1. „Boosted Lean Burn Gas Engine“
INGAS Sub Project A3
„Boosted Lean Burn Gas Engine“
Review Meeting
07/04/2011 Brussels
RWTH, Martin Müther

2. Face to face meeting SP A3 – Brussels, 7 April 2011
Time
Item
Name (company)
14:30
Preamble with background
Motivations of face to face meeting
Coordinator Massimo Ferrera (CRF)
PM Stefania Zandiri (CRF)
14:40
FEV: executive summary of activities done in Period 1 and Period 2 versus effort planned and claimed (main engine project vs side engine project)
Christoph Bollig (FEV), Bertold Hüchtebrock (FEV), Michael Wittler (FEV)
15:00
OPEL: executive summary of activities done in Period 1 and Period 2 versus effort planned and claimed (main engine project vs side engine project)
Winfried Hartung (OPEL)
15:20
RWTH: executive summary of activities done in Period 1 and Period 2 versus effort planned and claimed
Martin Müther (RWTH), Philipp Simm (RWTH), Sandra Glück (RWTH)
15:40
Discussion
All
16:30
End of reviewers meeting
17:30
Feedback of the reviewers & PO 2

3. Review meeting – Brussels, April 2011 MM allocation RWTH

4. Review meeting – Brussels, April 2011 MM allocation RWTH

5. Review meeting – Brussels, April 2011
Task-No.
A3.1.1
Title
Definition of base engine and vehicle with fuel consumption and performance
Main Activities
Simulation work: Process calculation (engine decision  focus on peak firing pressure)
Main Result
A3 approach requires base diesel engine (pmax>150 bar!)
Engine: OPEL Z19DTH (diesel)
Vehicle: OPEL ZAFIRA

6. Performance prediction referenced to 1.9 l (Z19DTH)
Review meeting – Brussels, April 2011
Performance prediction referenced to 1.9 l (Z19DTH)
Engine Speed
4000 rpm
Rel. Air-Fuel Ratio
1,60
BMEP
17 bar
Efficiency (eff.)
37,1 % CA
°CA
Ignition Timing
157 °CA
Ignition Delay (0%-5%)
14,5 °CA
Combustion Duration (5%-95%)
31,5°CA
Combustion Centre (50%)
187 °CA

7. Design specifications of the power train and draft lay out
Review meeting – Brussels, April 2011
Task-No.
A3.1.2
Title
Design specifications of the power train and draft lay out
Main Activities
Spark plug application using manufacturer CAD data and investigation of base hardware. Spark plug dimensioning. Layout of the fuel metering system and intake manifold modification. Specific conversion work (dieselNG). Determination of CR and piston design. Application of cylinder pressure indication device. Definition and adaption of throttle. Definition of ignition system.
Main Result
Initially CR of 13. Squish height 0.8 mm. Spark plugs M12x1.25 (mm). Fuel injectors close coupled to intake ports via „spacer“-construction. Pressure indication with KISTLER 6041 (8 mm). Throttle from OPEL GT (2 l Turbo). Twin-coil ignition system (BOSCH).

8. Basic Diesel engine (Z19DTH): CAD-Data
 Spark plug application
 Analysis of CAD-Data

9. Draft packaging of power train and fuel system Main Activities
Review meeting – Brussels, April 2011
Task-No.
A3.1.4
Title
Draft packaging of power train and fuel system
Main Activities
Constructional data exchange with OPEL.
P1: Integration of PFI system („spacer“).
Main Result
Definition of spacer-length. Integration of PFI is feasible considering a spacer-length below 40 mm.

10. First lay out of the control strategy Main Activities
Review meeting – Brussels, April 2011
Task-No.
A3.1.6
Title
First lay out of the control strategy
Main Activities
Definition of EMS. Definition of required sensors and actuators. Definition of necessary functionalities (l-control (lean!); EGR; SCR; …). Study (recherche) on possible SCR strategies (NH3 dosing  NH3 storage modelling). P1: 2 MM‘s; P2: 0.5 MM.
Main Result
Input for EMS documentation supervised by FEV.

