THE MODULAR LARGE ENGINE FOR FUTURE MARKETS

Transcription

1 AVL List GmbH (Headquarters) THE MODULAR LARGE ENGINE FOR FUTURE MARKETS Dr. Helfried Sorger 8 th AVL Large Engines Techdays April 11 th -12 th, Graz, Austria Sorger, Helfried

2 Technology Drivers Legislation Fulfilment of Stringent Emission Requirements End User Low Fuel Consumption Low Life Cycle Costs Good Serviceability High Availability and Reliability High TBO (Time between Overhaul) Manufacturer High Diversity of Applications Low Production Costs Sorger, Helfried PTE - D2 11 April

3 What can be expected long-term? Worldwide trend for reduction of Greenhouse gases 10-25% reduction in comparison to uncontrolled baseline (Tier 0 or even older standards following CARB petition) Reduction of BSFC Regulation for Total HydroCarbon emissions (THC, not only none methane NMHC) EU Stage V THC = (1.5*A*GER) THC max. 6.19g/kWh for GER > 66,7% Methane slip Aftertreatment system in some cases (DF + EGR) Severe Dust and PM limitation / Particulate counting, demand for particulate filters Dust 2.7mg/kWh PM 10mg/kWh PN #/kwh Particulate Filter Sorger, Helfried PTE - D2 11 April

4 Gt CO2/year - tank to wheel Required reduction of CO 2 Emissions A dramatic CO2 reduction will be needed. Especially in areas, where it is possible by technology, like traffic. 10 9? CO2 scenarios for worldwide transportation - tank to wheel (ttw) emissions ? 4 We must utilize the limits of the traditionell ICE 3 We must use the new technologies as enabler 2 Worldwide CO2 Target % 20 % 40 % 60 % % share of E-vehicles? Based on data from: Dr.-Ing. Rolf Leonhard, Robert Bosch GmbH at AVL Exhaust and Particulate Forum, Ludwigsburg, 2016 Sorger, Helfried PTE - D2 11 April

5 High Diversity of Applications Example high speed engines Electric Power Oil & Gas Machines Marine Rail High Volume Commodity Type Market Fuel sensitive application Typical 1500/1800rpm Stand By: first cost prevails fuel eff. is not main criteria; Prime: fuel efficiency is most important Stand by not strictly regulated Strictest emission limits in regulated areas for prime and some standby apps. (e.g. data centers) High margin market Detains high market share Reliability and operation cost important Wide Spectrum of Apps.: - Well Frac: ( Stand By Load Factor w. high power density at low running hours); typical >1800rpm - Petr. El. Power: Typically 1200rpm (lower power density at longer running hours) - Petr. Mech. Drives Low Volume but high margin market Captive market for OEM also producing machines e.g. Mining Truck w. high torque back up and altitude capability No power reduction between Sea-Level & 5500ft (1680m) with single stage TC Strategies for operation above ft (3660m) e.g. 2-stage TC (Peru, La Rinconada 5100m) Reliability in harsh environment is key Commercial applications with high share at moderate load operation ( Prime Power type of load factor) Pleasure Boat applications w. high power density but low load factor and low utilization ( Stand By type of load factor) Wide speed range approx rpm Auxiliary power generation w. low load factors w. high utilization Small volume Business, located in North America and Europe Sorger, Helfried PTE - D2 11 April

6 The Cost Equation Objective: Manage Complexity Consideration of Application related Production Volumes Advantage of Application-Optimized Design Advantage of Volume Effect Customization High Complexity but Fit for Application Standardization Economy of Scale but Overdesigning Sorger, Helfried PTE - D2 11 April

7 Determining Technologies Combustion system Turbocharging system Engine control unit (ECU) Engine architecture Fuel injection equipment (FIE) Exhaust aftertreatment system (EAS) Sorger, Helfried PTE - D2 11 April

8 Turbocharging system Schorn, N.: Die Evolution der Abgasturboaufladung, 17. Aufladetechnische Konferenz 2012 Dresden Optimum efficiency at low Π V Standard Technology Advanced Technology Optimum efficiency at high Π V - Max. Π V ~ 4.5 (increased efficiency loss) + Max. Π V ~ 5.5 (low efficiency loss) + low cost due to economy of scale - Higher cost due to limited production numbers + Max. Π V >5 expected + Max. Π V >6 expected Advanced 1-stage charging moves the limit for introducing 2-stage charging Sorger, Helfried PTE - D2 11 April

9 Exhaust aftertreatment system Initially no acceptance for SCR infrastructure (Oil & Gas, Fracking) SCR infrastructure is accepted in the meanwhile Perspective: SCR will be used in the future for all applications including NRMM, Bi-fuel and challenging Emission scenarios Could include solutions for moderate EGR avoiding donor cylinder system Sorger, Helfried PTE - D2 11 April

