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GS/ENS-NA | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
2014 DOE Annual Merit Review – ACCESS
Hakan Yilmaz(PI) Li Jiang (Co-PI), Oliver Miersch-Wiemers (Co-PI)
Advanced System Engineering Gasoline Systems, Robert Bosch LLC
Award: DE-EE0003533 Project ID: ACE066
2014 DOE Vehicle Technologies Program Review
Advanced Combustion Concepts - Enabling Systems and Solutions (ACCESS) for High Efficiency Light Duty Vehicles
Arlington, Virginia June 19th, 2014
This presentation does not contain any proprietary, confidential, or otherwise restricted information 1
2014 DOE Annual Merit Review – ACCESS
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Technical Accomplishments
• Summary and Future Work
2
Gasoline Systems | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
2014 DOE Annual Merit Review – ACCESS Budget Barriers and Targets
Timeline Partners
US Department of Energy Robert Bosch LLC
AVL University of Michigan Stanford University
Emitec
Targets: The project targets 25% fuel efficiency improvement to support energy independence and CO2 reduction, while demonstrating SULEV emissions in a commercially viable system.
Barriers ! System complexity of advanced combustion ! Stringent emission requirements ! Fast adaptation of technology in the market
$24,556,737 – Total Project Budget $11,953,786 – DOE Funding $12,602,951 – Partner Funding
$19,227,349 – Actual expenditure (12/2013) $9,144,821 – DOE Funding $10,132,528 – Partner Funding
$5,279,388 – Remaining (12/2013) $2,808,965 – DOE Funding $2,470,423 – Partner Funding
Phase 3 (1.5 yrs)
Application Implementation
and Vehicle Demo
Phase 1 (1.5 yrs) Concept
Fundamental Research
Phase 2 (1 yr)
Development Technology
Development
Phase 3 Application
Implementation, Vehicle Demo
Phase 1 Concept
Fundamental Research
Phase 2 Development Technology
Development 9/30/2010- 02/28/2012
03/01/2012- 05/31/2013
06/01/2013 - 12/31/2014
GS/ENS-NA | 6/19/2014 | © 2014 R obert B os ch LLC and affiliates . All rights res erved. 3
GS/ENS-NA | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
2014 DOE Annual Merit Review – ACCESS Engine & Controls Development Phase III Vehicle Implementation
Engine Hardware Prototype IIb Controls Implementation
Prototype cylinder head design and cam profile switching mechanism upgraded and compression ratio adjusted for target combustion concepts.
• Target Multi Mode Combustion Engine is based on the GM Ecotec 2.0 L DI Turbo platform
• Base Engine HW design, improvements for target engine configuration and engine build led by AVL
• Engine Management System design, engineering and implementation led by Bosch
• Aftertreatment System design and emission concept led by Emitec
Build completed for development vehicle. Prototype engine installed and vehicle available for application, emission and fuel economy optimization with advanced combustion modes.
4
Advanced combustion control strategy, capable of real-time ECU implementation, demonstrated on engine and evaluated in development vehicle.
CR 11.4
GS/ENS-NA | 6/19/2014 | © 2014 R obert B os ch LLC and affiliates . All rights res erved.
2014 DOE Annual Merit Review – ACCESS
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Technical Accomplishments
• Summary and Future Work
5
Targets
System Complexity Technology to the Market Stringent Emissions
Demonstrate 25% fuel efficiency improvement over chosen vehicle baseline (G M HF V 6 in C adillac C T S ) Meet S ULE V emiss ions to demonstrate LE V 3 emiss ion capability K ey systems and controls implemented and concept is commercially viable
Demonstrating S ULE V • T he advanced combustion
concepts chosen show the potential to meet S ULE V with conventional T WC system.
• E xhaust after treatment system design (s izing and loading of the T WC ) was performed based on experimental dyno data and s imulation.
• Vehicle emiss ion optimization is focus of the current project phase.
