ingas sub project a3 „boosted lean burn gas engine“ review meeting 07/04/2011 brussels
DESCRIPTION
INGAS Sub Project A3 „Boosted Lean Burn Gas Engine“ Review Meeting 07/04/2011 Brussels. RWTH, Martin Müther. Face to face meeting SP A3 – Brussels, 7 April 2011. 2. Review meeting – Brussels, April 2011 MM allocation RWTH. Review meeting – Brussels, April 2011 MM allocation RWTH. - PowerPoint PPT PresentationTRANSCRIPT
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
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
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
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
3M. Müther, RWTHM. Müther, RWTH
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
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
4M. Müther, RWTHM. Müther, RWTH
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
Plan Y1 Y2 Y3Open MM
Completion [%]
WP Task DescriptionStart [month]
Dur. [months]
End [month]
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
5M. Müther, RWTHM. Müther, RWTH
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
WP Task DescriptionStart [month]
Dur. [months]
End [month]
WP A3.1 A3.1.1Definition of base engine and vehicle with fuel consumption and performance
0 4 4
Plan Y1 Y2 Y3Open MM
Completion [%]
1.6 1.6 0 0 100
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
6M. Müther, RWTHM. Müther, RWTH
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
Review meeting – Brussels, April 2011
Performance prediction referenced to 1.9 l (Z19DTH)
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
7M. Müther, RWTHM. Müther, RWTH
Review meeting – Brussels, April 2011
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).
WP Task DescriptionStart [month]
Dur. [months]
End [month]
Plan Y1 Y2 Y3Open MM
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
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
8M. Müther, RWTHM. Müther, RWTH
Basic Diesel engine (Z19DTH): CAD-Data Spark plug application
Analysis of CAD-Data
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
9M. Müther, RWTHM. Müther, RWTH
Review meeting – Brussels, April 2011
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.
WP Task DescriptionStart [month]
Dur. [months]
End [month]
Plan Y1 Y2 Y3Open MM
Completion [%]
WP A3.1 A3.1.4Draft packaging of power train and fuel system 3 10 13 0.8 0.8 0 0 100
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
10M. Müther, RWTHM. Müther, RWTH
Review meeting – Brussels, April 2011
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.
WP Task DescriptionStart [month]
Dur. [months]
End [month]
Plan Y1 Y2 Y3Open MM
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
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
11M. Müther, RWTHM. Müther, RWTH
Review meeting – Brussels, April 2011
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.
WP Task DescriptionStart [month]
Dur. [months]
End [month]
Plan Y1 Y2 Y3Open MM
Completion [%]
WP A3.2 A3.2.1Modelling, design, procurement and rig test of the boosting device 7 9 16 8 4 4 0 75
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
12M. Müther, RWTHM. Müther, RWTH
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
Review meeting – Brussels, April 2011
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
13M. Müther, RWTHM. Müther, RWTH
Review meeting – Brussels, April 2011
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.
WP Task DescriptionStart [month]
Dur. [months]
End [month]
Plan Y1 Y2 Y3Open MM
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
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
14M. Müther, RWTHM. Müther, RWTH
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
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
15M. Müther, RWTHM. Müther, RWTH
Review meeting – Brussels, April 2011
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.
WP Task DescriptionStart [month]
Dur. [months]
End [month]
Plan Y1 Y2 Y3Open MM
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
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
16M. Müther, RWTHM. Müther, RWTH
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)
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
17M. Müther, RWTHM. Müther, RWTH
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 !
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
18M. Müther, RWTHM. Müther, RWTH
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
INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain
19M. Müther, RWTHM. Müther, RWTH
Review meeting – Brussels, April 2011
BACKUP
Slides concerning documentation of activities