romi isetta

Transcription

romi isetta

Thanks to
07.05.2014
Powertrain Technologies
within a Rapidly Changing Global Environment
Maurilio Cassiani,
Mauro Giroldo,
Matthias Wellers
Welcome – Your Partner in Powertrain
USA
Colombia
Portugal
France
Czech Republic
Spain
UK
India
Belgium
Netherlands
Iran
China
‫وش آ د د‬
Fáilte
Welcome
Willkommen
Bienvenida
환영
Welkom
Vítejte
Accueil
Accueil
Bem-vindo
欢迎
Bienvenida
Welcome
Accueil
आपका
वागत है
Καλωσόρισµα
Bem-vindo
Welkom
Willkommen
Καλωσόρισµα
Benvenuto
Brazil
Senegal
Germany
Italy
Your Partner in Powertrain - AVL Powertrain UK
Cyprus
Greece
Austria
Hoşgeldin
Üdvözöljük
Ireland
Hungary
Turkey
Welcome
South Africa
Korea
New
2 Zealand
AVL
60+ YEARS CUSTOMER SATISFACTION
1948
A
Design
Development
2014
A
Project Management
D
Design
UK
Simulation
F
Mech. Develop.
Thermodynamics
Calibration
H
SW & Functions
TR
Electronics
SLO
Transmission
Testing
S
Hybrid & EV
Fuel Cell
Acoustics
Prototyping
RUS
USA
BRA
Racing
JPN
Driveability
KOR
Testing
Supply Chain Mgmt
CN
IND
3
POWERTRAIN ENGINEERING
CORNERSTONES OF EXPERTISE
IC Engine
More than 1500
development
projects
Battery
Transmission
Research and
Realisation of
latest
Technologies
Realised Design
& Optimization
Electric Drive
Control
Strategy
Expertise from Function
Development, Calibration to
Test
4
AVL
ONE SHOP POWERTRAIN COMPANY
We develop
new ideas and designs
We simulate and evaluate
We measure and test
5
An R&D driven company
6
The unique AVL
Powertrain Engineering Network
USA
CTC
Lake Forrest
CHINA
AVL-Beijing
TC
INDIA
KOREA
CHINA
AUSTRALIA
AVL India TC
AVL-Korea CC
AVL-Shanghai
NTC
Delhi
Incheon
TC
Sydney
/ Gurgaon
/ Seoul
FRANCE
LMM
Paris
/ Palaiseau
USA
AVL-PEI
Plymouth
U.K.
AVL-UK Ltd.
Millbrook
1994
1996 Tongji
1998
2000
University
(1926–1932)
USA
SWEDEN
AVL-PEI STPE AB
Ann Arbor Södertälje
2002
GERMANY
CROATIA
GERMANY
AVL-Trimerics
AVL-AST Croatia
AVL-D
Neuenstadt
Zagreb
Ingostadt
GERMANY
AVL-D
Munich
AVL China
Tianjin
2004
...
2006
BRASILGERMANY JAPAN
Sao Paulo
Dr. SCHRICK
AVL-Japan
Remscheid Tokyo
HUNGARY
GERMANY
AVL-Autokut
AVL S&F
Budapest
Regensburg
GERMANY
AVL-Tippelmann
Filderstadt
SLOVENIA
AVL-ASTSlovenia
Maribor
AVL
Tech Centre
South
America
TURKEY
AVL R&D Turkey
Gebze
U.K.
AVL Powertrain
Dunton
!
SWEDEN
AVL-MTC
Stockholm
7
Global Facts and Trends
Man made 4%
Public 2%
Domestic 16%
Business 20%
cuts
($/bbl)
25
Energy 40%
new 65 Million / more 35 Million
reg.cars in 2010 / 10 x car prod.in 2013
Water 10%
Air 12%
105
1950 2.5 billion – 30% in cities
2050 10 billion – 70%
2 in cities
2000
Transport 22%
CO
Trucks
23%
Buses 6%
Cars 45%
Rail 2%
Romi-Isetta
- 1955
2013
8
Powertrain Yesterday and Tomorrow
Society
Legislation
CO2
Emission
…
Costs
Romi-Isetta - 1955
Differentiation
9
PC Emission Legislation –
Expected Changes
2014
Limits
2013
2015
2016
2017
2019
2020
EU 6c
EU 6b
NEDC (CO2)
2021
2022
2023
EU 7
NEDC (Emissions)
RDE
Test
procedure for
pollutants
2018
WLTP (Emissions)
WLTP (CO2)
RDE (monitoring)
RDE (compl. factors open)
RDE (stringent compl. factors)
PN Limit
PFI: no limit
DI: 6*1011 /km (6*1012 on dem.)
CO2
Limit
CI: 6*1011 /km
CI, DI: 6*1011 /km
130 g/km (or adapted to WLTP)
tbd (WLTP); mod. procedure?
95 g/km (or adapted to WLTP)
adopted
discussed, no proposal available
Source: 25. TCMV meeting 19.12.2011
adopted proposal
rumors
NEDC - New European Driving Cycle
RDE - Real Driving Emissions
WLTP - World wide Light Duty Test Cycle
10
Load Collective NEDC vs. RDE
11
Real Driving Emissions
