WP3 Presentation - Paregen

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WP3 Presentation

Normann Freisinger/ Daimler, Jens Ewald / FEV, Helge Dageförde / BOSCH, Tobias Voßhall / RWTH, Francesco Endrici / UFI

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WP3: Stoichiometric small TC-VVA-DI water injection engine

12-13 November 2019 Joint Final Event PaREGEn & PEMs4Nano 2

Selection and optimization of the combustion system to reduce CO2 and to reach future emission demandsSet-up of a test vehicle with a research powertrain including

Rightsized engine and advanced components for stoichiometric Miller combustion system New Engine Control Unit with additional required functionsAdvanced turbocharger and aftertreatment system

Water injection as further enabler for increased compression ratioPort Water Injection (PWI) on demo vehicleDirect Water Injection (DWI) on testbench

Exhaust gas condensation for Water recovery and service free water supplyFinal evaluation of achievable CO2 reduction potential with investigated technology by cycle simulation


WP3 Engine & vehicle investigation overview


Hardware design & selectioncombustion process development

Comparison water direct & port

injection

Further investigations for additional CO2 reduction

Vehicle engine andcomponent calibration

Vehicle preparation for basis measurements

Vehicle set-up with PaREGEn powertrain & ECU

Vehicle calibration & chassis dyno

Basis measurements& target settings

Final vehicle assessment CO2 & emissions

results see WP5(assessment presentation)

Test

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design freeze vehicle powertrain


Experimental matrix for hardware design, selection and combustion process dev’t


6 intake camshafts ->1 sel.

3 exhaust camshafts ->1

3 turbochargers ->1

3 comp. ratios -> 2

3 intake manifolds-> 1

4 wastgate bodies -> 1

GDI injectors

PWI injectors

3 pistons -> 2

GDI injection pressure

PWI injection timing

PWI injection-Strategy

GDI multiple injection

Intake-phasing

Outlet-phasing

Function development

Knocking model

Boost pressure control

Water injection control

Camtronic control

Charge motion

Base exhaust system

Daimler PaREGEn exhaust system + GPF

JM prototype 1

JM prototype 2

JM exhaust system prototype 3

Emissions aftertreatment

GDI injection timing

CalibrationHardware

Hardware setting

Calibration setting

va

lve

lift

[%]

0%

25%

50%

75%

100%

crank angle [grdKW]

120 180 240 300 360 420 480 540

DWI Injectors

DWI injection timing

DWI injection-StrategyDaimlerBOSCHFEV

DaimlerJohnson Matthey

uncoated GPF

light-off TWC

TWC


PaREGEn vehicle engine


21

3 4 5

6 7 8

9

10 11

left: Machined protype crankcase with LDS coated liner (laser cladded, friction reduced surface)

right:Manufactured Cylinder Head with Port Water Injection, with Direct Water Injection and advanced inlet-port

1. Advanced cylinder head for GDI + PWI/DWI + Multi Spark Ignition

2. Variable valvetrain with 2 lifts on intaxe & exhaust side3. Miller valve timing and stroke4. Advanced gasoline injection system with increased injection

pressure5. Multi-hole solenid gasoline injector6. Port water injection (PWI)7. Advanced intake manifold with variable charge motion

meassures8. Advanced dual scroll turbocharger9. Advanced TWC+GPF aftertreatment10.Higher compression rate11.Higher stroke: bore ratio12.Direct water injection (DWI) (simulated)


Optimization of water injection


*Due to packaging restrictions no optimal mountingposition possible.


Further investigations for additional CO2 reduction


Base engine with CR=12:1, Miller and PWI was already close to thermodynamic optimum

Piston change to CR=13.5:1 as laid out by simulation activities for second campaign

DWI, going towards very high water/fuel shares to explore the limits

Valve timing was optimized for CR=12:1, for 13.5 valve timing re-adjustment required and partially realized

Test with exhaust condensate harvesting system

Tests with osmosis water and exhaust condensate: no significant difference in performance or emissions


Exhaust gas water harvesting sytem


Assembly for the engine test bed system


Exhaust gas condensate purification: particulates and chemicals


Particles removal was granted with a pre-filter + filter series that gives less than 20 mbar pressure drop and 95% efficiency for 10 microns particles at 0.45 l/min.

