Low Emissions IC Engine Development at Ford Motor Company
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1 Low Emissions IC Engine Development at Ford Motor Company George Davis Powertrain Research and Advanced Engineering ERC Symposium University of Wisconsin at Madison Research and Advanced Engineering June 8-9, 2005 Ford Motor Company 1
2 Presentation Overview Emission Standards Evolution PZEV PFI/DI Engine Development Electric-Gasoline Hybrid Vehicle HCCI Engine Development H2ICE Engine Development Summary Ford Motor Company 2
3 HC Emission Standards Evolution of Hydrocarbon Emission Standards - USA HC REDUCED BY 96% 98% ADDITIONAL REDUCTION 10 Hydrocarbons (grams per 50K) MODE FTP 1 st CLEAN AIR ACT 80 MODE FTP C/H 110 MODE FTP '66 '70 '75 '77 '80 '93 100% % % 99.9% REDUCTION OVERALL % % % 0.01 '93 Base Tier I TLEV LEV ULEV SULEV Ford Motor Company 3
4 NOx Emission Standards Evolution of Nitrogen Oxide Emission Standards- USA Oxides of Nitrogen (grams per 50K) NOx REDUCED BY 90% 1 st NOx STA NDA RD C/H 110 MODE FTP '66 '70 '73 '75 '77 '80 '93 CAA Base 99.5% REDUCTION OVERALL 95% ADDITIONAL REDUCTION 100% % % % TLEV LEV ULEV ULEV II SULEV Ford Motor Company 4
5 National Medal of Technology Haren Gandhi wins for his work in automotive exhaust catalyst technology Ford executives salute Gandhi's breakthrough accomplishment Today's automobiles are more than 96 percent cleaner due in part to Gandhi's efforts First time ever that auto industry researcher has been awarded Medal of Technology Past winners include Bill Gates, Steve Wozniak, and Edwin Land of Polaroid Ford Motor Company 5
6 IC Engine Technology Roadmap Gasoline Diesel Cost Effective Limited By Emissions Constraints Performance Fuel Economy Emissions Time Ford Motor Company 6
7 Gasoline IC Engine Technology Spectrum Now Future PFI FE, P DI FE, P Boosted/ Downsizing Fixed Cam FE, P Cam lift /phasing FE, E HCCI High EGR Ford Motor Company 7
8 Presentation Overview Emissions Standards Evolution PZEV PFI/DI Engine Development Electric-Gasoline Hybrid Vehicle HCCI Engine Development H2ICE Engine Development Summary Ford Motor Company 8
9 Emissions Example Catalyst Light-off Cumulative Cumulative Emissions Emissions Catalyst Light-off HC Minimize emissions before Cat light-off Minimize time to Cat light-off Maximize Cat efficiency (AFR Control) HC NMHC NMHC NOx NOx Vehicle Speed Vehicle Speed Time Time (s) (s) Ford Motor Company 9
10 PZEV with Improved Aftertreatment DISI enables late ignition for improved CC catalyst light-off. VCT Close Couple Catalyst Underbody Catalyst Ford Motor Company 10
11 PZEV PFI Engine: Improved AFR Control Injector Targeting Process MESIM CFD Injector Targeting Four Puddle Fuel Evaporation Model AFR Time (s) Simulated S_Type98 Transient Test Ford Motor Company 11
12 Injector Targeting Optimization for AFR Control Injector Rotation Injector Up/Down offset Cone Angle Tricky Spots Angle between Cones Ford Motor Company 12
13 Injector Targeting Optimization for AFR Control Nominal Design AFR Response Nominal Vs Worst Case Worst Case AFR AF_Worst_cert AF_Nominal_cert Time (s) Ford Motor Company 13
14 Direct Injection Engine For Low Emissions Ford Motor Company 14
15 Reducing Smoke at Part-Load Operation DI Engine 60 deg Injector 70 deg Injector u f d i u q i l d e z i l a m r o N spray 70 0 spray Computed Piston Wetting History FSN Measured Engine Smoke Number 60 deg 70 deg Crank angle (degree) Ford Motor Company 15
16 Ford Focus PZEV Ford Motor Company 16
17 Presentation Overview Emissions Standards Evolution PZEV PFI/DI Engine Development Electric-Gasoline Hybrid Vehicle HCCI Engine Development H2ICE Engine Development Summary Ford Motor Company 17
