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REWARD – Real World Advanced Technologies foR Diesel Engines

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EGVIA - ERTRAC 1st European Conference Results from Road Transport Research in H2020 projects
29 November 2017 to 30 November 2017
Brussels

Published in: Automotive
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REWARD – Real World Advanced Technologies foR Diesel Engines

  1. 1. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 REWARD REal World Advanced Technologies foR Diesel Engines Herwig Ofner herwig.ofner@avl.com www.project-reward.eu
  2. 2. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 REWARD REal World Advanced Technologies foR Diesel Engines EC CALL MG.3.1-2014 Technologies for low emission powertrains Consortium (16 partners): AVL (AT), CRF (IT), Renault (FR), Volvo (SE), Delphi (LU), Johnson Matthey (UK), LMM (FR), Ricardo (UK), Schaeffler (DE), IFPEN (FR), ViF (AT), CNR (IT), Chalmers (SE), CTU (CZ), UPVLC (ES), Uniresearch (NL) Contract Type of action Project budget EU Funding Project Start-End 636380 Innovation Action € 12.5 M € 9.9 M 1/05 2015 – 30/04 2018
  3. 3. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Subject: Diesel powertrains and aftertreatment technologies for class B/C, D/E passenger cars R&D objectives/ basic research Objective 1: Advanced EATS optimized for the new combustion concepts Objective 2: Technologies for high efficiency (combustion & friction) Objective 3: 2-stroke Diesel engine architecture for B/C class vehicles R&D objectives/ demonstrators Pollutant emissions of diesel class B,C,D,E passenger cars < EU6 RDE Improved fuel efficiency ≥ 5% (reference vehicles 2013) Objective 4: Future 4-stroke B/C class Diesel engine; “efficiency concept” Objective 5: Future 4-stroke D/E class Diesel engine; “downsizing concept”
  4. 4. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Project implementation WP2 - Advanced aftertreatment technologies development WP4 Future 2-stroke Diesel engine architecture for B/C class vehicles WP5 Future 4-stroke B/C class Diesel engine WP6 Future 4-stroke D/E class Diesel engine WP7 - Independent testing & cost assessment Integration into demonstrator vehicles WP3 - Technologies for high efficiency WP1 -Management,coordi- nation & administration WP8 -Dissemination and Exploitation
  5. 5. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Project timeline REWARD REal World Advanced Technologies foR Diesel Engines Engines & Vehicles WP 5,6 Catalysts & EAS WP 2 Tribology WP 3 Vehicle testing & assessment WP 7 05/2015 05/2017 Project Start Completion : Two demo vehicles tested 05/2018 Industrialization Steps ~ 2022 today 09/2017 New catalysts available New Research Direction Supporting Measures (Infrastructure, Regulation, Standards) 05/2016 Specification prototype engines Prototype engines completed on test bed Valve train & bearing material available 10/2017
  6. 6. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Objectives WP2 (EAS) Advanced aftertreatment technologies development § EATS modelling over various RDE drive cycle scenarios for WPs 2,5,6 § Integration of WP2-EATS into test vehicle; tests with focus on urban conditions § Thermal management strategies vs. deterioration of fuel consumption § Assessment of exhaust VVT for thermal management with 1,6L diesel engine § Baseline investigations -> effect of soot on the ammonia oxidation and SCR reactions, effect of gas composition on the soot regeneration
  7. 7. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Technologies for high efficiency (friction reduction & combustion efficiency ) § Friction and wear reduction: o Test campaign with oils and coated parts using different tribological model tests o Engine friction measurements at motored conditions and under load § Combustion efficiency improvement o Optical engine – fuel injection & combustion o CFD, 1-cylinder engine and multicylinder engine Objectives WP3 (efficiency) engine friction vs. load
  8. 8. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Objectives WP4 (2-stroke architecture) Future 2-stroke Diesel engine architecture for B/C class vehicles § Main target: § Optimize the scavenging process, the combustion system and the engine operating parameters, in order to achieve improved performances, i.e. compliance with post EU6 RDE and fuel saving of 5% compared to state of the art EU6 4-stroke engine on the same class B/C application. § Optimized engine architecture considered: § Standard uniflow scavenging configuration § Long stroke engine Displaced volume 500 cm3 Stroke 76 mm Bore 110 mm Stroke-to-Bore ratio 1.45 Scavenging architecture Standard Uniflow