E nabling Technology • downsizing with turbo charging
and fuel direct injection • variable valve timing and profile
switching • cooled high pressure E G R with
sensor based closed loop control • combustion control with in-
cylinder pressure sens ing • injector individual adaptive fuel
metering • estimated total system cost within
current market targets
P roducts • E ngine C ontrol Unit (E C U) with
combustion controls
F ully implemented advanced combustion controls in a production level E C U, meeting production A-sample requirements (no rapid prototyping tools required for OE M application).
• cooled E G R sub system • combustion pressure sensor
commercially attractive technology made available meets 2025 emission goals
2014 DOE Annual Merit Review – ACCESS – Relevance
6
Relevant research and development areas to meet fuel economy and emission targets
• Advanced combustion control modeled and integrated for HC C I and S AC I
• C ontrol s tability limit investigated (C F D) • E ngine Management S ystem configuration
completed and concept implemented • Hardware des ign finalized and prototype
engines and vehicles built
E miss ion Development
Vehicle Integration
C ontrol Application
P hase 1 (R esearch)
P hase 2 (Development)
P hase 3 (Integration)
F uel E fficiency - C ontributors
J un 1, 2013 Dec 31, 2014
downsizing DI TC
variable cam timing/lift
advanced combustion
control
start stop
E ngine/Vehicle C alibration
Performance of the system and combustion concept demonstrated on engine dyno and vehicle.
2014 DOE Annual Merit Review – ACCESS – Relevance
7
2014 DOE Annual Merit Review – ACCESS
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination • Technical Accomplishments
• Summary and Future Work
8
2014 DOE Annual Merit Review – ACCESS – Approach
Baseline Powertrain: 3.6L V6, PFI, 6 Speed MT with SI Combustion
Target Powertrain: 2.0L I4, DI, Turbo, 6 Speed MT with Multi-Mode Advanced Combustion and Start-Stop System
Enabling Systems and Components
9
Vehicle Demonstration
2014 DOE Annual Merit Review – ACCESS – Approach
C ombustion C oncepts
C ontrol S trategies
S oftware Integration S trategies C ombustion C oncepts
E ngine system design C ombustion concept evaluation
w/ C F D s imulations and experiments
C ontrol S trategies E ngine Management S ystem design C ontrol s trategy development w/ rapid prototyping
S oftware Integration E ngine C ontrol Unit des ign C ontrol algorithm integration into B osch E C U software
Multidisciplinary T eam Approach
Vehicle Demonstration E miss ion and aftertreatment strategy optimization Vehicle s imulation (fuel economy and emiss ions) In-vehicle advanced combustion experience
10
GS/ENS-NA | 6/19/2014 | © 2014 R obert B os ch LLC and affiliates . All rights res erved.
2014 DOE Annual Merit Review – ACCESS – Approach
Phase
I P
hase II
Phase III
• C omplete s imulations demonstrating the feas ibility of proposed technologies
• E valuate fuel economy and emiss ion performance of HC C I combustion with prototype I engine
• E stablish control architecture for HC C I combustion
• Demonstrate fuel economy and emiss ion performance with prototype II engine
• C omplete integration of controls for HC C I combustion into production-ready E C U
• C omplete vehicle integration enabling drive-cycle testing
• Validate controls for advanced combustion on production-ready E C U
• E valuate fuel economy and emiss ion performance with demonstration vehicle
\
Milestones
11
GS/ENS-NA | 6/19/2014 | © 2014 R obert B os ch LLC and affiliates . All rights res erved.
2014 DOE Annual Merit Review – ACCESS
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Technical Accomplishments
• Summary and Future Work
12
GS/ENS-NA | 6/19/2014 | © 2014 R obert B os ch LLC and affiliates . All rights res erved.
2014 DOE Annual Merit Review – ACCESS – Collaboration & Coordination
Combustion DevelopmentEngine Design
Combustion Modeling Project Lead System Concepts
US Department of Energy
Project / Contract Management
Steering Committee
Project Scope Definition
Robert Bosch Research and Technology Center
Robert Bosch LLCGasoline Systems
AVL North AmericaPowertrain Engineering
Stanford University
Combustion Modeling Research
University of Michigan
Engine Control & Combustion Research
Emitec
After-treatment System Development
Organization C hart
13
Chevron Energy Technology Co.
