André RAULT General Secretary Mid and Long Term Powertrains Evolution Associated Fuels

Chairman IntroductionPresentation to OICA Feb. 20 2002

EUCAR 2002

André RAULTGeneral Secretary

Mid and Long Term Powertrains EvolutionAssociated Fuels

European Council for Automotive R&D

E RUCA


EUCAR 2002

EUCAR Presentation• What is EUCAR ?

• Present Research Activities and Trends in Powertrain

• EUCAR Vision on Future Powertrain

• EUCAR Scenario of Future Powertrain and associated Fuels


EUCAR 2002

EUCAR Members


EUCAR 2002

Precompetitive Working Themes

Environment,Energy, Resources

Safety forRoad Users

Mobility,Transport


EUCAR 2002

European Approach to CO2 Reduction

1995

1998 2004

2003Review

2008

CO2 g/km

190

140

120

2012

CO2perateCO2 R&D

CEC - ACEA Agreement

Year


EUCAR 2002

CO2 Monitoring: Achievements on 1995-2000

140

160

180

20019

85

1987

1989

1991

1993

1995

1997

1999

2001

2003

2005

2007

CO

2 E

mis

sion

s, g

/km

, New

Cyc

le

ACEA

EU 15

Targets

Monitoring the CO2 Emission Reduction


EUCAR 2002

Control SystemsOverall Power Train

Management

Exhaust Gas Aftertreatment

Engine

Transmission

Materials-Light Weight

-Reduced Friction-New Materials for

higher Demands

Demands Additional Needs

Engine, Transmissionand specify

Legislation

•Emissions•CO2

Customer Demands•Driving Pleasure / Agility•Consumption•Comfort

Today the Powertrain has to be viewed as a complete system Engine - Transmission - Powertrain Management - Materials - Fuels

FuelsModified

Fuels, Lubricants

PowertrainCombustion

ProcessImprovement


EUCAR 2002

Potential of Internal Combustion Engines100

95

90

85

80

75

70

65

60

Fu

el C

on

su

mp

tion

( %

)

PFI GDI = 1

PFIDownsized+ TC

VVT GDI > 1

Gasoline engines Diesel engines

DI DIincreasedinjectionpressure

Sp

read

HCCI(laboratory

status)

• NOx

• PM Trap

weak

starting

torque

• NOx

• comb.

process

• Valve

operation

Main problem

for GDI, DDI

Sulfur

• costsUnder condition of EURO IV


EUCAR 2002

The Hybrid will succeed if it can reach a Win-Win-Win-Situationbetween Legislation Customer Costs

PC

TTR-Hybrid

Been suitable very wellasPower-Hybrid, 4WD

The power, generated by the combustion engine,can be transformed with the generator into electric power and/or transmitted directly to the drive axle.It is a combination of the parallel and the serial Hybrid.

Split-Hybrid Through the Road-Hybrid

ConventionalCar

ElectricCar

The Hybrid - between conventional car and electric car


EUCAR 2002

EUCAR Vision of the Future

• The coming views of future powertrain trends have been consensually established by the EUCAR Powertrain experts group constituted of all member companies


EUCAR 2002

Overall powertrain strategy

advanced combustion engines and drive train(plus Starter/Generator, Light weight design, FC - APU)

HybridPropulsion

Fuel CellPropulsion

today tomorrow

Mild Hybrid Propulsion(ICE plus small electric drive)

conventionalcombustion

engines

The recent strategy of expanding the vehicle range will be applied to expand the powertrain options in the future


EUCAR 2002

1970 1980 1990 2000 2005 2010

100

80

60

40

20

Emission %

Greenhouse Effect, CO2

Energy

Exhaust Emission HC, CO, NOx, PM

Diesel HDTPM, NOx

Emission reduction and legislation needs

Emission reduction and legislation focus Energy resources and reduction of CO2 will gain importance

Diesel PCHC+NOx, CO


EUCAR 2002

Different technologies for different markets?

