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GS/ENA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 1
DEER 2012 – Bosch Powertrain Technologies
Gasoline Systems 1
Hakan Yilmaz Chief Engineer – Gasoline Systems Robert Bosch, North America
GS/ENA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 2
DEER 2012 – Bosch Powertrain Technologies
Gasoline Systems 2
• Bosch Automotive Sector Introduction
• Regulations and Market Trends
• Electrification Overview
• ICE Technologies
• DOE / Bosch Collaboration
• Conclusion
Bosch: Automotive Technology business sector
C/CC | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 3
Divisions of Automotive Technology
GS/MKC | 1111 | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Gasoline Systems Injection & Ignition for Gasoline & Alternative Fuels, Air Management, Transmission Controls and Components, Electrification, Controls and Sensors, System and Application Engineering
Diesel Systems Diesel fuel injection system, Exhaust-gas treatment, Start system
Chassis Systems Brakes Brake booster, Disc-brake calipers
Chassis Systems Control ABS, ESP
Electrical Drives Actuation, thermal and wiper systems, steering
Starter Motors and Generators Products for commercial vehicles, starter motors and generators
Car Multimedia Navigation system, Car radio, indication instrument
Automotive Electronics Sensors, Electronic Control Units, Semiconductor, Airbag-control
Automotive Aftermarket Automobile spare parts, Accessories, test engineering
ZF Lenksysteme GmbH (50 % Bosch) Steering system for passenger cars and commercial vehicles (including steering pumps and columns)
4
Bosch: Automotive Technology business sector
GS/MKC | 1111 | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Powertrain Domains
System Integration
Gasoline Systems – Driving Powertrain
Injection & Ignition for Gasoline
& Alternative Fuels
Air Management
Transmission Control &
Components
Electrification
Controls and Sensors
System and Application Engineering
Bosch Gasoline Systems Overview
5
Legislation & Commitments EU US CAFE Japan China Korea
0
50
100
150
200
250
2010 2015 2020 2025 2030
GS/ENS2-Te | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Gasoline Systems
CAFE LT/MDV
CAFE PC
mpg
22,3 24,9
36,5 41,6
54,8 62,3
110 125
CO2 g/km
l/100 km
8,6 7,5
6,4 5,7
4,3 3,8
2,1 1,9
CAFE = Corporate Average Fuel Economy PC = Pass. Cars LT / LDT = Light Trucks (pick-ups, vans, SUVs) MD(P)V = Medium Duty (Pass.) Vehicles LCV Light Commercial Vehicles
gasoline (diesel)
130
175 EU LCV
EU PC
70 EU Com. PC 95
99 CAFE PC
137 CAFE LT 147
114 / 116
proposed vision
183 166
119
146 166
192
217
229
Global Fuel Economy Regulations
6
Limit values for SI PC EU IV-6 and CARB LEV II/III
DS/EPD1-GS Te (GS/ESP3) | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
NOx [mg/km] CO [mg/km] 100
PM [mg/km]
1305 44
4.5
6.2
100
1000 622 80 12
34
68
60
EU IV EU 5/6
LEV II ULEV
LEV III ULEV125
LEV II SULEV
LEV III SULEV20
EU HC/NHMC LEV NMOG [mg/km]
EU PM/PN limits only for GDI EU6b 9/2014 PN = 6*1012 #/km EU6c 9/2017 PN = 6*1011 #/km
CARB LEV III PM limits PM 1.86 mg/km (3 mg/mi) 2017-21 PM 0.62 mg/km (1 mg/mi) 2025-28
EU and CARB different test cycles: NEDC resp. FTP75
Emission Regulations for US and EU
7
Development of key factors from 2015 to 2020
GS/ENS-NA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Key factors influencing powertrain development
Gasoline Systems
FE legislation
NOx legislation
EV incentive per vehicle
Battery price
Oil price (inflation adjusted2))
Annual mileage
EV infrastructure
ICE optimization
1) Incentive paid in 2015, decreasing to $0 until 2025 2) 200 USD/bl in 2020 means 260 USD/bl nominal (at ~2% inflation)
Reduction 25% / 5years US CAFE: 54.5 mpg in 2025
SCR/NSC in all Diesel powertrains (2015: US)
Max. $75001) decreasing to $1000 ($3 bn p.a. global 2020)
Decrease from $500kWh to $250/kWh EV with battery leasing increasing from 10% to 30%
Steady increase from 100 to 150 USD/bbl
Slow decrease (~10%)
Slow build-up, 2020 major city centers covered
OEMs/Suppliers continue optimization until 2020
Soft Factors Additional willingness to pay for Green Image, E-Motion, Performance
legi
slat
ion
end
cust
omer
* CO2 limit for PC in 2017, light trucks 200 g/km
8
Market Development per Powertrain Type – Sales *
GS/ENS-NA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Bosch Gasoline Systems Technology 2016+
Gasoline Systems
Sal
es E
lect
rifie
d P
C &
LC
V<6
t (m
io. v
eh.)
2020 2015
JP
5.9
0.5 3.4
0.9 0.8 0.2
CN
28.3
4.5
18.9
4.5
0.2 0.1
US
16.5
1.6
6.4
6.1
2.1 0.3
WEU
16.2
7.2
3.3
4.2
0.6 0.6
1.7 0.3
JP
4.8
1.0 1.1 0.3
0.3
CN
32.0
4.7
19.9
4.8
1.4 0.6 0.5
US
17.8
1.8
2.6
8.8
3.0 1.0 0.6
WEU
17.2
8.0
1.5
4.3
1.0 1.2
1.1
WEU: EU15 + NO + CH, w/o LU * Prognosis RB
CNG
Diesel PFI GDI
HEV PHEV EV
pure ICE
HEV = sHEV & mHEV, thereof ca. 90% sHEV
The conventional combustion engine keeps dominating the powertrain the next 15-20 years. Broad introduction of electrification hindered by system cost and unattractive solutions.
