© by FEV – all rights reserved. Confidential – no passing on to third parties
LCV Cenex 2016
Dr.-Ing. R. Tharmakulasingam, Dr.-Ing. T. Uhlmann, Dr.-Ing. H. Baumgarten, Dipl.-Ing. B. Franzke,
Dr.-Ing. J. Scharf, Dr.-Ing. M. Thewes, Dr.-Ing. G. Birmes
EXTREME DOWNSIZING FOR GASOLINE ENGINES
FUN TO DRIVE WITH EXTREMELY LOW EMISSIONS
Millbrook, 15.09.2016
Extreme downsizing for Gasoline Engines – Motivation & Challenges
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Majority of current automotive fleet shows spec. power from 50-60 kW/l
High performance segments have small market shares
Yet the production forecast for the high performance segment is significant
Histogram of Gasoline*) Engine vehicles produced in 2015// Development of High Performance Engines (2015-2022)
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
Development of specific power
Extreme downsizing for Gasoline Engines – Motivation & Challenges
Source: LMC Automotive, FEV Consulting *) Including Flex Fuel (Ethanol), CNG and LPG Applications
70.553
> 90
1.427
> 80
2.993
> 70
5.460
> 60
10.437
>= 50
35.221
<50
14.478
total
107
20
15
pro
du
ction
rate
x1
03
> 100 > 110
430
total <80 kW/l 80 - 100 kW/l >100 kW/l
+3,0%
‘22
86.743
‘15
70.553
ICE specific power / kW/L
+2,2%
‘22
76.247
‘15
65.596 +11,1%
‘22
9.263
‘15
4.421
+12,6%
5361.233
‘15 ‘22
13% annual growth of
high performance
engines (>100kW/l)
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Trend:
Further downsizing
High specific power & LET
Several high performance
engines in development at FEV
Boosting system is key
component
1-stage boosting limited
2-stage boosting to combine
high specific power and low-
end-torque (LET):
TC + eC
TC + TC
TC + SC
High interest in engines with increased specific power over 200 kW/l parallel to main trend (major volume of engines downsized up to 100 kW/l)
Trend at FEV
Extreme downsizing for Gasoline Engines – Motivation & Challenges
NA engines 1-stage boosted engines 2-stage boosted engines Motorcycle engines under development at FEV
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
96
97
98
99
100
101
100 110 120 130 140 150 160 170 180
Norm
.NE
DC
Fu
el
Con
su
mption
/ %
Specific Power / kW/l
1 3 5
9 12
25
40
0
10
20
30
40
50
Con
su
mer
tax
rate
/ %
Motivation for High Performance Taxation - Modularization - Fuel Consumption - Weigth/Package
0 1 1,5 2 2,5 3 4 Engine displacement / l
< 1.5 l TCDI in B-Segment < 4.0 l TCDI in Supersport
0
100
200
300
400
500
600
700
800
1 2 3 4 5 6 7 8 9
En
gin
e p
ow
er
/ k
W
Cylinder number / -
TC 2 Stage TC 1 Stage NA
Extreme downsizing for Gasoline Engines – Motivation & Challenges
100
120
140
160
180
200
220
0,6
0,8
1,0
1,2
1,4
2 3 4 5 6 7 En
gin
e m
ass
/ kg
Po
we
r to
we
igh
t ra
tio
/
kg/k
W
Cylinder number / -
Weight with 240 kW
4 LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Challenges of High Performance Transient Response
150
200
250
300
350
400
450
500
100020003000400050006000
To
rqu
e / N
m
Engine Speed / 1/min
TC 90 kW/l TC 140 kW/l
0
10
20
30
40
50
60
70
80
90
100
1500 2000 3000 4000
Norm
al.