Technical Consultation Advisory and Information Exchange
GS/ENS-NA | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Robert Bosch LLC Gasoline Systems AVL North America
Powertrain Engineering
Stanford University
University of Michigan
Emitec
Paul Whitaker - Co-PI, Combustion System Dusan Polovina - Co-PI, Combustion System Roger Faber - Project Management David McKenna - Combustion System Matthew Dunlavey - Engine Design
Dr. Srikanth Reddy - Co-PI, After-treatment Sys.
Robert Bosch Research and Technology Center
Hakan Yilmaz - PI Oliver Miersch-Wiemers - Co-PI, Project Mmgt. Dr. Li Jiang - Co-PI, Technical Lead Jeff Sterniak - Combustion Concepts Julien Vanier - Software Integration Jason Schwanke - Control System Kyle Davidson - Vehicle Integration Shyam Jade - Software Integration Jacob Larimore - Combustion Modeling Angela Dragan - Government Affairs
Joel Oudart - Co-PI, Adv. Combustion Dr. Alexandar Kojic - Project Management Dr. Nikhil Ravi - Combustion Control Dr. Eric Doran - CFD Simulations
Prof. Chris Edwards - Co-PI, Adv. Combustion Julie Blumreiter - Advanced Combustion
Adv. Powertrain Control Laboratory
Prof. Anna Stefanopoulou - Co-PI, Adv. Controls Patrick Gorzelic - Combustion Mode Switch Yi Chen - After-treatment System Sandro Nuesch - Vehicle Simulations
Walter E. Lay Automotive Laboratory
Dr. Stani Bohac - Co-PI, Adv. Combustion Dr. Jason Martz - Combustion Simulations Vassilis Triantopoulos - Advanced Combustion Prasad Shingne - Engine Simulations Adam Vaughan - Combustion Modeling
US OEMs
Information Exchange Technology Alignment
Multidisciplinary team with 30+ researchers and engineers
2014 DOE Annual Merit Review – ACCESS – Collaboration & Coordination
Team Members
14
GS/ENS-NA | 6/19/2014 | © 2014 R obert B os ch LLC and affiliates . All rights res erved.
2014 DOE Annual Merit Review – ACCESS
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination
• Technical Accomplishments
• Summary and Future Work
15
Overview
GS/ENS-NA | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
$ Multi-Mode Combustion Strategy % Operation Regime % Fuel Efficiency % Emissions Performance
$ Multi-Mode Combustion Controls % HCCI Controls % SACI Controls % Combustion Mode Switch
16
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
SI SI+eEGR
SI+eEGR
SACI
SI: Spark Ignition HCCI: Homogeneous Charge Compression Ignition SACI: Spark Assisted Compression Ignition eEGR: external Exhaust Gas Recirculation
1500 3500 Speed [RPM]
BMEP [bar] 22
6.0
3.5
10
2.0 HCCI
Advanced combustion enables fuel economy benefits in highly visited operating points, while high peak load capability ensures vehicle performance
Multi-Mode Combustion Operation Regime 2014 DOE Annual Merit Review – ACCESS - Technical Accomplishments
17
HCCI
HC C I C oncept Development Homogeneous Charge Compression Ignition
Hot trapped res iduals , air, and fuel are compressed Auto-ignition happens from numerous s ites near T DC Low temperature flameless reaction rapidly takes place
