Recent Developments in BMW s Diesel Technology. DEER Conference 2003 Newport, USA August 2003

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1 EA Recent Developments in BMW s Diesel Technology DEER Conference 2003 Newport, USA August 2003

2 EA Recent Developments in BMW s Diesel Technology BMW Diesel History R6 - DI - VNT 55 revision 3 rd generation DI-Engines Spec. Power [kw/dm 3 ] V8 - DI - VNT revision R6 - DI - VNT revision R4 - DI - VNT 2 nd generation 1 st generation IDI-Engines R6 NA-Engine R6 - ATL R4 - ATL R6 - ATL

3 EA Recent Developments in BMW s Diesel Technology BMW Diesel Production Engines /year Σ 1 st generation: Σ 2 nd generation: Year of production st generation 2 nd generation 3 rd generation

4 BMW Market Share 04/2003 X5 World wide Europe Petrol 65% Diesel 35% Petrol 32% Diesel 68%

5 EA Recent Developments in BMW s Diesel Technology BMW Diesel Engine Family cylinder 2.5 / 3.0 l Power [kw] cylinder 2.0 l 8-cylinder 3.9 l Displacement [ I ]

6 EA Recent Developments in BMW s Diesel Technology BMW Diesel Product Range 4 cylinder 6 cylinder 8 cylinder 3-Series 85 kw 110 kw 150 kw 5-Series 100 kw 120 kw 160 kw 7-Series 160 kw 190 kw X5 135 kw 160 kw MJ 03 MJ 04 Power Output

7 Key Technologies Core engine Durability for cylinder pressures up to 180 bar High thermal resistance Low friction Combustion concept Combustion chamber layout Port design for efficient swirl generation BMW Diesel- Development Outstanding performance Low consumption and emissions Injection system High hydraulic performance Sophisticated application strategy Air management VNT-Turbochargers Optimised intake / exhaust system with intercooling

8 EA Recent Developments in BMW s Diesel Technology Core Engine Design Cylinder head Aluminium alloy with specific thermal treatment Design based on sophisticated simulation methods - Mould filling - Residual stress simulation - Strength and fatigue analysis Crank case Material GGV-500 Cracked main bearing walls Two main bearing bolts

9 Combustion Chamber and Port Design 6-Cylinder Engine Swirl port from the top Tangential port with swirl flap from the side 8-Cylinder Engine Inlet ports coming from one side

10 EA Recent Developments in BMW s Diesel Technology Fuel Injection System Common rail system 2 nd Generation 1600 bar Fuel metering Small pilot quantities High flexible injection strategy Reduced dispersion

11 Injection Strategy 2,5 2,0 PiI... Pilot Injection MI... Main Injection PoI... Post Injection spec. Work [kj/dm 3 ] 1,5 1,0 PiI1+MI+Pol PiI1+MI MI 0,5 0 PiI1+PiI2+MI 1000 PiI1+PiI2+MI+Pol Engine Speed [1/min]

12 Characteristics Diesel Electronic Control Units 730d 740d Start of Production ECU-Type DDE1 DDE2 DDE4 DDE5 Data Length bit Computer Performance MIPS < Number of Transistors Mio <1 <1 <1 7 Memory kbyte Number Labels for Calibration * Number of ECU - Pins * With Master / Slave ECU s: Labels for Calibration

13 Spontaneous Glow System Previous Engine 12V Glow Plug Pre Glow Phase < 3 sec Reduction Power Consumption ECU Mounted to the Engine New Engine 6V Glow Plug

14 Spontaneous Glow System Temperature Glow Plugs Pre Glow Time Temperature [ C] Time [s] Time [s] Temperature [ C] New Engine Previous Engine

15 EA Recent Developments in BMW s Diesel Technology Air Management

16 EA Recent Developments in BMW s Diesel Technology Air Management

17 Improvements DI 1 st to 2 nd Generation 1 st gen. 2 nd gen. Base Engine: Cylinder pressure bar Compression Ratio 18:1 17:1 Injection System: Rail pressure bar Number of Injection 3 4 Min. Pilot quantity mm 3 /cyc Fuel metering without with Turbocharging: Max. Boost pressure bar Pressure ratio Max. Turbine Eff. % Max. Compressor Eff. % 59 63

18 Engine Performance 6-Cylinder in X5 Torque [Nm] Diesel MJ kw Engine 1000 Diesel MJ kw Engine Power [kw] Engine Speed [1/min] Torque Power

19 Performance / Fuel Consumption - X5 AT Acceleration km/h Maximum speed Fuel Consumption X5 MJ 04 X5 MJ03

20 Fuel Consumption in X5 AT Comparison Diesel / Petrol 30 X5 with cylinder engines 28 Diesel MJ kw Engine Diesel MJ kw Engine FC [mile/gal] CO2 Reduction 20 percent Petrol Acceleration [sec] Petrol Diesel

21 NOx- and PM-Reduction for BMW 5 Series Diesel cars EU NOx [g/km] EU EU tds tds 1996 EU Potential with DPF 530d d Particulate Matter [g/km]

22 Emission Legislation in USA 1.2 X5 situation 1.0 EPA till MJ NOx [g/mi] EPA BIN 10 MJ04 to MJ08 additional DPF Biggest challenge (technology and time) X5 3.0 da with specific US-tune CARB LEV 1 MJ04 to MJ EPA BIN 8 MJ With DPF and DeNOx-System EPA BIN 5 MJ09 = CARB LEV 2 MJ Particulate Matter [g/mi]

23 Conclusion Diesel engines could play a major role in saving crude oil and reducing CO2-emissions in USA too Modern BMW Diesel technology offers powerful, clean and economic engines for the new decade Improved combustion systems combined with filter technologies can virtually remove PM-emissions The 2007 US NOx-limits are the biggest challenge Technology for highly efficient NOx-aftertreatment Time scale for 2007 very demanding The introduction of diesels with durable and enabling emission control technologies should be supported by: Better fuel quality similar to ECE Slightly legislation adaptations to take account of the specific diesel advantages (long term emission stability, CO2)

24 DEER Conference Newport USA

9 th Diesel Engine Emission Reduction Conference Newport, Rhode Island, August 2003

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