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CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
Project title: CORE –
CO2 REduction for long distance transport
Coordinator Johan Engström, Volvo
Status May 2015
Internal Combustion Engines ERTRAC Workshop, 2 June 2015
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
CORE - CO2 REduction for long distance transport
Current status: Start date 1st of January 2012 Coordinator: VOLVO Total number of partners: 16 Partners: Volvo, Daimler, CRF, Ricardo, Federal Mogul, Honeywell, IAV, University
of Hanover, University of Milano, University of Turin, Rhodia, Umicore, Chalmers, Johnson Matthey, Metatron, JRC,
Core Group: CRF, Daimler, VOLVO, IAV, Ricardo OEM: CRF, Daimler, VOLVO Duration: 4 year Budget Total budget ~17 000 kEuro, EC contribution up to ~9 000 kEuro
Project general information
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
Structure
SP A1 Daimler
Diesel engine optimized for
HEV
SP A2 Volvo
High efficiency Diesel engine for long haul
SP A3 CRF
Advanced combustion
system for Diesel and NG HD engines
SP A4 Final assessment
SP B1 Friction Reduction
SP B2 Aftertreatment systems
SP D
Pr
ojec
t Man
agem
ent
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
Motivation q Improved fuel efficiency for long haul transport
q Development of innovative and competitive solutions for HD engines with a market introduction target before the end of this decade.
Objectives
q CO2RE will focus on developing highly efficient drivelines for long distance transport contributing to a 15% reduction in fuel consumption
Milestones plan
q The main result will be achieved during the last year, and validated by complete powertarin test and vehicle simulation in real life application jointly with JRC
Motivation / objectives / milestones
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
Roadmap towards 11-18% reduction in fuel consumption
Fuel Consumption
Euro V MY2009
6-9%
To comply with Euro VI std
Friction, EAS 11%
Engine Platform
Hybridization
3-5% 2-4%
18%
Main objective – roadmap
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport Status report on progress and deliverables
• CORE has been on-going for nearly 3,5 years. • The progress of work is almost according to the plan, no major
changes.
• Fuel efficiency has been obtained in all sub-projects.
• CORE target of 15% reduction has been achieved for MD engine in a hybrid application.
• In-progress optimisation of engine system in the different sub-projects
• Vehicle simulations, assessment of CORE developed technologies, with objective to investigate other pathways to the target of 15% CO2 reduction
• External review has been performed after the 36 months. Follow up in-progress.
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
Fuel Consumption
Euro V MY2009
6-9%
To comply with Euro VI
std
Friction, EAS 11%
Engine Platform
Hybridization 3-5% 2-4%
18%
Achivied results in respecte to CORE –roadmap
Engine platform: • Results: 5-7% (CNG,MD,HD) • In-progress: Engine system optimisation
Hybridisation Results: over 6% In-progress: energy strategies
EATS Results: improved SCR performance in lower temperature range In-progress: duty cycle optimisation
Friction Results: about 1% on MD engine In-progress: 2nd test with new piston ring design
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport Main technical challenges and solutions in the project Main technical development • Increased peak cylinder pressure, above 230bar • Downspeeding
• High performance turbo system, variable geometry and dual stage technologies
• Variable vale technologies, advanced strategies and transient operations
• Aftertreatment improved NOx conversion at lower temperature range
• Reduced engine friction
Challenges for sub-development are that novel design need and should meet • improved performance, • durability and robustness, • cost effective
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport Main technical challenges and solutions in the project
Concept „VRT“ = Variable rotary turbine - variability of segment angle and flow area at turbine inlet via rotating tongues
Solutions: Examples of new procurement of prototype hardware
New piston rings – lower friction Rings profile changed Reduce ring tension Increased skirt/bore clearance Reduced viscosity oil Low friction coating
High efficiency, Dual Stage Turbo system, containing novel design, such as low solidity airfoil diffusers, radial-axial turbines configuration and ball bearings technology.
Variable Valve Attenuation – Enable Miller cycle and internal EGR for reduce of Nox emissions
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
Currently on-going: full engine tests – application
concept test – optimisation engein & EATS Vehicle test in dyno
DOC
DPF
AdBlue
Fuel
SCR
AMOX
ETC&WHVC cycles on dyno rolling bench at JRC
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
• Vehicle type:
– Heavy Duty 40t
– Tractor with semitrailer
• Mass: 40,000 kg
• Tractor tyre rolling radius: 0.522 m
• Drag Coefficient
– Cd.A = 5.82 m2
• Tyre friction factor: 0.0058
Volvo – Vehicle Model Data Summary
Assessment of CORE technologies by vehicle simulations performed by Ricardo, example Volvo
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport Expected final results: exploitation and impact
• Main benefits from final results: Demonstration of sub-technologies performance and concepts potential that can
reduce the fuel consumption in near time frame. This is beneficial and competitive for the OEMs
• How will these results be used? Knowledge and part of the novel hardware /concept will be put in production
• Impact of these results on future research and development Increased efficiency of the engine → lower the exhaust temperature → higher
demand on EATS, specific on lower temperature
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
Research issues – more potential to reach based from CORE
• Physics: - Heat management (thermodynamics, heat rejection etc)
• Simulations tool: – Improved precision • Sub-technologies: -EATS, improved efficiency at lower temperatures
- Variable valve applications
• Concepts -Down speeding, hybridisation, PCP above 250bar, transmission
• Powertrains -Intelligent powertrains – increased flexibility and further integration of engine, EATS, hybrids, WHR. Require better simulations models (physical), better sensors & regulators and control strategies
CORE - Collaborative Project
Johan Engström / VOLVO Internal Combustion Engine - ETRAC Workshop 2 June 2015
CO2 REduction for long distance transport
Thank you