HC C I can enable high thermal efficiency with low engine out emiss ions at low load
Benefits: • High thermal efficiency
• Low NOx even when lean
Challenges:
• Limited operating range
• C ombustion noise Engine Speed [RPM]
BM
EP
[bar
]
1500 2000 2500 3000
5
10
15
20
250
300
350
400
450
500
550
600
BS
FC
[g/kWh]
HCCI relative BSFC vs. SI w/ HP EGR [%]
18
2014 DOE Quarterly Meeting - ACCESS
-40 -30 -20 -10 0 10 20 30 400
10
20
30
40
Crank Angle [deg]
Hea
t Rel
ease
Rat
e [J
/deg
]
3 bar4 bar5 bar
BMEPFlame consumes more mass with load
S park ass ist extends advanced combustion range w/o boosting or lean aftertreatment
Combustion Chamber Cross-Section
0 CAD
4 CAD
Premixed Flame Propagation
Auto-ignition
Spark Assisted Compression Ignition F lame propagation compresses unburned mixture to auto-ignition
Lower peak heat release rate Large stochiometric operating range
E xtens ion of Advanced C ombustion R ange with S AC I
Engine Speed [RPM]
BM
EP
[bar
]
1500 2000 2500 3000
5
10
15
20
250
300
350
400
450
500
550
600
BS
FC
[g/kWh]
Increase of load limit
with spark-ass ist
1000 2000 30002
3
4
5
6
BS
FC (S
AC
I-SI)/
SI [
%]
-20
-15
-10
-5
SACI relative BSFC vs. SI w/ HP EGR [%]
19
F E penalty of mode s witch mandates full-time s toichiometric operation
Lean – Stoichiometric Mode Switch Lean HCCI
Oxygen stored in TWC until full No NOx conversion
Stoichiometric modes
Catalyst efficiency is still low until stored oxygen is depleted
Drive cycle simulations Benefit of HCCI wiped out by catalyst
depletion SULEV emission levels unreachable
without additional aftertreatment
T P NOx s pike
0
15
30
45
60
75
90
105
120
23.5
23.8
24.0
24.3
24.5
24.8
25.0
25.3
25.5
Tail
Pip
e N
Ox
[mg/
mi]
Fuel
Eco
nom
y [M
PG
]
FE Ph2,3 NOx Ph2,3
SI + HCCI + Catalyst O2 Purge
LE V II S ULE V NOx Limit
F E +3.7%
Multi-Mode C ombustion Aftertreatment C hallenge
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
20
F E penalty of mode s witch mandates full-time s toichiometric operation
Lean – Stoichiometric Mode Switch Lean HCCI
Oxygen stored in TWC until full No NOx conversion
Stoichiometric modes
Catalyst efficiency is still low until stored oxygen is depleted
Drive cycle simulations Benefit of HCCI wiped out by catalyst
depletion SULEV emission levels unreachable
without additional aftertreatment
0
15
30
45
60
75
90
105
120
23.5
23.8
24.0
24.3
24.5
24.8
25.0
25.3
25.5
Tail
Pip
e N
Ox
[mg/
mi]
Fuel
Eco
nom
y [M
PG
]
FE Ph2,3 NOx Ph2,3
SI + HCCI + Catalyst O2 Purge
LE V II S ULE V NOx Limit
F E +3.7%
Multi-Mode C ombustion Aftertreatment C hallenge
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
21
F E penalty of mode s witch mandates full-time s toichiometric operation
Lean – Stoichiometric Mode Switch Lean HCCI
Oxygen stored in TWC until full No NOx conversion
Stoichiometric modes
Catalyst efficiency is still low until stored oxygen is depleted
Drive cycle simulations Benefit of HCCI wiped out by catalyst
depletion SULEV emission levels unreachable
without additional aftertreatment
T P NOx s pike
0
15
30
