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Copyright © 2004 Caterpillar Engine Research
Heavy Truck Clean Diesel (HTCD) Program
Transient Simulation of a Transient Simulation of a 2007 Prototype Heavy2007 Prototype Heavy--Duty EngineDuty Engine
PI’s: Kent Rutan, Josh Driscoll, Maarten Verkiel
Prog. Mgr.: David Milam
DOE Contract DE- FC05- 00OR22806
DOE Team Leader: Gurpreet Singh Prog. Mgr.: Roland GravelTech. Mgr.: Carl Maronde
2004 DEER ConferenceCoronado, CA
Caterpillar
Copyright © 2004 Caterpillar Engine Research
Presentation Overview
n HTCD Program Background
n Simulation Tools Overview
n Test Cell Model Contents
n Transient Test Cell Results
n Truck Model
n Summary
n Truck Model Movie
Copyright © 2004 Caterpillar Engine Research
Heavy Truck Clean Diesel Goalsn Funded by HTCD CAT/DOE programn Phase 1 goal 2007 emissions, 45% efficiency
NOx + NMHC (g/hphr)
PM
(g
/hp
hr)
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
NOx + NMHC (g/hphr)
PM
(g
/hp
hr)
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
47% identified in analysisn 2007 In-chassis demonstration
DEER 2003
n Phase 2 goal 2010 emissions, 50% efficiencyn 2010 In-chassis demonstrationnn Simulation critical to achieving HTCD goalsSimulation critical to achieving HTCD goals
Copyright © 2004 Caterpillar Engine Research
More with Less – High Fidelity Simulation
Steady-statePerformance
Multi Cylinder Steady State
Develo
pm
ent C
ycle
Simulation World <$Objectives Test World $$$
Transient/SystemPerformance
Multi Cylinder Transient
Detailed Comb.+ Emissions
Single Cylinder Test Cell
Real-worldSystemPerformance
2007 DemonstratorTruck
Copyright © 2004 Caterpillar Engine Research
More with Less – High Fidelity Simulation
In-cylinder 3DCombustion
Detailed Comb.+ Emissions
Steady-statePerformance
Develo
pm
ent C
ycle
Simulation World <$Objectives
Transient/SystemPerformance
Real-worldSystemPerformance
Multi Cylinder Steady State
Test World $$$
Multi Cylinder Transient
Single Cylinder Test Cell
2007 DemonstratorTruck
Copyright © 2004 Caterpillar Engine Research
More with Less – High Fidelity SimulationCaterpillar 3D Combustion Simulation Software
Copyright © 2004 Caterpillar Engine Research
In-cylinder 3DCombustion
More with Less – High Fidelity Simulation
Detailed Comb.+ Emissions
Steady-statePerformance
Develo
pm
ent C
ycle
Simulation World <$Objectives
Transient/SystemPerformance
Real-worldSystemPerformance
Multi Cylinder Steady State
Test World $$$
Multi Cylinder Transient
Single Cylinder Test Cell
2007 DemonstratorTruck
EngineAftertreatment (A/T)(Separately)
Copyright © 2004 Caterpillar Engine Research
More with Less – High Fidelity SimulationCaterpillar Engine Cycle Simulation Software
n Thermodynamicsn Heat Transfern Fuelingn Combustionn Air systemsn Components
Copyright © 2004 Caterpillar Engine Research
In-cylinder 3DCombustion
More with Less – High Fidelity Simulation
Detailed Comb.+ Emissions
Steady-statePerformance
Develo
pm
ent C
ycle
Simulation World <$Objectives
Transient/SystemPerformance
Real-worldSystemPerformance
Multi Cylinder Steady State
Test World $$$
Multi Cylinder Transient
Single Cylinder Test Cell
2007 DemonstratorTruck
EngineAftertreatment (A/T)(Separately)
Engine + A/T+ Test Cell
Engine + A/T+ Vehicle
(Coupled Together)
(Coupled Together)
Copyright © 2004 Caterpillar Engine Research
More with Less – High Fidelity Simulation
Caterpillar Dynasty™
“for toolbox of components to simulate the whole system”
Engine Simulation Software+
Caterpillar Confidential: YellowKent Rutan 8 Apr 2004
Caterpillar Engine ResearchDiesel & Emissions Technology
Tool Development
n Tool development funded 100% by Cat
n Tool application for HTCD 50/50 cost share
Copyright © 2004 Caterpillar Engine Research
Dynasty Components and Applications
Drivelines• Transmissions• Clutches• Final drives• Wheels & Tires• Gear dynamics
Linkages & Structures• 2D & 3D rigid bodies• Flexible body dynamics
Controls & Electronics • Component & full vehicle
simulation• Algorithm development• User programming• Co-simulation
Fluid Systems• Fuel• Hydraulic• Lube • Brake• Steering
Engine Systems• Cycle simulation• Valve trains• Crankshafts• Aftertreatment
Cooling Systems• Radiators• ATAAC• Fans• A/C• Parasitics
Component-based architecture supports diverse modeling applications