10 Engine control unit (ECU) Combustion Control Tˆ, Torque, Emiss. Combustion Model m, T, PM NO, O, HC ^ x 2 EO SCR Control ˆ, NH 3 TˆSurf SCR Model T ^, NO x DS _ SCR Current Rationale models Feedback Rationale information based solely on sensors is usually time-delayed or controlled variables can only be measured indirectly Embedded Physical Plant Models: Inj. / Air Ctl.. Adapt. Combustion Observer Speed, Load (EGR), Adapt. SCR Observer Cylinder pressure-based control Physical models e.g. from the air path or the exhaust aftertreatment run in real time on the ECU and are continuously adapted with the help of sensors T, ( NO x ) EO Urea Dosing Unit NO x SCR DS _ SCR Advantages: Control loops can be adjusted faster and more stable Model calculations can be used as a reference for diagnostics because they are not subject to aging, unlike the sensors Sorger, Helfried PTE - D2 11 April

11 Futue Large Engine Platform How does it look like? Sorger, Helfried PTE - D2 11 April

12 Targets High Speed Modular Engine Family Platform Power Range between 400 and 1800 kw with different Cylinder Configurations High Speed Engine characteristics in the range of RPM Emission compliance for all applications Low Specific weight in the range of kg/kw Ease of Maintenance and Durability Customized Technology Modules for meeting the required Emission Standards Flexible configuration achieved by Design Modularity High Commonality for the Base Engine High Commonality of features for all applications Package prepared for future Upgrades and Expansion of the Product Range Sorger, Helfried PTE - D2 11 April

13 Modular High Speed Engine Platform Engine Family Concept L6/ V12 / V16 V angle: 90 Bore x stroke: 150 x 175 mm Displacement/cylinder: 3,1 lt. Mean piston speed: 8,75 13,1 m/s Rated power/cylinder: 66,7 137,5 kw Rated BMEP-level: 15,3 23,7 bar Peak firing pressure: bar Multi-fuel capability 4 Applications Marine Genset Construction Rail Emission Compliance US TIER 4 interim / US TIER 2 IMO3 / IMO2 EPA TIER 4 Sorger, Helfried PTE - D2 11 April

14 Common Platform with Modular Architecture Common Components of Engine Platform Common Components with adaptable Configuration Application Specific Components Block Crankshaft and Bearings Connecting Rods Head and Liner Camshaft Drive Oil Sump Piston Damper Camshaft Coolers and Filters Engine Controls Air System incl. Air and Exhaust Gas Ducts Oil and Water Pumps Fuel System (Diesel or Gas) Generator Attachment (Single or Double Bearing) Hydraulic Pumps for Power Steering Auxiliary Drives Starter Motor Engine Mountings: Filters, Coolers Air Compressor After treatment Application specific packaging constraints Sorger, Helfried PTE - D2 11 April

15 Features ensuring highest Power Output PFP up to 260 bar CGI 450 cylinder head Cast iron crankcase (GGV300) Steel piston Sputter bearings Cooling system 100% cross flow cooling (external coolant distribution and collection rail) Upper side liner cooling (machined water jacket) AVL top down cooling Sorger, Helfried PTE - D2 11 April

16 Features ensuring highest Power Output Charging system Two stage turbo charger with intercooler Low temperature coolant circuit Sorger, Helfried PTE - D2 11 April

17 Features ensuring best Fuel Consumption Optimised combustion system layout Stroke to bore ratio: 1,17 Optimised main bearing and conrod bearing diameter Steel piston (optimised piston profile low friction coating) Optimised coolant and oil pump flow and pressure requirements Minimised piston ring tension Oil thermostat Sorger, Helfried PTE - D2 11 April

18 Features ensuring Emission Compliance EGR system Water cooled 4 standard egr coolers Twin flow Hot side mounted double flow EGR vale Integrated reed valves (after EGR cooler) 2 throttle valves Integrated EGR mixture in the intake manifold Fuel injection system Common rail fuel system Jumper line Injection pressure up to 2500 bar Fuel cooler Combustion system layout Non swirl system (parallel valve pattern) Central vertical injector position Piston bowl design Sorger, Helfried PTE - D2 11 April

19 Features ensuring low Engine Weight Low height crankcase design Single aluminium water jackets Mid stop liner concept One camshaft in the cold V Outstanding pushrods integrated in cover tubes Major components made from aluminium Flyweel housing, gear housing,oil pan Oil pump water pump housing Valve train housing, intake manifold, breather system, coolant and air pipings Sorger, Helfried PTE - D2 11 April

20 Features ensuring Compact Package Optimised stroke / bore ratio 1,17 V-angle selection 90 as best compromise between width and height Shortest cylinder distance by optimizing cranktrain and crankcase by FEM Shortest possible conrod Very compact and highly innovative oil pan design oil guided from outer side to the inner side Very compact turbo charger and charge air cooler arrangement including air filtration Jumper line fuel system rail function divided &integrated in injector Cooler frame with integrated coolant line function Intake manifold with integrated EGR mixture Sorger, Helfried PTE - D2 11 April

