INGAS INtegrated GAS Powertrain B. Hüchtebrock, FEV 1 INGAS Sub Project A3 „Boosted Lean Burn Gas Engine“ SP A3 Change of DoW Summary & Rational Approach

INGAS INtegrated GAS PowertrainINGAS INtegrated GAS Powertrain

B. Hüchtebrock, FEVB. Hüchtebrock, FEV 1

INGAS Sub Project A3

„Boosted Lean Burn Gas Engine“

SP A3

Change of DoW

Summary & Rational Approach

01/06/2010



SummarySubproject A3 was planned and started with the common understanding between all A3 partners and CRF (as main IP coordinator) that a parallel approach in terms of base engine will be pursued.This means: FEV uses a 1.9l Diesel based engine

GMPT-G uses a 1.6l Gasoline based engine (parallel study)

Rational for the parallel approachThe "parallel study" which focuses on the investigation of the potential of a 1.6l CNG (gasoline-based) engine was well aligned and related to the main stream activities (1.9l Diesel engine) since it follows the same boundary conditions in terms of a high-boost and ultra-lean combustion concept. From base engine perspective the 1.6l gasoline based engine offers an increased peak pressure capability of about +30bar – i.e. improved suitability for the combustion concept. Also the same aftertreatment system / philosophy was planned to be used for both engine concepts. The mainstream activities are being performed on the basis of a 1.9l Diesel engine (as base engine in the light duty vehicle Opel “Zafira”). This engine offers great capabilities to cope with the expected increased cylinder pressures since it is principally laid out for higher maximum allowable boost and peak cylinder pressures as well as compression ratio.But, it has also some (considerable) disadvantages which may prevent from achieving the maximum feasible CO2-reduction.



Summary - continuedTherefore it was decided to pursue an alternative technical path in parallel to the main concept to evaluate the potential (advantages) of a smaller gasoline based engine as there are:

- Lower weight

- Lower friction / parasitic losses (e.g. bearing losses)

- Lower cost

- Combustion chamber better suited for gasoline / CNG combustion

- More flexibility in generating charge motion and gas exchange (dual independent cam-phasers)

- Higher possible engine speeds (compensates for smaller displacement and lower torque and lower peak-pressures) The adopted 1.6l gasoline-based engine concept allows also the evaluation of the benefit of downsizing.



Summary - continued

The potentials of the two concepts with their inherent advantages / disadvantages as mentioned above could then be compared with regard to (in vehicle) performance, F/C and emissions.Both paths could not be realized in one single engine concept for cost and technical complexity reasons.This approach has been reported in the status reports from beginning and was also presented during the „12 Month Meeting in Naples“ in Nov. 2009 – the approach was never questioned until EC reviewers commented on the 12 months report that the work on the 1.6l gasoline engine might not be accepted.IssueThe alternative „parallel“ path of using a 1.6l Gasoline based engine was not taken over from the initial application documents into the final official description of work (DoW) (ANNEX I).The mutual understanding however was that the DoW has to be interpreted for both base engines (using a Diesel and a Gasoline base engine). However, this was only communicated verbally!Now, after the feedback on the 12 months report the Commission rejected the activities / support for the parallel study „1.6l gasoline based engine“ as being „extra content“. Even the attempt to clarify / justify the importance of the 1.6l gasoline based apporach as described above was not accepted (Meeting at Brussels, March 31st). Taking this rejection into account different project options for GMPT-G were discussed and parts of the work at GMPT-G had to be re-evaluated for the remaining project duration. As a reaction of the changed boundary/funding conditions GM is unfortunately forced to pull out all 1.6l gasoline engine based activities .



GMPT-G options for EU funded InGas Project: As discussed and rated by GMPT-G internally (Apr. 23rd 2010)

Option 1: Continue w/o funding -> underfunding 400k€-X -> recommendation: No!

Option 2: Change all activities to 1.6 MGE- 2 additional MGE needed (not available; IP issues) -> recommendation: No!

Option 3: change to 1.9l Diesel -> no use (redundant work) -> recommendation: No!

Option 4: FEV continues with 1.9l + basic support by GMPT-G acc. to DoW / change of DoWno further work possible on 1.6l MGE (rejection of 1.6l parallel study by EU Project

Officer; Mar. 31st 2010)!

Option 5: STOP all activites and exit project. -> recommendation: No!

Overall recommendation: Option 4DoW = Description of Work (official contract ANNEX1)MM = Man MonthsMGE = Midsize Gasoline Engine



In a following step the affore mentioned project options were dicussed in a face to face meeting between FEV and GMPT-G (Apr. 28th 2010)

Common understanding is that „Option 4“ is the most favourable option. Based on this, the remaining activities according to the DoW (ANNEX1) were modified accordingly.

