Gasoline Direct Injection – SIA / CNAM...
Transcript of Gasoline Direct Injection – SIA / CNAM...
1 Confidential | GS/EPC-EM | 21/03/2012 | P_12_0089 | ©
Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Paris, 27.03.2012
Georgis
Levée
Gasoline Direct Injection
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Robert Bosch GmbH 2012. All rights reserved, also regarding any
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Gasoline direct injection: A long history
Electronic direct injection
Main components of the gasoline direct injection
New challenges with Euro 6 legislation
3
Gasoline direct injection: Historic
33
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Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
Gasoline Systems
Gasoline direct injection introduced by Bosch in 1937 on engines
for aviation.
Advantages :
No impact of the negative G on the fuel supply in contrast with carburetor
No explosion risk of the intake manifold in case of «
back-fire
»
No risk of ice formation (venturi
of carburetor)
3
444
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Gasoline Systems
Direct injection in aviation: historic
In-line fuel injection pump with 12 pistons for aviation engine (V12 Daimler, L=70 cm)
4
555
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Gasoline Systems
Direct injection in aviation: historic
Daimler engine
DB603 with
« inversed » V12 architecture (Mercedes Museum
in Stuttgart)
The fuel injection pump
is
placed
inside
the V
5
666
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Gasoline Systems
Direct injection in aviation: historic
6
Radial engine with 9 cyl. (BMW) Fuel injection pump (Boxer form)
777
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Gasoline Systems
Direct injection in car: historic
After 2nd
world war, development of several economical cars with 2 stroke engine.
The direct injection allowed a reduction of consumption by removing the fuel losses through scavenging.
7
Gutbrod
Superior 600 Cabrio
(1950-
1954 ; direct injection from 1952)Goliath GP700E (1951-1957 ; direct injection from 1954)
888
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Gasoline Systems
Direct injection in car: historic
8
Injection pump for 2 cyl. Engine (L=15cm)
Direct injection system for 2 stroke engine
999
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Gasoline Systems
Direct injection: Sport car
9
In 1955, launch of Mercedes 300 SL with direct injection.
First serial application with 4 stroke engine.
Target: Increase of the maximum engine performance.
101010
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Gasoline Systems
300 SL engine
Direct injection: Sport car
10
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Gasoline direct injection: A long history
Electronic direct injection
Main components of the gasoline direct injection
New challenges with Euro 6 legislation
121212
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SIA / CNAM 2012
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Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
Gasoline Systems
Electronic
injection: historic
In 1967, first serial application of the indirect injection controlled by electronics (VW 1600).
First legislation for the emission in USA.
12
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Gasoline Systems
Evolution of the European legislation
13
Introduction ratio of catalytic converter on
passenger cars in Germany
Legislation
NMVEG
141414
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Gasoline Systems
Evolution of the European legislation
14
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Gasoline Systems
Electronic Direct Injection
1996: First stratified gasoline direct injection on Mitsubishi Galant
1998: Toyota D4
1999: Renault IDE (Lambda 1 with high EGR rate)
2000: First Bosch gasoline direct injection VW «
FSI
»
engine
2000:
PSA HPI engine
2005: PSA Prince engine THP
Target: Consumption reduction by removing the suction losses at partial engine load (stratified mode).
Difficulty: Global
air-fuel mixture
lower than ignition readiness limit Necessity to create a stratified mixture with the condition to have enough fuel near to the spark plug.
Issue: Large NOx
generation
without any reduction possibility by three way catalytic converter due to
Lambda > 1. Necessity to have a NOx-Trap, but expensive and tricky (fuel without sulfur).
15
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Gasoline Systems
NOx
after-treatment equipment
16
ECU
Temperature sensor NOX sensor
Oxygen sensor
NOX trap
Three way catalytic converter
VW –
Lupo
FSI 1.4
171717
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Gasoline Systems
Electronic Direct Injection
Due to the technical issue and the costs associated to the stratified direct injection, the concept «
direct injection, homogeneous, Lambda=1
»
has emerged on the market in recent years.
