Engine Oil Requirements from an OEM Point of View - umtf.de. Hirano - Engine Oil... · –Chosen from Commercial Products from the European Market with known Performance Claims –ACEA

Engine Oil Requirements from an OEM Point of View

- Prevention of Diesel Turbocharger Compressor Deposit -

4th – 5th April, 2017 in Stuttgart UNITI Mineral Oil Technology Congress

Satoshi Hirano

TOYOTA MOTOR CORPORATION Paul Decker-Brentano

TOYOTA Motorsport GmbH

4th - 5th April, 2017 UNITI Mineral Oil Technology Congress 2017 in Stuttgart 1

Agenda

1. Background

2. Mechanism of Diesel Turbocharger Compressor Deposit

3. Test Engine and Test Conditions

4. Reference Engine Oils

5. Test Results and Discussion

6. Summary

7. Acknowledgements


Agenda

1. Background





6. Summary

7. Acknowledgements


1. Background

• Turbocharger is a requisite element for modern diesel engines to meet ;

– Stringent emission regulations

– Engine performance requirements such as fuel economy, power output

• Turbocharger cannot get away from simple physics

– PV = nRT

– Increasing engine performance requires higher outlet pressure and results in higher outlet temperature


1. Background


NOx

PM DPF

SCR

DI + NA DI + TC

DI +TC + Common Rail EGR

Fig. 1 Trade-Off between NOx and PM, and Improvements by Engine/After-treatment Hardware

Turbocharger is an essential device to meet emission regulations.

1. Background


After-Treatment

Mu

ffle

r

Compressor Turbine

Exhaust Intake D-Throttle

Blow-By Intercooler

Air Cleaner

Temperature (T1) Pressure (P1)


Fig. 2 Diesel Engine with Turbocharger

1. Background


Turbine Side Compressor Side

Fig. 3 Cross Section of Turbocharger

Recover Exhaust Gas Energy and Utilize it to compress Intake Air

PV = nRT

When the inlet air is compressed,

its temperature goes up.

Higher Temp

1. Background


Fig. 4 Comparison of Typical Torque Curves and Turbocharger Map

Turbocharger Map

Pre

ssu

re R

atio

Air Flow Rate Engine Speed

Torq

ue

/L

Engine Torque Curve

Boosted by Turbocharger

1. Background


Torq

ue

Engine Speed

Fig. 5 Engine Operation and Compressor Outlet Temperature (T3)

Compressor Outlet Temp. (T3) Drivability Fuel Economy

Maximum Power Output

Turbocharger Efficiency

Turbine Housing Water Cooling Jacket

Bearing Housing

Compressor Housing Variable Nozzle

1. Background


Fig. 6 Deposit Formation in Turbocharger Compressor

Intake Air +

Ventilation Gas with Oil Mist

Concerned Areas for Deposit Formation

Diffuser

Diffuser

Scroll

Agenda

1. Background





6. Summary

7. Acknowledgements


2. Mechanism of Diesel TCC Deposit


Fig. 7 IR Analysis and Elemental Analysis of New Oil and Deposit

a.u. = arbitrary units

2000 10001500[cm-1]

New oil

Deposits

Tra

nsm

itta

nce

[a

.u.]

Oxidation degradation

components: 1710 cm-1

S

Ca

Zn

P

MoNew oil

S

Ca

Zn

P

Mo

Fe, Cu, Si etc. Deposits

Similar Composition

No Oxidation

Simply Concentration of Oil + Soot



GC

Sig

nal

300 400 500 600 700 800

Boiling Temp.(oC) by GC Distillation

New Engine Oil

Evaporated portion

Extracted Oil Portion from Deposit

Fig. 8 Distillation Characteristics by GC Distillation Analysis (ASTM D6352)

Adjustment of scale

High temperature and high flow speed In the compressor

Compressor Diffuser Surface



Small particle of soot-containing engine oil from crankcase ventilation

Evaporation

Concentrated and thickened

Fig. 9 Mechanism of Deposit Formation

It was confirmed that the concentration of sooted oil by evaporation is the major mechanism of deposit formation in the turbocharger compressor. (SAE 2013-01-2500)

Attaches on surface

Deposit formation



Less Residual Base Oil by Evaporation

Thickening Effects

Base Oil Volatility Engine Oil Formulation Factors

Fig. 10 Cause Effect Diagram of Turbocharger Compressor Deposit

Soot Accumulation in Engine Oil

Compressor Outlet Temperature (T3)

