TU Darmstadt. Institute for Internal Combustion Engines and Powertrain Systems. Tuevhessen

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1 TU Darmstadt Institute for Internal Combustion Engines and Powertrain Systems Tuevhessen April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 1

2 Institute for Internal Combustion Engines and Powertrain Systems Staff Prof. Dr. Christian Beidl (Head of Institute) Prof. Dr. Günter Hohenberg (Emeritus) Dr. Bernd Lenzen Christoph Halscheidt Mikula Thiem Alexander Feiling Hauke Maschmeyer Harun Zlojo Markus Münz Raja Sangili Vadamalu Deborah Schmidt Christian von Pyschow Sebastian Fischer Johannes Hipp Sascha Bauer April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 2

3 VKM Research Areas ICE Optimization, Fuels Electrification Emission Control Real Driving Emissions Methodology & Simulation April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 3

4 Research Area ICE Optimization and Fuels Thermodynamic Analysis Indicating Calculation Visualization Optimization of internal engine processes Cylinder Zylinderdruck pressure [bar] [bar] IA Variation from ZW Variation von 0 0 to bis 33 CA 33 KW after TDC n. ZOT 19 CA 19 KW after n. TDC ZOT Late ZW ignition nach spät Outlet Auslass opens öffnet Late ignition ZW nach spät Crank angle [ CA] Kurbelwinkel [ KW] Heat Heizverlauf release rate [kj/m³/ CA] [kj/m³grd] Application Design of experiments Dynamic application Map based application Catalyst thermal management Freely programmable engine electronics Ignition delay [ CA] ZV [ KW] DRALLKLAPPENPOSITION [ ] ZZP [ KWvZOT] Gas Exchange Flow bench Simulation Optimization Alternative Fuels CNG LPG GTL BTL H 2 -Additives OME 1-Cylinder research engine Special fuel supply on each testbed April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 4

5 Research Area Emission Control Analysis of DPF and GPF Heavy & light duty Maximum soot load Balance point Regeneration strategies Backpressure Filtration efficiency Catalyst Investigations Heavy & light duty Light-off determination Aging factors Sulphur contamination (DOC) Characteristics in dyn. test cycles Thermal management for catalysts Operating conditions and specific requirements in hybrid electric vehicles SCR-Analysis Heavy & light duty Light-off behaviour Dosing strategies NH 3 -storage charact. NO X -conversion Active / passive SCR Nozzle geometry / evaporation Catalytic reduction of particulate matter Particulate Measurement Gravimetric analysis of TPM HPLC-Liquid- Chromatography Thermodissorption analysis Particle size distribution April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 5

6 Research Area Methodology and Simulation CAx-Systems GT-Power CFD Combustion analysis Gas exchange calculation NVH-Simulation Drivetrain simulation CAD 3D vehicle / driving environment simulation Highly Dynamic Testbed High resolution simulation Driveability analysis Analysis of drivetrain dynamics Start simulation for component specification Drivetrain evaluation X in the Loop Test bed System design and construction Evaluation methodology Maneuver based testing Electric motor controller with universal inverter and battery simulator Implementation of the Fahrermodell Fahrzeugmodell + - Batterie methodology in the development process Real Driving Emissions at the test bed Umgebung Automatisierungssystem Drehzahlregelung Fahrer- Wunsch v ist Betriebsstrategie CAN Klemme 15, alpha ~ = Batterie Simulator. RT-Simulationsplattform n soll M gemessen n ist Test Design Design of Experiments Optimization of hybrid strategies using DoE Workshop for professionals and students April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 6

7 Research Area Electrification Testbed X-in-the-Loop Vehicle realtime simulation Comparison vehicle testbed with real world driving Concept evaluation Operating strategy Multicriteria optimization Battery simulation Measurement of electric motors Testing Hybrids 3 own plus external hybrid test vehicles Concept evaluation & comparison vehicle testbed on real world test tracks Mobile exhaust measurement Mobile combustion analysis Concept development and application Range-Extender-Concept Comfort optimization vibration damping with electrical motor NVH-Analysis and evaluation Operating strategy development and optimization Direct-start/ Hybrid-start Simulation Realtime simulation Concept evaluation Fuel consumption simulation Driveability evaluation Offline optimization Real world driving RealSiMM April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 7

8 Research Area Real Driving Emissions RDE at passenger car engine dyno with RDE module Realtime simulation of vehicle, driver, track and traffic Identification of critical emission relevant dirving scenarios Evaluation using EMROAD & CLEAR Operating strategy development Multicriteria optimization RDE at chassis dyno Real time simulation of track and traffic Measurement with PEMS and stationary measurement systems Maneuver based RDE tests Robot driver or real driver RDE at heavy duty engine dyno with RDE module SCR system calibration with dosing strategy development DeNOx-Performance Optimization: stationary and transient RDE compliant engine design and combustion system development Road tests Measurement with PEMS System Influence of real driver characteristics Statistical evaluation of track severity April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 8

