Deutz Diesel

1

30.10.00 2000 GT-Suite User Conference / Deutz AG2000 GT-Suite Users ConferenceOctober 30, 2000 - Frankfurt, Germany

„Analysis of Alternative EGR Systems on the

DEUTZ BF6M 2013C Diesel Engine‘‘

„Analysis of Alternative EGR Systems on the

DEUTZ BF6M 2013C Diesel Engine‘‘

Dr. F. Schmitt

1) Deutz is an independent engine manufacturer. The engines are basically designed for industrial engine applications like agricultural and construction machinery, power generation as well as for transport applications in commercial vehicles like Volvo. One of these commercial vehicle engine is the engine 2013. My talk is about “Analysis ofAlternative EGR Systems on this DEUTZ BF6M 2013C Diesel Engine‘‘.

2

30.10.00 2000 GT-Suite User Conference / Deutz AG

Contents

Introduction

- engine series 2013

- egr concept

Modelling of egr and injection system

Summary

- injection system

Simulation / Testing of egr

2) I will start my talk about some basics about the engine 2013, I haveto model in GTPower. Further technologies to consider are the injection systems and the egr concepts of this engine. For each of new the technologies I will also give some information about the modelling inGtpower. Further I will compare testing and simulation. Finally I will givea summary.

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30.10.00 2000 GT-Suite User Conference / Deutz AG

Engine family DEUTZ 2013

E n g i n e D a t a S e r i e s R e s e a r c hIn j ec t ion sys t em U P S , 6 - h o l e C R , 7 u n d 8 - h o l e

C o m b u s t i o n s y s t e m D I , w / o e g r w i t h e g r

T u r b o c h a r g e r A T L w i t h W G V G T

B o r e / S t r o k e d 9 8 m m / 1 2 6 m m

D i s p l a c e m e n t V h 5 , 7 d m 3

C o n n e c t i n g R o d l e n g t h l 1 9 4 m m

C o m p r e s s i o n r a t i o ε 1 8 , 5 1 8 , 1

M a x P o w e r P eff 1 9 0 k W @ 2 5 0 0 m i n -1

M e a n e f f . p r e ssu re 2 1 b a r @ 1 2 0 0 - 1 6 0 0 m i n -1

E m i s s i o n s t a n d a r d E U R O 3 E U R O 4 ( t a r g e t )

E n g i n e s p e c i f i c a t i o n

c o m p a c t n e s s

l o w f u e l c o n s u m p t i o n

4 -v a l v e, 4- a n d 6- c y l i n d e r

3 ) T h e e n g i n e f a m i l y D E U T Z 2 0 1 3 i s v e r y c o m p a c t , has l ow f ue l

c o n s u m p t i o n a n d i s a v a i l a b l e a s a 4 v a l v e, 4- a n d 6 - c y l i n d e r e n g i n e.

F u r t h e r E n g i n e D a t a i s g i v e n i n t h e t a b l e. The se r i es eng ine , that fu l f i l l s

t h e E U R O 3 E m i s s i o n s t a n d a r d , has a U n i t P u m p I n j e c t i o n s y s t e m

( U P S ) w i t h a 6- h o l e n o z z l e. T h e C o m b u s t i o n s y s t e m i s a DI s y s t e m

w i thou t eg r . A tu rbocha rge r o f 3 K w i th was te ga te i s used. Bore of 98

m m and St roke o f 1 2 6 m m l e a d s t o a d i sp lacemen t o f 5 , 7 li ter. W i t h a

compress ion ra t i o o f 1 8 . 5 a m a x i m u m p o w e r o f 1 9 0 k W @ 2 5 0 0 U / m i n

a n d a mean e f fec t i ve p ressu re o f 21 ba r i n the range o f 1 2 0 0 t o 1 6 0 0

r o u n d p e r m i n u t e c a n b e r e a c h e d.

F o r t h e r e s e a r c h e n g i n e a C o m m o n R a i l I n j e c t i o n S y s t e m wi th egr is

u s e d. A t u r b o c h a r g e r w i t h v a r i a b l e t u r b i n e g e o m e t r y i s u s e d i n s t e a d o f

w a s t e- gate at l . The a im o f t he i nves t i ga t i ons w a s t o r e a c h o r t o get

c l o s e t o E U R O 4 e m i s s i o n s t a n d a r d w i t h o u t e x h a u s t a f t e r t r e a t m e n t l i k e

par t ic le f i l te r or S C R s y s t e m

4

3 0 . 1 0 . 0 0 2 0 0 0 G T -S u i t e U s e r C o n f e r e n c e / D e u t z A G

4)T h i s p i c t u r e s h o w s t h e e n g i n e 2 0 1 3 . C h a r g e a i r man i f o l d and exhaus t

p i p e s a r e o n t h e s a m e s i d e. B e t w e e n c y l i n d e r 1 a n d 2 a n d c y l i n d e r 5

a n d 6, y o u c a n s e e t w o f l a n g e s f o r e g r v a l v e s .