Tim
e-t
o-T
orq
ue
(90
% )
/ s
Engine Speed / 1/min
TC 140 kW/l TC 90 kW/l
Extreme downsizing for Gasoline Engines – Motivation & Challenges
90 kW/l
100 kW/l
110 kW/l
120 kW/l
130 kW/l
140 kW/l
0
20
40
60
80
100
120
Norm
.T
C R
oto
r I
ne
rtia
/ %
TC 140 kW/l
TC 90 kW/l
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
FEV High Performance Demonstrator Vehicles
Innovative EGR Concept for Low Fuel Consumption
Alternative Boosting Concept
Summary & Outlook
Extreme downsizing for Gasoline Engines – Content
Content
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
FEV Boosting Demonstrator Vehicle Illustration of Different Boosting System Architectures
TC + eC TC + TC
Extreme downsizing for Gasoline Engines – FEV High Performance Demonstrator Vehicles
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Illustration of Different Boosting System Compressor Maps
eC Map
1,0
1,5
2,0
2,5
3,0
3,5
4,0
0 10 20 30 40 50 60 70 80 90 100
Normal. Corr. Mass Flow Rate / %
eC Boosting TC Boosting
Total
TC 140 kW/l
1,0
1,5
2,0
2,5
3,0
3,5
4,0
0 10 20 30 40 50 60 70 80 90 100
HP TC LP TC
LP Stage
LP Stage
Total
Normal. Corr. Mass Flow Rate / %
Extreme downsizing for Gasoline Engines – FEV High Performance Demonstrator Vehicles
Com
pre
ssio
nP
ressu
reR
atio
p2t/p
1t
Com
pre
ssio
nP
ressu
reR
atio
p2t/p
1t
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
eC – TC – CAC
Surge behavior
Package
TC – CAC – eC
Low-end-torque
Transient performance
Package
TC – eC – CAC
Low-end-torque
Transient performance
Package
Illustration of Different Boosting System Architectures
Assessment of eC position
Extreme downsizing for Gasoline Engines – Motivation & Challenges
eC – TC – CAC TC – CAC – eC TC – eC – CAC
Abbreviations:
eC: electric Compressor TC: Turbocharger CAC: Charge Air Cooler
✚
✚✚
−
✚
−
✚✚
✚
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Optimum interaction between eC and TC
Compact package of BorgWarner eBooster leads to
Optimal design of airpath
Low pressure losses
Improved performance
No changes on the vehicle structure with given solution
Illustration of Final Variant of TC with eCompressor (eC)
Summary TC - eC - CAC Layout
eBooster
Turbocharger Air Filter
Air Bypass
Passive Shut-Off Valve
Extreme downsizing for Gasoline Engines – FEV High Performance Demonstrator Vehicles
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Illustration of Different Boosting System Architectures eCompressor Results
Extreme downsizing for Gasoline Engines – FEV High Performance Demonstrator Vehicles
0
10
20
30
40
50
60
70
80
90
100
1500 2000 3000 4000
Norm
al.
Tim
e-t
o-T
orq
ue
(90
% )
/ s
Engine Speed / 1/min
TC 140 kW/l TC 90 kW/l TC+eC
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
FEV High Performance Demonstrator Vehicles
Innovative EGR Concept for Low Fuel Consumption
Alternative Boosting Concept
Summary & Outlook
Extreme downsizing for Gasoline Engines – Content
Content
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
85%
90%
95%
100%
105%
0 5 10 15 20 25 30
No
rma
lize
dB
SF
C
External EGR / %
Innovative EGR Concept for Low Fuel Consumption Effect of cooled EGR on BSFC and Nox-Emissions
Cooled EGR
Extreme downsizing for Gasoline Engines – Innovative EGR Concept for Low Fuel Consumption
10
15
20
25
30
0 5 10 15 20 25 30
Pe
ak
Pre
ssu
reP
ositio
n/ °C
A
External EGR / %
00,20,40,60,8
11,2
0 5 10 15 20 25 30
No
rm. N
OX
Em
ssio
n
External EGR / %
Potential 2-% Points
Test bench limit
Vehicle limit
Engine Speed = 2000 1/ min, Engine Load = 12 bar
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Innovative EGR Concept for Low Fuel Consumption Fresh Air Bypass
Fresh Air Bypass (FAB)
Extreme downsizing for Gasoline Engines – Innovative EGR Concept for Low Fuel Consumption
10
20
30
40
50
Time / s0 2 4 6
EGR rate in cylinder / %
0