9 Infrastructure & Equipment 12 Testbeds with Emission Testing & Combustion Analysis Highend-Multiflex Testbed (VVETB) 4x4 Advanced Chassis Dyno (TUZ) Hybrid Testbed Engine-in-the-Loop Test Vehicles Test Tracks & Real World Cycles Vehicle Test Instrumentation & Gas/ Particle PEMS RT-Vehicle Simulation GT-Power Flow Bench Chemistry Lab FTIR Particle Counter Battery simulator Simulation Environment April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 9

10 Mobile emission measurement Real Driving Emissions April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 10

11 Real Driving Emissions Development Methodology Transfer Road-to-Rig SPEED km/h Consideration of driver influence RDE Measurements (PEMS) Evaluation of customer specific Real world driving scenarios Identification of significant scenario parameters Approach to parameterize for real driving scenarios Implementation of connected functionality Real world test for Engine-, Chassisand X-in-the-Loop Testbeds April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 11

12 Cooperation with the Center for Innovation and Environment, TÜV Hessen AVL 4x4 Advanced Chassis Dyno with RealTime Simulation Consistent toolchain with engine and powertrain testbeds Idealy suited for manoeverbased testing and future RDE requirements Joint Methodology development with TUZ, TÜV Hessen, Pfungstadt April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 12

13 Electromobility Center 2015 April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 13

14 Renovation of Testbed Infrastructure 2010/2011 April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 14

15 Events 2016 Vehicle & Powertrain Seminar, TU Darmstadt Invited Keynote Speakers from Industry HdT Tagung Plug-In-Hybride und Range Extender , Darmstadt Tech Day Indizierung, TU Darmstadt, 27. September 2016 Workshop Design of Experiments for students and professionals, TU Darmstadt, September 2016 VPC - Simulation und Test 2016, 18. MTZ-Fachtagung, Hanau bei Frankfurt am Main, September 2016 April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 15

16 Publications 2016/2015 Raja Sangili Vadamalu, M.Sc.; Mikula Thiem, M.Sc.; Prof. Dr. techn. Christian Beidl: Methodology for model-based development, validation and calibration of connected electrified powertrain systems, Conference on Future Automotive Technology (CoFAT), May Raja Sangili Vadamalu, M.Sc.; Prof. Dr. techn. Christian Beidl: Online optimization based energy management of hybrid electric vehicles using direct optimal control method, 16th Stuttgart International Symposium, March Münz, M.; Feiling, A.; Beidl, C.; Härtl, M.; Pélerin, D.; Wachtmeister, G.; Lehrstuhl für Verbrennungskraftmaschinen (Ivk), Technische Universität München: Oxymethylene Ether (OME1) as Synthetic Low Emission Fuel for DI Diesel Engines. 3. Internationaler Motorenkongress. Baden-Baden. Februar Alexander Feiling, M.Sc.; Markus Münz, M.Sc.;Prof. Dr. techn. Christian Beidl: Potential des synthetischen Kraftstoffs OME1b zum rußfreien Dieselmotor, MTZextra 01/2016, Januar Hauke Maschmeyer, Deborah Schmidt, Christian Beidl, Simulations- und Testmethoden für die Entwicklung von Fahrzeugantrieben unter Real Driving Emissions Randbedingungen, 6. Internationales Symposium für Entwicklungsmethodik, November, Raja Sangili Vadamalu, David Buch, Hong Xiao, Christian Beidl, Energy Management of Hybrid Electric Powertrain using Predictive Trajectory Planning Based on Direct Optimal Control, 16th IFAC workshop on control applications of optimization, October Raja Sangili Vadamalu, Christian Beidl, Methodik zur funktionalen Evaluierung und Robustheitsanalyse einer online-optimierenden Längsführung in einer vernetzten Umgebung, 17. MTZ-Fachtagung, VPC Simulation und Test, Oktober Buch, D.; Beidl, C.; Hohenberg, G. (IVD): Möglichkeiten der Drehschwingungsberuhigung bei Parallelhybriden mittels E-Motor; VDI- Tagung: Schwingungsreduzierung in mobilen Systemen 2015, Karlsruhe, April 2015 Dr.-Ing. F. Atzler, Dipl.-Ing. M. Wegener, Dipl.-Ing. (FH) F. Mehne, Dipl.-Ing. (FH) S. Rohrer, Continental Automotive GmbH, Regensburg; C. Rathgeber, M.Sc., S. Fischer, M.Sc., Institut für Verbrennungskraftmaschinen und Fahrzeugantriebe, TU Darmstadt: Kraftstoffverbrauch und Emissionseinflüsse der Phlegmatisierung von PKW-Dieselmotoren, HdT-Tagung Motorische Verbrennung, Erlangen-Nürnberg, April 2015 Dr.-Ing. F. Atzler, Dipl.-Ing. M. Wegener, Dipl.-Ing. (FH) F. Mehne, Dipl.-Ing. (FH) S. Rohrer, Continental Automotive GmbH, Regensburg; C. Rathgeber, M.Sc., S. Fischer, M.Sc., Institut für Verbrennungskraftmaschinen und Fahrzeugantriebe, TU Darmstadt: Fuel consumption and emissions effect from the phlegmatisation of a passenger Car Diesel engines, SAE World Congress 2015, Detroit (USA), April 2015 April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 16