5


G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3i n t a k e a n d e x h a u s t m a n i f o l d

V a l v e

c o v e r

R o c k e r a r m

h o u s i n g

S e a l i n g

C y l i n d e r

h e a d

C y l i n d e r h e a d

g a s k e t

C h a r g e a i r

m a n i f o l d

E x h a u s t

p i p e

5)A de ta i l ed desc r i p t i on o t t he i n t ake and exhaus t man i f o l d i s g i ven

h e r e. F o r t h e G T P o w e r M o d e l w e h a v e t o c o n s i d e r t h e s p e c i a l c h a r g e

a i r man i f o l d. A i r l e a v e s t h e c h a r g e a i r p i p e a n d e n t e r s t h e r o c k e r a rm

h o u s i n g . T h e n t h e a i r f l o w i s s e p a r a t e d i n t o a ma in sw i r l p i pe and a m a i n

f i l l ing pipe. T h e s e p i p e s a r e s e p a r a t e d a g a i n i n t o t h e t w o n e i g h b o u r i n g

cy l i nders .

6

C h a r g e

a i r c o o l e r

T c h a r g e air

P charge a i r

V T G

E C U

e l e c t r . g o v e r n o r

m air

E G R - c o n t r o l

v a l v e

E G R - c o o l e r

R e e d

v a l v e s

E G R C o n c e p t : H i g h - P r e s s u r e E G Rp u l s e-E G R

6) N e x t p i c t u r e s h o w s a s c h e m a t i c d e s c r i p t i o n o f t h e e n g i n e 2 0 1 3 w i t h

c o m p r e s s o r , cha rge a i r coo le r , c y l i n d e r s a n d t u r b i n e. T h e h i g h p r e s s u r e

e g r s y s t e m c o n s o s t s o f t h e e g r- con t ro l va l ves , t he eg r -coo le r a n d t h e

r e e d v a l v e s .

7


G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3h i g h p r e s s u r e E G R

7)T h e G T P o w e r M o d e l looks l i ke th i s . A i r e n t e r s t h r o u g h t h e

c o m p r e s s o r a n d t h e c h a r g e a i r coo le r i n t o t he cy l i nde rs . T h e i n t a k e

m a n i f o l d i s m o d e l e d a c c o r d i n g t o t h e e x p l a n a t i o n a l r e a d y g i v e n. Fu r the r

you can see t he exhaus t gas sys tem t i l l t he ou t l e t a f t e r t u rb i ne . T h e e g r

s y s t e m c o n s i s t s o f t h e e g r-c o n t r o l v a l v e s , the egr p ipes , t h e e g r-c o o l e r

a n d t h e r e e d v a l v e s . T h e M o d e l i n g o f t h e r e e d v a l v e s a n d t h e c o m m o n

ra i l i n jec t i on sys tem i s g i ven i n a m o r e d e t a i l e d w a y .

8


E G R c o n c e p t : r e e d v a l v e s

8)T h e r e e d v a l v e s l o o k l i k e i n t h e f o l l o w i n g e x a m p l e s . I n our

i n ves t i ga t i ons we used t he one on t he r i gh t s i de, m a d e b y P i e r b u r g.

9


E G R : c h a r g e a i r p r e s s u r e u n d b o o s t p r e s s u r e b e f o r e T u r b i n e

9) H e r e y o u c a n s e e t h e c h a r g e a i r p r e s s u r e a n d t h e b o o s t p r e s s u r e

b e f o r e t u r b i n e a s a func t i on o f c rank ang le . E a c h t i m e p r e s s u r e b e f o r e

t u rb i ne i s h i ghe r t han cha rge a i r p ressu re, e x h a u s t g a s f l o w s t h r o u g h

t h e o p e n r e e d v a l v e s i n t o t h e c h a r g e a i r p i p e. I n t h e o t h e r c a s e, t h e

r eed va l ves a re c l osed .