18 Hybrid Vehicle Technology Ford Hybrid Escape 2005 North American Truck of the Year High FE vehicle at low emission levels Fuel efficient driving Regenerative braking captures over 90% of braking energy on EPA city cycle 2.3 L Atkinson Engine E-CVT Ford Motor Company 18
19 Presentation Overview Emissions Standards Evolution PZEV PFI/DI Engine Development Electric-Gasoline Hybrid Vehicle HCCI Engine Development H2ICE Engine Development Summary Ford Motor Company 19
20 HCCI Combustion System Concept Flame Propagation Kinetics Diffusion Spark Ignition (Gasoline) Spark Ignition Wall Guided (Spray Guided) Stratified (Gasoline) Low temperature combustion Homogeneous Charge Compression Ignition (HCCI) (Gasoline & Diesel) Compression Ignition (Diesel) Requirements: Homogenization Temperature of ~1100 K Cycle-to-cycle control parameter Ford Motor Company 20
21 Gasoline HCCI Technology Controlled Auto Ignition (CAI) Optimized Kinetics Process (OKP) to exhaust heat exchanger exhaust TCV to radiator heat exchanger intake air in engine coolant out Negative Valve Overlap and pilot fuel injection is the key for controlled ignition timing Intake air heating & fast intake T control Ford Motor Company 21
22 HCCI Significantly Reduces CO 2 Emission 1500 rpm Engine Speed NSFC (g/kwh) AVL CSI (HCCI) (70 kpa) (85 kpa) throttling PFI CAI (HCCI) PFI 5.4L V8 PFI 4.0L V6 SC-DISI CAI OKP in HCCI PFI 190 Diesel OKP (HCCI) NMEP (bar) Ford Motor Company 22
23 Presentation Overview Emissions Standards Evolution PZEV PFI/DI Engine Development Electric-Gasoline Hybrid Vehicle HCCI Engine Development H2ICE Engine Development Summary Ford Motor Company 23
24 Why Hydrogen Internal Combustion Engine? Ford Motor Company is dedicated to the realization of Fuel Cell powertrains in mass produced consumer vehicles Fuel cell powertrains are not ready for mass production in the near term H 2 ICE is regarded as a transition or bridging strategy to stimulate the hydrogen infrastructure, and related hydrogen technologies: On-board hydrogen fuel storage Hydrogen Fuel dispensing Hydrogen safety sensors Ford Motor Company 24
25 H2 Focus Breaks SULEV NOx Barrier NOx CO NMHC (g/mi) (g/mi) (g/mi) SULEV Standard H 2 ICE Test 1 << H 2 ICE Test 2 <<< Ford Motor Company 25
26 Hydrogen DI Provides Further Opportunities Power density improvement Air is not displaced by H2 during intake stroke Elimination of backfire H2 injection after intake valve closing Higher CR & improved thermal efficiency opportunity due to charge cooling Optimized injection strategy may provide: Reduced pre-ignition tendency Reduced NOx Increased fuel efficiency (less unburned H2) Ford Motor Company 26
27 Volumetric Efficiency Comparison Gasoline H2 H2 H2 H2 Fuel PFI PFI Cryogenic PFI DI PFI Positive Displacement Supercharger Vol. Effy. Base 70% ~115% (Source: HyICE) 102% 125+% Ford Motor Company 27
28 CFD-Based Engine Upfront Design Methodology Modeling Up-front Design Optimization Thermo Engine Design Evaluation/ Confirmation Design Optical Engine Models/Design Validation Ford Motor Company 28
29 Injector Included Angle Optimization t (ms) Cutting plane Included angles A/F Ford Motor Company 29
30 H 2 ICE Vehicle/Application Programs 2.0L I4 2.3L Supercharged I P NAIAS Model U 2003 H2ICE Focus 6.8L Boosted V H2ICE C-Max 2003 Centennial H2RV 2006 H2ICE Demo/Fleet 2004 H2ICE Generator (Generac) 2005 H2ICE Hybrid Bus (Designline) 2004 H2ICE Hybrid Bus (ISE) 2004 H2ICE Rotary (Mazda) 2005 Airport Tractor 4.2L V-6 Ford Motor Company 30
31 Summary Ford has been recognized among the leaders in environmental stewardship. Ford will continue developing a spectrum of vehicle technologies to meet and/or exceed environmental regulations and customers needs. Ford Motor Company 31
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