Influencing Factors on Particle Formation and Optimisation Potential under Real Driving Conditions
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- Judith Fischer
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1 APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen Influencing Factors on Particle Formation and Optimisation Potential under Real Driving Conditions Dipl.- Ing. Christian Lensch-Franzen Co-Writers: Prof. Dr.-Ing. J. Hadler, Dr.-Ing. M. Gohl, Dr.-Ing. J. Becker, Dipl.-Ing. C. Krohn, Dipl.-Ing. T. Mink, Dipl.-Ing. A. Schuhardt, M.Sc. A. Ebel, B.Eng. D. Portugall, Dipl.-Ing. M. Schäfer, APL Automobil-Prüftechnik Landau GmbH Apply & Innovate 216 Karlsruhe, 2th and 21st of September 216
2 INTRODUCTION Influencing Factors on Particle Formation and Optimisation Potential under Real Driving Conditions (RDE) APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 2
3 CHALLENGES FOR RDE Normalized Engine Torque [%] Torque Gradient (normalized) [%] Emission [%] Shift in Load Points System Robustness Engine Speed [rpm] Time [h] Gradient Validation over Lifetime Influencing Factors on Particle Formation and Optimisation Potential under Power Real Gradient (normalized) Driving [%] Conditions (RDE) 5 1 September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 3
4 INFLUENCING FACTORS Operation Strategy Operating Fluids Hardware Engine Operation - Steady-State - Transient Temperature Lubricant Fuel Combustion Process Interaction Components Air Mass Flow Injection Timing Crankcase/Piston Assembly Injection System Camshaft Timing Ignition Timing Turbocharger Cylinder Head Air / Fuel Mixture Fuel Entrainment into Lubricant Deposits & Wear September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 4
5 APL DEVELOPMENT STRATEGY Simulation Component Test Stand Engine Test Stand Powertrain Test Stand Vehicle / Dynamometer Requirements Society / Legislation RDE-capable Powertrain Specification NEDC WLTC, RDE Robustness, Lifetime RDE / Synthetic Cycle on Test Stand System Emissions, Drivability, Electrification, Subsystem Thermodynamic, Fuel, Oil, Exhaust Aftertreatment Component Mechanical System, Friction, Wear, Tools for Function Development Soot/Fuel Content in Oil, Mass Spectrometer, Optical Measurement, RNT, EHD, MBS, CFD, etc. September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 5
6 SIMULATION ENVIRONMENT Boundary Conditions Vehicle Model - Weight Class Load Condition - Powertrain Concept Engine & Gear Box Electrification - Aerodynamics Driver Model (IPGDriver) - Characteristics - Dynamics Acceleration Deceleration - Prediction Track Model APL Track Kit - Modular Design (currently 31 Modules) Boundary Conditions for RDE-Cycle Modeling: - Topography - Stand Still Time/ Driving Time - Driving Speed Average and Classification Traffic Model (IPGTraffic) - Traffic Load - Traffic Lights & Signs - Roadworks Environment - Temperature - Air Pressure - Humidity Target Values: - Efficiency (CO 2 ) - Limited Emissions (CO, HC, NO X, PM, PN) - Operation Strategy (Energy Balance) - Driveability September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 6
7 SIMULATION ENVIRONMENT APL Track Kit September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 7
8 CONCEPT ANALYSIS POWERTRAIN CONCEPT ANALYSIS DEVELOPMENT STAGE SIMULATION Vehicle Model Raw Emissions Model After-Treatment Model HARDWARE IN THE LOOP Component Test Bench Engine Test Bench Powertrain Test Bench ON-ROAD EMISSION MEASUREMENT REAL DRIVING Determination of the Main Factors (DOE) VEHICLE DRIVER TRAFFIC ENVIRONMENT TRACK HARDWARE, CALIBRATION & OPERATION STRATEGY Determination of the Main Factors (DOE) TARGET CONFIGURATION EMISSION FUEL CONSUMPTION DRIVEABILITY September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 8
9 MEASURES Package of measures APL Real Driving (Particle Number) > Injection Pressure > > > > > > Injection Strategy Calibration Optimisation Nozzle Tolerance Investigation Ring Design Oil Supply Oil Formulation September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 9
