Project title - ERTRAC ICE workshop... · Internal Combustion Engine ... Status report on progress...

CORE - Collaborative Project

Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015

CO2 REduction for long distance transport

Project title: CORE –


Coordinator Johan Engström, Volvo

Status May 2015

Internal Combustion Engines ERTRAC Workshop, 2 June 2015




CORE - CO2 REduction for long distance transport

Current status: Start date 1st of January 2012 Coordinator: VOLVO Total number of partners: 16 Partners: Volvo, Daimler, CRF, Ricardo, Federal Mogul, Honeywell, IAV, University

of Hanover, University of Milano, University of Turin, Rhodia, Umicore, Chalmers, Johnson Matthey, Metatron, JRC,

Core Group: CRF, Daimler, VOLVO, IAV, Ricardo OEM: CRF, Daimler, VOLVO Duration: 4 year Budget Total budget ~17 000 kEuro, EC contribution up to ~9 000 kEuro

Project general information




Structure

SP A1 Daimler

Diesel engine optimized for

HEV

SP A2 Volvo

High efficiency Diesel engine for long haul

SP A3 CRF

Advanced combustion

system for Diesel and NG HD engines

SP A4 Final assessment

SP B1 Friction Reduction

SP B2 Aftertreatment systems

SP D

Pr

ojec

t Man

agem

ent




Motivation q  Improved fuel efficiency for long haul transport

q  Development of innovative and competitive solutions for HD engines with a market introduction target before the end of this decade.

Objectives

q  CO2RE will focus on developing highly efficient drivelines for long distance transport contributing to a 15% reduction in fuel consumption

Milestones plan

q  The main result will be achieved during the last year, and validated by complete powertarin test and vehicle simulation in real life application jointly with JRC

Motivation / objectives / milestones




Roadmap towards 11-18% reduction in fuel consumption

Fuel Consumption

Euro V MY2009

6-9%

To comply with Euro VI std

Friction, EAS 11%

Engine Platform

Hybridization

3-5% 2-4%

18%

Main objective – roadmap



CO2 REduction for long distance transport Status report on progress and deliverables

•  CORE has been on-going for nearly 3,5 years. •  The progress of work is almost according to the plan, no major

changes.

•  Fuel efficiency has been obtained in all sub-projects.

•  CORE target of 15% reduction has been achieved for MD engine in a hybrid application.

•  In-progress optimisation of engine system in the different sub-projects

•  Vehicle simulations, assessment of CORE developed technologies, with objective to investigate other pathways to the target of 15% CO2 reduction

•  External review has been performed after the 36 months. Follow up in-progress.




Fuel Consumption

Euro V MY2009

6-9%

To comply with Euro VI

std

Friction, EAS 11%

Engine Platform

Hybridization 3-5% 2-4%

18%

Achivied results in respecte to CORE –roadmap

Engine platform: •  Results: 5-7% (CNG,MD,HD) •  In-progress: Engine system optimisation

Hybridisation Results: over 6% In-progress: energy strategies

EATS Results: improved SCR performance in lower temperature range In-progress: duty cycle optimisation

Friction Results: about 1% on MD engine In-progress: 2nd test with new piston ring design



CO2 REduction for long distance transport Main technical challenges and solutions in the project Main technical development •  Increased peak cylinder pressure, above 230bar •  Downspeeding

•  High performance turbo system, variable geometry and dual stage technologies

•  Variable vale technologies, advanced strategies and transient operations

•  Aftertreatment improved NOx conversion at lower temperature range

•  Reduced engine friction

Challenges for sub-development are that novel design need and should meet •  improved performance, •  durability and robustness, •  cost effective



CO2 REduction for long distance transport Main technical challenges and solutions in the project

Concept „VRT“ = Variable rotary turbine - variability of segment angle and flow area at turbine inlet via rotating tongues

Solutions: Examples of new procurement of prototype hardware

New piston rings – lower friction Rings profile changed Reduce ring tension Increased skirt/bore clearance Reduced viscosity oil Low friction coating

High efficiency, Dual Stage Turbo system, containing novel design, such as low solidity airfoil diffusers, radial-axial turbines configuration and ball bearings technology.

Variable Valve Attenuation – Enable Miller cycle and internal EGR for reduce of Nox emissions




Currently on-going: full engine tests – application

concept test – optimisation engein & EATS Vehicle test in dyno

DOC

DPF

AdBlue

Fuel

SCR

AMOX

ETC&WHVC cycles on dyno rolling bench at JRC




•  Vehicle type:

–  Heavy Duty 40t

–  Tractor with semitrailer

•  Mass: 40,000 kg

•  Tractor tyre rolling radius: 0.522 m

•  Drag Coefficient

–  Cd.A = 5.82 m2

•  Tyre friction factor: 0.0058

Volvo – Vehicle Model Data Summary

Assessment of CORE technologies by vehicle simulations performed by Ricardo, example Volvo



CO2 REduction for long distance transport Expected final results: exploitation and impact

•  Main benefits from final results: Demonstration of sub-technologies performance and concepts potential that can

reduce the fuel consumption in near time frame. This is beneficial and competitive for the OEMs

•  How will these results be used? Knowledge and part of the novel hardware /concept will be put in production

•  Impact of these results on future research and development Increased efficiency of the engine → lower the exhaust temperature → higher

demand on EATS, specific on lower temperature




Research issues – more potential to reach based from CORE

• Physics: - Heat management (thermodynamics, heat rejection etc)

• Simulations tool: – Improved precision • Sub-technologies: -EATS, improved efficiency at lower temperatures

- Variable valve applications

•  Concepts -Down speeding, hybridisation, PCP above 250bar, transmission

• Powertrains -Intelligent powertrains – increased flexibility and further integration of engine, EATS, hybrids, WHR. Require better simulations models (physical), better sensors & regulators and control strategies




Thank you

Project title - ERTRAC ICE workshop... · Internal Combustion Engine ... Status report on progress...

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