Advantages:
Effective cooling of the combustion chamber (fuel evaporation) with the possibility to push the knock limit
Increase of the compression ratio of 1 point with consumption gain
Associated to supercharging controlled by electronics, new turbochargers (twin-scroll), possibility to enlarge the use of «
down-
sized »
engines Consumption reduction, torque increase
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Gasoline Systems
Electronic Direct Injection: The come back!
18
The Audi R8 4.2l FSI gained the victory in 2001 of the famous race “24 heures
du Mans”
with the gasoline direct injection technology!
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Gasoline direct injection: A long history
Electronic direct injection
Main components of the gasoline direct injection
New challenges with Euro 6 legislation
202020
Gasoline Direct Injection –
SIA / CNAM 2012
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Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
Gasoline Systems
Main components of the gasoline direct injection
20
212121
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disposal, exploitation, reproduction, editing, distribution, as well as in
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Gasoline Systems
High Pressure Gasoline Injector (solenoid)
FlachsteckerTERMINAL
UmspritzungCONNECTOR MOLD
MagnetspuleCOIL
VentilsitzVALVE SEAT
DichtringSEAL RING
O-
RingO-
RING
SiebkorbFILTER
DeckelCOVER
StützscheibeSUPPORTING DISC
EinstellhülseADJUSTMENT SLEEVE
DruckfederSPRING
AusgleichsringCOMPENSATING RING
VentilnadelVALVE NEEDLE
MagnetankerARMATURE
AnschlaghülseSTOP SLEEVE
Druckfeder (AFW)SPRING (AFW)
FederaufnahmeSPRING -
LOCATOR
AnschlagringSTOP RING
VentilkugelVALVE BALL
VentilhülseVALVE HOUSING
InnenpolINTERNAL POLE
MagnettopfHOUSING
AnschlusshülseCONNECTING SLEEVE
SicherungsringC-CLIP
21
222222
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Gasoline Systems
High Pressure Gasoline Injector (piezo)
22
Injection part
Coupler
Control unit
Fuel guide
Hydr. connection
Connector
232323
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Gasoline Systems
HDP: High Pressure Pump
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Gasoline Systems
High Pressure Pump HDP5: Working
24
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Gasoline Systems
Pressure regulation by dosing fuel quantity
Rail
AuV
MSVcurrentless
deliverychamber
EiV
IMSV
Intake Stroke Delivery Stroke
MSVcurrentless
deliverychamber
MSVcurrent flows
deliverychamber
Rail
MSVcurrentless
deliverychamber
EiVEiVEiV
AuV AuV AuV
25
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Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Gasoline direct injection: A long history
Electronic direct injection
Main components of the gasoline direct injection
New challenges with Euro 6 legislation
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Robert Bosch GmbH 2012. All rights reserved, also regarding any
disposal, exploitation, reproduction, editing, distribution, as well as in
the event of applications for industrial property rights.
Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Major Drivers and Requirements
Advanced Spray Technologies for DI
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Major Drivers for Powertrain Systems
Driving comfort
Noise, vibration, harshness
Shift-
& launch quality
Easy driving
Image & Emotions
Fuel Economy Labeling
Willingness-to-pay for green image and emotions
Variants
Globalization
Powertrain & vehicle diversification
Fuel differences
Quality and Safety
Reliability, Robustness
ISO26262
Main market drivers are still emission legislations incl. CO2
which impacts fuel economy. Costs remain very important.