  9. 9. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Objectives WP4 (2-stroke architecture) Future 2-stroke Diesel engine architecture for B/C class vehicles § Single cylinder engine delivered. § Scavenging optimization ongoing with testing different intake port designs, selected from 0D/1D and CFD simulation activities: § Will be followed by combustion optimization with testing different piston bowl shapes selected from CFD simulation activities:
  10. 10. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 4-stroke Diesel engines for B/C vehicles: “Rightsizing” & Low swirl combustion § “Rightsizing” means the application of a low friction concept in combination with approaches to improve the thermodynamic efficiency for the target rated power § This requires the improvement of charging (flexibility & efficiency) and EGR (HP+LP) concepts including corresponding control strategies § EGR rates & charging are optimized in a wide range of the engine operating map for low RDE § The new combustion concept aims at a reduced swirl with reduced flow resistance and heat losses § Novelty refers to the holistic approach (charging, EGR, fuel injection, swirl, control, friction, exhaust aftertreatment) § TRL-level (initial and approached): 4 ® 7 Objectives WP5 (demo B/C vehicle)
  11. 11. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Objectives WP5 (demo B/C vehicle) 4-stroke Diesel engines for B/C vehicles: “Rightsizing” & Low swirl combustion § Engine performance & emissions development completed optimum combustion optimum calibration
  12. 12. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Objectives WP5 (demo B/C vehicle) 4-stroke Diesel engines for B/C vehicles: EAS § Initial approach → single NSC concept - not pursued any more § Single NSC replaced by diesel Cold Start Concept (dCSC™/JM) and a novel SCR on filter (SCRF®/JM) with urea dosing dCSC™: NOx storage in NEDC SCRF®: NOx conversion in different cycles
  13. 13. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Objectives WP6 (demo D/E vehicle) 4-stroke Diesel engines for D/E vehicles: “Aggressive Downsizing” & Quiescent combustion § The approach for larger vehicles stronger focuses on an increase of specific power by “Downsizing” § It requires very demanding solutions for boosting, EGR strategies, fuel injection and exhaust aftertreatment systems § Quiescent combustion concepts could provide attractive solutions for improved NOx engine-out emission & fuel efficiency if regarding a large engine operating field § A further advantage is the compact intake ports design with reduced flow resistance and heat losses § The development of such a new combustion concept requires new methods for the design and layout with simulation tools for engine cycle, CFD, strength, cooling, … § Novelty refers to the new combustion concept with extremely demanding targets § TRL-level (initial and approached): 4 ® 7
  14. 14. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Objectives WP6 (demo D/E vehicle) 4-stroke Diesel engines for D/E vehicles: “Aggressive Downsizing” & Quiescent combustion § Engine performance & emissions development completed § Demonstrator vehicle XC60 MY2018 Engine Base engine (D4204T23) REWARD Type In-line 4-cyl. twin turbo ← Displacement 1969 cm3 ← Bore/ stroke 82,0 / 93,2 mm ← Max power 173 kW @ 4000 rpm 200 kW @ 4250 rpm Max torque 480 Nm 560 Nm EATS LNT + DPF (EU5) LNT + SCRF + u/f SCR
  15. 15. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Objectives WP6 (demo D/E vehicle) 4-stroke Diesel engines for D/E vehicles: “Aggressive Downsizing” & Quiescent combustion § Multi cylinder engine specification and EATS based on extensive simulation work, 1-cylinder engine development and EATS testing on engine New port concept incl. adaptation for high performing water jacket Complete system verification in SCE: Ports, nozzle & bowl CFD optimization of Combustion concept DoE approach Sector analysis Optimization LNT + SCRF + u/f SCR
  16. 16. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Expected or potential impact Cleaner, more efficient road transport through advances in powertrains: § Development of new advanced catalyst formulations for NSC, PNA, SCR, SCRF technologies and supply of selected solutions (catalyst samples) § Catalyst thermal management via engine parameters (e.g. VVT) control § Clean Diesel powertrains: Pollutant emissions < EU6 RDE Demonstration vehicles must prove: RDE, Eu6, targeting at future 'Super Low Emission Vehicles' standard § Highly efficient Diesel powertrains: FC improvement > 5% in RDE o “Efficiency concept” for B/C class vehicles (60 kW/l) – cost efficient/ right sizing/ loss reduction o “Downsizing concept” for D/E class vehicles (≈ 100 kW/l) – increase of thermodynamic efficiency
