Internal Combustion Engines ERTRAC Workshop, 2 June Project title: CORE. Coordinator Johan Engström, Volvo. Status May 2015

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1 Internal Combustion Engines ERTRAC Workshop, 2 June 2015 Project title: CORE CO 2 REduction for long distance transport Coordinator Johan Engström, Volvo Status May 2015

2 Project general information CORE - CO2 REduction for long distance transport Current status: Start date 1 st of January 2012 Coordinator: VOLVO Total number of partners: 16 Partners: Volvo, Daimler, CRF, Ricardo, Federal Mogul, Honeywell, IAV, University of Hanover, University of Milano, University of Turin, Rhodia, Umicore, Chalmers, Johnson Matthey, Metatron, JRC, Core Group: CRF, Daimler, VOLVO, IAV, Ricardo OEM: CRF, Daimler, VOLVO Duration: 4 year Budget Total budget ~ keuro, EC contribution up to ~9 000 keuro

3 Structure SP B1 Friction Reduction SP B2 Aftertreatment systems SP A1 Daimler Diesel engine optimized for HEV SP A2 Volvo High efficiency Diesel engine for long haul SP A3 CRF Advanced combustion system for Diesel and NG HD engines SP D Project Management SP A4 Final assessment

4 Motivation / objectives / milestones Motivation q q Improved fuel efficiency for long haul transport Development of innovative and competitive solutions for HD engines with a market introduction target before the end of this decade. Objectives q CO2RE will focus on developing highly efficient drivelines for long distance transport contributing to a 15% reduction in fuel consumption Milestones plan q The main result will be achieved during the last year, and validated by complete powertarin test and vehicle simulation in real life application jointly with JRC

5 Main objective roadmap Roadmap towards 11-18% reduction in fuel consumption Fuel Consumption Euro V MY2009 To comply with Euro VI std Engine Platform 11% 6-9% Hybridization 3-5% 2-4% Friction, EAS 18%

6 Status report on progress and deliverables CORE has been on-going for nearly 3,5 years. The progress of work is almost according to the plan, no major changes. Fuel efficiency has been obtained in all sub-projects. CORE target of 15% reduction has been achieved for MD engine in a hybrid application. In-progress optimisation of engine system in the different subprojects Vehicle simulations, assessment of CORE developed technologies, with objective to investigate other pathways to the target of 15% CO2 reduction External review has been performed after the 36 months. Follow up in-progress.

7 Achivied results in respecte to CORE roadmap Engine platform: Results: 5-7% (CNG,MD,HD) In-progress: Engine system optimisation Fuel onsumption Euro V MY % 18% To comply with Euro VI std 6-9% Hybridisation Results: over 6% In-progress: energy strategies Engine Platform EATS Results: improved SCR performance in lower temperature range In-progress: duty cycle optimisation Hybridization 3-5% 2-4% Friction, EAS Friction Results: about 1% on MD engine In-progress: 2 nd test with new piston ring design

8 Main technical challenges and solutions in the project Main technical development Increased peak cylinder pressure, above 230bar Downspeeding High performance turbo system, variable geometry and dual stage technologies Variable vale technologies, advanced strategies and transient operations Aftertreatment improved NOx conversion at lower temperature range Reduced engine friction Challenges for sub-development are that novel design need and should meet improved performance, durability and robustness, cost effective

9 Main technical challenges and solutions in the project Solutions: Examples of new procurement of prototype hardware Concept VRT = Variable rotary turbine - variability of segment angle and flow area at turbine inlet via rotating tongues High efficiency, Dual Stage Turbo system, containing novel design, such as low solidity airfoil diffusers, radial-axial turbines configuration and ball bearings technology. Variable Valve Attenuation Enable Miller cycle and internal EGR for reduce of Nox emissions New piston rings lower friction Rings profile changed Reduce ring tension Increased skirt/bore clearance Reduced viscosity oil Low friction coating

10 Currently on-going: full engine tests application concept test optimisation engein & EATS Vehicle test in dyno AdBlue Fuel DOC DPF SCR AMOX ETC&WHVC cycles on dyno rolling bench at JRC

11 Assessment of CORE technologies by vehicle simulations performed by Ricardo, example Volvo Volvo Vehicle Model Data Summary Vehicle type: Heavy Duty 40t Tractor with semitrailer Mass: 40,000 kg Tractor tyre rolling radius: m Drag Coefficient Cd.A = 5.82 m 2 Tyre friction factor:

12 Expected final results: exploitation and impact Main benefits from final results: Demonstration of sub-technologies performance and concepts potential that can reduce the fuel consumption in near time frame. This is beneficial and competitive for the OEMs How will these results be used? Knowledge and part of the novel hardware /concept will be put in production Impact of these results on future research and development Increased efficiency of the engine lower the exhaust temperature higher demand on EATS, specific on lower temperature

13 Research issues more potential to reach based from CORE Physics: - Heat management (thermodynamics, heat rejection etc) Simulations tool: Improved precision Sub-technologies: -EATS, improved efficiency at lower temperatures - Variable valve applications Concepts -Down speeding, hybridisation, PCP above 250bar, transmission Powertrains -Intelligent powertrains increased flexibility and further integration of engine, EATS, hybrids, WHR. Require better simulations models (physical), better sensors & regulators and control strategies

14 Thank you