TNO Automotive Diesel Emission Control Introduction New Concepts Tools Testing
Presentation Content 1. Introduction 2. TNO Powertrains Roadmap 3. Proposition 4. Track record 5. Wrap-up 14-okt-09 2
Presentation Content 1. Introduction 2. TNO Powertrains Roadmap 3. Proposition 4. Track record 5. Wrap-up 14-okt-09 3
About TNO Mission Statement To apply scientific knowledge with the aim of strengthening the innovative power of industry and government Key Figures TNO is the Netherlands Organization for Applied Scientific Research Independent Research & Technology Development Founded by law in 1932 4,600 employees world-wide HQ in Delft, the Netherlands Annual turnover approx. 400 m 14-okt-09 4
Automotive Campus / Location TNO Automotive High Tech Automotive Campus: High tech automotive companies Facilities Education programmes Knowledge institutes Engineering companies 14-okt-09 5
Automotive Facilities Crash Testing Homologations Powertrian Test Center (PTC) Offices PT & IS Vehicle HiL testing (VEHiL) 14-okt-09 6
TNO Automotive Global Presence Coventry, United Kingdom Helmond The Netherlands Shanghai, China Seoul, Korea Livonia, MI, USA Nogent / Marne, France Stuttgart & Frankfurt Germany Bangalore, India Yokohama, Japan Wheelers Hill, Vic. Australia 14-okt-09 7
Business Unit Automotive Focus area s: Integrated Safety and Powertrains Over 35 years of automotive experience Close to 200 employees Over 65% Master or PhD Located in Helmond, the Netherlands International customers Annual turnover approx. 30 m Multiple expertises in one location http://www.automotive.tno.nl 14-okt-09 8
Diesel Emission Control within TNO Science and Industry Automotive (Helmond) Quality of of Life Defense, Security and Safety Powertrains Integrated Safety Homologations Built Environment and Geosciences Diesel Emission Control Information and Communication Technology Future Automotive Fuels Powertrain Testing Facilities Advanced Powertrains 14-okt-09 9
Connections within TNO Monitoring Systems Case examples Environmental Sust. Transport (Delft) Legal requirements Test procedures Traffic studies Oil & Gas Science and Industry Quality of of Life Automotive (Helmond) Thermal processes (Apeldoorn) Separation technologies (Delft) SCR chemistry CFD modelling Injector technology Food & Biotechnologies 2 nd gen. Biofuels Defense, Security and Safety Advanced concepts & products Plasma assisted gas cleaning Limit Built Environment and Geosciences Information and Communication Technology TTAI TÜV Rheinland TNO Automotive International (Helmond) Crash barrier engine aftertreatment Vehicle safety and crash testing 14-okt-09 10
TNO Role & Position TNO within the value chain Pull Automotive Market & Strategy Concepts Research & Adv. Eng. Engineering Industrialisation & Certification Push 14-okt-09 11
Value within the Development V-cycle Requirements, properties, specifications Validated, certified product Vehicle Simulation HD / LD to be intensified SiL / HiL Vehicle Testing LD dyno, HD climaticaltitude chamber Design & Development System Simulation Powertrain, engine, aftertreatment Module Fuel system, urea dosing system Component Sensor, injector Powertrain Testing engine, transmission dynamometers Module Testing Component testing Integration & Validation TNO = Focus and strong areas = Supporting 14-okt-09 12
About Diesel Emission Control group Mission Statement To provide validated new concepts, tools & controls for meeting future diesel exhaust emission requirements by applied R&D Engine-out NO x prediction Open-loop control T Desorption compensation urea correction Torque revs NO x engine-out prediction NO x prediction T SV NSR map urea dosage Tailpipe NO x target Torque Tailpipe NO x ref NO x target revs NO x sensor NO x sensor feedback control T Adaptation & cross-sensitivity compensation correction factor Model Based Control Test Facilities 14-okt-09 13
About Diesel Emission Control group Areas of expertise Combustion control research Emission targets feasibility study Model based control development System & control strategy development Design of exhaust lay-outs Engine testing and calibration Pre-production programs Demonstration vehicles Vehicle field testing Homologation, certification Benchmarking, reverse engineering Engine-out NO x prediction Torque revs NO x engine-out prediction Tailpipe NOx target Torque Tailpipe NO x ref NO x target revs NOx sensor Open-loop control T Desorption urea correction compensation NOx prediction T SV NSR map NO x sensor feedback control T Adaptation & cross-sensitivity compensation correction factor urea dosage 14-okt-09 14
Presentation Content 1. Introduction 2. TNO Powertrains Roadmap 3. Proposition 4. Track record 5. Wrap-up 14-okt-09 15