Next stepsA document which describes the modifications of the DoW will be prepared by FEV. Revision of this document by GMPT-G and FEV is planned for May 7th. (phone conference).The final document (notice of change) should then be discussed with CRF (IP Coordinator) during the „18 month InGas Meeting in Paris“ (May 20th/21st).Finally the notice of change document should be discussed with the PO (Project Officer – representative of the European Commission), CRF, FEV and GMPT-G to get approval.

DoW = Description of Work (official contract ANNEX1)IP Coordinator = Lead Coordinator of the InGas ProjectCRF = Centro Ricerche Fiat



INGAS Sub Project A3

„Boosted Lean Burn Gas Engine“

SP A3

Change of DoW

Details

01/06/2010



Result of 12 M-Review-Meeting / Brussels:

Statement of PO and reviewers, that parallel investigations concerning the diesel-engine based approach (1.9 l) and the gasoline-engine based approach (1.6 l) are not in line with the DoW.

Clear request for clarification of the further proceeding in the SP A3.

A3-internal decision (GMPT-G / FEV):

The activities regarding the gasoline-based engine approach will be stopped.

GMPT-G intends to proceed in such an extent, that all outstanding deliverables respective essential support to the A3-partners will be reached. This includes a transfer of work packages as well as budget transfer between A3 partners.

Conclusion:

The following slides contain a suggestion for an alternative DoW. In detail a possible shift of MM‘s (task related) from GMPT-G to A3 partners is mentioned.

Change of DoW in SP A3Background



Change of DoW in SP A3WP A3.1







Task A3.1.1:

No changes; completed

Task A3.1.2:


Task A3.1.3:

GMPT-G will support FEV using 1 MM

Task A3.1.4:

No changes

Task A3.1.5:











Task A3.2.1:


Task A3.2.2:

No changes

Task A3.2.3:

No changes

Task A3.2.4:

2,5 MM‘s are completed. Remaining 2,5 MM‘s will be used.










Task A3.3.1:

No changes

Task A3.3.2:

No changes

Task A3.3.3:

No changes

Task A3.3.4:

No changes

Task A3.3.5:

2 MM‘s had been used (check of applicability of the series EMS for the 1.9 l engine). Transfer of 5 MM‘s to FEV regarding DSPACE-activities.

Task A3.3.6:

No changes







Task A3.4.1:

No changes. 2,4 MM‘s will be completed by GMPT-G. Package study and package recommendations finally will be documented.

Change: FEV buys vehicle. GMPT-G transfers the corresponding budget.

Task A3.4.2:

GMPT-G transfers 13 MM’s.

Task A3.4.3:

GMPT-G transfers 3 MM’s.



Task Content / Description MM (DoW)

MM (Done)

Open (June 2010)

Remaining at GM

Transfer to FEV

3.1.3 Support Gas Storage => FEV 1 0 1 0

3.1.4 Draft Packaging 6 4 2 0

3.2.4 Packaging 5 2,5 2,5 0

3.3.5 Control Strategy 7 2 0 5

3.4.1 Vehicle Procurement 2,4 1,9 0,5 0

3.4.2 Vehicle Calibration and Testing 13 0 0 13

3.4.3 Potential Evaluation 3 0 0 3

Change of DoW in SP A3Summary of MM-transfer from GMPT-G



DA Content / Description

3.3 1 Engine will be delivered (if needed)

1 Gear box (2nd gear box will be delivered, if needed)

3.8 Vehicle Procurement

Anticipated solution: FEV will buy the vehicle

3.9 Report (Potential Evaluation) Will be done by FEV

Change of DoW in SP A3Open Deliverables @ GMPT-G



Change of DoW in SP A3Consumables and other major cost items [kEURO] @ GMPT-G

Description Plan (DoW) Used Open (June 2010)

Remaining at GM

To be transferred

Engines 180 153 0 27

Gearboxes 20 0 10 10

Spare Parts 40 17 3 20

Fuel 40 3 0 37

Workshop 60 43 17 0

CAD / CAE Stations 30 0 0 30

Vehicle Testing 50 0 0 50

Bench Engine Testing 60 60 0 0

Transfer of consumables/cost items preferably should be done to FEV, because it is closed linked to work/MM-transfer.

Documents

INGAS INtegrated GAS Powertrain B. Hüchtebrock, FEV 1 INGAS Sub Project A3 „Boosted Lean Burn Gas Engine“ SP A3 Change of DoW Summary & Rational Approach