Cummins/DOE Light Truck Clean Diesel Engine Progress Report August 2003
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 ~ NO x = 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 60 Cars 50 40 30 Light Trucks 20 10 0 3 51% 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 '00 '01 '02 % of Vehicles Sold Source - Automotive News
Light Truck Major Segments Vans 22% 8.4M Vehicles Sport Utility Vehicles 39% Pickup Trucks 39% 2001 Sales 4
Importance of Fuel Economy Over Time Percent of respondents who declared fuel economy to be very important or critical to them. 80% 60% 40% 43% 56% 58% 50% 20% 0% All Women Younger CD Buyers Source: J D Power 2002 Clean Diesel Study 5
Consumer Demand for Clean Diesels Definite willingness to consider buying clean diesels. 60% 2001 2002 Respondents 50% 40% 30% 20% 10% 0% All Vehicles Entry Compact FS Car FS SUV LD FS PU HD FS PU Source: J D Power 2002 Clean Diesel Study 6
V Family Goals and Status Description Emissions Noise, dba Fuel Economy, MPG Quality/Reliability Rated Speed Actual (status) V6 V8 Tier 2 Interim Demonstrated, Tier 2 Bin 5 Final, Met in Vehicle 72.7, Bare Engine in Test Cell 22.1 Combined, Durango (+60%) Current Work Focus 4000 rpm (5000 max.) 49.7 Interior Idle Park Ram1500 Pickup 21.7 Combined, Ram1500 (+60%) Useful Life km(mi) Performance 10.7 sec, 0-60 mph, 5500 # PTW 9.6 sec, 0-60 mph, Ram1500, 6000 # PTW Displacement, liter 4.2 5.6 Power, kw(hp) @ rpm 8000 hr Total Development Testing (equivalent usage >1.9M(1.2M) 177(237) @ 3600 WG 201(270) @ 3800 VNT 224(300) @ 4000 Interim target met. Torque Peak, Nm(ft-lb) 584(430) 623(460) Warm-Up 34C in 200 sec @ -10C Future Work Serviceability No Adjustments Diesel fuel filter added. Cold Start 3.2 sec (10 sec glow) @ -10C Future Work Weight, kg(lb) 301(663) 357(788) Meets Goal Partially Meets Goal; Plan in Place 7
Light Duty Automotive Engine - V6 8
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 denox catalyst (Bin 10) 4-Way Catalyst (Tier 2, Bin 5) Aspiration Wastegated turbocharged Intercooling Vehicle mounted air-to-air Block Cast iron, thin-walled Head High temperature alloy aluminum NVH Control Deep skirted block, with bedplate Accessories Common automotive V-8 gasoline Accessory Drive Single serpentine belt, self-adjusted 9
Chassis Certification Method 60 50 Cold start: 0-505 sec 3.6 mi Running start: 506-1372 sec plus shutdown 3.9 miles 10 min. soak Hot start: 0-505 sec plus shutdown Running start: 506-1372 sec (not actually run) FTP-75 Speed (mph) 40 30 20 10 0 0 1000 2000 3000 4000 Time (sec) Fresh Sample Filter 10
Demonstrated Emissions Interim Results 1.0 Sulfur = 350 ppm NOx (gm/mile) 0.8 0.6 0.4 0.2 0.0 MY2004-8 DOE Target Max. Tier 2 Bin MY09+ Ultimate Tier 2 Fleet Average Maximum Interim Bin 5250 lb Passive denox 10.6 l/100 km (22.2 mpg) city 5750 lb Passive denox 10.8 l/100 km (21.8 mpg) city 5750 lb Passive denox 10.6 l/100 km (22.2 mpg) city 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 TPM [gm/mile] 11
Prime-Path-System with 4-Way Catalyst System Delta Pressure Sensor Close-Coupled: Oxidation cat. O 2 Sensor O 2, Temperature Sensors MY 07+, Tier 2 EPA & LEV II CA Underfloor: PM Filter N0 x Adsorber HC & CO 12
Regeneration Strategy Condition Engine Out Combustion Condition NO x Regen Rich Pilot + Main Injection Thermal Management Soot Regen Lean + Pilot + Main + Post Sulfur Regen Rich Pilot + Main + Post 13
Demonstration Emission System CCC (Pt); NAC (Pt & Rh); DPF (Pt) 1.3L, Metallic NOx and THC analyzer (CC out or UF in) P sensor NOx and THC analyzer (UF out or Tailpipe) CCC NAC CSF Temp and O2 sensor 7.5x7 (5.1L) 7.5x12 (8.7L) Temp and O2 sensor 14
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 4.2-0.07 0.090-0.01 FTP-75 FTP-75 0.399 0.367 480.27 491.67 0.033 0.038 0.089 0.056 21.12 20.32 0.006 - Start +1600 mi bag 1 0.971 1.051 547.87 583.44 0.141 0.181 0.222 0.269 18.47 17.08 0.008 - bag 2 0.272 0.200 475.03 475.27 0.003 0.000 0.057 0.000 21.37 21.04 0.004 - bag 3 0.207 0.166 439.17 453.40 0.009 0.003 0.049 0.000 23.11 22.05 0.007-15
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] HFET 0.122 0.101 309.94 332.70 0.005 0.007 0.000 0.015 32.8 30.1 0.006 - Start +1600 mi SC03 0.229 0.200 479.49 484.82 0.009 0.015 0.000 0.000 21.16 20.93 0.013 - US06 0.138 0.120 451.28 496.23 0.158 0.228 0.011 0.005 22.53 20.20 0.023-16
Analyzer Results - Bag 1 & 2 7 6 Tailpipe NOx Engine Out NOx Vehicle Speed 70 60 Cumulative NOx [gm] 5 4 3 2 50 40 30 20 Vehicle Speed [MPH] 1 10 0 0 200 400 600 800 1000 1200 Time [sec] 17 0
Typical Results City, mpg* Highway, mpg* Combined, mpg* Combined gal/mi CO 2 Dodge Durango - Gasoline 12 17 13.8 0.072 - Diesel 20.3 25.0 22.1 0.045 +60% Improve 37% Reduction 27% Reduction Dodge Ram 1500 - Gasoline 12 16 13.5 0.074 - Diesel 19.8 24.6 21.7 0.046 +61% Improve 38% Reduction *Adjusted values for vehicle labeling 18
V6 Performance Results 700 600 201 kw (270 hp) @ 3800 rpm Torque, N-m 500 400 300 200 100 0 0 1000 2000 3000 4000 5000 Engine Speed, rpm 19
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 10.0 0.0 Wendy's, Park @ Idle Interior, Park @ Idle Interior, 60 mph Open Hood, 3 ft at 45 deg 20
Acceleration Test Results V8 in Ram 1500 15.00 Gas = 330 hp @ 5400 rpm Diesel = 300 hp @ 4000 rpm Time, sec 10.00 5.00 3.97 4.54 8.60 9.62 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 21
Conclusions Light Truck Diesel Family continues to show promise Fuel economy advantage is clear, approaching 60 percent Performance and sociability are becoming gasoline-like Interim Tier 2 emissions, met using known technology Final Tier 2 emissions, met in a complete vehicle system using advanced aftertreatment devices There is a path to market for the Light Truck Diesel Cost/Robustness issues are the ongoing challenge 22