45
60
75
90
105
120
23.5
23.8
24.0
24.3
24.5
24.8
25.0
25.3
25.5
Tail
Pip
e N
Ox
[mg/
mi]
Fuel
Eco
nom
y [M
PG
]
FE Ph2,3 NOx Ph2,3
SI + HCCI + Catalyst O2 Purge
LE V II S ULE V NOx Limit
F E +3.7%
Multi-Mode C ombustion Aftertreatment C hallenge
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
22
F E penalty of mode s witch mandates full-time s toichiometric operation
Lean – Stoichiometric Mode Switch Lean HCCI
Oxygen stored in TWC until full No NOx conversion
Stoichiometric modes
Catalyst efficiency is still low until stored oxygen is depleted
Drive cycle simulations Benefit of HCCI wiped out by catalyst
depletion SULEV emission levels unreachable
without additional aftertreatment
T P NOx s pike
0
15
30
45
60
75
90
105
120
23.5
23.8
24.0
24.3
24.5
24.8
25.0
25.3
25.5
Tail
Pip
e N
Ox
[mg/
mi]
Fuel
Eco
nom
y [M
PG
]
FE Ph2,3 NOx Ph2,3
SI + HCCI + Catalyst O2 Purge
LE V II S ULE V NOx Limit
F E +3.7%
Multi-Mode C ombustion Aftertreatment C hallenge
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
23
P rototype II engine data demonstrate s ignificant fuel efficiency improvements over baseline engine at frequently-vis ited drive-cycle operation points
Engine Dyno at AVL
Prototype II Engine
B as eline: 3.6L V 6 P F I E ngine H
CC
I
SAC
I
SAC
I
HC
CI
SAC
I
SAC
I
SAC
I
SI
SI
F uel E fficiency G ains – P rototype II E ngine
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
1500 RPM31.8 Nm
1500 RPM63.7 Nm
1500 RPM95.5 Nm
2000 RPM47.7 Nm
2000 RPM79.6 Nm
2500 RPM31.8 Nm
2500 RPM63.7 Nm
2500 RPM95.5 Nm
% B
SFC
impr
ovem
ent v
s Bas
elin
e V6
ACCESS
Turbo Downsized SI
HC
CI
SAC
I
SI
HC
CI
SAC
I
SI
SAC
I
SI
SI
24
V ehicle F uel E conomy Walk
Target
30%
25%
20%
15%
s imulated potential
FE
Impr
ov. O
ver
Bas
elin
e [%
]
lean HC C I
red. fuel cut-off
ext . cat. heating S AC I w/
C A50 control E G R S tart/S top &
T hermal Mmgt
S I T C DZ
C ompromised F uel E fficiency due to S ULE V emiss ions w/ T WC
C hallenges existing but project remains on track to meet 25% target
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
25
Gasoline Systems | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
Emissions C urrently ~2x S ULE V target Near 100% convers ion efficiency when warm Mitigation for HC during catalyst light off
• E nhanced split injection calibration • Wastegate actuation for faster light off • Modified exhaust valve timing with eP haser
Mitigation for NOx after catalyst light off
• C atalyst oxygen storage target optimization Fuel Economy
0
0.02
0.04
0.06
0.08
0.1
0.12
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 500 1000 1500 2000
Cum
ulat
ive
TailP
ipe
Emiss
Mas
s
Inst
anta
neou
s Tai
lPip
e Em
iss M
ass
Time [s]THC TP Mass Cum. NOx TP Mass Cum.THC TP Mass NOx TP Mass
0
0.02
0.04
0.06
0.08
0.1
0.12
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 20 40 60 80 100
Cum
ulat
ive
TailP
ipe
Emiss
Mas
s
Inst
anta
neou
s Tai
lPip
e Em
iss M
ass
Time [s]THC TP Mass Cum. NOx TP Mass Cum.THC TP Mass NOx TP Mass
Stock CTS P2b SI w/o EGR Rel. Improv.
