The Power of Joint Research

The Power of Joint Research The role of ethanol in the future engines & institutional R&D partnerships Dipl.- Ing. Dietmar Goericke Managing Director FVV e.v. Research Association for Combustion Engines VDMA, Frankfurt, Germany

Content 1. Introduction to FVV Who we are How we work What is the benefit being a member 2. Project examples Survey on Future Fuels Future Fuels SI Engines Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 2

FVV Who we are FVV is a non profit research association is a spin off of German Engineering Federation (VDMA) membership is exclusively for industry covers all applications of combustion engines members are paying yearly fees, in total 5 Mio. Euro in 2012 triples money from industry by other sources of funding projects are pre-competitive and initiated by industry projects are contracted mainly to universities all members have free access to all activities and results FVV a clear focus on industrial needs Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 3

FVV - Network The FVV was founded in 1956 as a non-profit society for engineering and research in order to promote pre-competitive, joint research for combustion engines. 27 founding members Today 150 members => including 2 US and 20 European corporations Member companies are manufacturers of combustion engines (motor vehicle and industrial engines) components and systems for the automotive, industrial engine and turbomachinery industry R&D service providers and engineering firms turbomachinery (gas and steam turbines, superchargers, axial and radial compressors) FVV - competence in research for more than 50 years Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 4

FVV Mission and Vision FVV is the platform of the combustion engine and turbine industry for joint research projects in Europe and the world with its core competences joint, strategic and pre-competitive research fast and efficient transfer of research to industrial practice qualified and practice oriented education & training of young scientists a permanent and comprehensive network of corporate and industrial competence FVV a strong and reliable network of competence Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 5

FVV - Members ist GmbH Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 6

Membership Structure Suppliers and service providers represent 70%, mostly SMEs 35% 9% 6% 7% OEM industrial engine manufacturers turbomachinery manufacturers suppliers 43% R&D service providers FVV - covers the process chain Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 7

FVV Sources of Research Funding 2011 Total Funding 16 Mio. Euro BMWi 4,0 Fees by members 4,0 CO2-programm 1,0 Hardware 4,0 Other cooperation 3,0 FVV constant growth excellent reputation in the industry Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 8

Main Areas of Research I Engines I. > complete Systems potential evaluation of new technologies alternative drives and APU overall balance Recovery of lost energy recovery model based engine control and management supercharging Engines II. > mechanics and acoustics new materials and coolants tribology and coatings sliding fit additives and lubricants Engine mechanics and strength engine dynamics and acoustics Engines III. > Combustion processes and fuel preparation HCCI (diesel/gasoline engine) hydrogen combustion variable valve control combined with direct injection downsizing concepts fuel distribution and preparation, high pressure injection modeling of combustion and emission generation (gasoline/ diesel engines) Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 9

Main Areas of Research II Engines IV. > fuels with the focus on CO 2 emissions biofuels synfuel hydrogen natural gas Engines V. > exhaust gas recirculation catalytic converter modeling for reaction kinetics local determination of emission states (e.g. N 2 0, NH 3, H 2 S) high resolution online measurement techniques for new combustion processes Turbomachinery aerodynamics materials optimization of components development tools Currently over 200 ongoing FVV research projects (Sept. 2012) Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 10

FVV Research Partners 30 universities and research centres 80 research institutes 300 scientists involved in FVV-projects 3-5 BSc-, MSc-, PhD thesis p. project FVV- young scientist award FVV supports education of young scientists Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 11

FVV - Transfer of Know How Project related discussion groups and working committees influence on the orientation / execution of projects discussion of the latest project findings and direct transfer of know how Planning groups planning and control of research programs setting priorities for new projects on the main areas of research Scientific advisory board and general meeting of the members determination and controlling of the overall program Spring and fall conferences status reports on ongoing research program networking ProMeta - the web based project center document and software download, events and meetings, communication FVV publications complete final documentation of projects Internet The latest developments, newsletter, download of general documents. Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 12

FVV Project examples with focus on ethanol 1. Future Fuels Preparation of a new research priority by a survey with 130 participants from 150 members 2. Future Fuels SI Engines 3. Fatigue in corrosive fuels Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 13

Example 1: Inquiry Future Fuels Importance and temporal relevance Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 14

Example 1: Inquiry Future Fuels Which application areas are relevant? Application Area Passenger Car Gasoline Passenger Car Diesel Passenger Car Gas Truck Industrial Engine Off-Road Ship Railway Stationary Engine Methan (CNG) Ethanol Biodiesel Poor Quality Diesel Methan (LNG) Additive Poor Quality Gasoline Paraffinic Diesel Methan/H2 Blends LPG Methanol Synthetic Gas Pure H2 DME (Dimethylether) OME (Oxymethylenether) Butanol Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 15

