Bosch Diesel Systems beyond Fuel Injection & Exhaust Gas Treatment: Air System and Hybridization

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1 Bosch beyond FIE & EGT Bosch beyond Fuel Injection & Exhaust Gas Treatment: Air System and Hybridization ICE 215, Capri, Sept. 16 th 215 Dipl.-Ing. Joachim Paul,, Robert Bosch GmbH 1

2 Bosch beyond FIE & EGT Content Introduction Air system approach Diesel hybridization concept Summary 2

3 Bosch beyond FIE & EGT emission CO 2 cycle EU 5 EU 6 post-eu 6 13 g/km 1% fleet 95% 95 g/km 1% fleet, proposals Next step? MNEDC-based testing WLTP-based testing RDE Development phase limit cf criteria emission limit 26 Source ADAC 215/3 35 Source: Long Term Forecast w/o 3-wheelers and OHW CO 2 [g/km] vehicle mass [kg] Gasoline vehicles Diesel vehicles Europe 2 ) Veh. [m] % % 11,4% -1,2% 17 39% % % 15 1) includes Gasoline / Diesel Hybrid and 48V 2) includes EU27 + other countries (non-eu, RU, TR, ) 2 34% 21 9% Hybrid, EV, Hydrogen 1) Flex-Fuel, CNG, LPG, Alcohol Gasoline Gasoline DI Diesel

4 Bosch beyond FIE & EGT WLTC and Real Driving Emissions Increase of Transient Operations Wider engine operating area acceleration [m/s²] NEDC WLTC RDE velocity [km/h] BMEP [bar] WLTC Euro 1 5 (6) MNEDC Euro 6 + RDE WLTP & RDE engine speed [rpm] Significant increase of transient operations and wider operation area for new driving cycles 4

5 Bosch beyond FIE & EGT innovative concepts Air System Advanced T/C HW New SW functions (transient and model based engine control) Diesel Hybridization Boost recuperation system Operating mode strategy (stationary and transient conditions) FIE benchmark future legislation injection strategy exhaust gas after treatment platform demonstrator single cylinder engine 5 Complete testing platform for future technologies

6 Bosch beyond FIE & EGT Content Introduction Air system approach Diesel hybridization concept Summary 6

7 Bosch beyond FIE & EGT ball bearing improved transient behavior reduced fuel consumption VTG 2 nd gen reduced axial vane clearance minimal hysteresis titanium aluminide turbine wheel 5% reduced inertia due to material improved transient behavior MIM process in Bosch electrical actuator minimal hysteresis high actuating speed and force compressor wheel hard anodized compressor wheel to prevent damages due to low pressure EGR new aero design High flow turbine and compressor wheel Bosch speed sensor no over speed damages use of whole compressor map additional OBD functions Deriving turbocharger requirements within Bosch s overall system approach 7

8 Bosch beyond FIE & EGT 8 displacement rated power max. torque basic configuration compr. ratio 16 bore stroke 1.65 l 11kW@4rpm 34Nm@17rpm 81mm 8.5mm EGR low pressure + high pressure bmep [bar] bmep [bar] bsfc [g/kwh] WLTC, compact class NO x [g/kwh] engine speed [rpm] Dedicated optimization of main driving area necessary 3.

9 Bosch beyond FIE & EGT 9 bmep [bar] bmep [bar] p 2 - p 3 [mbar] engine speed [rpm] [-] T / T max [-] p 2 /p 1 [-] C / C max [-].8 m red T [kgk.5 /kpas] m red C [kg/s].95 π T =2.8 Increased bsfc caused by low air-fuel ratio and high gas exchange work at low engine speed.85

