Cummins Light Truck Clean Diesel Engine September 2004
Technical Program Overview Partnership, Cummins and U.S. Department of Energy Focus Development of technologies that will result in a product in the near term Emissions ~ U.S. Tier 2 6000-8500 lb GVW ~ NOx = 0.07 g/mi; PM = 0.01 g/mi Fuel economy - 50 percent MPG improvement over 1997 gasoline powered vehicle it replaces Acknowledgment Partnership funding from DOE Vehicle and installation design assistance from Dodge Truck Engineering Engine Development Team at Cummins 2
US Passenger-Car & Light-Truck Market 80 70 Cars 60 50 40 30 Light Trucks 20 10 0 54% 3 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 '00 '01 '02 '03 '04/7 % of Vehicles Sold Source - Automotive News
V Family Goals and Status Emissions Description Target Actual (Status) V6 V8 V6 V8 Tier 2 Bin 10 Interim Demonstrated, EPA Tier 2 & CA LEV II Tier 2 Bin 5 Final, Met in Vehicle Noise, dba 69 Hood Open, Equal to Gas 72.7 db, Bare Engine in Test Cell 65.0 Interior, Cruise @ 65 mph, 1500 Pickup Fuel Economy, MPG Quality/Reliability Rated Speed 50 % Better than Gas Equal to Gas, <2 RPH First Year and <10 RPH Five Years 22.1 Combined, Durango (+60%) Focus in Phase 3 4000 rpm (5000 max.) 4000 rpm (5000 max.) 21.7 Combined, BR1500 (+60%) Useful Life km(mi) B10 > 325,000 (200,000) Focus in Phase 3 Performance 9.6 sec, 0-60 mph, 5940 lb PTW 8.8 sec, 0-60 mph, 6200 lb PTW Displacement, Liter 4.2 5.6 4.2 5.6 Power, kw(hp) @ rpm Torque Peak, Nm(ft-lb) Warm Up Serviceability Gasoline-Like (9-10 sec 0-60 mph) 190 (250) @ 4000 455(335), 569(420) max. 260 (350) @ 4000 597(440), 760(560) max. 75 C(167 F) Coolant in 10 min. @ -30 C(-22 F) Equal to Gasoline 189(254) @ 3600 WG 201(270) @ 3800 VNT 224 (300) @ 4000, Interim Target Met 569 (420) 623 (460) 49C in 10 min @ -30C Focus in Phase 3 No Adjustments, Diesel Fuel Flter Added 7.1 sec (1.2 sec Cold Start < 20 sec. @ -30 C (-22F) Focus in Phase 3 Glow) @ -30C Weight, kg(lb) 295 (650) 340 (750) 301 (663) 357 (788) Meets Goal Partially Meets Goal; Plan in Place 4
Phase 3 Engine with Integrated Air Cleaner 5
Light Truck Diesel Subsystem Description Subsystem Description Configuration 90 V Displacement 4.2 L V6 5.6 L V8 Bore and Stroke 94 X 100 mm Valvetrain and Drive Single overhead cam, chain-driven Valve System Four valves per cylinder with hydraulic lash adjustment Fuel System High-pressure common rail (HPCR) Control System Full electronic Emissions Control Modulated-cooled EGR plus 4-Way Catalyst (Tier 2, Bin 5) Aspiration Variable-Nozzle or Wastegated turbocharged Intercooling Vehicle mounted air-to-air Block Cast iron, thin-walled Head High temperature alloy aluminum NVH Control Ladderframe Accessories Common automotive V-8 gasoline Accessory Drive Single serpentine belt, self-adjusted 6