Example 1: Inquiry Future Fuels Which fuel properties are of interest? Fuel Properties Fuel Quality, Fuel Variation Aging Resistance Fuel Blends Fuel Characteristic Numbers Emission Characteristic Material Compatibility System- Sensitivity Suitability of Additives Methan (CNG) Ethanol Biodiesel Poor Quality Diesel Methan (LNG) Additive Poor Quality Gasoline Paraffinice Diesel Methan/H2 Blends LPG Methanol Synthetic Gas Pure H2 DME (Dimethylether) OME (Oxymethylenether) Butanol Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 16

Example 1: Inquiry Future Fuels Results The topic of fuel is of great interest in the FVV. Methane, ethanol, biodiesel, additives and poor quality fuels are particularly relevant. In the next 5 years, results are needed. All applications / engine types will be considered. The following properties of the fuels are the focus: Fuel quality, fluctuation, margin Fuel key figures Emission behavior Material compatibility System sensitivity (Components affected by new fuels) FVV future fuels are becoming a research priority Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 17

Example 2: Future Fuels SI Engines Determination of potential and challenges of new synthetic fuels as a basis for premium gasoline fuels in outlook of the European biofuel share for 2020. Participating companies Daimler AG (Initiator), AFT Atlas, APC Advanced Pro, Audi, BMW, BASF, Bosch, Continental,BP, Deutz, Federal-Mogul, FEV, Ford, IAV, IFPEN, Lurgi, Mahle, MAN, Nedalco Alcohol, Opel, Porsche, PSA Peugeot, Renault, Sasol Solvents, Südzucker AG, Total, ACS, Volkswagen RTD-partner RWTH Aachen University, VKA, Prof. Dr.-Ing. S. Pischinger Project funding and budget Public funding (BMWi) / 280.000 Euro (365.000 $) Duration: 24 Month Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 18

Example 2: Inquiry Future Fuels SI Engines Workplan & Results Determination of the maximum compression ratio increase of ethanolgasoline fuel blends in comparison to a conventional RON95 fuel. Optical investigation of spray penetration and evaporation in a high pressure chamber. Experimental investigations using a turbocharged direct injection research engine. Part load testing was carried out to determine efficiency benefits. Climate chamber testing was used to test low temperature starts. E20 fuel evaporation is similar, sometimes better than conventional fuel The higher knock resistance enables an increased compression ratio E85 evaporates worse under all investigated boundary conditions. Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 19

Example 2: Inquiry Future Fuels SI Engines Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 20

Example 3: Fatigue in corrosive fuels Development and experimental verification of a fatigue assessment method for highly loaded engine components in corrosive fuels Participating companies Robert Bosch (Initiator), AVL List, Benteler Automotive, BMW Group, Continental Automotive, Daimler, L'Orange, Mahle, Opel, Porsche, Volkswagen AG RTD-partner Prof. Oechsner, Technische Universität (TU) Darmstadt, Institut für Werkstoffkunde Prof. Zoch, Stiftung Institut für Werkstofftechnik (IWT), Bremen Prof. Sonsino, Systemzuverlässigkeit und Maschinenakustik (SzM), TU Darmstadt Project funding and budget Funding: FVV in cooperation with DFG (German Research Foundation) Budget: 875.000 Euro ( 1.135 Mio. US$) Duration 36 months Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 21

Example 3: Fatigue in corrosive fuels Workplan & Results Worldwide a variety of alternative fuels are increasingly used. Fatigue in corrosive surroundings (e.g. ethanol fuel) leads to a number of phenomena which at present are cleared only insufficiently. Corrosion fatigue at simultaneous cyclical loads leads to a reduction of the component strength. Primary objective of the project is the development of safe fatigue assessment methods for highly loaded components (fuel injection system) in corrosive media. Challenges (for example) Determination of the influence of the corrosive media on the dynamic strength Extrapolation of S-N(Wöhler)-curve to the Very-High-Cycle-Fatigue (VHCF) area beyond 1E7 load cycles High pressure section Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 22

FVV Cooperation with Brazil The challenges for the combustion engine industry are worldwide the same Brazil is one of the major markets for FVV-member companies Most of them are represented in Brazil Excellent research capabilities in Brazil Strong relations in RTD-cooperation between Brazil and Germany This cooperation is strongly supported by both governments Time seems to be right to cooperate FVV the power of joint research Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 23

Forschungsvereinigung Verbrennungskraftmaschinen e.v. Lyoner Straße 18 60528 Frankfurt Dietmar Goericke Tel.: (+49 69) 6603-1821 Email: goericke@fvv-net.de Presentation of FVV e.v., Sao Paulo, Brasil, 2012-10-03/04 24