18.04 mpg 21.28 mpg 18.0%
~100% convers ion
C old start HC focus
NOx focus after s tart
FTP-75 Modal Emissions V ehicle F uel E conomy and E miss ion S tatus
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
26
Multi-Combustion Mode Coordination Modeling
C ontrol Development
E C U Integration
Air Path Control for EGR and Advanced Valve-train Modeling
C ontrol Development
E C U Integration
Advanced Combustion Controls
T orque demand driven engine control architecture enables multi-mode combustion control
Modeling
C ontrol Development
E C U Integration
Key Development Areas for Advanced Combustion
Modularized B osch E C U C ontrol Architecture
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
27
HC C I C ombustion C ontrol Operating
Coordination
Driver Demands
Engine Torque
Structure
N, M* BMOD
+SOI [MR] MFB50-EVC FB Controller
(Reference Cylinder)
ENG
INE
Exhaust Valve Controller
Combustion Feature
Calculation
pcyl
State Estimator(Cylinder Individual)+ MFB50-SOI FB Controller
(Cylinder Individual)MFB50*
MFB50
MFB50-SOI FF Controller (Cylinder Individual)
NMEP FB Controller(Cylinder Individual)
NMEP FF Controller(Reference Cylinder)
+NMEP*
NMEP
+ Injector Controller
Reference Cylinder Identificaiton
+
λ* Wcyl,air
N, pint
φINJ
ΔtINJ
WINJ,FF
WINJ,FB
φINJ,FF
φINJ,FB
Torque Structure Air System Fuel System
EVC
cylinder engine over typical drive cycle trans ients
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
Combustion Phasing Control • Mid-R anging C ontrol of S OI and E V C • Model-B ased F F C ontrol of S OI to enable fast trans itions • F B C ontrol of S OI to enable MF B 50 balancing Torque Control • F B C ontrol of fuel quantity to enable NME P balancing Cylinder Pressure Sensing • E C U integrated real-time calculation of MF B 50, NME P
1500 3500 Speed [RPM]
SI SI+eEGR
BMEP [bar]22
6.0
3.5
10
2.0HCCI
SI+eEGR
28
HC C I control validated on prototype multi-
S AC I C ombustion C ontrol
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
S AC I combustion control evaluated on prototype multi-cylinder engine
C ontroller Input-Output: MFB50 MFB10-90 λ
S park ++ +
cE G R + ++ +
E V C + + ++
0.7
0.8
0.9
1
1.1
1.2
1.3
1
2
3
4
5
6
7
18 19 20 21 22 23 24 25
Lam
bda
[-]
IMEP
[Bar
]
Time [s]
0.7
0.8
0.9
1
1.1
1.2
1.3
1
2
3
4
5
6
7
18.5 19.5 20.5 21.5 22.5
Lam
bda
[-]
IMEP
[Bar
]
Time [s]
0
10
20
30
40
50
-45
-35
-25
-15
-5
5
18 19 20 21 22 23 24 25
CA10
75 {C
rank
shaf
t D
egre
es]
CA50
[Cra
nksh
aft
Deg
rees
]
Time [s]
0
10
20
30
40
50
-45
-35
-25
-15
-5
5
18.5 19.5 20.5 21.5 22.5
CA10
75 {C
rank
shaf
t D
egre
es]
CA50
[Cra
nksh
aft
Deg
rees
]
Time [s]
(A) (B ) IMEP
λ IMEP λ
CA50 [°bTDC]
CA10-75
CA50 [°bTDC]
CA10-75
multi-cylinder engine:
(A) load trans ition: 2.5bar to 5.5bar B ME P ramp @ 1500R P M
(B ) speed trans ition: 3bar B ME P @ 1500 to 2500R P M ramp
1500 3500 Speed [RPM]
BMEP [bar]22
6.0
3.5
10
2.0
SI SI+eEGR
SI+eEGR
SACI
Gasoline Systems | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved. 29
IVO: Intake Valve Open | EVC: Exhaust Valve Closing | SOI: Start of Injection | cEGR: cooled Exhaust Gas Recirculation | HFM: Mass Flow Rate | MAP: Manifold Absolute Pressure | LSU-IM: Intake Manifold Oxygen Sensor
Gasoline Systems | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
SI/SACI Combustion Mode Switch Strategy Performance Targets: torque neutral, stable combustion phasing, stoichiometric operation
Key Actuators: intake & exhaust valve timing, throttle position, spark timing, fuel injection timing & mass
SI!SACI Strategy: % SI with low lift IV and EV % De-throttle SI with coordinated NVO & EGR % Regulate phasing with SOI, spark % Switch into SACI
SACI SI
SCRE @ 1500 rpm, 3.4 bar NMEP
Combustion mode switch strategy identified on single-cylinder research engine
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
30
SI/SACI Combustion Mode Switch
SI/SACI combustion mode switch strategy evaluated on prototype multi-cylinder engine
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
SI-SACI Mode Switch, 2000RPM, 3bar BMEP
SACI-SI Mode Switch, 2000RPM, 3bar BMEP
SI-SACI-SI Mode Switch, 2000RPM, 5bar BMEP
31
2014 DOE Annual Merit Review – ACCESS
• Project Overview
• Relevance
• Approach
• Collaboration and Coordination)
• Technical Accomplishments
• Summary and Future Work
32
Combustion System Summary – Approach
Combustion System Summary – Major Accomplishments
GS/ENS-NA | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
• Advanced combustion concepts finalized for vehicle implementation.