EGR w/o DPF

2003 2004 2005 2007 2008 2010 2012 2014

EPAEURO 4 EURO 5EPAEPA

year

legislation

Comb. Heterogeneous/HCCI + DENOX 0,9 +(DPF) comb. system

EGR (20%) + DPF 0,9 + DENOX 0,9

SCR 0,65...0,70~ SCR 0,80...0,85~

US

EUROPE

EGR+DPF+DENOX 0,65

US market: no urea desired, Denox +DPF +(EGR) preferred(4 - 5% increase of fuel consumption)

EU market: SCR technology (urea/NH3), combined sytem preferred

?

Legislation for Heavy Duty Trucks


EUCAR 2002

Statements With EURO IV legislation in 2005, the vehicles emissions

are reduced to a level with a negligible impact on environment.The effective emissions are almost zero.

Beyond EURO IV there will be no need for further emission legislation.

After 2005 the R&D activities will bring the fuel efficiency and CO2 emissions into focus.

The demand is: only one aftertreatment technologyfor all markets.


EUCAR 2002

Drive train & transmission

Future main technology fields

Supercharging

Fuels and lubes Internal combustion engine

Overall powertrain management

Increase efficiency and reduce raw emissions Develop complex aftertreatment systems Develop modern clean fuels and lubes

Exhaust gas aftertreatment


EUCAR 2002

Advanced combustion process

and combinations

Main ICE technologies to reduce energy consumption

Clutch 1Clutch 21. 3. 5. 2.4. 6.

S1 S2 S3 S4

Toroidal-CVT Automated manual transmission

Supercharging and downsizing

0

40

80

120

rated-Revolutions [1/min]

To

rqu

e [%

]

Aspirating mapdownsized

engine

supercharged range

standard naturally aspirated engine

Capacity reduction

idle-

Transmission

Variable Valve Timing

0

2

4

6

8

10

freiwählbar

OutletInlet

Valv

e L

ift

[mm

]

PRE MAIN AFTERPILOT POST

Multiple InjectionDI HCCI / CAI


EUCAR 2002

Main technology trends - IC engines (PC)

Market Introduction 2005 2010 2015 2020

Thermal Management

Multiple Injection SystemsSingle Cycle Control

Non Precious Metal Aftertreatment Systems

GDI/DDI Continuous NOx-Reduction

Reduced Friction by New Material and Design

Multivariable Model Based Control Systems

DI Spray Guided / Stratified Charge

Essential increase bmep = 28...30 bar+ advanced charging technologies

Near Controlled Auto Ignition

High Pressure Supercharged, VNT/VCG

Starter / Generator with start/stop

Starter / Generator with driving support

Die

sel

Gasolin

e

Homogeneous Combustion

Downsizing bmep = 28...30 barHigh Pressure ChargingReduction In-Cylinder Pressure

Combined heterogeneous/homogeneous Combustion

Combined Soot Trap and Catalytic NOx-Reduction (no fuel additive)

Fully Flexible Injection SystemsStarter / Generator

Hybrid Transmission (CVT + e-drive)


EUCAR 2002

Main technology trends - Diesel engines (HDT)

Market Introduction 2005 2010 2015 2020

Homogeneous Combustion

Downsizing bmep= 28...30 barTwo Stage Turbocharging

Variable Compression Ratio

Single cylinder control

Combined heterogeneous/homogeneous Combustion

Combined Soot Trap and Catalytic NOx-Reduction

Variable Injection Nozzle Geometry

Downsizing bmep = 25 barVariable Nozzle Turbine with reduced gaps

Exhaust Gas Recirculation (EGR)

Reduced Friction by New Material and Design

Variable Compressor Geometry

Multivariable Model Based Control Systems

High Pressure, Fully Flexible Injection Systems


EUCAR 2002

SystemSystem

InternalCombusti

onEngine

Electric/ElectronicManagement

Transmission

Exhaust GasAftertreatmentAutomated

ManualTransmission

IntegrationIntegration

Integrated adaptive systems fulfil customer demandsand further legislations

Clutch 1

Clutch 2 1

.3.

