Experimental Investigations of Transient Emissions Behaviour Using Engine-in-the-Loop

Transcription

1 TSI.InP.P_User5.Temperature7 [degc] TSI.InP.P_User4.Temperature [degc] TSI.InP.P_User4.Temperature3 [degc] Car.v [m/s] IO.Emission.CO_ DM.Gas Car.ay [m/s^] Car.ax [m/s^] Experimental Investigations of Transient Emissions Behaviour Using Engine-in-the-Loop Dipl.-Ing. Christian Disch *, Dr.-Ing. Heiko Kubach *, Prof. Dr.-Ing. Ulrich Spicher *, Dr.-Ing. Christian Schyr * * (IFKM), Karlsruhe Institute of Technology (KIT) * IPG Automotive GmbH, Karlsruhe INSTITUT FÜR KOLBENMASCHINEN KIT University of the State of Baden-Württemberg and National Research Center of the Helmholtz Association

2 Abstract Keywords: Engine-in-the-Loop (EiL), IFKM real world driving cycle, engine transient operation, raw emissions, fast response gas analyser, tip-in, HC emission peaks, diesel-hybrid, e-boost, SULEV In order to fulfil growing demands of new emission legislation and customer requirements real world driving cycles become more important. Investigations, especially under highly dynamic engine operation conditions have shown that the level of raw emissions could reach levels far greater than those under steady-state operation. Current legislative driving cycles like the NEDC do not have high proportions of transient operation. This finally leads to comparatively big differences in fuel consumption and raw emissions between legislative and real world driving cycles. Investigations to improve the combustion process under highly transient engine operation conditions using a real vehicle on public roads do not offer the required reproducibility due to ever changing traffic situations and other ambient conditions. Therefore the approach to use the internal combustion engine operated in a simulated environment is a promising technique, especially when stationary installed high-end testing equipment is indispensable to measure very detailed improvements. The simulation of the demonstrated Engine-in-the-Loop (EiL) method contains the vehicle-, track-, and the driver behaviour model. In this research project different newly defined IFKM driving cycles with a larger proportion of transient engine operation have been used to evaluate the level of CO, CO, NO and HC emissions of a diesel engine operated virtually in a C-class vehicle. The potential of combining an Engine-in-the-Loop test bench with fast emission measurement techniques is exemplarily shown for an approach to reduce identified HC emission peaks during a tip-in situation. The improvement is finally demonstrated by using an additional virtual e-boost functionality like in a diesel-hybrid vehicle architecture. It is shown that the diesel-hybrid concept could be an opportunity not only for an improvement in fuel consumption but also be a part of a global vehicle emission-optimized operating strategy. Current developments in reducing diesel engine raw emissions are focusing on PM and NO x but future legislative restrictions like in the US SULEV LEVIII also require improvements for HCs. In conclusion the project demonstrates the possibility to identify elementary events causing transient emissions onset within a real world driving cycle. The aim is to show the potential of the EiL method in combination with fast response gas analyser for investigation and improvement of HC emission peaks with regard to reproducibility and level of detail. 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

3 Outline Introduction EiL Measurement Setup Conclusion and Outlook Live-Demo KIT 3 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

4 Introduction / Engine-in-the-Loop (EiL) Body Tires Acceleration Driver Behaviour Vehicle Brakes Real World EiL Power- train Clutch Cycle Environment / Driving Cycle Gearbox Legislative Cycle Experimental Measurement Technique 4 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

5 Introduction / Engine-in-the-Loop (EiL) Engine-in-the-Loop = Synergetic Effect of Experiment and Simulation Hardware (Engine-Level) Two Approaches EiL Software One Method / Development Tool (Vehicle-Level) EiL = Only possibility to investigate transient emissions behaviour in detail under real world operating conditions Keywords Virtual test driving Legislative driving cycles Real world driving cycles Driver behaviour Detailed investigations with highest reproducibility Traffic conditions Ambient conditions Onboard diagnostics vs. additional high-end measurement equipment Efficient ECU calibration (transient operation) Combustion process Fuel consumption Raw emissions Driveability Flexibility in powertrain architecture (virtual and experimental) Global vehicle performance Electrification/ HEV Frontloading & Simultaneous engineering 5 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