Major Challenges (1/2) Stringent Emission Legislation Standards: EURO VI / 6, US2010 Transient cycles: ETC, FTP, JE05 Cold start impact Focus of TNO s Diesel Emission Control group Passenger Car Heavy Duty PM [g/km] PM [g/kwh] 25 5 Euro 4 ( 05) Euro 6 Euro 5a ( 12) ( 09) NO x [g/km] 0.02 0.01 Euro V ( 08) Euro VI ( 12) Euro IV ( 05) NO x [g/kwh] 80 180 250 0.4 2.0 3.5 14-okt-09 16
Major Challenges (2/2) Energy Demand & Climate Change Upcoming CO 2 legislation (LD) Fuel costs increases Pressure to reduce fuel consumption Diversification of fuels to bio s, synthetics, gaseous Electrification of mobility: hybrids, EV s See also TNO s Advanced Powertrains group Oil Price $ CO 2 emissions [g/km] Petrol (current) Diesel (current) Micro hybrid Petrol (future) Mild hybrid Diesel (future) Hybrid potentials based on current petrol engine Full hybrid Additional cost 14-okt-09 17
Presentation Content 1. Introduction 2. TNO Powertrains Roadmap 3. Proposition 4. Track record 5. Wrap-up 14-okt-09 18
Proposition Overview Research and Application Customer Need Next generation solutions TNO Proposition New Concepts Current technology application Tools Calibration, validation Testing 14-okt-09 19
New Concepts - Overview Integrated Powertrain Control (IPC) Supervisory control of engine, aftertreatment and driveline to optimize trade-off s (fuel consumption vs. emissions vs. power output) Integrated Emission Management (IEM) Synergy between engine and aftertreatment to optimize trade-off s (fuel consumption vs. emissions) Aftertreatment OBD Model-based OBD control for more robust performance and less calibration effort Closed-loop combustion control C 3 Apply in-cylinder pressure information to minimise variations in power output and combustion phasing, avoiding misfires and knock and increasing stable operating range (HCCI/PCCI/fuels) TNO Euro VI SCR concept Future emission limits realized with limited EGR, based on maximized SCR efficiency for better fuel consumption at less costs New Concepts Tools Testing 14-okt-09 20
TNO Euro VI SCR concept TNO Euro VI SCR concept utilizes a closecoupled SCR catalyst NO x conversion is maximized by smart control, thermal management and EGR/SCR balancing New Concepts Tools Testing Reduced engine complexity compared to high volume EGR solution and better fuel consumption (CO 2 ) Simulation and testbench validation show: Close-coupled SCR catalyst NO x conversion of 95% over a weighted cold and hot WHTC is possible PM [g/kwh] Engine out NO x emission of 7 g/kwh is low enough to meet Euro VI emission legislation Testbench program made possible by: 0.03 0.02 V IV Engine out DPF 0.01 Tailpipe out 0.4 VI TNO Euro VI SCR concept 2.0 3.5 NO x [g/kwh] 7.0 14-okt-09 21
Example project: SCR Development 2006-2008 Complete design & validation of SCR system (hard- and software) from concept to vehicle European LD OEM, US market Base MY 2005, Euro 4, 2.2litre turbo diesel Budget ~ 1.5 m Issues tackled: Euro6 catalyst performance, homogeneity of urea distribution, crystallization, catalyst aging characterization for OBD Design & Development Simulation Vehicle System Module Component Powertrain Module Vehicle 249.4 C 23.9 C Integration & Validation Testing 200 100 Design & Development Testing Simulation Testing initial design catalyst & injector system & component characterisation geometry (cfd, cad) catalyst performance (fit tool, simcat) control development and precalibration (simcat) rapid control prototyping (macs) control calibration (winspecs) vehicle testing (roller dyno) EURO 4 EURO 6 Integration & Validation 14-okt-09 22
Tools - Overview New Concepts SIMCAT Exhaust aftertreatment modeling based on physical models Tools Objective Tools Testing Fit Tool Automatic fitting of testbench data towards a validated SIMCAT model Model Based Supported Calibration SIMCAT supported calibration of aftertreatment and OBD control strategies DYNAMO+ Control oriented dynamic engine model to predict mechanical and thermal power output and emissions MACS 565 Flexible and cost effective rapid control prototyping system consisting of controller and calibration tool Fuel Efficiency Potential within emission boundaries Tools R&D&E time/costs Achieve more in less time at less costs 14-okt-09 23
SIMCAT Diesel Aftertreatment Modelling New Concepts Tools Testing Diesel aftertreatment catalyst models build using actual physical models (instead of mathematical fitting) for increased result robustness Real-time capability Reduce time in development and calibration, especially in multi-configuration applications (e.g. different power ratings) Duration [# of days] 18 16 14 12 10 8 6 4 2 0 Conventional SIMCAT based 16 16 15 15 31% 11 50% 60% 8 67% 6 5 Man-hours Dyno testing Man-hours Dyno testing 1st configuration 2nd configuration Simcat 14-okt-09 24