10


G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3r e e d v a l v e s

10) I n G T P o w e r t h e V a l v e R e e d R e f e r e n c e i s u s e d. W i t h t h e E x c e l

M a c r o Chkva l50 . x ls the input w a s d e f i n e d . T o d e f i n e t h e p a r a m e t e r s f o r

t h e E x c e l -f i l e s o m e t e s t i n g s f o r t h e u s e d r e e d v a l v e h a v e b e e n d o n e t o

e s t i m a t e p r e s s u r e n e e d e d f o r o p e n i n g t h e v a l v e a n d t h e p r e s s u r e fo r

t h e c a s e, tha t va l ve i s f u l l open .

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30 .10 .00 2000 GT-Suite User Conference / Deutz AG

C o m m o n R a i l S y s t e m ( C R S )E lec t r i c un i t p u m p s y s t e m ( U P S )

I n j e c t i o n s y s t e m o f t h e e n g i n e f a m i l y 2 0 1 3

11)F o r o u r s e r i e s e n g i n e a U P S i s u s e d. T h i s i n j e c t i o n s y s t e m h a s b e e n

r e p l a c e d b y a C R s y s t e m i n t h e r e s e a r c h e n g i n e. U s i n g a C R s y s t e m ,

we have the poss ib i l i t y f o r m u l t i p l e in jec t i ons . I n o u r c a s e t h e i n f l u e n c e

of pre- and pos t -i n j e c t i o n w a s i n v e s t i g a t e d . T h e p i c t u r e s s h o w s t h e t w o

s y s t e m .

12


G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3I n j e c t i o n s y s t e m

12) I n t h e G T P o w e r M o d e l o f t he eng ine 2013 , f o r m o d e l l i n g a c o m m o n

ra i l sys tem, the in jec t ion p ro f i le o f the need le l i f t i s g iven as a func t ion o f

c r a n k angle. For Un i t p u m p s y s t e m, w e u s e d t h e i n j e c t i o n p r e s s u r e.

13


G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3un i t p u m p i n j e c t i o n s y s t e m ( U P S )

13)The p ro f i l es o f i n j ec t i on p ressu re, need le l i f t and cy l i nde r p ressu re

a re g i ven fo r a n e x a m p l e i n th i s p i c tu re.

14


G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3c o m m o n r a i l i n j e c t i o n s y s t e m ( C R )

C R S w / o

p o s t i n j e c t i o n

b e : 2 1 6 . 7 g / k W h

N O x : 2 7 8 p p m

B S Z : 0 . 2 5

C R S w i t h

p o s t i n j e c t i o n

b e : 2 1 8 . 4 g / k W h

N O x : 2 6 3 p p m

B S Z : 0 . 1 1

I n f l u e n c e o f P o s t I n j e c t i o n o n E m i s s i o n s a n d S F C : E S C -tes t po in t 3 :1 8 4 5 r p m, 9 . 7 b a r

cylinder pressure needle lift heat release rate

14) C o n s i d e r i n g c o m m o n r a i l i n j e c t i o n w e h a v e t h e f o l l o w i n g p r o f i l e s of

c y l i nde r p ressu re, n e e d l e l i f t a n d h e a t r e l e a s e ra te . I n t h i s c a s e E S C

T e s t (E u r o p e a n S t a t i o n a r y C y c l e T e s t ) point 3 w i t h 1 8 4 5 r p m a n d 9.7

b a r i s i n v e s t i g a t e d. The i n f l uence o f pos t i n j ec t i on i s a l s o s h o w n .

P a r t i c l e c o n c e n t r a t i o n d e c r e a s e s v e r y m u c h w h i l e f u e l c o n s u m p t i o n and

N o x c o n c e n t r a t i o n s t a y a p p r o x i m a t e l y t h e s a m e. C a l c u l a t i o n i s s h o w n

for E S C T e s t (E u r o p e a n S t a t i o n a r y C y c l e ).

15


C o m p r e s s o r m a p E S C -T e s t w / o E G R

15)T h e E S C p o i n t s w i t h o u t e g r a r e s h o w n i n t h i s c o m p r e s s o r m a p . T h e

speeds o f 1 4 8 0 , 1 8 4 5 a n d 2 2 0 0 wi th fu l l l oad and severa l pa r t l oad

c a s e s a r e i n t h i s m a p .

16


C o m p r e s s o r m a p E S C -T e s t w i t h E G R

16)E g r l e a d s t o s m a l l e r m a s s f l o w r a t e s f o r t u r b i n e a n d c o m p r e s s o r s .

T h e E S C p o i n t l e a d a c c o r d i n g t o a s u m f o r m u l a t o t h e E S C T e s t v a l u e s .