• Engine operation conditions and transient performance requirements defined by using vehicle-level simulations as well as vehicle tests.
• Evaluated emissions and after-treatment performance impact of transient HCCI operation and mode switch on the transient dyno.
• Vehicle demonstration focusing on stoichiometric advanced combustion operation modes to support the SULEV emission requirement.
33
2014 DOE Annual Merit Review – ACCESS – Summary and Future Work
• Utilize advanced combustion concepts derived from extensive experiments on single and multi-cylinder engines, as well as simulation, to demonstrate the fuel economy potential of multiple mode advanced combustion operation in a vehicle.
• Evaluate tradeoff between efficiency and emissions and demonstrate SULEV potential of the concept under drive cycle conditions.
C ombustion S ystem F uture Work
2014 DOE Annual Merit Review – ACCESS – Summary and Future Work
Extending advanced combustion to future systems : S toichiometric high C R HC C I S ingle C ylinder Investigations
• S ynergy with dilute Miller cycle S I concept • S I in engine peak efficiency region, HC C I in what would otherwise comprise throttled region
• E xploring boosted region with diesel-like C R • Using high pressure capable, optical access to study and mitigate ringing through charge preparation
B oosted S AC I Multi-cylinder Investigations • Determine efficiency potential, valving strategy (P V O & NV O), and engine requirements for boosted S AC I concept
T ransient HC C I modeling for combustion control • Intra-cycle combustion modeling and control with charge preparation strategy • HC C I actuator trajectory optimization through enhanced phenomenonological boosted HC C I model
1000 3000Speed [RPM]
BM
EP[b
ar]
10
20
2000
5
4000
2.5
dilute Miller SI
HCCI / SACIhigh geo. CR
1000 3000Speed [RPM]
BM
EP[b
ar]
10
20
2000
5
4000
2.5
boostedSACI
dilute SI
HCCI / SACI
34
• S AC I combustion control and mode switch strategies evaluated on multi-cylinder engine transient dyno
• Model based HC C I combustion control and mode switch strategy are evaluated on multi-cylinder transient dyno
• P roposed control strategies are validated for real-time operations and compatible with in-production E C U
• Vehicle is operational with advanced combustion
C ontrols S ystem S ummary – Approach
C ontrols S ystem S ummary – Major Accomplishments
• Utilize s imulation and experimental data to define controls s trategy for S AC I operation and combustion mode switch.
• Validate the operable range and dynamic requirements for advanced combustion modes accounting for combustion and controllability limits .
• Implement real time controls in production-ready engine control unit, us ing rapid prototyping function development techniques .