NEDC
New European
Driving Cycle
12
NEDC
New European
Driving Cycle
Random Test cycle
Chassis Dyno
Simulation
13
NEDC
New European
Driving Cycle
Random Test cycle
Chassis Dyno
Simulation
PEMS
Portable Emission
Measurement
System
Decision open
14
Fuel economy improvement by
Transmission Measures
24
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
Engine &
4 speed
22
270
8
20
Traction Force - N
2 70
260
Max. Power Curve
(Theoretical)
18
16
6
330
3
27 0 0
0
14
12
240
10
4
BMEP
Power
Drop
30 0
250
8
260
6
2
270
4
3 00
360
2
0
500
330
400
500
BSFC
[g/kWh]
700 1000
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
N [1/min]
Engine Speed
15
BSFC < 240 g/kWh
24
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
Engine &
4 speed
22
270
8
20
BSFC < 240 g/kWh
260
2 70
Energy consumed
(WLTC)
16
330
6
30 0
3
27 0 0
0
BMEP
14
12
240
10
4
Traction Force - N
18
250
8
260
6
2
270
4
3 00
360
2
0
500
330
400
500
BSFC
[g/kWh]
700 1000
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
N [1/min]
Engine Speed
16
Engine &
4 speed
Traction Force - N
BSFC < 240 g/kWh
Engine &
9 speed
BSFC < 240 g/kWh
Energy consumed
(WLTC)
Increased no. of gears
17
17
Engine &
4 speed
Traction Force - N
BSFC < 240 g/kWh
Engine &
9 speed
BSFC < 240 g/kWh
Energy consumed
(WLTC)
Increased no. of gears
Vienna Motor Symposium
26. 4. 2013:
“ VW will introduce
10--Speed Double Clutch
10
Transmission”
18
18
Engine Measures
BSFC < 240 g/kWh
24
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
Engine &
4 speed
22
270
8
20
BSFC < 240 g/kWh
260
2 70
Energy consumed
(WLTC)
16
330
6
30 0
3
27 0 0
0
Engine &
6 speed
BMEP
14
12
240
10
4
Traction Force - N
18
250
8
260
6
2
270
4
3 00
360
2
0
500
330
400
500
BSFC
[g/kWh]
700 1000
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
N [1/min]
Engine Speed
19
19
Engine Measures
BSFC < 240 g/kWh
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
24
Engine &
6 speed
22
270
8
20
BSFC < 240 g/kWh
260
2 70
Energy consumed
(WLTC)
16
330
6
30 0
3
27 0 0
0
Engine &
6 speed
BMEP
14
12
240
10
4
Traction Force - N
18
250
8
260
6
2
270
4
3 00
360
2
0
500
330
400
500
BSFC
[g/kWh]
700 1000
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
N [1/min]
Engine Speed
20
20
Engine Measures
BSFC < 240 g/kWh
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
24
Engine &
6 speed
22
270
8
20
BSFC < 240 g/kWh
260
2 70
Energy consumed
(WLTC)
16
330
6
30 0
3
27 0 0
0
BMEP
14
12
240
10
4
Traction Force - N
18
250
8
260
6
2
270
4
3 00
360
2
0
500
330
400
500
BSFC
[g/kWh]
700 1000
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
N [1/min]
Engine Speed
21
21
Further Measures
Engine &
6 speed
BSFC < 240 g/kWh
+
Traction Force - N
Energy consumed
(WLTC)
Recharging
Hybridization allows
electric driving at
low power requirerequirements where the ICE
would otherwise
operate inefficiently
22
22
Efficiency
23
The Smart Concept
Handling the complexity
…
Alternative Combustion
Technology Elements
Further Hybridisation, Mild/Full Hybrid
Start / Stop
Lean NOX Trap, Selective Catalytic Reduction
Diesel Particulate Filter, Catalyst
Temperature & Energy management
Downsizing
Direct injection, Advanced FIE (Diesel - common rail)
Exhaust Gas Recirculation, High pressure, Low pressure
Turbocharging (two stage)
now
time
24
The Smart Concept
Complexity
Timing
Cost…
Mechanics
Electronics
Model based
Transient ...
Guided calibration
DOE steady state ...
Transient (concepts)
25
The Smart Concept
26
Two topics
Smart Concept
