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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Optimization of EngineOptimization of Engine--out Emissions from out Emissions from a Diesel Engine to meet Tier2 Bin5 a Diesel Engine to meet Tier2 Bin5
Emission LimitsEmission Limits
August 7, 2008, Detroit, MichiganAugust 7, 2008, Detroit, Michigan
SeungSeung--SukSuk
Yoon*, Yoon*, HaeHae--WookWook
Lee, Lee, YoYo--Han Chi, Han Chi, KumKum--Jung YoonJung YoonPassenger Diesel Engine Test TeamPassenger Diesel Engine Test Team
PowertrainPowertrain
R&D Center, HyundaiR&D Center, Hyundai--Kia MotorsKia Motors
2
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
The US Diesel MarketFuel price higher than everStrong demand for good mileage (CO2 cut-down)Growing interest in passenger diesel vehicle
Challenge for US Diesel MarketStringent emission regulation
Strategy to meet Tier2 Bin5 Emission StandardEngine Hardware improvementCalibration optimizationDeNOx after-treatment
Summary
Contents
2/232/23
3
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
US Diesel Market
Forecast Diesel Demand for US MarketExcellent driving performance and good mileageIncreasing demand
Forecasted by BOSCH (2008)
3/233/23
4
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Barriers to US Diesel Market
Stringent Emission LimitTier2 bin5 standard requires extremely low NOx levelEmission level should be satisfied even at high altitude Various diesel fuel qualities have to be considered
Customers Expectation for Excellent NVH (Noise, Vibration and Harshness)
Outstanding Fuel Efficiency to attract drivers
Not only extremely low but robust emission levelwith excellent NVH behavior and outstanding fuel efficiency
4/234/23
5
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Base Engine
Engine Type V-6 DOHC 4VDisplacement (cc) 2,959Bore x Stroke (mm) 84 X 89Compression Ratio 17.3
FIE System 1600bar Piezo
Air Handling E-VGT, Variable Swirl System
Glow System ISS with GCUEmission Target EURO ⅣExhaust System DOC+DPF
Base Engine
V6 3.0 litre Diesel Engine (Euro4)
5/235/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Electric Actuator VGT
CGI Cylinder blockEGR Cooler with
Electronic EGR Valve
Variable Swirl ControlSystem
2nd
Common Rail with Piezo
Injector
Technical Features of Base Engine
6/236/23
7
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Target Vehicles
Heavy SUVs : Veracruz and Mohavediesel and gasoline engines for domestic and European marketscurrently gasoline engine only for US market
VERACRUZ (Hyundai): -
Domestic (2006), Europe (2008)-
Front Wheel Drive-
Max Power/Troque: 176KW / 451Nm
MOHAVE (Kia): -
Domestic (2008)-
Rear Wheel Drive-
Max Power/Troque: 184KW / 540Nm
7/237/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
0.07
FTP NOx
(g/mile)
FTP
Part
icul
ate
Mat
ter (
g/m
ile)
0.10 0.20 0.30 0.35 0.40 0.45
0.01
0.02
0.03
0.04
0.05
0.06
0.50 0.55
Tir2 bin5
Tir2 bin8
Tir2 bin10
Base Engine
Emissions : Challenge for US Market
PM(-
80 %)
NOx
(-
90 %)
8/238/23
9
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Strategy to meet Tier2 bin5
Strategy to meet NOx and PM requirement
Hardware Improvement1. combustion-
chamber, fuel injection, air handling
2. EGR -
switchable cooler
-
fast and precise actuator3. exhaust after-treatment -
DPF and SCR
Optimization of Operating Area acc. Emission Cycle1. gear reduction ratio
Calibration Optimization1. best trade-off of emissions, NVH and fuel efficiency2. DoE
calibration: modeling of mapping parameter
3. transient calibration at engine test bench for FTP cycle
9/239/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Hardware Improvement
Hardware Improvementengine-out emission: combustion / air handling / EGRtail-pipe emission: after-treatment
Combustion : chamber: 1800bar: piezo
injector
after-treatment: DPF and SCR
Air handling: turbocharger: intake manifolds: swirl control
EGR: cooler: valve actuator
10/2310/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Variant 1Variant 2Variant 3Variant 4
Combustion Chamberlower compression ratiobowl shape, mixing pattern, and swirl motion
H/W Improvement –
Combustion (Chamber)
numerical simulation of combustion pattern
Combustion Chamber
11/2311/23
12
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
FIEBosch 3rd Generation 1800bar Common Rail System
CRS3.2 Piezo Injector-
higher injection rate and efficiency-
precise injection control for robust emission behavior-
smaller tolerance of injection quantities-
multiple injection up to 5 shots per cycle