  17. 17. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 « achievements of the project » from the factsheet Indicator Units used Project reference Project objective Current achievements Types of vehicles CO2 or fuel consumption [g/km] and [%] Best in class 2013 -5% engine development on test bed Passenger cars, Diesel Pollutant emissions [g/km], and% EU6, NEDC < EU6 RDE, - 50% PM, – 3 dB noise engine development on test bed Passenger cars, Diesel Demonstrator Renault Kadjar passenger car, Diesel B/C class Demonstrator Volvo XC60 passenger car, Diesel D/E class
  18. 18. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Publications (1) Title 1st Author Partner Conference/ Journal Year Impact of soot on selective catalytic reduction of NH3, NH3 oxidation and NH3-TPD over Cu/SSZ-13 zeolite Trandafilovic, L. Chalmers Yearly report KCK (Competence Center Catalysis, Chalmers University) 2016 2016 The effects of catalyst aging on sulfur degradation over fully formulated Lean NOx Trap catalysts Wentworth, T Chalmers Yearly report KCK Competence Center Catalysis, Chalmers University) 2016 2016 The effects of catalyst aging on sulfur degradation over fully formulated Lean NOx Trap catalysts Wentworth, T Chalmers Presented at the 2nd International Symposium on Catalytic Science and Technology in Sustainable Energy and Environment (EECAT) TianJin, China, October 2016 2016 The effects of catalyst aging on sulfur degradation over fully formulated Lean NOx Trap catalysts Wentworth, T Chalmers Presented at the 2016 American Institute of Chemical Engineering (AIChE) Annual Meeting, San Francisco, California, November 2016. 2016 Impact of Soot on NH3-SCR, NH3 Oxidation and NH3 TPD over Cu/SSZ-13 Zeolite Trandafilovic, L Chalmers Presented at 18th International Conference on Chemical Engineering and Heterogeneous Catalysis (ICCEHC), Paris, France, November 2016 2016 Experiment and kinetic modelling of SCR coated filters Trandafilovic, L Chalmers AVL International Simulation Conference, Graz, Austria, June 2017. 2017
  19. 19. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Publications (2) Title 1st Author Partner Conference/ Journal Year Kinetic model of DPF and SCR coated filter – Impact of ammonia Trandafilovic, L Chalmers Paper in preparation (2017). 2017 The effects of combining hydro thermal and sulfur agidng over Lean NOx Trap catalysts Trandafilovic, L Chalmers Paper in manuscript, 2017. 2017 Model based combustion-chamber layout for passenger car Diesel engines Machold, A. AVL, VCC 4th International Engine Congress, Baden-Baden, 21-22 Feb 2017 2017 Friction Reduction Tested for a Downsized Diesel Engine with Low-Viscosity Lubricants Including a Novel Polyalkylene Glycol Sander, D. VIF, REN Lubricants 2017, 5(2), 9 2017 Assessment of Light Duty Diesel After-treatment Technology Targeting Beyond Euro 6d Emissions Levels Auld, A., RIC SAE Paper 2017-01-0978 2017 Design of a fuel-efficient two-stroke Diesel engine for medium passenger cars: comparison between standard and reverse uniflow scavenging architectures Galpin, J. IFPEN, REN 2017 SAE World Congress Detroit SAE Paper 2017-01-0645 2017 Experimental and Numerical Characterization of Diesel Injection in SCRE with Rate Shaping Strategy E. Mancaruso. CNR ICE2017 – International Conference on Engines ans Vehicles, Capri, Napoli, 10- 14 september 2017 2017
  20. 20. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Publications (3) Title 1st Author Partner Conference/ Journal Year Diesel Engine Technologies Evolution for Future Challenges Tonetti, M. CRF ICE2017 – International Conference on Engines ans Vehicles, Capri, Napoli, 10- 14 september 2017 2017 Vehicle demonstration of performance and economy of a comprehensive B/C class Diesel engine and aftertreatment system approach for emissions beyond Euro 6 Bürgler, L. AVL, REN, JM, IFPEN Transport Research Arena 2018; Vienna, 16-19 April 2018 2018 A 4-Cylinder High Performance Diesel Engine Concept for D/E-class vehicles featuring low fuel consumption and EU7 emission levels Bohatsch, S. VCC, AVL Transport Research Arena 2018; Vienna, 16-19 April 2018 2018 Design of a fuel-efficient two-stroke Diesel engine for medium passenger cars: assessment of the best suited scavenging architecture, stroke-to-bore ratio and air- loop lay-out Galpin, J. IFPEN, CTU, UPVLC, REN Transport Research Arena 2018; Vienna, 16-19 April 2018 2018
  21. 21. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380 Final Meeting; April 2018 Final Meeting TRA2018 Vienna: § Conference: Monday Apr 16 - Thursday Apr 19 § Booked: Meeting room for 1 day (Wednesday 18th); show/ demonstrate objects and present findings § Presentation of demonstrator cars outside; ½ - 1 day § REWARD Final Meeting will be announced in conference program (e.g. presentations Wednesday morning, test drives Wednesday afternoon) § Mid term presentation of project Dieper (Call GV-02-2016)
  22. 22. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 636380

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