21 Features ensuring Serviceability Engine Service Side Front And Top Side For Marine Application Right And Top Side For Genset and Construction Application Hydraulic Lash Adjustment Gear Driven Fan Gear Driven Water Pump Double Head Switchable Pre- And Main Fuel Filter Design Protected For Active Oil Filter Switchable Cartridge Oil Filter Double Oil Centrifuge Oil Level Sensor Low Max Oil Temperature Sorger, Helfried PTE - D2 11 April

22 Features ensuring Life Time Oil pre-heating on the engine side Oil pre-lubrication pump mounted to the engine Ventilator gear driven Gear driven air compressor Gear driven hydraulic pump Gear driven coolant pumps Optional scrapper ring Coated piston rings Gallery cooled steel piston Metal ring for cylinder head gasket Sputter bearings on conrod side Optimised component temperatures High sophisticated control and monitoring system Sorger, Helfried PTE - D2 11 April

23 Efficiency What s next? Sorger, Helfried PTE - D2 11 April

24 Next Level Efficiency Medium Speed Engine Landscape Potenzialabschätzung unterschiedlicher Ansätze zur Optimierung des Wirkungsgrades [Quelle: MTU; Stuttgart, , Dr.-Ing. Andreas Lingens, Sorger, Helfried PTE - D2 11 April

25 Building blocks for Future Large Engines Multi purpose & integrated into system Fuel Flexibility Electrification, Hybridization & Fuel Cells are Knocking on the Door of HS-Engines High peak firing Pressure (>300 bar) Aggressive Miller High Efficiency Charging 2-/Multistage Variable Valve Actuation (De-coupled intake valve closing) New materials EGR SCR Exhaust Aftertreatment Systems Friction reduction (actually niche only) New architecture WHR Condition / Emission Monitoring & Field Service Sorger, Helfried PTE - D2 11 April

26 BSFC and TFC Reduction Potential 300 bar PFP Technical Measures Advance combustion timing Increased CR Increased EAR Strong Miller Timing Advancing Combustion Timing Increased EAR, CR Efficiency Potential -7.0 % BSFC reduction -6.1 % TFC reduction Speed BASE NOx BASE MFB50 BASE PFP BASE EAR BASE BMEP BASE CR BASE IVC TARGET NOx rpm g/kwh degcra bar - bar - deg CrA g/kwh Sorger, Helfried PTE - D2 11 April

27 BSFC and TFC Reduction Potential 300 bar PFP Technical Measures Advance combustion timing Increased CR Increased EAR 15% EGR Advancing Combustion Timing Increased EAR, CR Efficiency Potential -4.4 % BSFC reduction -6.5 % TFC reduction Speed BASE NOx BASE MFB50 BASE PFP BASE EAR BASE BMEP BASE CR BASE IVC TARGET NOx rpm g/kwh degcra bar - bar - deg CrA g/kwh Sorger, Helfried PTE - D2 11 April

28 Future challenges for key components Cylinder Head & valves High BMEP at PFP lead to high thermal load into valve bridge area Target conflict of robustness, package vs. weight & cost Valves & Valve Train Valve deflections produce valve seat wear Extreme miller cycle Liner & Piston Bore Interface High bolt forces lead to bore deformation Conflict of oil consumption vs. friction losses Connecting rod Big end bearing load Small end Lubrication Oil consumption & Blowby Increases blowby force crankcase emissions Piston High component temperatures, increased deformation Target conflict cooling vs. stiffness & weight Major technology step required Crankshaft High bearing load Target conflict of stiffness vs. weight Sorger, Helfried PTE - D2 11 April

29 AVL 300 bar cylinder unit Key features Cylinder Head Assembly Advanced top down cooling High grade of cylinder head material Increased global and local stiffness Valve seat wear seat ring cooling Valve train System Intake VVT for Miller Cylinder Liner Trade-off friction vs. oil consumption High thermal load Connecting rod Big end bearing technology Pressure lubrication for small end Piston & Pin Optimized cooling gallery Cooling of 1st piston ring Optimized shape of piston pin bore Piston bore interface friction vs. oil consumption Sorger, Helfried PTE - D2 11 April

30 AVL 300 bar cylinder unit Key features AVL Seat Ring Cooling concept Higher heat transfer coefficient Equal temperature distribution on seat ring Lower pressure trop No HCF critical connection to injector bore Tangential coolant flow inlet into seat cooling gallery Straight coolant flow outlet from the seat cooling gallery Both supply drillings parallel to fire deck Reduced O-Ring temperature in case of O-Ring sealing Base Seat Ring Cooling AVL Advanced Seat Ring Cooling Sorger, Helfried PTE - D2 11 April

31 AVL 300 bar cylinder unit Key features Cranktrain High grade material with heat treatment Barrel shape main bearing in combination with high performance bearing Main Bearing Dimensions Bearing diameter limited by circumferential speed Crankcase High grade material GJS Integrated main oil gallery pipes Main Bearing Wall Matching MBW stiffness to crankshaft stiffness Sorger, Helfried PTE - D2 11 April

32 Modular single cylinder engine platform Single cylinder engine portfolio Bore mm Stroke mm Enabler for validating 300 bar technologies Speed Power rpm kw Sorger, Helfried PTE - D2 11 April