17 Publications 2015/2014 Prof. Dr. techn. Christian Beidl; Rathgeber, C.; Spurk, P.; Göbel, U., Umicore AG & Co. KG: Impacts of Diesel-HEVs on exhaust gas aftertreatment systems for future emission legislations, 15. Internationales Fahrzeug- und Automobilsymposium, Stuttgart, März 2015 Christian von Pyschow, M. Sc.; Alexander Feiling, M. Sc.; Prof. Dr. techn. Christian Beidl; Dipl.-Ing. Magnus Schmitt, alle Institut für Verbrennungskraftmaschinen und Fahrzeugantriebe, Technische Universität Darmstadt; Dr. Eberhard Jacob, Continental Emitec GmbH: Der synthetische Kraftstoff OME im Betrieb am Nfz-Vollmotor Herausforderungen und Potentiale, Internationaler Motorenkongress, Baden-Baden, Februar 2015 Alexander Feiling, M. Sc.; Dipl.-Ing. Magnus Schmitt; Christian von Pyschow, M. Sc.; Prof. Dr. techn. Christian Beidl, alle Institut für Verbrennungskraftmaschinen und Fahrzeugantriebe, Technische Universität Darmstadt; Dr. Eberhard Jacob, Continental Emitec GmbH: Potential des synthetischen Kraftstoffs OME1 zur Emissionsreduzierung bei Dieselbrennverfahren, Internationaler Motorenkongress, Baden-Baden, Februar 2015 Maschmeyer, H.; Kluin, M.; Beidl, C.: Real Driving Emissions Ein Paradigmenwechsel in der Entwicklung, MTZ-Artikel, 76. Jahrgang, Wiesbaden, Februar 2015 Feiling A, M.Sc., Schmidt D, M.Sc., Beidl C, Dipl.-Ing. Michael Fischer, Honda R&D Europe (Deutschland) GmbH : NO x exhaust gas aftertreatment in context to Real Driving Emissions, VDI-Fachkonferenz AGN-Systeme, Frankfurt, October Rathgeber C, M.Sc., Beidl C, Waldhelm A, P. Spurk, U. Göbel, both Umicore AG & Co. KG, Hanau-Wolfgang : The requirements and potentials of the exhaust aftertreatment diesel hybrid applications, VDI Fachkonferenz Abgasnachbehandlungssysteme, Frankfurt am Main, Octobre 2014 Lenzen, B.; Beidl, C.; Maschmeyer, H.: Hybrid powertrains and RDE: Symbiosis or especial challenge, 2nd International Conference Real Driving Emissions, Düsseldorf, August 2014 Maschmeyer, H.; Kluin, M.; Mädler, J.; Beidl, C.: Integrated development process for Real Driving Emissions tests - From simulation to PEMS measurements at the street, MTZ-Fachtagung VPC.plus, Hanau, Septembre 2014 Beidl, C.: Evolution in a revolutionary environment; MTZ anniversary issue 2014, Wiesbaden, June 2014 April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 17

18 Education Institute for Internal Combustion Engines and Powertrain Systems Lectures Verbrennungskraftmaschinen I + II Konstruktion im Motorenbau I + II Berechnungsmethoden im Motorenbau I + II Bachelor and Master theses Tutorial for students Advanced Design Project Training course for professionals and students April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 18

19 Thank you for your attention! April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 19

20 Backup Tuevhessen April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 20

21 Range-Extender-Concept with ICE Combustion Engine Assist (CEA) 2-cylinder engine 850 ccm 40 kw simple and cost-effective high tumble design optimized fuel consumption be opt = 236 g/kwh E-Motor for automotives 40 kw Permanently excited synchronous machine High efficiency and power density 300 Nm maximum torque CEA - Concept Research partners: Robert Bosch GmbH Weber Motor GmbH IVD Prof. Hohenberg GmbH Compact and efficient E-Motor = Main drive ICE assists if required Consumption in the NEDC Cycle < 50 gco 2 /km April 13, 2016 Institute for Internal Combustion Engines and Powertrain Systems Prof. Beidl 21