EA Recent Developments in BMW s Diesel Technology DEER Conference 2003 Newport, USA August 2003
EA Recent Developments in BMW s Diesel Technology BMW Diesel History 2.5 - R6 - DI - VNT 55 revision 3 rd generation DI-Engines Spec. Power [kw/dm 3 ] 35 42 3.9 - V8 - DI - VNT revision 3.0 - R6 - DI - VNT revision 2.0 - R4 - DI - VNT 2 nd generation 1 st generation IDI-Engines 2.4 - R6 NA-Engine 2.4 - R6 - ATL 1.67 - R4 - ATL 2.5 - R6 - ATL 1985 1990 1995 2000 2005
EA Recent Developments in BMW s Diesel Technology BMW Diesel Production 350 300 Engines - 1000/year 250 200 150 100 Σ 1 st generation: 262.000 Σ 2 nd generation: 635.000 50 0 83 84 85 86 87 88 89 90 91 92 93 Year of production 94 95 96 97 98 99 00 01 02 1 st generation 2 nd generation 3 rd generation
BMW Market Share 04/2003 X5 World wide Europe Petrol 65% Diesel 35% Petrol 32% Diesel 68%
EA Recent Developments in BMW s Diesel Technology BMW Diesel Engine Family 200 175 6-cylinder 2.5 / 3.0 l Power [kw] 150 125 4-cylinder 2.0 l 8-cylinder 3.9 l 100 75 1.5 2 2.5 3 3.5 4 4.5 Displacement [ I ]
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
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
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
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
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
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 2000 3000 4000 Engine Speed [1/min]
Characteristics Diesel Electronic Control Units 730d 740d Start of Production 1989 1993 1998 2002 ECU-Type DDE1 DDE2 DDE4 DDE5 Data Length bit 8 16 16 32 Computer Performance MIPS <1 1 4 40 Number of Transistors Mio <1 <1 <1 7 Memory kbyte 33 64 256 1000 Number Labels for Calibration 500 1500 4500 7800* Number of ECU - Pins 55 55 121 154 * With Master / Slave ECU s: 15600 Labels for Calibration
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
Spontaneous Glow System Temperature Glow Plugs Pre Glow Time 1200 10 1000 8 Temperature [ C] 800 600 400 Time [s] 6 4 200 2 0 0 5 10 15 Time [s] 0-25 -15-5 5 Temperature [ C] New Engine Previous Engine
EA Recent Developments in BMW s Diesel Technology Air Management
EA Recent Developments in BMW s Diesel Technology Air Management
Improvements DI 1 st to 2 nd Generation 1 st gen. 2 nd gen. Base Engine: Cylinder pressure bar 160 180 Compression Ratio 18:1 17:1 Injection System: Rail pressure bar 1350 1600 Number of Injection 3 4 Min. Pilot quantity mm 3 /cyc 1.6 1.0 Fuel metering without with Turbocharging: Max. Boost pressure bar 2.1 2.3 Pressure ratio 2.48 2.72 Max. Turbine Eff. % 64 70 Max. Compressor Eff. % 59 63
Engine Performance 6-Cylinder in X5 Torque [Nm] 540 500 460 420 380 340 300 260 Diesel MJ 04 160 kw Engine 1000 Diesel MJ 03 135 kw Engine 2000 3000 4000 180 160 140 120 100 80 60 40 20 5000 Power [kw] Engine Speed [1/min] Torque Power
Performance / Fuel Consumption - X5 AT Acceleration 0-100 km/h Maximum speed Fuel Consumption X5 MJ 04 X5 MJ03
Fuel Consumption in X5 AT Comparison Diesel / Petrol 30 X5 with 3.0 6-cylinder engines 28 Diesel MJ 04 160 kw Engine Diesel MJ 03 135 kw Engine FC [mile/gal] 26 24 CO2 Reduction 20 percent 22 20 8 Petrol 8.5 9 9.5 10 10.5 11 Acceleration 0-100 [sec] Petrol Diesel
NOx- and PM-Reduction for BMW 5 Series Diesel cars 1.2 1.0 EU 1 1992 NOx [g/km] 0.8 0.6 EU 2 1996 EU 2 2000 525tds 1992 0.4 525tds 1996 EU 4 2005 0.2 Potential with DPF 530d 2005 530d 2000 0 0 0.02 0.04 0.06 0.08 0.10 0.12 0.14 Particulate Matter [g/km]
Emission Legislation in USA 1.2 X5 situation 1.0 EPA till MJ03 0.8 NOx [g/mi] 0.6 0.4 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 MJ06 0.2 EPA BIN 8 MJ09 0 0 With DPF and DeNOx-System EPA BIN 5 MJ09 = CARB LEV 2 MJ07 0.02 0.04 0.06 0.08 0.10 0.12 0.14 Particulate Matter [g/mi]
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 2005+ Slightly legislation adaptations to take account of the specific diesel advantages (long term emission stability, CO2)
DEER Conference 2003 - Newport USA