Prime-Path-System with 4-Way Catalyst System 7
Catalyst Aging Cycle Description 1 cycle 700 C 10 min Average Fuel Sulphur Level = 9.5 ppm, 20 mpg Average Oil Sulphur Level = 4000 ppm, 25K miles/qt 3.6 ltr NOx adsorber Sulphur Tolerance of 1 gm-s/ltr catalyst Temp 600 C 5 min One DeSOx cycle per ~2200 miles (~110 gallon fuel consumed) ~ 68 DeSOx cycles prior to 150K emissions check Lambda Time 8
Chassis Test Results - Bag Results V6-5000 lb. - 12.7 hp@50 mph Test CO [g/mi] CO2 [g/mi] NOx [g/mi] NMHC [g/mi] FE [mpg] PM [g/mi] FTP-75 FUL limits FTP-75 FTP-75 4.2-0.07 0.090-0.01 0.399 0.367 0.241 bag 1 0.971 1.051 1.121 bag 2 0.272 0.200 0.060 bag 3 0.207 0.166 0.018 480.27 491.67 519.18 547.87 583.44 578.14 475.03 475.27 517.34 439.17 453.40 478.05 0.033 0.038 0.074 0.141 0.181 0.243 0.003 0.000 0.002 0.009 0.003 0.080 0.089 0.056 0.043 0.222 0.269 0.207 0.057 0.000 0.001 0.049 0.000 0.000 21.12 20.32 19.16 18.47 17.08 17.15 21.37 21.04 19.24 23.11 22.05 20.83 0.006 - - 0.008 - - 0.004 - - 0.007 - - Start 1600 mi Aged & Alt. ~150,000 mi 5400 ft 9
V6 Emissions Progression 1 0.9 0.8 NOx (g/mi) 0.7 0.6 0.5 0.4 Catalyst Steady State Engine Out Vehicle Engine Out Catalyst 0.3 0.2 0.1 Vehicle Tailpipe 5000 lb ETW 0.9 g/mi EOE NOx 5500 lb ETW 0.9 g/mi EOE NOx Catalyst 5000 lb ETW VNT, 0.6 g/mi EOE NOx Aged catalyst 0 Sep-02 Dec-02 Mar-03 Jun-03 Oct-03 Jan-04 Apr-04 Aug-04 Nov-04 10
Combustion Parameter Development 11
Acceleration Test Results 15.00 Gas = 345 hp @ 5400 rpm Diesel = 300 hp @ 4000 rpm Time, sec 10.00 5.00 3.97 4.54 4.17 8.60 9.62 8.84 04 ½- ton 5.33 6.00 0.00 0-100 ft 0-60 mph 50-70 mph 5.7 l Gasoline @ 6000 lb 5.6 l Diesel @ 6000 lb 5.6 l Diesel Comp. @ 6200 lb 12
Fuel Economy Results 35 30 Durango 4.7 l Vs 4.2 l V6 Ram 1500 5.7 l Vs 5.6 l V8 MPG 25 20 15 13.7 20.3 17.9 25 22.1 44% 15.3 13.1 19.8 17.1 24.6 04 ½- ton 14.6 21.7 49% 10 5 Gas Diesel 0 City Hwy Comb City Hwy Comb Test Condition 13
Noise Test Results V8 in Ram 1500 90.0 80.0 72.1 76.3 70.0 66.6 Sound Pressure Level, dba 60.0 50.0 40.0 30.0 20.0 49.7 04 ½- ton 10.0 0.0 Wendy's, Park @ Idle Interior, Park @ Idle Interior, 60 mph Open Hood, 3 ft at 45 deg 14
Comparison Phase 2 V6 vs Phase 3 V8 15
Base Engine Durability & Stability Cost Focused Areas * Based on high-volume European diesel usage 16
Conclusions Light Truck Diesel Family continues to show promise Customer features: Performance, comparable to Top Rated gasoline Fuel economy, advantage 44-49% (improves CAFE) Noise, approaching gasoline Smoke and odor, eliminated Cost approached on a fundamental basis Lower Engine-Out Emissions High-Volume Gasoline Supply Base Final Tier 2 emissions, met in a complete vehicle system There is a path to market for the Light Truck Diesel 17