trends in gasoline powertrain technology for … · dr. hubert friedl avl list gmbh trends in...

Dr. Hubert FRIEDL

AVL List GmbH

TRENDS IN GASOLINE POWERTRAIN TECHNOLOGY

FOR HIGH PERFORMANCE AND LOW EMISSION

CAR2017Pitesti, November 7th, 2017

| November 7th, 2017 | 2CAR2017-Pitesti

SOME HEADLINES


EXTENDED CONSEQUENCES OF “DIESELGATE”

• Extremely negative image of whole automotive industry

• “War” of Non Government Organizations against Diesel

• Aggressive scenarios (e.g. city access restrictions or even ban)

• Severe aggravation of RDE boundaries short termed

• Industry changes to proactive role regarding EV`s

• Over fulfillment of emission limits

• Broad introduction of Gasoline Particulate Filter in Europe


CO2 Reduction

Emission Compliance

Development Drivers

CO2 Emissions▪ Enhanced CO2 limits additionally

aggravated by boundaries (e.g. WLTP) ▪ Well to Wheel as next discussion point

Pollutant Emissions▪ Extended consequences of Diesel Gate▪ ICE ban under discussion ▪ Minimum emissions under all operating

conditions – over fulfillment of legislation “Zero Impact ICE”

▪ Shift towards electrification

GENERIC TRENDS FOR PASSENGER CARS

CO2 / EMISSION REDUCTION

Tailored Electrification

ADAS

Zero Impact ICE

City Access ?ICE Ban 2030 ?

Connectivity

Connectivity /ADAS▪ Intensively used for optimized

powertrain control (e.g. energy management, emission, CO2)

Real Driving Emissions

New ICE & Transmission

AUTONOMOUS


EXTENDED EMISSION COMPLIANCE

REAL DRIVING EMISSION

R

D

E RDE REGULATIONSCOME INTO FORCE


EXTENDED EMISSION COMPLIANCE

IMPACT TEST PROCEDURE

From EXACTLY REPRODUCIBLE TESTCYCLE towards STATISTICAL PROPABILITY

Paradigm shift in technology, development and testing

R

D

E


RDE IMPLEMENTATION WORLDWIDE

RDE is a Global Topic

R

D

ERDE is not restricted to Europe, it becomes a Global Topic


Alt

itu

de -

m

Temperature - °C

Application Real Driving Emissions (2016/427 1st package, 2016/646 2nd package, 3rd package)

Standard

Light duty vehicle on Real Driving Emission testing:

• Portable Emission Measurement System (PEMS) to measure CO2, CO, NOx, PN, Exhaust flow, Speed and GPS data.

• Implementation: EU 2016, Korea 2018, China 2020, India 2020, Japan 20xx

RDE Test requirements:

• Cold- and hot-start test, 30min conditioning drive, 5-56h soak time,

• RDE Drive between 90 to 120min in normal traffic

• 34% Urban (<60km/h), 33% Rural (60 ... 90km/h), 33% Motorway (>90km/h)

• max. Speed 145km/h (can be extended to 160km/h)

• positive altitude gain < 1200m/100km

• PlugIn Hybrid test in Charge–Sustaining mode

(will be revised in Package 4)

• Periodical Regeneration w/o Regeneration use ki-factors

Ambient conditions:

• Temperature 0°C to 30°C (extended range -7°C to 35°C)

• Altitude up to 700m (extended range 1300m) (China 2400m)

Limits:

• CF NOx: 2.1 CF PN: 1.5 to be fulfilled in each phase

• 2 calculation options, EMROAD (JRC) or CLEAR (TU-Graz)

China

Extended

Extended

Standard

RDE TECHNICAL REGULATIONS

CHALLENGES FROM LATEST AGGRAVATIONS


0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000

Time [s]

Ve

loc

ity

[k

m/h

]

0

50

100

150

Dis

ta

nc

e [

km

]

0

50

100

NO

x_

CF

_o

nlin

e

0

2

4

6

8

10

12

PN

_C

F_

on

lin

e [

-]

0

2

4

6

8

10

12

New RDE acc. Package 3

PN

CF-O

nlin

e

12

10

8

6

4

2

0

NO

x C

F-O

nlin

e

12

10

8

6

4

2

0

Veh

icle

Sp

eed

km

/h

150

100

50

0

R

D

E


IMPACT OF NEW RDE BOUNDARIES (PACKAGE 3)

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000

Time [s]

Ve

loc

ity

[k

m/h

]

0

50

100

150

Dis

ta

nc

e [

km

]

0

50

100

NO

x_

CF

_o

nlin

e

0

2

4

6

8

10

12

PN

_C

F_

on

lin

e [

-]

0

2

4

6

8

10

12

RDE Evaluation up to Dec. 2016

Driving Style:

moderate

dynamicdrive off

TGDI Lifetime aged

4-way cat 20° Start

PN

CF-O

nlin

e

12

10

8

6

4

2

0

NO

x C

F-O

nlin

e

12

10

8

6

4

2

0

Veh

icle

Sp

eed

km

/h

150

100

50

0

Average w/o cold start / warm up

over total distance Average with

cold startsingle phase

Significant aggravation of RDE compliance by RDE Package 3 (2016-12-20)

CF 1.5

CF 2.1

NOx

PN

Distance driven


GPF APPLICATIONS FOR HIGHER EMISSION ROBUSTNESS

EXHAUST GAS AFTERTREATMENT SYSTEMS

GPF Configuration Concepts

GPF expected to become mandatory at least for GDI – short termed !