10 Bosch beyond FIE & EGT T / max T [-] p 2 /p 1 [-] 27Nm@14rpm % m T red [kgk.5 /kpas] C / max C [-] %.8 1. performance efficiency TC TC 65kW/l 5kW/l 34Nm@17rpm 34Nm@14rpm m C red [kg/s] bmep [bar] bmep [bar] 3 pumping losses [mbar] performance TC 25 efficiency TC bsfc [g/kwh] performance TC efficiency TC engine speed [rpm] High fuel consumption benefit in main driving area with the efficiency TC 1

11 torque [Nm] NO NO x [ppm] x [ppm] Bosch beyond FIE & EGT desired actual time time [s] [s] boost boost pressure pres. [mbar] [mbar] Transient ECU strategy load step 12rpm stationary low load operating point 1 transient: temporary lack of boost pressure torque forced 2T control 2E 3 emission forced control* *EGR + fuel injection system control stationary high load operating point Transient turbocharger performance as essential key parameter AIR EGR fuel 11

12 boost pres.[mbar] main inj. NOx x [ppm] φ main inj. [ CA] [ CA] Bosch beyond FIE & EGT % -28% -4% time [s] No fuel consumption penalty fuel consumption penalty EGR EGR valve valve [%] [%] torque [Nm] [Nm] Load step 12rpm Emission forced NO x peak reduction performance TC base efficiency TC -12% performance TC + transient control efficiency TC + transient control performance TC efficiency TC performance TC + transient control efficiency TC + transient control -28% -4% Significant reduction of NO x peaks w/o reduced engine efficiency possible 12

13 torque torque [Nm] [Nm] Bosch beyond FIE & EGT % -33% T 3Nm time [s] [s] boost pressure pres. [mbar] [mbar] Load step 15 rpm Torque forced performance TC efficiency TC 2-stage TC (simulation) Transient behavior performance TC base efficiency TC -33% 2-stage TC (simulation) -4% Significant increase of transient performance due to efficiency turbocharger 13

14 Bosch beyond FIE & EGT Relative relative fuel Fuel consumption Consumption [%] in % MNEDC -2.7% Meas. based -3.5% Sim. based WLTP -1.8% Meas. based -2.6% Sim. based Fuel consumption benefit up to 2-3% due to efficiency turbocharger 14

15 Bosch beyond FIE & EGT Content Introduction Air system approach Diesel hybridization concept Summary 15

16 Bosch beyond FIE & EGT System description: P1m configuration engine clutch Fuel tank P1m System description: Vehicle 147 kg curb weight ICE Diesel Swept volume 1,65 litre Battery BRM starter gearbox Cylinders 4 Valves 4 CR 16 Considered Degrees of Freedom: Clutch open/closed Torque distribution Vehicle velocity Power Torque Emissions Gearbox Clutch E-Drive E-Motor (BRM) Battery 4 rpm rpm EU6 MT5 electrical actuated 48V 11kW peak power, air cooled Ratio E-Motor/Crank shaft 3/1 Lithium Ion Torque distribution as major degree of freedom for P1m configuration 16 BRM Boost recuperation machine

17 Bosch beyond FIE & EGT Basic ECMS controller structure: SOC ref SOC equivalence function s Control CO2 P edrive P costs P Driver min Cost function - Vehicle Fuel tank P ICE engine clutch P edrive Battery BRM starter gearbox 17 ECMS: Equivalent Consumption Minimization Strategy

18 Bosch beyond FIE & EGT Diesel ECMS controller structure: SOC ref SOC equivalence function s Control w fuel *CO2 + w NOx *NOx P edrive P costs P Driver min Cost function - Vehicle Fuel tank P ICE engine clutch P edrive Battery BRM starter gearbox P1m 18 ECMS: Equivalent Consumption Minimization Strategy

19 Bosch beyond FIE & EGT Results Diesel ECMS: SOC [%] Conventional w fuel =1 w fuel =,8 6 5 NOx [g/h] Sum CO2 [g] Sum NOx [g] Time [s] Speed [km/h] Reduced NO x -Emissions w/ comparable consumption improvement for w fuel =,8 19