DYNAMO+ Model-based combustion and aftertreatment control New Concepts Tools Testing Ambient conditions Compressor Intercooler Intake NO x, PM, temperature... Turbine Exhaust gas Cooling Valve Exhaust Fuel injection settings IMEP, ISFC, CA50, p max, dp/dca Application examples: Off-line calibration tool Model-based control development and OBD DYNAMO+ Enabler of advanced combustion concepts Maximise combustion and aftertreatment performance NO x and PM EURO IV/V EURO VI Combustion concepts Aftertreatment Conventional DYNAMO+ Fuel Consumption 14-okt-09 25
MACS 565 Modular Automotive Control System (MACS) is TNO s in-house developed flexible controller for prototype systems, vehicles and small scale fleets Simulation ADVANCE MACS 565 RCP Controller New Concepts Tools Analog I/O s Testing CAN & Ethernet Digital/timer I/O s 4 custom pins Calibration Winspecs Communication buses 3x hi-speed CAN Ethernet MACS saves time and cost in the early phases of the development proces. After prototyping the hybrid control software can be developed into production code suited for a production controller CAN Display & Control Panel I/O Modules: Analog/digital/timer I/O Otto engine Injection and /ignition Diesel engine Injection Electronic Throttle Control Client specific 14-okt-09 26
Powertrain Test Centre New Concepts Tools Mission Statement To provide R&D testing services in the field of combustion engines, drivetrains and vehicles Testing 14-okt-09 27
Powertrain Test Centre Engine dyno s transient, 20-700kW Transmission test bed with 2 transient dyno s Chassis dynamometer for LD Digatron electrical load simulator (750V, 300kW) Emissions analysis of both regulated (NO x, CO, THC, PM, ) and unregulated (NO, NO 2, CH 4, ) emissions by CVS, FTIR, PEMS, etc. Fuels liquid and gaseous types, biofuels Climatic - Altitude Chamber engines, powertrains and complete HD vehicle testing at temperatures from 45 to +55 ºC and up to an altitude of 4000m New Concepts Tools Testing 14-okt-09 28
Powertrain Test Centre New Concepts Tools Testing Engine dynamometer & Emission measurement equipment 14-okt-09 29
Powertrain Test Centre Climatic - Altitude Chamber New Concepts Tools Testing 14-okt-09 30
Powertrain Test Centre Climatic chamber application examples New Concepts Tools Testing Altitude [meters] 4000 3000 2000 1000 0 DPF regen. NTE (US) Cold start, White smoke Engine power, Turbo speed, Black smoke OBD (UN) NO x control OBD (EU) Temperature [ C] IUPR (EU) TNO climatic altitude chamber range ISC (EU) Cooling, Enginebrake -50-40 -30-20 -10 0 10 20 30 40 50 60 14-okt-09 31
Powertrain Test Centre Climatic Altitude Chamber Specifications Temperature range -45 to +55 C Altitude range 0 to 4000 m Wind speed, nozzle area 120 km/h, 1.25 x 0.7 m Dynamometer power, torque 550 kw, 7000 Nm Regulated emissions NO x, CO, THC, CO 2 Unregulated emissions NO, N 2 O, O 2, NH 3 Analysers: FTIR, particulate partial flow sampler, full flow CVS (at standard ambient conditions) Two direct emission lines at all ambient conditions Full transient hub-mounted dynamometers Pressure Vehicle temperature ~ 2 hrs -45 C New Concepts Tools Testing 4,000 m ~ ½ hrs + 55 C + 21 C ~ 8 hrs Duration Duration 14-okt-09 32
Presentation Content 1. Introduction 2. TNO Powertrains Roadmap 3. Proposition 4. Track record 5. Wrap-up 14-okt-09 33
Track Record Examples TNO Internal Research First SCR project from 1993 to 1996 and first SCR demonstrator truck in 1999 Euro VI testbench demonstrator Closed-loop combustion control engine demonstrator. Real-time model based control Customer Projects Commercial vehicle Development of DPF soot load predictor based on pressure drop and a regeneration strategy based upon this predictor Full engine and SCR calibration of two HD diesel applications for Tier 4i non-road emission standard Calibration and certification of Euro III common rail diesel engine Evaluation, calibration and certification of a complete aftertreatment system for a Euro IV truck application Passenger car Multiple SCR research and application projects Evaluation of a DPF regeneration assistance system (HC doser) and development of a production-intent control strategy Impact analysis of HD test procedures on a LD vehicle (van) diesel engine and aftertreatment system 14-okt-09 34
Presentation Content 1. Introduction 2. TNO Powertrains Roadmap 3. Proposition 4. Track record 5. Wrap-up 14-okt-09 35
Summary TNO Diesel Emission Control New Concepts Tools Next generation solutions Innovative concepts for cost-effective modelling and control of advanced combustion and exhaust aftertreatment systems Testing Tools for current technology Tools to reduce time and effort in the application of available technology Testing State-of-the art test facilities, including a fullsized climatic-altitude chamber, to support in a wide spectrum of testing needs 14-okt-09 36
Q & A Questions? How to continue 14-okt-09 37
Contact Information TNO Science and Industry BU Automotive Steenovenweg 1 5708 HN Helmond P.O. Box 756 5700 AT Helmond The Netherlands www.automotive.tno.nl T +31 40 265 2600 F +31 40 265 2601 E automotive@tno.nl 14-okt-09 38