5.

2.

4.

6.

S1

S2

S3

S4

Homogeneous chargecompression ignition

(HCCI)

System integration - the key to success


EUCAR 2002

StatementPropulsion systems using ICE’s will demonstrate their potential for meeting future needs:

- minimal emissions- drastically reduced fuel consumption- high efficiency- good driving performance

by exploiting the R&D activities on- adaptive control systems for integrated powertrain management- new combustion processes- hybridization of internal combustion engines (mild hybrid)- advanced materials for higher performance (light weight, high temperature/ pressure resistance, etc.)


EUCAR 2002

Why fuel cell vehicles?

customer

environment /society

vehicleemissions

Driving pleasure without remorse

efficiency

Independence from petroleum

Greenhouseeffect

(hydrogen)


EUCAR 2002

0

5

10

15

20

25

30

Eff

icie

ncy

[%

] in

NE

DC

today

until 2003

after 2010

ICE gasoline ICE Diesel ICE MeOH FC CH2 FC LH2 FC MeOH

Internal Combustion Engine Fuel Cell

Comparison between fuel cell and combustion engineEfficiency - well to wheel -

Source: DC, Dr. Fortnagel, 13 th International Conference Engine & Environment, AVL, Graz, September 2001


EUCAR 2002

Fuel cell vehicles worldwide

1995 2000 2005 2010 2015 2020

10.000.000

1.000.000

100.000

10.000

1.000

100

10

Population/Forecast

Source: FH Gelsenkirchen, Prof. Dudenhöfer; Audi, 10. Aachener Kolloquium

Test-phase Niche-phase Production-phase


EUCAR 2002

Statements

Fuel-cell vehicles have still a long development-path to go (weight & costs

reduction, maturing the technologies), production start not before 2015

Hydrogen is only meaningful in the mobile applications, if all technologicaland economical barriers have been overcome ( past 2020)


EUCAR 2002

today best in consumption (high efficiency)

need for further reduction of NOx and PM emissions

meets high requests on emissions

need for further reduction of CO2 (consumption)

promotion of the combustion engines through combinations with electric drives

battery-and storage-technologies

Diesel engine

Gasoline engine

Hybrid

Fuel cell best solution for the environment if hydrogenis available

costs, infrastructure, fuel storage

Conclusion


EUCAR 2002

Beyond the year 2010, the share of engines depends mainly on: legislation availability of mature new technologies infrastructure of alternative fuels (CNG, Methanol, Hydrogen) availability of modified / synthetic fuels and lubricants costs and customer acceptance

• For the Internal Combustion Engine (ICE)the diversity of solutions and technologies will continue.

Future scenario in Europe


EUCAR 2002

Future scenario in Europe

Conventional (MPI)

Mar

ket

Sh

are

(%)

100

80

60

40

20

IDI

InternalCombustion Engine

starter / battery

Model Year 2000 2005 2010 2015 2020 Year 2020

Hybrid

Fuel Cell

Future Share of: Engines (Passenger Cars) Fuels

Oil basedfuels

•Improved fuels•Clean fuels•Designed fuels

Gas based fuels

•CNG•GTL fuels

Bio-fuels

Hydrogen

GASOLINE

DIESEL

Gasoline/Diesel Engine

with Starter/Generator with HCCI

+ supercharging DI-Diesel + Starter/generator

and VVA / multiple injection?

w/o HCCI

with CAI+ supercharging+ Starter/generator

DI-Gasoline and VVA ?and/or VCR ?and combinations

w/o CAI

Documents

André RAULT General Secretary Mid and Long Term Powertrains Evolution Associated Fuels