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

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

Review meeting – Brussels, April 2011 MM allocation RWTH

Review meeting – Brussels, April 2011 MM allocation RWTH

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

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 % Pmax @ CA 139 bar @ 191°CA Ignition Timing 157 °CA Ignition Delay (0%-5%) 14,5 °CA Combustion Duration (5%-95%) 31,5°CA Combustion Centre (50%) 187 °CA

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).

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

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.

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.

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.

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

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.

Piston design (CR=13CR=12 (Final)) IMG_2592.jpg K:\B_Technical_Status\04_Engine\044_Kolben\Fotos\20090605 IMG_0004.jpg K:\B_Technical_Status\04_Engine\044_Kolben\Fotos\20100601 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

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.

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

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

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

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