-Turbochager speed-
The realisation of technologies
-The Range Extender-
27
Example – Turbocharger Protection
Validation
Identification
p2
p2
p1
x
1 / p1
1/ x
p1
curve
Function development
n
pref
Compressor
map
& red
m
x
m& MAF
x
T1
1 / Tref
x
curve
Turbocharger Theory
Calibration steps
28
Turbocharger Protection
Compressor
Electronic
actuator
Turbo charger speed < limit
Condition: Heat and Altitude
!
Target:
1. Estimation of the turbo charger speed
2. Guarantee of the limitation of the charger speed
Turbine with
variable
nozzle
29
Turbocharger Theory
ECU - calculation
n
T1
p2
ECU - Curves
&
m
Max. pressure ratio
p1
&
m
T2
n=max
pmax
norm. mass flow
ECU - Formulas
p:
pressure
mbar
T:
&:
m
temperature
K
mass flow
kg/sec
charger speed
U/sec
pressure ratio
-
n:
p2
p1
:
& norm : norm. mass flow
m
m& MAFS
p1
T1
& norm = m
&⋅
m
T1 pref
⋅
Tref p1
p
pmax = max ⋅ p1
p1
kg/sec
30
Turbocharger Theory & Experiment
ECU - calculation
n
&
m
1
- CalibrationT
/ all projects
1
- Procedures necessary
- Process / Identification
p2
ECU - Curves
&
m
T2
Experimental knowledge
Theoretical knowledge
p:
pressure in
T:
temperatur
- Experts
/ few
people e in
& : documentation
m
mass flow in
- Good
n:
charger
speed in
- Explanation
necessary
p2
:
pressure ratio in
p1
& norm : norm. mass flow in
m
Max. pressure ratio
Experimental
p knowledge
n=max
pmax
norm. mass flow
ECU - Formulas
m& MAFS
mbar
K
p1
Theoretical
knowledge
kg/sec
U/sec
T
1
& norm = m
&⋅
m
T1 pref
⋅
Tref
p1
p
pmax = max ⋅ p1
p1
kg/sec
31
Turbocharger Function Development
&
m
p1
T1
ECU - calculation
n
p2
ECU - Curves
&
m
Max. pressure ratio
y
T2
n=max
pmax
norm. mass flow
ECU - Formulas
m& MAFS
T1
⋅ pref
Tref
p1
1/ x
T1
& norm = m
&⋅
m
T1 pref
⋅
Tref
p1
p
pmax = max ⋅ p1
p1
32
Turbocharger Function Calibration
Measured Data
Automatic Mapping
Turbocharger Map
Turbochager Speed
x 10
5
2
1.8
1.6
1.4
1.2
1
0.8
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Pressure Ratio
2 .6
2 .4
2 .2
2
1 .8
1 .6
1 .4
1 .2
1
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Norm. Mass Flow
0 .1 4
0 .1 3
0 .1 2
0 .1 1
0.1
0 .0 9
0 .0 8
0 .0 7
0 .0 6
0 .0 5
0 .0 4
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
33
Turbocharger Function Development
n
p1
p2
T1
T2
&
m
&
m
T1 pref
& norm = m
&⋅
m
⋅
Tref
p1
m& MAFS
T1
T1
⋅ pref
Tref
Max. pressure ratio
y
n=max
p
pmax = max ⋅ p1
p1
pmax
norm. mass flow
1/ x
p1
34
Two topics
Smart Concept
-Turbochager speed-
The realisation of technologies
-The Range Extender-
35
Electrification versus costs
Battery Costs - based on energy consumption of 20 kWh / 100km
€ 25.000
AER = All Electric Range
€ 22.500
AER pure EV
RE = Range Extender
EV = Electric Vehicle
€ 20.000
12.200 € Saving
€ 17.500
€ 15.000
AER with RE
€ 12.500
€ 10.000
€ 7.500
RE Cost
5.400 € Saving
€ 5.000
Total Range
with RE
RE Cost
€ 2.500
€0
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
> 300
Range [km]
36
Range Extender – Rotary Engine Concept
37
Highly Integrated
Range Extender
Rotary Engine
Range Extender
from
existing engine
38
the system
39
vehicle integration
75kW traction motor:
- 0 – 60km/h in 6sec
- top speed 130km/h
integrated
behind rear axle
Li-Ion Battery system
in front of rear axle
and in middle tunnel
40
Thank you
41
POWERTRAIN
IS
GREAT
BRITAIN
WITH SOME HELP
42
AVL LIST GmbH
YOUR INDEPENDENT ENGINEERING PARTNER
Thank you
Matthias Wellers
Mauro Giroldo
Maurilio Cassiani
Obrigado
43

romi isetta

Transcription

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