10
20
30
40EGR rate in
intake system / %
-25
0
25
50
Time / s0 2 4 6
EVC
IVO
IVO & EVC / ° CA ATDC
0
5
10
15
20BMEP / bar
Without FABWith FAB + 15 %-P EGR
- 2 %-P BSFC
Engine Speed = 2000 1/ min, Engine Load = 12 bar idle
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
FEV High Performance Demonstrator Vehicles
Innovative EGR Concept for Low Fuel Consumption
Alternative Boosting Concept
Summary & Outlook
Extreme downsizing for Gasoline Engines – Content
Content
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Alternative Boosting Concept
150
200
250
300
350
400
450
500
1000 2000 3000 4000 5000 6000
To
rqu
e / N
m
Engine Speed / 1/min
TC 90 kW/l TC 140 kW/l TC+eC
90 kW/l
100 kW/l
140 kW/l
110 kW/l
120 kW/l
130 kW/l
Extreme downsizing for Gasoline Engines – Alternative Boosting Concept
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Alternative Boosting Concept
150
200
250
300
350
400
450
500
1000 2000 3000 4000 5000 6000
To
rqu
e / N
m
Engine Speed / 1/min
TC 90 kW/l TC 140 kW/l
TC+eC eTC
90 kW/l
100 kW/l
140 kW/l
110 kW/l
120 kW/l
130 kW/l
Extreme downsizing for Gasoline Engines – Alternative Boosting Concept
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
1,0
1,5
2,0
2,5
3,0
3,5
4,0
0 10 20 30 40 50 60 70 80 90 100
Com
pre
ssor
Pre
ssu
reR
atio p
2t/p
1t
/ -
Normal. Corr. Mass Flow Rate ṁcor,C
/ %
Alternative Boosting Concept
Extreme downsizing for Gasoline Engines – Alternative Boosting Concept
TC full load engine operation below LET
Limit of eTC operation due to surge line
eTC
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Alternative Boosting Concept
Extreme downsizing for Gasoline Engines – Alternative Boosting Concept
Bypass valve for
both directions
1,0
1,5
2,0
2,5
3,0
3,5
4,0
0 10 20 30 40 50 60 70 80 90 100
Co
mp
resso
rP
ressu
reR
atio p
2t/p
1t
/ -
Normal. Corr. Mass Flow Rate ṁcor,C
/ %
TC full load engine operation below LET
Dual FAB scavenging effect
eTC and Dual FAB
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Alternative Boosting Concept
150
200
250
300
350
400
450
500
1000 2000 3000 4000 5000 6000
To
rqu
e / N
m
Engine Speed / 1/min
TC 90 kW/l TC 140 kW/lTC+eC eTCeTC+FAB
90 kW/l
100 kW/l
140 kW/l
110 kW/l
120 kW/l
130 kW/l
0
10
20
30
40
50
60
70
80
90
100
1500 2000 3000 4000
No
rma
l.T
ime
-to
-To
rque
(90
% )
/ s
Engine Speed / 1/min
TC 140 kW/l TC 90 kW/l TC+eC eTC+FAB
Extreme downsizing for Gasoline Engines – Alternative Boosting Concept
+ 135 Nm with eTC+FAB compared eTC only to
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
FEV High Performance Demonstrator Vehicles
Innovative EGR Concept for Low Fuel Consumption
Alternative Boosting Concept
Summary & Outlook
Extreme downsizing for Gasoline Engines – Content
Content
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Summary
Trend towards high performance will continue (+13 % annual growth until ‘22)
eCompressor leads to improvement of transient performance up to 80 %
FEV Fresh air bypass (FAB) leads to real drive BSFC improvement up to 2 %
FEV Dual FAB enables usage of eTC at low engine speeds without surge limitation
The combination of eTC and FEV Dual FAB shows potential for improved transient behavior at high engine speeds
Acknowledgements: The Authors would like to thank BorgWarner Turbo System and
AMG for their outstanding support during this project.
Extreme downsizing for Gasoline Engines – Summary & Outlook
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
© by FEV – all rights reserved. Confidential – no passing on to third parties |
Thank you for your attention
Contact person: Dr. Georg Birmes ([email protected])
Book your personal test ride!
Extreme downsizing for Gasoline Engines – Summary & Outlook
LCV Cenex 2016, Tharmakulasingam, FEV GmbH 2
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