6 Measurement and Test Bench Setup Research Topics EiL Test Bench IFKM Combustion Process Transient Emissions Behaviour Real World Driving Cycles Global Vehicle Performance Example of use in presentation: Detailed investigations of diesel engine transient emissions behaviour Possibility for improvement of HC emission peaks using a virtual diesel-hybrid powertrain 6 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

7 Measurement and Test Bench Setup EiL Test Bench Setup raw emissions (after turbine) emissions after catalyst Fast Response Gas Analyser (FRGA) Cambustion NDIR5 Non-Dispersive Infra Red Carbon Monoxide CO Carbon Dioxide CO Cambustion CLD5 CLD5 Chemiluminescence Detector Chemiluminescence Detector Nitrogene Monoxide NO Response Nitrogene T 9-% Monoxide ~ms NO Response T 9-% ~ms Cambustion HFR5 (FID) Flame Ionization Detector Total Hydrocarbons THC Response T 9-% ~.9ms Response T 9-% ~8ms fan simulated gearbox : real clutch (for real start) AVL - APA 34/8 33 kw 8 rpm 4 Nm Inertia:,9 kg m dyno AVL EMCON CONTROLLER AVL Puma Open AVL InMotion powered by IPG CarMaker Real Time Node 4-cylinder diesel engine 7 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

8 Vehicle speed [km/h ] Car.v [km/h] Real fuel consumption [l/km] Real fuel consumption [l/km] Real World Driving Cycle vs. Legislative Driving Cycle Gasoline Diesel Certified fuel consumption vs. Real world fuel consumption Fuel consumption in NEDC [l/km] Fuel consumption in NEDC [l/km] NEDC Source: Spicher, MTZ / Increasing ecological and economical awareness of customers New legislative driving cycles (e.g. WHDC, US- SULEV LEVIII) Necessity for investigations of real world driving cycles 8 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

9 Definition of Real World Driving Cycles Possibility to compare vehicle through real and virtual test driving IFKM - Part Load IFKM - High Load Bad Herrenalb Dobel Rotensol Bad Herrenalb Distance:.5 km Start/Finish KIT- IFKM (Rintheimer Querallee) Right Theodor-Heuss- Allee Left L64 Right B36 Right L559 Right L56 Right Hirtenweg KIT- IFKM (Rintheimer Querallee) Start/Finish Source: Google maps Distance: 3.3km Source: Google maps 9 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

10 Vehicle Car.v speed [km/h] [km/h ] Comparison of Different Driving Cycles 4 IFKM - High Load IFKM - Part Load NEDC Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

11 Engine Map - Requirements NEDC IFKM - Part Load ADAC Highway Cycle IFKM - High Load Different driving cycles Different engine map requirements (Legislative vs. Real World Driving Cycles) 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

12 HC [ppm] Measurement Simulation NO [ppm] CO [%] CO [%] Car ax [m/s^] Brake [-] IFKM - High Load (Raw Emissions (after Turbine)) Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

13 HC [ppm] NO [ppm] CO [%] CO [%] Car ax [m/s^] Event Event Event 3 Event 4 Event 5 Event 6 Brake [-] IFKM - High Load (Raw Emissions (after Turbine)) Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

14 PM [mg/m 3 ] HC-emissions during/after tip-in HC [ppm] HC [ppm] HC [ppm] HC [ppm] HC [ppm] HC [ppm] Identification of HC Emission Peaks,,8 6 5,,8, 6, Event Event Event 3 6,8 5,8 6,,8 6 5,,8 6,6 4,6,6 4,6,6 4,6,4,4 8,4,4 8,4,4 8,, 4,, 4,, 4,,,8 6 5, 7,6 7, 7,6 7, 7,6 73, 73,6,,8 6,,,8 6 5, 9,8 9,3 9,8 9,3 9,8 93,3 93,8,,8 6,,,8 6 5, 95,7 96, 96,7 97, 97,7 98, 98,7 Event 4 Event 5 Event 6,,8 6,6 4,6,6 4,6,6 4,6,4,4 8,4,4 8,4,4 8,, 4,, 4,, 4,, 35,4 35,9 36,4 36,9 37,4 37,9 38,4,, 434,3 434,8 435,3 435,8 436,3 436,8 437,3,, 476,5 477, 477,5 478, 478,5 479, 479,5 Example for PM during tip-in AVL 483 MicroSoot Sensor testrun testrun testrun 3 testrun 4 average Today: Focus for diesel engine on PM and NO x Future: Due to new legislative driving cycles (e.g. SULEV LEV-III) PM, NO x and HC 4 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