17


t e s t i n g / c a l c u l a t i o n : R e s u l t s f o r E S C - T e s th i g h p r e s s u r e / p u l s e e g r

0 1 2 3 4 5 6 7 8 9 100.00

0.02

0.04

0.06

0.08

0.10

0.12

CR-injection systemwith postinjection,ATL with WG

CR, VTG

UPS-injection system, CR-injectionsystem w/o preinjection,ATL with WG

tes t ing h igh p ressure egr

s imu la t ion h igh p ressure egrP

artic

les

[g/k

Wh]

NOx [g / kWh ]

EURO4

EURO3

17) I n t h i s m a p i n c l u d i n g t h e E U R O 3 a n d E U R O 4 e m i i s i o n s t a n d a r d s ,

t he t r ade - o f f s f o r p a r t i c l e s a n d N o x a r e s h o w n. T h e s e r i e s e n g i n e w i t h

U P S a n d w a s t e- g a t e t u r b o c h a r g e r, we fu l f i l l the E U R O 3 e m i s s i o n

s t a n d a r d . T h e C R sys tem w i t hou t p re i n j ec t i on l eads t o s im i l a r r esu l t s .

The resu l t s w i t h p re i n j ec t i on a re show by the second t rade o f f . T u r b i n e

w i t h v a r i a b l e t u r b i n e g e o m e t r y l e a d s t o the th i rd t rade o f f . F o r t h i s c a s e

tes t i ng ( b lack) a n d s i m u l a t i o n ( r e d ) a r e s h o w n . W i th r a the r sma l l eg r

ra tes o f about 10 pe r cent , a r e d u c t i o n o f N o x f r o m 6 to 4 .5 g /kWh c a n

b e r e a c h e d. A g r e e m e n t b e t w e e n t e s t i n g a n d s i m u l a t i o n i s v e r y g o o d .

F u e l c o n s u m p t i o n s t a y s c o n s t a n t . Fo r h igher e rg ra tes the resu l t s a re

r a t h e r p o o r r e g a r d i n g r e d u c t i o n p o t e n t i a l s a n d a g r e e m e n t .

18


0

20

4060

80

100

120140

160

180

200

220

gem. Motorleistung ber. Motorleistung ohne AGR

en

gin

e p

ow

er

[KW

]

40

60

80

100

120

140

160

180

200

exp.erm. Zünddruck mit GTPower ber. Zünddruck ohne AGRm

ax.

cylin

der

pres

sure

[ba

r]

0 2 4 6 8 10 12 14

1.0

1 .5

2 .0

2 .5

3 .0

3 .5

4 .0

4 .5

5 .0

gem. Ladedruck ber. Ladedruck ohne AGR

Nr. [-]

char

ge a

ir p

ress

ure

[bar

]

t e s t i n g / c a l c u l a t i o n : E S C-T e s t

G o o d A g r e e m e n t b e t w e e n m e a s u r e m e n t a n d c a l c u l a t i o n f o r :

e n g i n e p o w e rm a x . c y l i n d e r p r e s s u r ec h a r g e a i r p r e s s u r e

18)The resu l t s fo r each tes t po in t o f E S C tes t w i thou t eg r a re g i ven

h e r e. T h e r e i s g o o d a g r e e m e n t b e t w e e n t e s t i n g a n d c a l c u l a t i o n f o r

e n g i n e p o w e r, c y l i n d e r p r e s s u r e a n d c h a r g e a i r p r e s s u r e f o r e x a m p l e.

19


0

20

4060

80

100

120140

160

180

200

220 gem. Motorleistung ber. Motorleistung ohne AGR ber. Motorleistung mitAGR

Mo

torl

eis

tun

g [

KW

]

40

60

80

100

120

140

160

180

200

gem. Zünddruck ber. Zünddruck ohne AGR ber. Zünddruck mit AGR

Zü

nd

dru

ck [

ba

r]

0 2 4 6 8 10 12 14

1.0

1 .5

2 .0

2 .5

3 .0

3 .5

4 .0

4 .5

5 .0

gem. Ladedruck ber. Ladedruck ohne AGR ber. Ladedruck mit AGR

Nr. [-]

La

de

dru

ck [b

ar]

t e s t i n g / c a l c u l a t i o n : E S C-T e s t w i t h e g r

E G R : R e g u l a t i o n of c h a r g e a i rp r e s s u r e by V G T con t ro le r

i n n e r a i r-fu le ra t io λ V c a l c u l a t e d f r o m f resh a i r f low and a i r ( o x y g e n ) in b o o s t :

0 2 4 6 8 10 12 14

0

1

2

3

4

5

Nr. [-]

ber. λ V ohne AGR ber. λ

V mit HD-AGR

"inn

eres

" V

erbr

ennu

ngsl

uft-

Kra

ftst

off-

Ver

hält

nis

λ V[-

]

19) Wi th eg r t he resu l t s a re st i l l v e r y g o o d. Fo r eg r ca l cu la t i on and

tes t i ng, t he cha rge a i r p ressu re i s con t r o l ed by V G T con t ro l l e r . T o h a v e

s a m e e m i s s i o n l e v e l s , the inner a i r -f u e l r a t i o, ca l cu laed f r om f resh a i r

a n d o x y g e n i n b o o s t , i s s im i la r l y cons tan t .

