDC relevant operating points referenced to ZAFIRA (6 modes). Integration of DoE methodology into test planning and result analysis. 3-dimensional experiment space (Inj.-Tim., Ign.-Tim., ). Definition of constraints. Test bench measurements.

Setup and application of SW-tool for map-optimization assuming predefined szenarios. Result analysis.

Main Result Operation points in lower load area identified (6 modes). All hypercubes for DoE testing created. Modified SW tool generates accurate maps.


Dur. [months]

End [month]


Completion [%]

WP A3.3 A3.3.4

Multicylinder testing under steady state and transient conditions on a test bench and improvementof the engine

17 14 31 12.6 0 9 3.6 75



MCE-TestingDefinition of Operation Points

Steady-State-Replacement-Test (NEDC)

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

800 1000 1200 1400 1600 1800 2000 2200 2400

Modes

Punkte

Urban: 3x Extra-Urban: 1x

BMEP vs. Eng.-Speed

Highest Relevance

Idle: 326 s Push: 138 s Part Load: 716 s

Reference:ZAFIRA (1.9 CDTI)6 Speed Gearbox

Additional Points MAP-Completion

Mode Eng.-Speed BMEP Time Slice[1/min] [bar] [s]

1 1050 3.39 67

2 1378 1.44 129

3 1535 3.21 140

4 1754 6.19 157

5 1867 0.86 202

6 1960 11.06 21

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

800 1000 1200 1400 1600 1800 2000 2200 2400

Breakdown (Modes)



Operation point (Mode 4):n=1754 rpmBMEP=6.2 bar

LAMEOI

ZZ

P

Hypercube 3-dimensional experiment space (DoE-Methodic)

Engine Testing / Procedure

Variables: Ignition Timing (ZZP) Rel. A/F-Ratio (LAM; ) End of NG-Injection (EOI)

Due to the significant impact of the NG-injection-window on engine behaviour, this parameter has been included in the DoE-Testing !

Hypercube-Parametrisation is Mode-specific !



MCE-TestingMAP-Generation / Procedure

Setup of DoE-Modell for each defined operation pointconsidering operation limits

Stationary MCE-Testing ( DoE-Parameterisation)

DoE-Analysis Modell-Calculation / Generation of functionalities

Engine MAP-Generation assuming different szenarios TExhaust > Limit value (presetting) BSFC, NOx, HC min. Ignition Timing (presetting) …

Projection on cycle (i.e. NEDC) (Presetting: Vehicle & gear box)

(Weighted) Combination possible

Testing

Calculation




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Slides concerning documentation of activities

ingas integrated gas powertrain m. müther, rwth 1 ingas sub project a3 „boosted lean burn gas...

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