15 PM [mg/m 3 ] HC-emissions during/after tip-in HC [ ppm ] HC [ ppm ] HC [ ppm ] HC [ppm] HC [ ppm ] HC [ ppm ] HC [ ppm ] Identification of HC Emission Peaks, 6,,8 5,,8 6, 5,,8 6 5,,8 5 Event Event Event 3,,8 6 5,,8 5,6 4,8,6 5,8 9,6 4,6 9 6,6 4,6 9,4,4 6,4,4 6,4,4 6,,6, 4,6 3,, 3,, 3,, 7,6 7,8 7, 7, 7,4 7,6 7,8 7, 7, 7,4 7,6 7,8 73, 73, 73,4 73,6,, 9,8 9, 9, 9,4 9,6 9,8 9, 9, 9,4 9,6 9,8 93, 93, 93,4 93,6 93,8,, 95,7 95,9 96, 96,3 96,5 96,7 96,9 97, 97,3 97,5 97,7 97,9 98, 98,3 98,5 98,7, 6,4,8 5,,8,4 5, 6, 5, 6, 8 Event 4 Event 5 Event 6,8 5,8,8 5,8 5,6 4,,6, 9,6 4,6 4 9,6 4,6 9,4,4 6,4,4 6,4,4 6,,,,, 35,4 35,6 35,8 36, 36, 36,4, 36,6 36,8 7,6 7, 7,6, 7,, 7,6 73, 73,6 37, 37, 37,4 37,6 37,8 38, 38, 38,4 3,, 434,3 434,5 434,7 434,9 435, 435,3 435,5 435,7 435,9 436, 436,3 436,5 436,7 436,9 437, 437,3 3,,,, 476,6 476,8 477, 477, 477,4 477,6 477,8 478, 478, 478,4 478,6 478,8 479, 479, 479,4 479,6 3 Example for PM during tip-in AVL 483 MicroSoot Sensor testrun testrun testrun 3 testrun 4 average Today: Focus for diesel engine on PM and NO x Future: Due to new legislative driving cycles (e.g. SULEV LEV-III) PM, NO x and HC 5 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

16 HC [ ppm ] trailing throttle rpm decrease HC [ ppm ] Sensitivity of Pedal Movement α and Engine Speed rpm const. =,,9,8,7,6,5,4,3,,, Δt Alpha % =.5 s Δt Alpha % =. s Δt Alpha % =. s Δt Alpha % = 5. s 63,4 63,6 63,8 64, 64, 64,4 64,6 64,8 65, 65, ,,9,8,7,6,5,4,3,,, 9,4 9,6 9,8 93, 93, 93,4 93,6 93,8 94, 94, ,,9,8,7,6,5,4,3,,, 5,4 5,6 5,8 53, 53, 53,4 53,6 53,8 54, 54, ,,9,8,7,6,5,4,3,,, 6,5 7, 7,5 8, 8,5 9, 9,5,,5, pedal movement α decrease rpm const. =,,9,8,7,6,5,4,3,,, Δt Alpha % =.5 s Δt Alpha % =. s Δt Alpha % =. s Δt Alpha % = 5. s 63,4 63,6 63,8 64, 64, 64,4 64,6 64,8 65, 65, ,,9,8,7,6,5,4,3,,,,,,4,6,8 3, 3, 3,4 3,6 3, ,,9,8,7,6,5,4,3,,, 83,8 84, 84, 84,4 84,6 84,8 85, 85, 85,4 85, ,,9,8,7,6,5,4,3,,, 54, 54,5 55, 55,5 56, 56,5 57, 57,5 58, 58, Higher engine speed and higher pedal movement α enables higher HC emission peaks during tip-in 6 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