Copyright © 2004 Caterpillar Engine Research
In-cylinder 3DCombustion
More with Less – High Fidelity Simulation
Detailed Comb.+ Emissions
Steady-statePerformance
Develo
pm
ent C
ycle
Simulation World <$Objectives
Transient/SystemPerformance
Real-worldSystemPerformance
Multi Cylinder Steady State
Test World $$$
Multi Cylinder Transient
Single Cylinder Test Cell
2007 DemonstratorTruck
EngineAftertreatment (A/T)(Separately)
Engine + A/T+ Test Cell
Engine + A/T+ Vehicle
(Coupled Together)
(Coupled Together)
Focus of presentation
Copyright © 2004 Caterpillar Engine Research
Heavy Truck Clean Diesel Goalsn Funded by HTCD CAT/DOE programn Phase 1 goal 2007 emissions, 45% efficiency
NOx + NMHC (g/hphr)
PM
(g
/hp
hr)
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
NOx + NMHC (g/hphr)
PM
(g
/hp
hr)
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
47% identified in analysisn 2007 In-chassis demonstration
DEER 2003
n Phase 2 goal 2010 emissions, 50% efficiencyn 2010 In-chassis demonstrationnn Simulation critical to achieving HTCD goalsSimulation critical to achieving HTCD goals
Copyright © 2004 Caterpillar Engine Research
NOx + NMHC (g/hphr)P
M (
g/h
phr )
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
NOx hphr)P
M (
g/h
phr )
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
NOx + NMHC (g/hphr)P
M (
g/h
phr )
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
NOx hphr)P
M (
g/h
phr )
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
NOx + NMHC (g/hphr)P
M (
g/h
phr )
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
NOx hphr)P
M (
g/h
phr )
2.5
0.1
1.2
0.01
0.2
2010 Demo
2007 Demo
n Feed into production process
Simulation Process Follows HTCD Goals
Emissions
Fuel Economy
Design Integration
Reliability & Durability
Val
ue
Timeline
Standar
d Com
mercial
ProgramDOE HTCD
Program
Emissions
Fuel Economy
Design Integration
Reliability & Durability
Cu
sto
mer
Timeline
Standar
d Com
mercial
Program
Production
DOE HTCD
ProgramDOE HTCD
Program
nModel validation on 2007 demo engine, truck
n Basis for 2010 system models
Copyright © 2004 Caterpillar Engine Research
In-cylinder 3DCombustion
More with Less – High Fidelity Simulation
Detailed Comb.+ Emissions
Steady-statePerformance
Develo
pm
ent C
ycle
Simulation World <$Objectives
Transient/SystemPerformance
Real-worldSystemPerformance
Multi Cylinder Steady State
Test World $$$
Multi Cylinder Transient
Single Cylinder Test Cell
2007 DemonstratorTruck
EngineAftertreatment (A/T)(Separately)
Engine + A/T+ Test Cell
Engine + A/T+ Vehicle
(Coupled Together)
(Coupled Together)
Copyright © 2004 Caterpillar Engine Research
2007 Demo Builds on ACERT Technology
Electronics and Controls
CombustionAftertreatment
Air Systems
i=1
Exhaust Gas Volume
Catalyst Surface
,...),],NO([]NO[
PTxfdt
xd=
i=1
Exhaust Gas Volume
Catalyst Surface
,...),],NO([]NO[
PTxfdt
xd=
i=1
Exhaust Gas Volume
Catalyst Surface
,...),],NO([]NO[
PTxfdt
xd=
Integrated Integrated Engine SystemEngine System
®
Copyright © 2004 Caterpillar Engine Research
Details Included in Simulation
Electronics and Controls
CombustionAftertreatment
Air Systems
i=1
Exhaust Gas Volume
Catalyst Surface
,...),],NO([]NO[
PTxfdt
xd=
i=1
Exhaust Gas Volume
Catalyst Surface
,...),],NO([]NO[
PTxfdt
xd=
i=1
Exhaust Gas Volume
Catalyst Surface
,...),],NO([]NO[
PTxfdt
xd=
Integrated Integrated Engine SystemEngine System
Multiple Injections
Same Control Code for Test or Simulation
Series Turbos
Variable Valve Timing
Particulate Filter
This project was undertaken pursuant to an agreement with the United States in connection with settlement of disputed claims in an enforcement action under the Clean Air Act
Copyright © 2004 Caterpillar Engine Research
Engine + A/T + Test Cell Simulation
Transient Test CellTransient Test Cell
n Computer cycle command
n Dynamometer with speed/torque mode switching
n Transient torque controller
Engine & Engine & Aftertreatment SystemAftertreatment System
Copyright © 2004 Caterpillar Engine Research
Next Slides: FTP Cycle Results20 minute Heavy-Duty Federal Test Procedure
Time (20 min. total)
Spee
d (%
)Lo
ad (
%)
Copyright © 2004 Caterpillar Engine Research
Fuel consumption difference < 0.5% No transient performance
calibration for these results!