PN EMISSIONS AT TEMPERATURES < 20°CEngine Out PN Potential per Real World Driving Warmup Phase, EU6c calibration

• Driving style has a huge influence in soot accumulation at cold temperatures, dominated by drive-off emissions

RDE DynamicDrive off

RDE moderate

CFPN Urban

incl. ColdEngine out

75

150

75

15 1,02,5

En

gin

e O

ut

PN

Em

iss

ion



PN EMISSIONS AT TEMPERATURES < 20°CEngine Out PN Potential per Real World Driving Warmup Phase, EU6c calibration

0,00

0,30

0,60

0,90

1,20

1,50

1,80

2,10

2,40

2,70

3,00

-40 -30 -20 -10 0 10 20 30

Engine Start Temperature [°C]

Critical Soot LoadingEn

gin

e O

ut

PM

Em

issi

on

3x 5x 10x 25x1x 3x 5x

RDE moderate

RDE DynamicDrive off

∫PM per Engine Warmup PhaseEngine out

• Driving style has a huge influence in soot accumulation at cold temperatures, dominated by drive-off emissions

Control Passive Regeneration to avoid thermal GPF damage

Active Regeneration will be necessary for GPFs in winter city operation


Cylinder Deactivation- Mechanically- Electronically

“Smart Hybridization”- electric auxiliaries- 48V systems

Combustion System- Miller, Atkinson- high BMEP TGDI- Low PN- CNG-DI- Water Injection

Variable Valvetrain- 2-step / 3-step- fully flexible

Variable Crank Train- Var. Compression Ratio- Var. Expansion Ratio

Boosting- 2-stage - electric boosting- water cooled VGT

2-steplow lift

2-stephigh lift

3-stepl/h lift

cont.

Exhaust Gas Cooling- External cooled EGR- Cooled / integrated

manifold ExhaustAir

GASOLINE POWERTRAIN TECHNOLOGY

FEATURES FOR INCREASING EFFICIENCY

http://www.heise.de/autos/artikel/VW-bringt-dem-1-4-TSI-Zylinderabschaltung-bei-1334947.html?bild=1;view=bildergalerie


GASOLINE ENGINE

TECHNOLOGY TRENDS

Source: Toyota, (HMC, VW), Vienna Motor Symposium 2016, 2017

• Hybridization enables shift

towards higher loads high

load area and max. efficiency

gaining importance.

• Trade-off between maximum

efficiency and spec. power

becomes the key trade-off

• Miller / Atkinson Cycle con-

firmed as most cost effective

CO2 solutions (e.g. Toyota, Audi,

VW, HMC, etc.)

Maxim

um

Sp

ecif

ic P

ow

er –

kW

/l

TARGETshort term

Improving the trade-off between max. efficiency and max. specific performance at attractive cost is the key development target for SI engines

100

90

80

70

60

50

40

30

Maximum Thermal Efficiency - %

32 34 36 38 40 42 44

Toyota 2,5 TNGA , GDI, EGR

AUDI 2.0 TGDI Miller, no EGR

AVL 1.5 TGDI Miller

no EGR, SOP 2017

Toyota 1.8 MPI, EGR

VW 1.5 TGDI Miller, no EGR

HMC 1.6 GDI, EGR

AVL 1,6 TGDI Miller, EGR, no VVL

Future Potential AVL 2.0 TGDI Miller,

SqC-TC, no EGR


Pre

ssu

re

Volume

Isothermal compression

1-stage compression

(2-st w/o interstage cooling)

Compressor work saved

2-stage boosting with interstage

cooling

2-stage compression + interstage cooling instead of single stage

ADVANCED CHARGING SEQUENTIAL COMPRESSOR TC

• Lower turbine power demand• Lower compression temperature

schematic


EVOLUTION OF GASOLINE TECHNOLOGIES

EXTENDING HIGH EFFICIENCY OPERATION

Telescopic Conrod

for VCR Variable

Compression Ratio


• Compression ratio variation

of 3-6 units

• Simple and cost-effective

design

• Minimized friction impact

compared to other VCR

systems

• Applicable for Gasoline and

Diesel engines

Actuation module

Telescopic module

Conrod base module

COMBINED HIGH EFFICIENCY & HIGH PERFORMANCE

AVL 2-STEP VARIABLE COMPRESSION RATIO

Full modularity with conventional ICE

Variable Compression Ratio enables combination of high efficiency & high performance. Modular systems enable easy integration into std. engines


Future

Potential

TGDI Miller,

SqC-TC

• Formula 1 engines offer the by far

most outstanding efficiency vs. spec.