20


C h a r g e

a i r c o o l e r

E g r - c o o l e rE g r c o n t r o l v a l v e

m a i r

C h a r g e a i r

V G T

D i e s e l p a r t i c l e f i l t e r

T charge air

E l e c t r .

g o v e r n o r

E G R C o n c e p t : L o w -P r e s s u r e E G R

E C U

20)T h e s e c o n d s y s t e m , t h a t h a s b e e n i n v e s t i g a t e d i s t h e l o w p r e s s u r e e g r. A part of

t h e e x h a u s t g a s h a s t o b e c l e a n e d i n a part ic le f i l ter , a n d f l o w s t h e n t h r o u g h a n e g r-

c o o l e r a n d a n e g r -c o n t r o l v a l v e.

21


G T P o w e r S i m u l a t i o n M o d e l l o f E n g i n e 2 0 1 3l o w p r e s s u r e E G R

21)T h e G T P o w e r m o d e l l o o k s l i k e f o l l o w s. The mode l i s s im i l a r t o t h e h igh p r e s s u r e

e g r m o d e l .

22


0 1 2 3 4 5 6 7 8 9 1 00.00

0.02

0.04

0.06

0.08

0.10

0.12

CR-injection systemwith postinjection,ATL w i th WG

CR, VTG

UPS-inject ion system, CR-inject ionsystem w/o preinjection,ATL w i th WG

t e s t i n g l o w p r e s s u r e e g r

s i m u l a t i o n l o w p r e s s u r e e g rP

artic

les

[g/k

Wh]

N O x [ g / k W h ]

E U R O 4

E U R O 3

t e s t i n g / c a l c u l a t i o n : R e s u l t s f o r E S C - T e s tl o w p r e s s u r e e g r

22)T h e r e s u l t s a r e a l s o s h o w n i n the par t ic les - n o x m a p . T h e r e f e r e n c e p o i n t i s d i f f e ren t

t o the resu l t s f o r h i gh p r e s s u r e e g r. Fo r eg r ra tes o f abou t 11 pe r cent , a r e d u c t i o n f o r

n o x i s o b t a i n e d f r o m 9 to 6 .5 g /kWh. B u t t h e p a r t i c l e s i n c r e a s e s v e r y m u c h i n t h i s c a s e.

T h e r e s u l t s a r e e v e n w o r s e r t h a n m o v i n g o n t h e t r a d e o f f w i t h o u t egr.

23


S u m m a r y

Fulf i l l ing of E U R O 4 : f u r t he r op t im i za t i ons (i n j e c t i o n p r e s s u r e,c h a r g e a i r p r e s s u r e, E G R ) E T C : a f t e r t r e a t m e n t D iese l par t ic le f i l ter or S C R

Inves t i ga t i on o f d i f fe rent e g r s y s t e m s

Deta i l ed Mode l l i ng o f

G o o d a g r e e m e n t b e t w e e n t e s t i n g a n d s i m u l a t i o n r e s u l t s

- E G R -s y s t e m

- C R i n j e c t i o n s y s t e m

- i m p l e m e n t a t i o n o f V T G

23) L e t m e s u m m a r i z e t h e r e s u l t s. W e i n v e s t i g a t e d H I G H P R E S S U R E a n d L O W

P R E S S U R E e g r s y s t e m s f o r t h e D E U T Z d i e s e l e n g i n e 2 0 1 3 . The de ta i l ed mode l i ng o f

e g r a n d i n j e c t i o n s y s t e m h a s b e e n d i s c u s s e d . T h e r e s u l t s s h o w s g o o d a g r e e m e n t

b e t w e e n t e s t i n g a n d s i m u l a t i o n. For fu l f i l l ing E U R 4 e m i s s i o n s t a n d a r d i n s ta t i ona ry t es t ,

f u r t h e r o p t i m i z a t i o n s h a v e t o b e i n v e s t i g a t e d . Fo r t r ans ien t t es t E T C e x h a u s t g a s

a f te r t rea tment l i ke par t i c le f i l t e r o r S C R a r e n e e d e d .

24


... k n o w i n g i t ‘ s D E U T Z

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