Beyond 2010 What s s Next

Transcription

1 Beyond 2010 What s s Next Kevin L. Bruch Division Manager Engine Research Caterpillar, Inc.

2 The drumbeat of Regulation and Innovation

3 Other Potential Issues many other forces at play Safety, Sound & Ergonomic requirements Greenhouse Gas regulations and Kyoto implementation Petroleum, as the primary energy source, being replaced by: Coal, Tar Sands, Solar, Nuclear, Bio-Mass, Wind Breakthroughs in energy conversion and/or energy carrier: Photovoltaic, Fuel Cell, Thermal Electric, Hydrogen, Battery Recycling / Reuse requirements Internet / Wireless -- everywhere, free, unlimited bandwidth

4 Heavy Duty Engine Industry Challenge Technology Investment Fuel Consumption NOx (g/hphr) Improving fuel consumption and customer value while meeting much more stringent emissions standards is a tremendous technical challenge. Additional In-Use Performance Regulation and OBD

5 National Efficiency Benefit Commercial Truck Fuel Use (Million Barrels per Day) New Trucks 10% Worse Without Government/Industry/University Collaboration New Trucks 10% Better With Government/Industry/University Collaboration Emissions Regulation 20% difference! + Bio-Diesel Alt Fuels

6 diesel engine solutions will need to be the most innovated and analyzed engine systems in the industry s history, likely to result in Novel combustion systems New aftertreatment performance levels Clever efficiency efforts New powertrain solutions Unique system solutions at multiple levels This will drive massive changes in technology. Q: What will have to be in place to enable the industry to perform at the highest level?

7 More with Less High Fidelity Simulation Development Cycle Test world $$$$$ Simulation World <$ Yield Single Cylinder Test Cell In-cylinder 3D Detailed $$ Combustion Emissions Multi Cylinder Steady State $$$ Multi Cylinder Transient $$$$ Engine System Engine System + Test Cell Steady-state Performance Transient Performance Demonstrator Vehicles $$$$$ Engine System + Power Train + Vehicle Reliability/System Performance

8 Thermodynamic Analysis Tool Definitions 3D 1D-973 Multidimensional reactive and non-reactive flow for: Diesel engine combustion Customized to applications (component level) Engine cycle simulation - Steady state or transient - Thermo, breathing, manifolds, components, air systems, fueling, combustion (engine system / component level) Dynasty TM Integrates mechanical, thermodynamic, hydraulic, electrical systems in time domain (system level)

9 More with Less High Fidelity Simulation Development Cycle Test world $$$$$ Simulation World <$ Yield Single Cylinder Test Cell In-cylinder 3D Detailed $$ Combustion Emissions Multi Cylinder Steady State $$$ Multi Cylinder Transient $$$$ Engine System Engine System + Test Cell Steady-state Performance Transient Performance Demonstrator Vehicles $$$$$ Engine System + Power Train + Vehicle Reliability/System Performance

10 HCCI Combustion Modeling Measured Simulation Measured CAT3D Simulation CO(g) EOI (CA - ATDC) Aided by University/National Lab/ Government Collaboration

11 Genetic Algorithm Optimization Soot (g/kw-hr) Mode 1 Baseline GA-1 OPTIMUM GA-2 OPTIMUM NOx (g/kw-hr) Soot (g/kw-hr) Mode 5 Baseline 0.07 GA-1 OPTIMUM 0.06 GA-2 OPTIMUM NOx (g/kw-hr) 3 Modes 21 parameters Population Size = 9 24 cpus Mode 1 Baseline GA-1 OPTIMUM GA-2 OPTIMUM Mode 5 Baseline GA-1 OPTIMUM GA-2 OPTIMUM ISFC (g/kw-hr) ISFC (g/kw-hr) NOx (g/kw-hr) NOx (g/kw-hr)

12 Improved Boundary Conditions for Durability Assessment 1D Code Boundary Conditons from 1D Cycle S imulation Code 1D + 3D Code Boundary Conditions using 1D + 3D Combustion S imulation

13 3D Research/Tool Needs Driven by new Combustion Solutions to Environmental and Customer Value Equation Fuels Understanding fuel properties on combustion chemistry and spray side of simulation New surrogate fuels for low temp combustion Multiple surrogates for appropriate analysis may be needed Wall film chemistry HC and CO wall interaction needs correlation and validation Incident spray characterization (just prior to hitting the wall film) Soot Modeling Linkage to particulate absorption and HC adherence to soot surface Need to predict size and distribution Must be properly validated with engine data University/National Labs/Industry solution for Advanced Soot modeling

14 Fuel Injection Research/Tool Needs Driven by new Combustion Solutions to Environmental and Customer Value Equation Higher Pressure for smoke reduction Materials (injector tips, valve bodies) Goal: Highly efficient, high pressure fuel system w/o leakage Injection Pressure and PM Level History New spray model may be needed Rethink spray dynamics for higher pressures Assumptions may break down Higher pressures, smaller droplet sizes Need to revalidate models in this new domain Inj Press (MPa) Pressure PM Level? PM (g/hp-h)