performance trade-off

• Emission compliance, esp. RDE

compromises ultra high efficiency

concepts, especially lean operation

• Water injection as enabler to extend

the potential of advanced boosting

• Combined processes as long term

concept for efficiencies > 50 %

Different development directions: high performance + low efficiency, low performance + high efficiency, best compromise: adv. boosting + water injection or VCR

Maxim

um

Sp

ecif

ic P

ow

er –

kW

/l

100

90

80

70

60

50

40

30

Maximum Efficiency - %

32 34 36 38 40 42 44 45 50 55 60

300

250

200

150

F1

Status

2017Hybrid Engines

Mid Term

Ultra High Performance

Engines Mid Term

Advanced Boosting

Combined Processes

GASOLINE ENGINE

FUTURE TECHNOLOGY TRENDS 2025

?


2025Global Engine ProductionAVL Prediction 1/2017

120

100

80

60

40

20

0

Glo

bal

En

gin

e P

ro

du

cti

on

–M

io/

Year

ICE:• Significantly higher effort for emission compliance (RDE,

China6, SULEV xx, …),

• “Zero Impact Emission Concepts” starting

• Increasing share turbocharging + Rightsizing,

• Advanced boosting, exhaust energy recuperation, full map stoichiometric, EGR

• E-fuels and E-gas increasing

Mild Hybrid: • 48 V in various configurations P0 – P4

• Power Increase 15 20 30 kW

• ICE utilizes synergies

Full Hybrid: Primarily with Japanese OEM´s

Plug In Hybrid: CAFE and city access as major driver

BEV: Dependent on infrastructure, incentives and access restr.

Fuel Cell: limited to specific markets

TECHNOLOGIES IN THE NEXT 10 YEARS

2025: 50% electrified, still 100 mio ICE´s , however, high scatter of predictions


FUTURE TECHNOLOGY IMPACT ON ENGINEERING DEMAND

Dramatically enhanced engineering demand

Connected & Autonomous

New EV / Fuel Cell

Significantly higher effort for emission compliance (RDE, China 6b, SULEV xx, …)

Huge variety of new complex XEV systems

120

100

80

60

40

20

0

En

gin

es

Pro

du

ced

[M

io.€

]

AVL(12/2016)


SUMMARY AND CONCLUSION

• The forthcoming Emission-Legislation together with RDE and CO2-limits will dramatically enhance technology requirements and optimization demand for powertrain and complete vehicle.

• For best Fuel Economy and RDE conformity, advanced powertrain technology features as well as Hybridization massively will be introduced to meet diversification requests from market globally.

• The “conventional” internal combustion engine proves to still have huge further improvement potential.

• Balancing the fuel economy and EAS measures on powertrain and vehicle side are essential to get optimum results at affordable product cost.


RIGHTSIZING THE FUTURE POWERTRAINS


Abbreviations (1/3) AER All Electrical range

AT Automatic Transmission

BEV Battery Electric Vehicle

BMEP Brake Mean Effective Pressure (spec. value for engine torque)

BSFC Brake Specific Fuel Consumption

BSG Belt Starter Generator

CAI Controlled Auto Ignition (general expression for HCCI)

CNG Compressed natural Gas

CSI Compression and Spark Ignition (AVL patented comb. system featuring HCCI)

CVT Continuously Variable Transmission

DCT Dual Clutch Transmission

DOC Diesel Oxidation Catalyst

DeNOx Nitrogen oxide reducing catalyst

DPF Diesel Particulate Filter

EAS Exhaust Aftertreatment System

EGR Exhaust Gas Recirculation

EU6 European Emission Limit Stage 6


Abbreviations (2/3) EV Electric Vehicle

FC Fuel Cell

FE Fuel Economy

FTP Federal Test Procedure (USA)

GDI Gasoline Direct Injection

GPF Gasoline Particle Filter

HSDI High Speed Direct Injected (Diesel)

ICE Internal Combustion Engine

ITW Vehicle Inertia Test Weight (curb weight)

LNT Lean NOx Trap

LPG Liquified Petrol Gas

MPI Multipoint Port Fuel Injection

MPV Multi Purpose Vehicle

MT Manual Transmission

MY Model Year

NA Naturally Aspirated

NEDC New European Driving Cycle


Abbreviations (3/3)

OBD On Board Diagnosis

OEM Original Equipment Manufacturer (=brand)

PEMS Portable Emission Measurement System

PHEV Plug-in Hybrid Electric Vehicle

PN Particle Number (Emission)

RDE Real Driving Emission

RPM Revolutions per Minute (engine speed)

SCR Selective Catalytic Reduction (for NOx)

SI Spark Ignited

SULEV Super Ultra Low Emission Vehicle (US, California Emission Standard)

SUV Sport Utility Vehicle

TCI Turbo Charged Intercooled

TGDI Turbo Charged Gasoline Direct Injection

TWC 3-Way Catalyst

VVL Variable Valve Lift

VVT Variable Valve Timing

WLTP World Harmonised Light Duty Vehicle Test Procedure

trends in gasoline powertrain technology for … · dr. hubert friedl avl list gmbh trends in...

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