City Restrictions
Ban on driving
Specific traffic lane, parking
Costs
Affordable mobility (price, TCO)
OEM entry efforts (invest, E&A)
Incentives and taxation
Fuel Economy / CO2
CO2 fleet targetsW-EU: 130/95g CO2/km 2012/20,US CAFE: 34,1 mpg in 2016
Fuel availability (“Peak Oil”)
Fun to Drive
Power and low end torque
Response time (dynamics)
Emissions & Diagnosis
EU6 (PM/PN, ext. EOBD)
LEV III (SULEV20, PM)
Worldwide Driving Cycle
Real Driving Emissions
TCO: Total cost of ownership PM: Particle massE&A: Engineering and application PN: Particle number
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Gasoline Direct Injection –
SIA / CNAM 2012
EU6 Emissions Legislation Roadmap
“EU7”
no PN limit
EU6cEU6b
2013 2014 2015 2016 2017 2018 2019 2020 2021 2022
WLTCEmissions Test: NEDC
RDE: monitoring only RDE mandatory : compliance factors open
additional testing: RDE: stringent com.fact.
PN: 6*1011
1/km
PN: 6*1012
1/km
upon choice of manufacturer
Emissions: PN-limitsSource: 25. TCMV meeting; 19.12.11
CO2 Test:
NEDC
PN standards and RDE PN testing only for DI. RDE limits to be defined for 2017.
Challenge Gasoline: Robust solution to fulfill
PN-limits.
PN: 6*1011
1/km
no PN limitPFI
GDI
Diesel
PN: tbd
for new cycle, modified PN test procedure
NEDC WLTC
(CO2
-targets to be adapted)NEDC
WLTC: Worldwide harmonized Light duty driving Test Cycle, RDE: Real Driving Emissions, TCMV: Technical Committee -
Motor vehiclesGasoline Systems
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Major Drivers and Requirements
Advanced Spray Technologies for DI
31
Diffusion combustion
1. Wall wetting piston
2. Wall wetting roof/valves
3. Fuel deposits injector tip
Inhomogeneous gas phase
4. Local rich areas (stratified/HSP)
5. Fire land stored fuel
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
real engine conditions
Sources of Particulate Emissions at DI Enginessources at DI formation / conditions
1
2
3
45
1
2
3
45
Fuel:
Cracking
Pyrolysis
Soot:
Precursors
GenerationPic
ture
:
DLR
, Ins
titut
für
Ver
bren
nung
stec
hnik
Ti
me
2500
2000
1500Tem
pera
ture
[K]
0.2 0.4 Lambda [-]
Soot formation region
• low O2• > 1500K
Com
bust
ion
Igni
tion
T[K]
O2[%]
°CA[BTDC]
-12
0-
20
>20
21
21-1
<1
400
500-
2500
~2000
Fuel
film
@
pis
ton
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Soot origin from wall film
1000
1500
2000
2500
3000
-
combustion finishedoxygen content < 1%
burn
ene
rgy
rele
ase
[%]
mea
n te
mpe
ratu
re [K
]
-20 -10 0 10 20 30 40 50 60
12°CA BTDC 9°CA ATDC
CA [°]
Very
small amountsof fuel film under:
• high temperature• low oxygen
conditionsresponsible for soot-emissions
0
25
50
75
100
Homogeneous2000 1/min5 bar pmiearly injection
Diffusive comb. fuel-
film @ piston
>> 20°CA ATDC
Combustion
~100 %
Ignition
2500
2000
1500
1000
Tem
pera
ture
[K]
0,2 0,4 0,6
Lambda [-]
Soot formation region
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Adv. Combustion Concepts: Challenge and Solution (Fuel Metering)
Downsizing / Displacement Reduction•
wetting (piston, valve)•
oil dilution•
mixture preparation (homogenization)•
spread (idling, catalyst heating, boosted full load)
Lean Burn Concepts (SGDI, HCCI)•
multiple injection >=3•
combustion concept robustness
Solution
Spray-Targeting
•
variable hole design
•
innovative manufac-
turing
technologies
Mixture Preparation
•
multiple injection
Adv. Injection Spread
•
using ballistic range towards smallest quantities @ 200 bar
source: MTZ 12/2010speed
torque build-upScavenging electrical
WG hybridization
knockingtumble design
active cyl. head cooling
comp. protectionintegr. exh. manifold
cooled EGR
high ignition voltagerobust ignition system
emissionsimproved mixture prep.