17 Hardware Real ICE Software Engine torque Diesel-Hybrid for Reduction of HC Emission Peaks during Tip-in ICE Hybrid Alpha EM CarMaker for Simulink Vehicle data C-class Validated with real vehicle data Electric motor data 6 Nm kw Internal combustion engine 4-cylinder engine Turbocharged diesel engine Production status 7 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

18 NO [ ppm ] HC [ ppm ] CO_ [%] CO [%] Vehicle speed [km/h] VC.Gas Hybrid Alpha Tip-in Test Run Definition Modified Tip-in Modified Tip-in Basic Tip-in 3, 6,5,6,,3, Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

19 HC emissions [ppm] Linear vs. Non-Linear Pedal Movement α t tip-in = s HC Average_max 75 ppm testrun testrun testrun testrun testrun testrun 3 3 testrun testrun 4 4 average average Identification: Pedal movement α and trailing throttle rpm before tip-in Explanation: Fast changes in mixture formation Challenge (trade-off): Driveability vs. Emissions Improvement: New definition of pedal movement (Hybrid Alpha) Result: Significant reduction of HCs during tip-in 9 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

20 HC emissions [ppm] Hybrid HC emissions [ppm] Linear vs. Non-Linear Pedal Movement α HC Average_max 75 ppm testrun testrun testrun 3 testrun 4 average Basic (linear) Basic (linear) f x = x 4 average result (five testruns) f x f x = x 4 = x 6 f x = x 6 f x = x f x = x absolute HC emission peaks can be reduced up to 8%! Data-Logging-Frequency = khz 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

21 HC emissions [ppm] Hybrid Linear vs. Non-Linear Pedal Movement α t tip-in = s f x = x 4 f x = x 6 f x = x Basic Differences between real alpha and emission-optimized hybrid alpha are only necessary up to 38% (acc. pedal position) Detailed modifications of the simulated pedal movement α (hybrid alpha) are temporarily of interest for <.4 sec. Very detailed modification of pedal movement α (injection quantity) significant impact on HC emission peaks High reproducibility! (f x = x ) testrun testrun testrun 3 testrun 4 testrun 5 average 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

22 Best modification HC [ ppm ] NO [ ppm ] Hybrid CO [%] Basic HC [ ppm ] NO [ ppm ] Hybrid CO [%] Comparison of Tip-in 3 and Tip-in,, Tip-in 3,9,8,8,6 4 7,7,4 6,6, 5,5, 8 4,4,8 6 3,3,6 4,,4,, ,,,, Tip-in,9,8,8,6 4 7,7,4 6,6, 5,5, 8 4,4,8 6 3,3,6 4,,4,, ,, The lower engine torque during the tip-in is finally compensated by the electric motor 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

23 Conclusion and Outlook Engine-in-the-Loop Real world driving cycles will become more important due to customer demands and legislative restrictions for emissions (e.g. SULEV, WHDC) increasing customer demands new emissions legislations for certification focus: fuel consumption focus: raw emissions The increasing complexity of new global vehicle architectures require R&D tools able to deal with all different subsystems involved in the process EiL The EiL-approach enables detailed experimental investigations of the engine performance in a virtual environment The combination of EiL-test bench and fast response gas analysers is the only way to study the detailed emissions behaviour in high dynamic engine operation during real world driving cycles The capability of the EiL-method is exemplarily demonstrated by an virtual diesel-hybrid concept to improve the HC emission peaks during a tip-in manoeuvre Addtional research work using EiL in combination with optical measurement technique and fast response gas analysers is in progress 3 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

24 Conclusion and Outlook Engine-in-the-Loop Virtual test driving Real vehicle data Real driver data Real world driving cycles Validation Identification High reproducibility High sensitivity High repeatabliity Detailed modification 4 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany

25 Live-Demo KIT Campus Ost X-in-the-Loop-Tour Performance and Emissions Assessments Using Engine-in-the-Loop Building 7.4 Contact: Dipl.-Ing. Christian Disch Christian.Disch@kit.edu 5 98 Dipl.-Ing. Christian Disch - Engine-in-the-Loop apply & innovate IPG Technology Conference September 8-9 Karlsruhe Germany