Ammonia removal is granted with a ion exchange resins bed that allows more than 97% efficiency

Other chemical are present in quantities that were not recognized as dangerous for the system

See disclaimerSee disclaimer12-13 November 2019 Joint Final Event PaREGEn & PEMs4Nano 10

Comparision water direct & port injection

Potential of water injection @ high load conditions

Blue diagrams:Best DWI spray (W4) compared to operation w/o water injection

Green diagrams:Best PWI spray (E-Type) compared to operation w/o water injection

Findings:

Low engine speed (LET):DWI shows higher mfb50 advancing potential than PWI

High engine speed (rated power):DWI and PWI show similar mfb50 advancing potential

mfb50 advancing [°CA]1 mfb50 advancing [°CA]1

water rate [%]2 water rate [%]2

DWIW4

DWIW4

PWIE-type

PWIE-type

1.compared to engine map without water injection 2.Water rate lowest ISFC


Final PaREGEn vehicle


In-vehicle engine status display

Engine bay package with electrical wiring

Demo vehicle on dyno

Measurement technology in the trunk Schematic diagram of the vehicle exhaust aftertreatment system

Water tank

uncoated GPF

light-off TWC

TWC


* Reduction of 15% based on the WLTC results of the baseline vehicle

* Additionally: reduction of 15% based on the 2015 BIC

WP3 vehicle results


CO2 Standard emissions PN

Complicane with Euro 6 (d)limits

RDEFinal Conformity Factor of 1.5 incase of NOx (*)

Reduction of sub-23 nm to at least 10 nm

RDEFinal Conformity Factor of 1.5 incase of PN

Vehicle-test THC(mg/km)

NOx(mg/km)

CO(mg/km)

CO2

(g/km)PM

(mg/km)PN ≥ 10nm(pk/km)

Mercedes DemonstratorWLTC Low

100 60 1000 Base Vehicle → -15 % 4.5 6.0E +11

Mercedes Demonstrator WLTC High

100 60 1000 Base Vehicle → -15 % 4.5 6.0E +11

Mercedes Demonstrator RDE

--- 90 --- --- --- 9.0E +11

Targets on vehicle dyno. and test bench fulfilled

Targ

ets

(*) New Reg 1.43 (2020)


CO2 emissions reduction potential with investigated technology: WLTP-H Cycle

95%

0%

85%

90%

100%

Vehicle SimulationCR12 PWI

with improved shift strategy

CO2 / (g/km)

Vehicle Simulationscaled engine mapCR14.5 with DWI

Vehicle TestMercedes E180Baseline Vehicle

Vehicle TestCR12 PWI

Demonstrator

Vehicle Simulationwith engine map from test benchCR13.5 with DWI

Target -15%


See disclaimer

• Copyright ©, all rights reserved. This document or any part thereof may not be made public or disclosed, copied or otherwise reproduced or used in any form or by any means, without prior permission in writing from the PaREGEn Consortium. All the material included in this document is based on: 1) data/information gathered from various sources, 2) certain assumptions and 3) forward-looking information and statements that are subject to risks and uncertainties. Although, due care and diligence has been taken to compile this document, the contained information may vary due to any change in any of the concerned factors and the actual results may differ substantially from the presented information. Further, there can be no assurances that results will prove accurate and, therefore, readers are advised to rely on their own evaluation of such uncertainties. Readers are encouraged to carry out their own due diligence and gather any information to be considered necessary for making an informed decision.

• Neither the PaREGEn Consortium nor any of its members, their officers, employees or agents shall be liable or responsible, in negligence or otherwise, for any loss, damage or expense whatever sustained by any person as a result of the use, in any manner or form, of any knowledge, information or data contained in this document, or due to any inaccuracy, omission or error therein contained.

• All Intellectual Property Rights, know-how and information provided by and/or arising from this document, such as designs, documentation, as well as preparatory material in that regard, is and shall remain the exclusive property of the PaREGEn Consortium and any of its members or its licensors. Nothing contained in this document shall give, or shall be construed as giving, any right, title, ownership, interest, license or any other right in or to any IP, know-how and information.

• This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 723954. The information and views set out in this publication does not necessarily reflect the official opinion of the European Commission. Neither the European Union institutions and bodies nor any person acting on their behalf, may be held responsible for the use which may be made of the information contained therein.

Disclaimer

See disclaimer12-13 November 2019 Joint Final Event PaREGEn & PEMs4Nano 14

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WP3 Presentation - Paregen