10 CYCLE EVALUATION Target Engine Load [%] APL Real Driving APL Synthetic Cycle Particle Number Motoring Time Load & Speed Gradient Start Engine Load [%] Target Engine Speed [rpm] 6 September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 1
11 FUNCTIONAL RELATIONS Particle Concentration [%] Oil Concentration [%] WOT after 1 sec WOT after 3 sec WOT after 5 sec WOT after 8 sec September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 11
12 CALIBRATION HOM1 HOM2 HSP2 Injection Strategy Particle Number, Soot Mass [%] Soot Mass [%] Injection Strategy: Homogeneous Combustion Process Particle Number Soot Mass 1. Injection 1 1. Inj. 2. Inj. 1. Inj. 2. Inj. 3. Inj. TDC BDC TDCF HOM1 HOM2 HSP2 Injection Strategy: Homogeneous-split 1 Improved Fuel Mixture 1. Injection 2. Injection HOM2 HOM1 1. Inj. 2. Inj. 3. Inj. 1. Inj. 2. Inj. 3. Inj. HSP2 TDC BDC TDCF Particle Number [%] 1 September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 12
13 CALIBRATION EFFORT Engine Torque [%] Combustion Process CALIBRATION EFFORT STEADY-STATE / TRANSIENT AIR MASS FLOW Throttle Valve Turbocharger / Compressor Camshaft Timing Residual Gas FUEL MASS FLOW Fuel Pressure Injection Timing Injection Splitting 1 st Injection 2 nd Injection : Air/Fuel Ratio IGNITION TIMING Engine Speed [rpm] LOCAL OPERATION POINT LOCAL OPERATION POINT (Speed / Load) FUEL CONSUMPTION EMISSION CO 2 CO THC NO X PN PM Oil Emission COMBUSTION Efficiency Center of Combustion (MBF5) Combustion Stability Combustion Noise NEDC WLTC RDE INFLUENCE FACTORS TARGET FIGURES LOCAL LOCAL LOCAL LOCAL LOCAL MODEL (Speed / Load) SPEED PEDAL GLOBAL MODEL CONSUMPTION EMISSIONS TORQUE September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 13
14 Interaction graph 3D graph CALIBRATION EFFORT Modelbased Concept Intersection graph Model structure Combustion Process September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 14
15 Deposits LIFETIME Aging, Wear, Deposits, Deviation Oil Aging Oil-Emission [%] Deviation Wear Cylinder Height Cylinder Height Particle Number [%] Lifetime Deposits Wear Oil Aging 1 Simulation Version 1 Version 2 Friction Force Hydrodynamic Percentage TDC RNT Measurement 8 6 Lubricating Oil 1 4 BDC TDC Friction Force Contact Percentage 2 Lubricating Oil Runtime [h] BDC ATS TS ATS TS Cylinder Circumference ATS Treated Area Top Ring Injector without Deposits EU6-Limit Engineering Target Injector with Deposits September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 15
16 Vehicle Speed [%] Particle Number [%] Oil Emission [%] OPTIMISATION Soot Mass [%] HC Emission [%] 1 NEDC before optimization after optimization RDE 1 1 NEDC RDE-cycle 1 Particle Number [%] HC Emission [%] 1 1 Oil Emission [%] Time [sec] Time [sec] September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 16
17 APL DEVELOPMENT CONCEPT RDE-capable Powertrain Vehicle Global Demand Engine Test Bench Chassis Dyno CO 2 - and Emission Reduction CFD & EHD Simulation Metallography Laboratory Component Test Stand Wear Measurement (Model based) Calibration Power Train Dyno Mass Spectrometer CarMaker Component and Function Combustion & Emission Model Chemistry Laboratory Tribometer Optical Measurement APL Method Chain for Power Train Development EHD, CFD, Laboratory, Oil/Particle-Emissions, RNT, Optical Investigation, RDE-Simulation, etc. September 2 th 216 Dipl.- Ing. Christian Lensch-Franzen APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 17
18 Factors influencing Particle Formation under Real Driving Conditions (RDE) THANK YOU FOR YOUR ATTENTION! APL Automobil-Prüftechnik Landau GmbH 212. Alle Rechte vorbehalten, auch bzgl. jeder Verfügung, Verwertung, Reproduktion, Bearbeitung, Weitergabe sowie für den Fall von Schutzrechtsanmeldungen 18
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