20 Bosch beyond FIE & EGT Transient Diesel ECMS controller structure: SOC ref SOC equivalence function s Control w fuel *CO2 + w NOx *NOx P edrive P Driver P costs min Cost function max BTC (BRS transient control) - Air System Dynamics Vehicle Fuel tank P ICE engine clutch P edrive Battery BRM starter gearbox P1m 2

21 1361_868xv121_P_597_C68_V45_ECS_eh5_pst_1_mAGR_ohneBRS.ipw Seite 15 Bosch beyond FIE & EGT BRS transient control (BTC): Motivation ECMS: Stationary Emissions BTC: Transient Emissions Diesel ECMS based on stationary NO x - /CO 2 -Maps BMEP [bar] NOBE_F [g/kg] Engine speed [rpm] NO x -& CO 2 -KF load pboost dynindi Dynamic indicator Dynamic indicator (rel. boost pressure deviation) w fuel *CO2 + w NOx *NOx dynindi * BRM_trqMax = BRM_trqDynAct P costs 1 max max min BRS-Strategie BRS-Transient-Control Additional transient torque intervention by BTC 21

22 Bosch beyond FIE & EGT Results Diesel ECMS + BTC: SOC [%] NOx [g/h] Conventional w fuel =1 w fuel =1 +BTC w fuel =,8 w fuel =,8 +BTC Part 1 Major impact for NOx reduction: BTC Part 2 Major impact for NOx reduction: Diesel ECMS Sum NOx [g] 1 1 Speed [km/h] Time [s] Minimal NO x -emissions with 8%-CO 2 +BTC 22

23 Bosch beyond FIE & EGT CO 2 and NO x potential: NO x [%] RTS95 w fuel = 1 w fuel = 1 + BTC WLTC MNEDC w fuel = 1 w fuel = 1 w fuel = 1 + BTC w fuel =,8 w fuel =,5 w fuel =,2 w fuel = 1 + BTC w/o BRS w fuel =,8 w fuel =,8 + BTC w fuel =,8 w fuel =,5 w fuel =, CO 2 [%] Increasing CO2 and NOx potential for real driving conditions 23

24 Bosch beyond FIE & EGT BOSCH HEV product portfolio: P-HEV S-HEV BRS 48V Components Systems Functions Engine CO 2 reduction NO x reduction P costs min EGT ECMS + BTC BOSCH enables optimized overall system w/ minimized CO 2 and NO x emissions 24

25 Bosch beyond FIE & EGT Content Introduction Air system approach Diesel hybridization concept Summary 25

26 Bosch beyond FIE & EGT Air System Approach performance TC efficiency TC 2-stage TC efficiency TC + transient control time to torque base line -33% -4% -33% Δfc MNEDC WLTP NO x peak reduction TiAl turbine ball bearing RDE compliant -2.7% -1.8% -12% -3.5% -2.6% not measured -2.7% -1.8% -4% Optimized overall system including RDE compliance developed by Bosch and BMTS Reduced fuel consumption demonstrated with further potential for down speeding Significant reduction of transient NO x emissions due to fast boost pressure built up and advanced transient control: Reduction of costs for the EGT system possible + Fuel and cost efficient overall system 26

27 Bosch beyond FIE & EGT Diesel Hybridization Concept A holistic approach for Diesel Hybrid Operating strategy was realized Potential for CO 2 and NO x reduction was demonstrated in three different driving cycles: MNEDC, WLTC, RTS95 Increasing CO 2 and NO x potential for realistic driving cycles compared to homologation cycles Diesel Hybrid Operating Strategy as one option for RDE fulfilment Available as platform ECU function Future development: Enlarge to higher hybridisation degrees (S-HEV, P-HEV) Adaptive closed loop operating strategy Include short-, mid- and long range prediction 27

28 Bosch beyond FIE & EGT Thank you for your attention! Questions? 28

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