Experimental Investigations of Transient Emissions Behaviour Using - PowerPoint PPT Presentation

Experimental Investigations of Transient Emissions Behaviour Using Engine-in-the-Loop Dipl.-Ing. Christian Disch *1, Dr.-Ing. Heiko Kubach *1 , Prof. Dr.-Ing. Ulrich Spicher *1 , Dr.-Ing. Christian Schyr *2 *1 Institut für Kolbenmaschinen (IFKM), Karlsruhe Institute of Technology (KIT) *2 IPG Automotive GmbH, Karlsruhe INSTITUT FÜR KOLBENMASCHINEN  Prof. Dr.-Ing. U. Spicher KIT – University of the State of Baden-Württemberg and www.kit.edu National Research Center of the Helmholtz Association

Abstract Keywords: Engine-in-the-Loop (EiL), IFKM real world driving cycle, engine transient operation, raw emissions, fast response gas analyser, tip-in, HC emission peaks, diesel-hybrid, e-boost, SULEV In order to fulfil growing demands of new emission legislation and customer requirements real world driving cycles become more important. Investigations, especially under highly dynamic engine operation conditions have shown that the level of raw emissions could reach levels far greater than those under steady-state operation. Current legislative driving cycles like the NEDC do not have high proportions of transient operation. This finally leads to comparatively big differences in fuel consumption and raw emissions between legislative and real world driving cycles. Investigations to improve the combustion process under highly transient engine operation conditions using a real vehicle on public roads do not offer the required reproducibility due to ever changing traffic situations and other ambient conditions. Therefore the approach to use the internal combustion engine operated in a simulated environment is a promising technique, especially when stationary installed high-end testing equipment is indispensable to measure very detailed improvements. The simulation of the demonstrated Engine-in-the-Loop (EiL) method contains the vehicle-, track-, and the driver behaviour model. In this research project different newly defined IFKM driving cycles with a larger proportion of transient engine operation have been used to evaluate the level of CO, CO 2 , NO and HC emissions of a diesel engine operated virtually in a C-class vehicle. The potential of combining an Engine-in-the-Loop test bench with fast emission measurement techniques is exemplarily shown for an approach to reduce identified HC emission peaks during a tip-in situation. The improvement is finally demonstrated by using an additional virtual e-boost functionality like in a diesel-hybrid vehicle architecture. It is shown that the diesel-hybrid concept could be an opportunity not only for an improvement in fuel consumption but also be a part of a global vehicle emission-optimized operating strategy. Current developments in reducing diesel engine raw emissions are focusing on PM and NO x but future legislative restrictions like in the US SULEV LEVIII also require improvements for HCs. In conclusion the project demonstrates the possibility to identify elementary events causing transient emissions onset within a real world driving cycle. The aim is to show the potential of the EiL method in combination with fast response gas analyser for investigation and improvement of HC emission peaks with regard to reproducibility and level of detail. 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 2 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany

Outline Introduction EiL Measurement Setup Testruns and Results Conclusion and Outlook Live-Demo KIT 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 3 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany

Introduction 1/2 Engine-in-the-Loop (EiL) Body Tires Acceleration Driver Vehicle Behaviour Brakes EiL Power- Clutch Real train World Cycle Environment / Gearbox Driving Cycle Legislative Experimental Cycle Measurement Technique 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 4 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany

Introduction 2/2 Engine-in-the-Loop (EiL) Engine-in-the-Loop = Synergetic Effect of Experiment and Simulation Keywords Two Approaches Virtual test driving Legislative driving cycles Real world driving cycles Driver behaviour Hardware Software Detailed investigations with highest EiL reproducibility ( Engine-Level ) ( Vehicle-Level ) Traffic conditions Ambient conditions Onboard diagnostics vs. additional high-end measurement equipment Efficient ECU calibration (transient operation) Combustion process One Fuel consumption Raw emissions Method / Development Tool Driveability Flexibility in powertrain architecture (virtual and experimental) EiL = Only possibility to investigate Global vehicle performance transient emissions behaviour in detail Electrification/ HEV Frontloading & Simultaneous engineering under real world operating conditions 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 5 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany

Measurement and Test Bench Setup Research Topics – EiL Test Bench IFKM Combustion Process Transient Emissions Behaviour Real World Driving Cycles Global Vehicle Performance Example of use in presentation: Detailed investigations of diesel engine transient emissions behaviour Possibility for improvement of HC emission peaks using a virtual diesel-hybrid powertrain 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 6 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany

Measurement and Test Bench Setup EiL Test Bench Setup Fast Response Gas Analyser (FRGA) Cambustion HFR500 (FID) Cambustion CLD500 CLD500 Chemiluminescence Flame Ionization Detector Cambustion Detector Chemiluminescence Total Hydrocarbons THC NDIR500 → Nitrogene Monoxide NO Detector emissions raw emissions Non-Dispersive Infra Red Nitrogene Monoxide NO after catalyst (after turbine) Response T 90-10% ~2ms Response T 90-10% ~0.9ms Carbon Monoxide CO Carbon Dioxide CO 2 Response T 90-10% ~2ms Response T 90-10% ~8ms AVL EMCON CONTROLLER fan simulated gearbox AVL InMotion 1:1 powered by IPG CarMaker AVL - APA 304/8 AVL 330 kW Puma 8000 rpm Open 1400 Nm Inertia: 1,9 kg m 2 real clutch dyno (for real start) Real Time Node 4-cylinder diesel engine 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 7 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany

Testruns and Results Real World Driving Cycle vs. Legislative Driving Cycle Certified fuel Gasoline Diesel Real fuel consumption [l/100km] Real fuel consumption [l/100km] consumption vs. Real world fuel consumption Fuel consumption in NEDC [l/100km] Fuel consumption in NEDC [l/100km] Source: Spicher, MTZ 02/2012 130 120 NEDC 110 Increasing ecological and economical Vehicle speed [km/h ] 100 awareness of customers 90 80 70 New legislative driving cycles Car.v [km/h] 60 (e.g. WHDC, US- SULEV LEVIII) 50 40 30 20 Necessity for investigations of 10 0 real world driving cycles -10 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 Time [s] Time [s] 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 8 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany

Testruns and Results Definition of Real World Driving Cycles Possibility to compare vehicle through IFKM - „Part Load “ real and virtual test driving IFKM - „High Load “ Bad Herrenalb ↓ Dobel ↓ Rotensol ↓ Bad Herrenalb Distance: 12.5 km KIT- IFKM (Rintheimer Querallee) ↓ Right Theodor-Heuss- Start/Finish Allee ↓ Left L604 ↓ Right B36 ↓ Right L559 ↓ Right L560 ↓ Right Hirtenweg Start/Finish ↓ KIT- IFKM (Rintheimer Querallee) Distance: 23.3km Source: Google maps Source: Google maps 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 9 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany

Testruns and Results Comparison of Different Driving Cycles 140 IFKM - „High Load “ 120 IFKM - „Part Load “ 100 NEDC Vehicle speed [km/h ] Car.v [km/h] 80 60 40 20 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 Time [s] Time [s] 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 10 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany

Testruns and Results Engine Map - Requirements IFKM - „Part Load “ NEDC IFKM - „High Load “ ADAC Highway Cycle D ifferent driving cycles → Different engine map requirements (Legislative vs. Real World Driving Cycles) 20120918 Dipl.-Ing. Christian Disch - Engine-in-the-Loop Institut für Kolbenmaschinen 11 Prof. Dr.-Ing. U. Spicher “ apply & innovate “ 2012 │ IPG Technology Conference │September 18 - 19 │Karlsruhe │Germany