reduced penetration(e.g. soft spray, split inj.)
nominal powerturbo-charger
Pmaxto
rque
higher injection spread /multiple injection
controlled valve operation
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Contribution of innovative manufacturing technologies
Reduced penetration:
Better spray break-up and increased
entrainment of air due to enhanced
turbulence generation at sharp edged
nozzle inlet
standard inno. man. tech.
standard inno. man. tech.
Sharp inlet edge
Reduced penetration
Optimization/adaptation of individual
spray pattern:
Flexible hole design of single beams
to avoid critical zones
Improvement of homogenization due to
improved capture of airBeam Flexibility
standard inno. man. tech.standard inno. man. tech.
Individual optimization of critical beams
35
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SIA / CNAM 2012
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Gasoline Systems
Spray examples: Eroded / inno. man. tech.
eroded
inno. man. tech.
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Gasoline Direct Injection –
SIA / CNAM 2012
Inno. Man. Technologies: Potential, Side Mounted
Gasoline Systems
•
Reduction of PN-emission, especially at higher loads•
Due to reduced penetration reduced oil dilution•
Widening of application area
Comparison Particle Emission
0,0E+00
1,0E+07
2,0E+07
3,0E+07
4,0E+07
5,0E+07
6,0E+07
2 5 8 11
Load, bmep
[bar]
PN
[N/m
s]
Oil dilution
0,0%
2.0%
4,0%
6,0%
8,0%
10,0%
12,0%
eroded
Oil
dilu
tion
%
IMT IMThole indiv.
erodedIMT IMT hole indiv.
2000 1/min, 280°bTDC
1000 1/minTmot=50°, 2h
bmep: brake mean effective pressureIMT: innovative manufacturing technologies
eroded
IMT
IMThole individual
37
Controlled Valve -
HDEV5 Operation
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Component
ti-co
rrec
tion
control-
algorithm
Software
ti
UBatt
UBoost
UBatt
UBoost
signal processing, A/D-control
Hardware
Current profileCurrentMotionInduced voltage
DGDI-S
CVO gains benchmark on small quantities with solenoid injector
Open loop Closed loop
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Optimized PN combining DI Advanced Spray
and Calibration
Start Calibration Catalyst Heating
Homogeneous Mode Overall Result in PN -
Reduction
06,0E+111,2E+121,8E+122,4E+123,0E+123,6E+124,2E+124,8E+12
series calibration
optimizedcalibration.
optimized calibration
and DI Advanced Spray
PN
[n/k
m]
discussed PN limit EU6c
Quick fuel pressure rise up
Multi injection in suction stroke to avoid wall wetting
Minimize wall wetting by minimized fuel quantity for turbulence injection
Minimize piston wetting by optimized start of injection
Multi injection (depending on combustion system)
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Summary
Drivers:
Main market drivers remain CO2/fuel economy and emissions
At least ‘til 2020 the ICE plays a major role for CO2 reduction
Advanced Fuel Metering as key feature for DI to fulfill the legislation requirements and gain the ultimate gasoline engine
DI solutions:
Innovative manufacturing technologies for optimized spray targeting and mixture preparation
Controlled Valve Operation for smallest quantities accurate @ 200 bar in combination of multiple injections
BOSCH offers DI Advanced Spray
Technologies to meet the worldwide market requirements
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Conclusion
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Conclusion
CO2/fuel economy and emissions are the main market drivers
The gasoline direct injection plays a major role in this technical context
The market share of the diesel engine is decreasing worldwide
The gasoline indirect injection remains at a high level worldwide
The gasoline injection will be the strong winner in 2020
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Gasoline Direct Injection –
SIA / CNAM 2012
Gasoline Systems
Thank you