15 More with Less High Fidelity Simulation Development Cycle Test world $$$$$ Simulation World <$ Yield Single Cylinder Test Cell In-cylinder 3D Detailed $$ Combustion Emissions Multi Cylinder Steady State $$$ Multi Cylinder Transient $$$$ Engine System Engine System + Test Cell Steady-state Performance Transient Performance Demonstrator Vehicles $$$$$ Engine System + Power Train + Vehicle Reliability/System Performance

16 ACERT System Simulation Identified System Synergy for Excellent NOx/BSFC Tradeoff Multiple Injection/Combustion Series Turbo Variable Valve Actuation Steady-State Engine Model Caterpillar Engine Cycle Simulation

17 Aftertreatment Research/Tool Needs Driven by the need for high performance aftertreatment Non Traditional Diesel Engine System Simulation Capability Validation of Aftertreatment system performance 3-way catalyst type NOx Performance (98%) in lean environment Wide temperature range Durable Small package size Engineering Nanotechnology to get right materials/coatings together at the molecular level / processing to make this effective

18 Air System Research/Tool Needs Driven by new Combustion Solutions and the need to enhance the Customer Value Equation Air System Tools/Technology Efficiency Pressure Ratio Packaging Exhaust Waste Heat Recovery Thermal barrier coatings to redirect energy to Turbocharger and Catalysts Fossil Fuel Opportunity Exhaust JW Heat Work DOE EWHR Program

19 More with Less High Fidelity Simulation Development Cycle Test world $$$$$ Simulation World <$ Yield Single Cylinder Test Cell In-cylinder 3D Detailed $$ Combustion Emissions Multi Cylinder Steady State $$$ Multi Cylinder Transient $$$$ Engine System Engine System + Test Cell Steady-state Performance Transient Performance Demonstrator Vehicles $$$$$ Engine System + Power Train + Vehicle Reliability/System Performance

20 Engine System + Test Cell Simulation Engine System Computer cycle command Dynamometer with speed/torque mode switching Transient torque controller Transient Test Cell

21 FTP CYCLE: System Performance Results (Simulation: Red Curves) (Test: Black Curves) Measurement technique averages instantaneous fuel rate Fuel consumption difference < 0.5% No transient performance calibration for these results!

22 Controls Research/Tool Needs Driven by Control System Integration Solutions to the Environmental and Customer Value Equation Increased Computing Speed 1D Real time model based controls in transient simulations Drive control strategies Continued accuracy improvements in 1D and 3D physics Speed and accuracy optimization Absolute accuracy improvements Control System Development

23 FEA/Dynamics Research/Tool Needs Driven by Reliable Solutions to the Environmental and Customer Value Equation Increased Computing Power Dynamic and Thermal Models will need complete engine models Meshless modeling for FEA (solid geometry direct to stress calculation) Multi Physics models (3D combustion, heat transfer, thermal stress) Conjugate Heat Transfer Start with combustion model Boundary condition creation Improved metal temperatures and loading conditions Casting Analysis Understand and predict Standard Deviation of casting material properties to determine probability of failure Heat Treat, Residual Stress, Micro-material fatigue modeling

24 More with Less High Fidelity Simulation Development Cycle Test world $$$$$ Simulation World <$ Yield Single Cylinder Test Cell In-cylinder 3D Detailed $$ Combustion Emissions Multi Cylinder Steady State $$$ Multi Cylinder Transient $$$$ Engine System Engine System + Test Cell Steady-state Performance Transient Performance Demonstrator Vehicles $$$$$ Engine System + Power Train + Vehicle Reliability/System Performance

25 Truck/Machine Demonstrator Model Engine from test cell model drops into truck or machine Similar level of detail in truck/machine model

26 Cat 797 Frame Stress Simulation When Trial and Error Is Not An Option Engine, Driveline, Suspension In This Model Suspension Strut Extension Shown Below

27 Caterpillar 5110 Digging Simulation Dynasty and Rocks3D Supply Realistic Boundary Conditions to Flexible Bodies

28 3D Combustion & Structural Modeling Future High Performance Computing Direction 2004/ /2008 MPI Parallel 64-bit SMP Parallel 64-bit Full Cycle 3D Engine Combustion: 1-2 days 95+% REDUCTION Serial 64-bit Serial 32-bit GA: 8 days GA: 4 days 95% REDUCTION GA: 3 months GA: 1 month Full Cycle 3D Engine Combustion: 54 days

29 Research/Tool Needs for Computing Driven by new Solutions to Environmental and Customer Value Equation Processing Speed for novel numerical methods Adaptive mesh refinement with 2 phase flow (combustion space) Save time in less critical areas and focus on most critical General computer technology Software matched to hardware improvements Faster Speed on Linux platforms/solutions Easily exchangeable codes Modularity, Plug & Play, Allow individual customization Common repository for Industry The need for parallellization More complex models coming Genetic Algorithms Adaptive Grids More chemistry and flow detail could drive New data structures Advanced solver technology

30 Beyond 2010 What s s Next Conclusions 1. Massive change is coming 2. Technology will change fast 3. In-use Performance failure is not an option 4. Analysis tools will be the key to much of our success 5. Help and support is needed for future in many areas 6. Universities/Labs/Industry Unite on Soot Model Combustion/Engine Modeling Interconnection Standards Techniques for Modeling Speed