Innovative Motorenentwicklung zur Senkung der Emissionen und des Energieverbrauchs

Transkript

1 Innovative Motorenentwicklung zur Senkung der Emissionen und des Energieverbrauchs Technologieforum 24. September 2012 Arbon Meinrad Signer General Manager FPT Motorenforschung Arbon Switzerland

2 Overview Vorstellung FPT Motorenforschung Fiat Industrial FPT Motorenforschung Arbon Reduktion der Abgasemissionen Euro VI Grenzwerte Lösungsansätze Hi-eSCR, die gewählte Lösung, Innovation aus Arbon Was wurde damit erreicht Was bringt die Zukunft Energie-Management, Reduktion Verbrauch und CO2 2

3 FIAT INDUSTRIAL 3

4 FIAT INDUSTRIAL: a global leader 4

5 5

6 A top world player 6

7 Alliances, Cooperation Agreements and Main Customers 7

8 Engine portfolio: all applications 8

9 6 R&D Centers Product Engineering Technical Centers Worldwide BURR-RIDGE Engines application for CNH and US non captive customers TURIN Engines and transmissions development and customization for on road, off road, marine and power generation applications ARBON Excellence center for advanced technologies and base engines development FECAMP Customization and homologation of power generation units CHONGQING (JV) SFH engines customization and application for Chinese market BELO HORIZONTE Engines customization and application for Latin American market (*) RANJANGAON Support for India and Turkey applications (*) SHANGHAI-Jiading Design and Testing for Chinese Market application and support to European R&D centers (*) R&D Support from Fiat SpA 9

10 10

11 Human Resources OVERALL EMPLOYEES / WORKERS Workers 79 Professional Experts 18 Professionals 72 Employees 37 Mechanic 70 Laboratory Designer 1 Admin 1 7 Electronics 10 NATIONALITY PROFESSIONALS / EXPERTS Germany 32 Slovenia 1 France 1 Spain 2 Greece 1 Tech grade 12 Dr.sc.tec 7 Master 36 Italy 15 Austria 11 Swiss 134 Bachelor 61 Belgium 1 UK 5 11

12 Testing Resources Equipment / Laboratories Engine Test-cells 11 dynamic test-cells 17 steady state test-cells 1 anechoic test-cell 1 light duty vehicle dyno 2 cold start test-cells Laboratories Injection systems Flow lab, port dev Structural analysis Exhaust after-treatment Engine electronics, sensors Testing / automation Instrumentation, emissions Workshops General machining Test-cell preparation Catalyst canning Maintenance Engine system test-rigs 4 diagnostic test-rigs 4 engine system test-rigs 1 inclination test-rig 1 sensor test-rig 12

13 Arbon Technical Centre History First truck diesel engine Direct injection diesel engine patent Common rail injection development, cooperation with CRF and Elasis. Patent in 1988 Double re-entrant combustion bowl First application of VGT on diesel engine First Common Rail on LCV First Common Rail on agricultural application Saurer Iveco Motorenforschung Dereco First small high speed direct injection diesel engine with turbocharger SiNOx / SCR development Among first with SCR and Euro V SCR only for Euro VI / Tier 4 / Stage IV 13

14 Mission Fully integrated in PE-Matrix-Organization All Base engine development (F1C) NEF Cursor Pre-development, concept studies, technology scouting All After-treatment development incl. Controls All Engine controls, function development, model based control All OBD / SCR inducement / diagnostics Applications and application support Support PE functions in all related areas 14

15 Competence need for efficient engine development Diesel Combustion Air handling and port dev After- Treatment ATS OBD and diagnostics Control Simulation and Computation NVH Stress Analysis and materials Injection Controls And Function dev Testbed Proto shop, canning Basic technologies Control and automation Electronic components 15

16 Arbon Tech Centre has all key competences in house After- Diesel Combustion Air handling and port dev Treatment ATS Control OBD and diagnostics Simulation and Computation NVH Stress Analysis and materials Injection Controls And Function dev Testbed Proto shop, canning Basic technologies Control and automation Electronic components 16

17 Overview Vorstellung FPT Motorenforschung Fiat Industrial FPT Motorenforschung Arbon Reduktion der Abgasemissionen Euro VI Grenzwerte Lösungsansätze Hi-eSCR, die gewählte Lösung, Innovation aus Arbon Was wurde damit erreicht Was bringt die Zukunft Energie-Management, Reduktion Verbrauch und CO2 17

18 Emissions: the pollutants 18

19 Emission Regulation in Europe 19

20 Euro VI: stricter emission limit values 20

21 A challenge for our industry, a massive commitment for the environment 21

22 Emissions: the dilemma 22

23 Emissions: the dilemma 23

24 Diesel Combustion, Fuel Injection Common Rail Injection, max pressure bar (LD+MD), bar (HD) MULTIPLE INJECTIONS DOUBLE RE-ENTRANT BOWL OPEN BOWL 24

25 Euro VI HI-eSCR 25

26 SCR catalyst system 26

27 SCR catalyst system 27

28 FPT INDUSTRIAL-patented dosing algorithm 28

29 A light and compact package 29

30 DPF + SCR vehicle installation 30

31 NOx Real Driving Emissions 31

32 FPT ATS strategy for non- and on-road Stage IV Euro VI FPT INDUSTRIAL-PATENTED FORECASTING ALGORITHM TO CONTROL ECU STRATEGIES FPT INDUSTRIAL-PATENTED MIXING PIPE FLUID-DYNAMICS DESIGN 32

33 Truck of the Year

34 Overview Vorstellung FPT Motorenforschung Fiat Industrial FPT Motorenforschung Arbon Reduktion der Abgasemissionen Euro VI Grenzwerte Lösungsansätze Hi-eSCR, die gewählte Lösung, Innovation aus Arbon Was wurde damit erreicht Was bringt die Zukunft Energie-Management, Reduktion Verbrauch und CO2 34

35 Engine Efficiency Development FIRST DIESEL ENGINE FIRST TURBOCHARG ED HEAVY DUTY ENGINE ADVANCED AIR-HANDLING SYSTEMS EURO VI HI-eSCR ENGINES 35

36 Future Thermal Efficiency (BTE) Targets 60% 50% 40% 30% 2011 DIESEL ENGINES EFFICIENCY RATE 2020 DIESEL ENGINES EFFICIENCY RATE 36

37 Fuel Consumption, the future issue HOW TO ADDRESS FUEL CONSUMPTION ISSUE? ENGINE EVOLUTION ENERGY MANAGEMENT ENERGY RECOVERY Combustion efficiency FC-optimised gear shifting Air handling Thermal management Auxiliary management Friction reduction Advanced turbo systems Waste-heat recovery Brake-energy recovery 37

38 Pumpe-Leitung-Düse Einspritzung 800bar Mechanische Regler Turboaufladung (mit Turbobloch) kommt Erste Fahrzeuge mit Ladeluftkühlung Common-Rail Einspritzung bis 2500bar Mehrfacheinspritzung Elektronisch geregelt Turbo mit variabler Geometrie, LLK 2-stufige Aufladung Abgasrückführung gekühlt SCR Abgasnachbehandlung Dieselpartikelfilter Leistungsdichte 20 kw/liter Mitteldruck bar Oelwechselintervall km NOx ~17-18 g/kwh ECE R49 13-Stufentest Leistungsdichte kw/liter Mitteldruck bar Oelwechselintervall km Euro VI: NOx 0.46 g/kwh im WHDC 38

39 39