Floating Nozzle Turbine: The Advanced Turbocharger Technology for the Gasoline Mass Market

Transcription

1 Floating Nozzle Turbine (FNT) Floating Nozzle Turbine: The Advanced Turbocharger Technology for the Gasoline Mass Market Vortragsreihe: Innovationen in der Fahrzeugtechnik FH Joanneum

2 Introduction Potential Design Summary Organization BMTS % % Stuttgart (DE) Headquarters, development center and prototype shop Blaichach plant (DE) Production of T/C components St. Michael plant (AT) Machining and final assembly 2

3 Grams of CO 2 per kilometer normalized to NEDC test cycle Number of vehicles Introduction Potential Design Summary Legislation and Market CO g/km 100% fleet 95% 95 g/km 100% fleet, proposals Next step? cycle RDE Development phase MNEDC-based testing WLTP-based testing limit cf criteria emission limit 220 China Japan EU US year Increased requirements due to upcoming legislation 3

4 torque [Nm] torque [Nm] Introduction Potential Design Summary Development Trends on Gasoline Engines NEFZ 3.2L nat. aspirated engine MPFI Downsizing 1.6L Turbo DI WLTC NEFZ engine speed [min -1 ] NEFZ engine speed [min -1 ] 1 WLTC T/C increases air density to compensate reduced displacement. Reduction of engine friction (especially with the reduced number of cylinders). Advantages of Downsizing Shifting main operation area to higher engine efficiencies (de-throttling). Increased downspeeding potential due to high low-end-torque. Significant reduction of CO 2 emissions by downsizing 4

5 Introduction Potential Design Summary Exhaust Gas Turbocharger for Gasoline Engines Rotor E-actuator Wastegate Compressor housing Turbine wheel Compressor Wheel Turbine housing Wastegate Turbocharger: Gasoline (passenger cars) Core unit Limit Value Limited by T/C speed up to krpm T/C Temperature upstream turbine Pressure upstream turbine up to 10 C up to 4bar T/C engine 5

6 torque [Nm] Introduction Potential Design Summary Challenges of Turbocharged Gasoline Engines NEFZ 1.6L Turbo DI Possible System Solutions WLTC speed [rpm] 2 Miller Cycle Cooled EGR Particulate Filter Strongly increasing requirements on the charging system Major Challenges in SI T/C engines Engine knocking Enriching for engine protection Fuel consumption Particle concentration Gasoline- VTG Increasing requirements on the charging system. 6

7 rel. Durchsatz [-] Drehmoment [Nm] rel. Durchsatz [-] BMW Development Meeting BMTS Vorteile der variablen Turbinengeometrie L Turbo DI LET P m c t t p3 p 4 p T ( ) t Drehzahl [min -1 ] 2 t FNT offen WG öffnet 1 2 Massenstrom über das WG Nicht genutzte Enthalpie 2 Anforderung LET / Dynamik 1 2 Hoher Ladedruck (LET) Niedriges Trägheitsmoment (Dynamik) kleines Turbinenrad Anforderung Nennleistung Niedriger Abgasgegendruck großes Turbinenrad FNT geschlossen Druckverhältnis [-] Durch die FNT wird die Enthalpie des Abgasmassenstroms komplett genutzt 7

8 bsfc [g/kwh] p Manifold [bar] pressure ratio [-] Introduction Potential Design Summary System Strategy Efficiency Concept Druckverhältnis [-] T Manifold [ C] korrigierter Massenstrom [kg/s] C T Krümmer [ C] Efficiency Concept GT-Power Simulation Boundary conditions : 100kW/l ; λ=1 ; e=10 WG VTG VTG + Miller 3.5 b eff [g/kwh] p Krümmer [bar] WG Δb eff,vl T manifold p manifold Basis engine Drehzahl speed [min [min -1 ] -1 ] nmot [RPM] engine speed [min -1 ] VTG VTG+ Miller up to -4% up to -6% -20 C -25 C -0.95bar -0.35bar Significant fuel consumption reduction w/ combination of VTG and Miller Cycle. 8

9 t 90 [s] [bar] Introduction Potential Design Summary System Strategy Influence of GPF Dynamics GT-Power Simulation Boundary conditions: 10rpm p me =2bar Full Load Low-End-Torque GT-Power Simulation Boundary conditions: 4-Cylinder Motor 80kW/l Miller-Concept e WG VTG 22.0 WG VTG 2.1 Ø TW 44mm MTM +70% -30% % Ø TW 41mm 19.5 Ø TW 40mm Ø TW 40mm 1.5 without GPF with GPF 19.0 without GPF with GPF The VTG enables significant increase in driveability. 9

10 Introduction Potential Design Summary The New BMTS Floating Nozzle Turbine VTG 1 st generation FNT simple, compact design Robust Design Successful in different diesel projects high thermal shock stability with patented floatingprinciple increased efficiency improved controllability Position 2 elastic deformation Position 2 elastic deformation Position 1 force transmission Position 1 force transmission 10

11 Introduction Potential Design Summary Summary Gasoline- FNT without GPF + with GPF Δb eff Δp me Δt 90 Δb eff Δp me Δt 90 Δ(FNT WG) -6% 0% -3% -6% +16% -30% Summary GPF increases exhaust back pressure Gasoline FNT shows significant advantages in comparison to wastegate turbocharger regarding: Fuel consumption Transient behavior Low End Torque System Approach Gasoline FNT in combination with Miller Cycle offers additional potential. Exhaust gas temperature up to 980 C possible BMTS can provide a Gasoline FNT mass market solution for different engine concepts due to its thermal robust and simultaneously simple design. 11

12 Introduction Potential Design Summary Thank you for your attention! 12