1st trial of S AC I combustion in vehicle
2014 DOE Annual Merit Review – ACCESS – Summary and Future Work
35
C ontrols S ys tem F uture Work
2014 DOE Annual Merit Review – ACCESS – Summary and Future Work
• C omplete integration of multi-mode combus tion s trategies into production-ready engine control unit
• C omplete vehicle calibration to improve driving experiences with advanced combus tion mode
0 50 100 1502
4
6
8
0 50 100 150
-10
0
10
20
30
40
BMEP
(bar
)C
A50
(CAD
)
Engine cycle
0 50
SISACI switch at 5barSACI switch at 4.5barSACI switch at 4bar
Engine speed: 2000 rpm
• Improve the multi-mode coordination s trategy by exploring the combus tion mode s witching boundaries between S I and S AC I
• G iven the different combus tion mode s witching behaviors obs erved, it is likely the s witching boundaries of in/out of S AC I mode will be different
In-cylinder flame propagation
• C omplete C F D modeling of premixed combus tion characterized for S AC I, providing ins ights for model s implification
• E valuate robus tnes s of advanced combus tion control under varying environmental conditions on s ingle-cylinder engine
-60 -40 -20 0 20 40 60-5
0
5
10
15
20
25
Engine position (CAD)
Hea
t rel
ease
rate
(J/C
AD
)
Wiebe 1: Flame propagation
Wiebe 2: Auto-ignition• Improve control-oriented modeling of S AC I
combus tion with findings from C F D modeling
36
• Low cost three way catalyst aftertreatment solution for multi-mode combustion concept
• Full-time stoichiometric operation in spark ignited and advanced combustion modes to minimize mode switch penalties
• Evaluate potential transient lean NOx handling aftertreatment options to extend benefits of low temperature (low NOx) combustion process to lean operation in multi-mode concept
• Determined aftertreatment system performance during transient mode switch conditions to evaluate tradeoff between fuel economy and emissions for lean HCCI concept
• Performed initial vehicle cold start and emissions calibration to evaluate baseline performance
• Designed SCR package, developed coating process, and built initial passive SCR substrate
• Initial FTP-75 drive cycle emissions results promising with key areas for cold start emissions reductions identified
• Excellent three way catalyst performance after light-off confirmed
• Lean HCCI with TWC alone not suitable for low emissions high efficiency concept # some lean aftertreatment would be required
Major Accomplishments Summary
Overview – Aftertreatment System Approach
2014 DOE Annual Merit Review – ACCESS – Summary and Future Work
37
Aftertreatment S ystem F uture Work
2014 DOE Annual Merit Review – ACCESS – Summary and Future Work
Improving the tradeoff of efficiency and emissions Aftertreatment for lean state operation
• P ass ive S C R performance trans ient operation • Lean HC C I s toich trans ition • Low emiss ion, fuel cut-off enabler
C old start emiss ion optimization • E xplore the system benefits during run-up and catalyst heating phases utilizing capabilities of multi-mode combustion platform
• C am profile switching, extended range cam phaser, P F DI fuel system
Handling mode switch and S AC I trans ients • Define cost optimization potential of T WC system accounting for air-fuel ratio deviations in trans ient operation of multi-mode combustion concept
38
>25% improved FE SULEV Capable Commercially Viable
Program Targets
started
performance evaluated
goal achieved
integrated
Team Competence / Project Management
B ase E ngine Hardware
E ngine Mgmt. S ystem Hardware
E miss ion S ystem
C ontrol S trategy
S oftware Architecture
C ombustion S trategy
V ehicle Integration
2014 DOE Annual Merit Review – ACCESS – Summary and Future Work
Phase 3(1.5 yrs)
Application
Implementationand
Vehicle Demo
Phase 1(1.5 yrs)Concept
FundamentalResearch
Phase 2(1 yr)
Development
TechnologyDevelopment
Phase 3
Application
Implementation,Vehicle Demo
Phase 1
Concept
FundamentalResearch
Phase 2
Development
TechnologyDevelopment
9/30/2010-02/28/2012
03/01/2012-05/31/2013
06/01/2013 -12/31/2014
39
2012 Q3 Quarterly R eview B osch P lymouth, MI October 18, 2013
2014 DOE Annual Merit Review – ACCESS
Impress ions from firs t S AC I R ide April 8th 2014
40
2014 DOE Annual Merit Review – ACCESS
Technical Backup Slides
41
SACI Combustion Control: Key Actuators
GS/ENS-NA | 6/19/2014 | © 2014 Robert Bosch LLC and affiliates. All rights reserved.
All sweeps recorded at 1500 RPM on ACCESS multi-cylinder prototype engine
Spark and EGR are identified as key actuators for combustion phasing and duration regulation, requiring coordinated control due to cross-sensitivity
2014 DOE Annual Merit Review – ACCESS – Technical Accomplishments
42