Measurement technique averages instantaneous fuel rate
System Performance Results(Test: Black Curves)(Simulation: Red Curves)
Copyright © 2004 Caterpillar Engine Research
Note how integrated measured fuel lags then catches back up
System Performance Results – Zoomed In(Test: Black Curves)(Simulation: Red Curves)
Copyright © 2004 Caterpillar Engine Research
FTP Cycle NOx
Dilu
te N
Ox
(pp
m)
n Modified PleeNOx model
n “Standard” coefficients with some transient matching
Test vs Simulated FTP Cycle NOxTest Point 4 Hot Run 7
Test NOx Sim NOx
NO
x(g
/hp.
hr)
Engine-Out NOx Results(Test: Black Curves)(Simulation: Red Curves)
Copyright © 2004 Caterpillar Engine Research
FTP Cycle Engine-Out PM
PM
Rat
e
Test vs Simulated FTP Cycle PMTest Point 4 Hot Run 7
0
Test Est PM Sim PMP
M (g
/hp.
hr)
n Test-based steady-state PM map
n Transient A/F multiplier
n Transient match
Engine-Out PM Results(Test: Black Curves)(Simulation: Red Curves)
(test estimated from opacity)
Copyright © 2004 Caterpillar Engine Research
Diesel Particulate Filter Results(Test: Black Curves)(Simulation: Red Curves)
Copyright © 2004 Caterpillar Engine Research
Engine-Out PM Reduction – System Effect
n High engine-out PM rate to accelerate filter loadingn Red: baselinen Blue: ½ steady-state engine-out PM rate across board
For this particular system, 2X higher engine-out PMrate gives about 2.6X faster filter loadingdue to increasing backpressure on engine. Leads to increased fuel consumption and increased need for regeneration.
Filt
erP
ress
ure
Dro
p
So
ot
in T
rap
(g/L
)
Copyright © 2004 Caterpillar Engine Research
In-cylinder 3DCombustion
More with Less – High Fidelity Simulation
Detailed Comb.+ Emissions
Steady-statePerformance
Develo
pm
ent C
ycle
Simulation World <$Objectives
Transient/SystemPerformance
Real-worldSystemPerformance
Multi Cylinder Steady State
Test World $$$
Multi Cylinder Transient
Single Cylinder Test Cell
2007 DemonstratorTruck
EngineAftertreatment (A/T)(Separately)
Engine + A/T+ Test Cell
Engine + A/T+ Vehicle
(Coupled Together)
(Coupled Together)
Copyright © 2004 Caterpillar Engine Research
2007 Demonstrator Truck Model
n Engine from test cell model drops into truckn Similar level of detail in truck modelnMore in video at end of presentation
Copyright © 2004 Caterpillar Engine Research
Summary – Transient Simulation
n Need to model details – accuracy, relevancy
n Need to include more than just engine
n Caterpillar has been practicing this for years with the help of excellent simulation tools
n Need to improve modeling of measurements (measurement error and dynamics become even more significant for 2007/2010)
n Need to pay attention to engine-out PM for best engine/particulate filter system
Copyright © 2004 Caterpillar Engine Research
Acknowledgements
n These results are built on the work of 100’s of Cat people over decades. Inventors of the basic computing tools are:
James R. Weber, Scott A. Leman, and Kem D. Ahlers, William L. Brown, and Eric C. Fluga.
n Cost share provided by the United States Department of Energy
Copyright © 2004 Caterpillar Engine Research
Truck Simulation Movie