11. Modelling, design, procurement and rig test of the boosting device
Review meeting – Brussels, April 2011
Task-No.
A3.2.1
Title
Modelling, design, procurement and rig test of the boosting device
Main Activities
Setup and matching (measurementcalculation) of GT Power engine model for 1.9 l diesel based NG engine. Performance calculation using TC maps from rig testing delivered by FEV.
Main Result
High power/torque-targets linked with high air excess (efficiency target) requires 2-stage TC in A3 approach.

12. System specific actuators
Review meeting – Brussels, April 2011
serial / serial
System specific actuators
High-Pressure-Turbine bypass
low speeds -> controlled wastegate function for High Pressure Turbine
from mid speed on complete mass flow bypassed toward Low Pressure Turbine
High-Pressure-Compressor bypass
back pressure valve
on/off bypass (not active)
Low-Pressure-Turbine wastegate
conventional function of turbine control
HPC-BP
HPT-BP
LPT-WG

13. Modelling, design and rig testing of lean burn combustion
Review meeting – Brussels, April 2011
Task-No.
A3.2.3
Title
Modelling, design and rig testing of lean burn combustion
Main Activities
close linked to Task A3.1.2 (design specifications)
Generation of CAD files regarding spark plug application, 1st piston modification on base diesel piston (e=13), intake manifold upgrading („spacer“) and other specific conversion aspects (i.e. removal of diesel HP pump). Layout of 2nd CR and corresponding piston design (1312).
Main Result
Transfer of CAD data  FEV regarding hardware machining.

14. Piston design (CR=13CR=12 (Final))
IMG_2592.jpg
K:\B_Technical_Status\04_Engine\044_Kolben\Fotos\
IMG_0004.jpg
K:\B_Technical_Status\04_Engine\044_Kolben\Fotos\
CR=13.0
CR=12.0
Increased bowl-diameter (‚open bowl‘)
Increased pocket-width
Unchanged Squish Height: 0.83 mm
Reduced squish area share
 Machining at FEV

15. Task-No. A3.3.4 Title Main Activities Main Result
Review meeting – Brussels, April 2011
Task-No.
A3.3.4
Title
Multicylinder testing under steady state and transient conditions on a test bench and improvement of the engine
Main Activities
Definition of NEDC relevant operating points referenced to ZAFIRA (6 modes). Integration of DoE methodology into test planning and result analysis. 3-dimensional experiment space (Inj.-Tim., Ign.-Tim., l). Definition of constraints. Test bench measurements.
Setup and application of SW-tool for map-optimization assuming predefined szenarios. Result analysis.
Main Result
Operation points in lower load area identified (6 modes). All hypercubes for DoE testing created. Modified SW tool generates accurate maps.

16. Steady-State-Replacement-Test (NEDC)
MCE-Testing Definition of Operation Points
Steady-State-Replacement-Test (NEDC)
Reference:
ZAFIRA (1.9 CDTI)
6 Speed Gearbox
BMEP vs. Eng.-Speed
S Idle: 326 s
S Push: 138 s
S Part Load: 716 s
Highest Relevance
Additional Points  MAP-Completion
Breakdown (Modes)
Urban: 3x
Extra-Urban: 1x

17. Engine Testing / Procedure
Hypercube  3-dimensional experiment space (DoE-Methodic)
Operation point (Mode 4):
n=1754 rpm
BMEP=6.2 bar
Variables:
Ignition Timing (ZZP)
Rel. A/F-Ratio (LAM; l)
End of NG-Injection (EOI)
Due to the significant impact of the NG-injection-window on engine behaviour, this parameter has been included in the DoE-Testing !
ZZP
 Hypercube-Parametrisation is Mode-specific !
EOI
LAM

18. MCE-Testing MAP-Generation / Procedure
Setup of DoE-Modell for each defined operation point considering operation limits
Stationary MCE-Testing ( DoE-Parameterisation)
DoE-Analysis  Modell-Calculation / Generation of functionalities
Engine MAP-Generation assuming different szenarios
TExhaust > Limit value (presetting)
BSFC, NOx, HC min.
Ignition Timing (presetting) …
Projection on cycle (i.e. NEDC) (Presetting: Vehicle & gear box)
Testing
Calculation
(Weighted) Combination possible

19. BACKUP  Slides concerning documentation of activities
Review meeting – Brussels, April 2011
BACKUP
 Slides concerning documentation of activities