Engine Operation Factors

Solidification of Oil Mist Particle

Viscous Components in Engine Oil*

* Not confirmed yet



T3 T

em

pe

ratu

re

Soot Concentration

No Deposit

Deposit

T3 T

em

pe

ratu

re

GC Distillation (496oC)

No Deposit

Deposit

Soo

t C

on

cen

trat

ion

GC Distillation (496oC)

No Deposit

Deposit

Fig. 11 Trade-Off Diagrams of Three Major Deposit Factors

Oil Soot Concentration

T3 Temperature

Engine Oil Volatility

Agenda

1. Background





6. Summary

7. Acknowledgements



• Test Engine – Toyota 1KD-FTV – Inline-4, 2,982 cc – Max Torque = 305Nm @ 3,600rpm (w modified ECU for test) – Max Output = 118KW @ 3,600rpm (w modified ECU for test)

• Test Cycle (Steady State) – Duration = 100hrs – Engine Speed = 3,600rpm – Engine Torque = 290Nm – Turbocharger Compressor Outlet Temperature = 190oC – Soot at EOT = 3.5 +/- 0.5% (CEC L-82-97 (UV))




Fig. 12 1KD-FTV Engine Bench at ISP

Engine Bench Build Up Intake Air Conditioner



Compressor Turbine

Exhaust Intake D-Throttle

Blow-By Intercooler



Facility Exhaust System

Inlet Air Conditioner

Fig. 13 1KD-FTV Engine Bench at ISP

Agenda

1. Background





6. Summary

7. Acknowledgements



• Reference Engine Oil Selection – Chosen from Commercial Products from the European Market

with known Performance Claims – ACEA Sequences, OEM In-house Specifications

• Low Reference Engine Oil – ACEA C2 – SAE 0W-30

• High Reference Engine Oil – ACEA C3, API SM/SL – BMW LL-04, dexos2, MB229.31/229.51/229.52, VW502 00/505 00/505 01 – SAE 5W-30


Agenda

1. Background





6. Summary

7. Acknowledgements



• Test Matrix

– Ran 4 High Reference Oil tests and 3 Low Reference Oil tests with randomized test order

– The same engine hardware was used for all tests

– Turbocharger was replaced with new one for every test

– The turbocharger unit was disassembled and rated by visual cleanliness rating




High Reference Oil Test

Low Reference Oil Test






Fig. 14 Test Sequence



Fig. 15 Turbocharger Deposit Rating Areas



Fig. 16 Turbocharger Deposit Rating Scale



Fig. 17 Turbocharger Deposit Examples



Fig. 18 Average Oil Consumption



Fig. 19 Soot Concentration at the EOT Used Oil



Fig. 20 Turbocharger Deposit Ratings

Average S. Deviation

Average (1+2) 8.4 1.2

Average (1+2+3+4) 5.5 1.9

Average 1+2+0.5*(3+4) 6.5 1.4

Average S. Deviation

Average (1+2) 66.1 5.9

Average (1+2+3+4) 61.5 6.4

Average 1+2+0.5*(3+4) 63.0 6.1



Fig. 21 Soot Concentration and Deposit Rating

Agenda

1. Background





6. Summary

7. Acknowledgements


6. Summary

• The mechanism of the turbocharger compressor deposit was proposed based on the deposit analysis and prove-out tests. (see details in SAE 2013-01-2500)

– Engine oil volatility, soot concentration, and turbocharger compressor outlet temperature are 3 key factors.

– Viscous components in engine oils may have the similar impact for oil thickening.

• Based on the mechanism, the preventative engine test for protecting turbocharger was developed.

– Anticipating more demands on improving over-all engine performance by increasing the boost by turbocharger.


6. Summary

• High and Low Reference Oils were chosen from commercially available products in the European market.

– High Reference : ACEA C3 + OEM specs, SAE 5W-30

– Low Reference : ACEA C2, SAE 0W-30

• The test procedure could discriminate high and low reference oils with repeatable results.

• This test will provide good tool to formulate better engine oils suitable for future diesel engines at improved performance level.


Agenda

1. Background





6. Summary

7. Acknowledgements


7. Acknowledgements

ISP Salzbergen GmbH & Co. KG

Dr. Tono Nasch

Managing Director

Mr. Michael Schulz

Manager Engine and Vehicle Testing

Mr. Johannes Villinger

Project Engineer, Engine Testing


Thank you for kind your attention !


Documents

Engine Oil Requirements from an OEM Point of View - umtf.de. Hirano - Engine Oil... · –Chosen from Commercial Products from the European Market with known Performance Claims –ACEA