Re-matching with the New Combustion Chamber -
nozzle hole number / diameter / length-
hydraulic flow rate
H/W Improvement –
Combustion (Fuel Injection)
12/2312/23
13
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Air HandlingPlastic In-manni-
improved intake air charging efficiency-
uniform EGR distribution Head and Swirl Valve-
optimization of intake air charge and swirl intensity
H/W Improvement –
Combustion (Air Handling)
plastic in-manni
DC-motorswirl valve
Optimized
Base
Air and EGR Distribution
13/2313/23
Cylinder Number
14
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
TurbochargerCompressor-
enhanced boost potential during cycle operationby wheel/housing shape optimization
Turbine- low inertia-
improved efficiency by shape optimization of guide vanes and wheels
H/W Improvement –
Combustion (Turbocharger)
14/2314/23
Vane
Compressor wheel
Compressor Housing Turbine wheel
Turbine Housing
15
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
H/W Improvement –
EGR Cooler
EGR SystemCooler-
U type structure with higher cooling efficiency-
switchable (bypass)Actuator-
DC-motor type valve-
model based charge control : fast response in dynamic operation
DC-motorEGR valve
EGRcooler
Optimized
BaseCoo
ling
Effic
ienc
y
15/2315/23
16
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
H/W Improvement –
Exhaust After-treatment
DPF (Diesel Particulate Filter)catalysed DPFregeneration strategy considering filter durabilityand fuel economyPM filtering more than 90% in FTP Cycle
SCR (Selective Catalytic Reduction)oxidation reduction reaction of NH3 and NOxurea Injection, mixer, and catalystdosing strategy optimized for high NOx conversion ratioand minimum ammonia slipNOx reduction more than 80% in FTP cycle
16/2316/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Calibration Optimization
Calibration ProcedureSimulation of Emission Cycle-
Identification of engine operating area in FTP cycle
Steady State Calibration : DoE (Design of Experiment) -
modeling of engine mapping parameters
-
optimization for the best trade-off of emissions, NVH and fuel economy using a model function
Transient Calibration-
emission cycle test at the engine test bench
-
validation and re-calibration of mapping parameters
17/2317/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Optimization for Emission Cycle
Simulation of Emission Cyclesimulation of vehicle operation at engine test bench-
input of transmission, gear shift pattern and the vehicle data-
engine operation to follow vehicle speed / load in emission cycle
18/2318/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Optimization for Emission Cycle -
FTP
FTP Emission Cycleengine operation area was optimized in FTP emission cyclepre-evaluation prior to vehicle test : consider different transmissions and gear reduction ratios : determine the best engine operation area for our engine
Engine Speed
Fuel
Qua
ntity
T/M v1T/M v2
FGR 1 FGR 2
19/2319/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
DoE
Optimization of Engine Mapping data
Steady State CalibrationDoE calibration procedure at engine operation area
Test Plan
Test Run
Modeling
Optimization
Map Calculation
Validation
20/2320/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Optimization of Transient Calibration for FTP Cycle
Transient Calibration for FTP Cycle Operationvalidation and recalibration of steady state optimization-
H/W, calibration optimization: 50% reduction of engine-out NOx-
SCR system: 80% reduction of tail pipe NOx
21/2321/23
Engine Speed
Engine-out NoxTail-Pipe NOx
Ammonia Slip
22
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Final Results
FTP NOx
(g/mile)
FTP
Part
icul
ate
Mat
er (g
/mile
)
0.10 0.20 0.30 0.35 0.40 0.45
0.01
0.02
0.03
0.04
0.05
0.06
0.50 0.55
0.07
Tir2 bin5
Tir2 bin8
Tir2 bin10
Base Engine
>90% Reduction- CPF
80% Reduction- SCR
50% Reduction -
H/W and S/W
22/2322/23
23
The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Summary
Tier2 Bin5 Limit have been successfully fulfilled
Strategy to Meet Tier2 Bin5 Emission Limitscombustion refinementcalibration optimization at steady state and transient operationgear reduction ratio re-matchingafter-treatment consisting of DPF and SCR
Future Workrobust calibration in terms of emission, drivability and NVH, covering wide range of fuel propertiesfurther optimization at high altitude
23/2323/23
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The 2008 Deer Conference, 4The 2008 Deer Conference, 4--7th August7th August
Thank you !!E-mail: [email protected]