Sales PC & LCV<6t (mio. vehicles) * 9
GS/ESC3, GS/EST | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Gasoline Systems
Evolution of Electrification
potential for CO2 saving
PHEV
Inno
vatio
n lin
e
Bosch innovation line to support future
market requirements! sHEV
mHEV <60V
Recuperation
Coasting
Boost
Advanced Start/Stop
Baseline: Start/Stop
Recuperation
Boost
e-Drive
Coasting
Recuperation
Boost
e-Drive
Coasting
A Start
Stop 2 4
6
x 1000 / min
40 80 120
160
200 km/h
12 0
A Start
Stop 2 4
6
x 1000 / min
40 80
160
200 km/h 0
120
A Start
Stop 2 4
6
x 1000 / min
40 80
160
200 km/h 0
120
A Start
Stop 2 4
6
x 1000 / min
40 80
160
200 km/h 0
120
2 4
6
x 1000 / min
40 80 120
160
200 km/h
A Start
Stop 0 0
Coasting
Start/Stop Coasting
A Start
Stop 2 4
6
x 1000 / min
40 80
160
200 km/h 0
75
Bosch Gasoline Systems Overview - Electrification
10
Evolution of Electrification / E-Drive with BRS
GS/ENS-NA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Bosch Gasoline Systems Technology 2016+
Gasoline Systems
A Start
Stop 2 4
6
x 1000 / min
40 80
160
200 km/h
-
0
PHEV
A Start
Stop 2 4
6
x 1000 / min
40 80
160
200 km/h
75
0
Coasting
Inno
vatio
n
A Start
Stop 2 4
6
x 1000 / min
40 80 120
160
200 km/h 0 12
A Start
Stop 2 4
6 40
80 160
- sHEV
Start/Stop Coasting
Advanced Start/Stop
2 4
6
x 1000 / min 0 40
80 120 160
200 km/h 0
A Start
Stop
Baseline: Start/Stop
x 1000 / min 200
km/h 0
Recuperation
Boost
e-drive
Coasting
Recuperation
Boost
e-drive
Coasting - A
Start
Stop 2 4
6
x 1000 / min
40 80
160
200 km/h 0
BRS <60V
Recuperation
Coasting
Boost
e-Drive Pacing
Environmental sensing with radar sensor and GPS enables smart drive
BRS: Boost Recuperation System - sHEV: Strong Hybrid - PHEV: Plug-In Hybrid
Fuel Economy Improvement
System Cost
11
Coasting in FTP75 (measurement)
GS/ENS-NA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Bosch Gasoline Systems Technology 2016+
Gasoline Systems compact class, 1.4l DI T/C, 90kW, 7-gear
FTP75 FTP75 speed profile SSC possible
inj. quantity [ml/s]
veh. speed [km/h] Start/Stop Coasting
time [s]
w/o SSC
FTP tolerance SSC
SSC
w/ SSC
veh. speed [km/h]
w/o SSC
w/o SSC
engine-off time
Fuel Economy Gain
7%
4%
up to +2%
9%
SS
SSC
BRS driver
FTP75 20% SSC share
12
GS/PRM-SYS | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Gasoline Powertrain Fuel Economy Measures
Gasoline engine measures for efficiency
Gasoline Systems
ICE PT Efficiency
Lean Burn (lambda >1 combustion, EGR)
De- throttling
Extreme Downsizing (downsizing to 1.1L)
eDZ
Cylinder Deactivation half engine operation w/ switching
CDA
LB
Best Efficiency Operation
Optimized Combustion (charge motion, eps+2)
ICE Friction Reduction (electric auxiliaries & extr. mech. friction)
OC
FR
ICE Operation
points
Downspeeding (gear ratios, shifting, n_max)
Start/Stop (no idle operation in stand-still)
Start/Stop Coasting
DoSp
SSC
S/S
Energy Recuperation
Electric Recuperation (for example w/ 48V BRS)
ReCu
13 13
GS/PRM-SYS | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Gasoline Powertrain Fuel Economy Measures
Gasoline Systems
PFI N/A
Downspeeding
Downsizing NVH Drivability (Turbolag) Displacement per cyl.
NVH, drivability No. of shifting operations Mass, friction, hydraulic
DI T/C
Gears+ CVT (DI)
VVT
VVT
VVL
+High Compression Ratio
+Lean Combustion De-throttling potential Emissions (NOx) Controllability (HCCI) SGDI HCCI
DI cooled EGR
var. eff. compress.
knock rest. fuels
Pre-Ignition Knocking Ignition
Friction reduction
Mass reduction
Thermal managm’t
Barriers/Limits
CDA
Due to new test cycles and trends towards downsizing and downspeeding, high compression ratios become more important to reduce CO2.
14 14
Adv. Combustion Concepts: Challenge and Solution (Fuel Metering)
GS/NE | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Advanced Fuel Control for Gasoline Engines
Gasoline Systems
Downsizing / Displacement Reduction • wetting (piston, valve) • oil dilution • mixture preparation (homogenization) • spread (idling, catalyst heating, boosted full load)
Lean Burn Concepts (SGDI, HCCI) • multiple injection >=3 • combustion concept robustness
Solution
Spray-Targeting
• variable hole design
• innovative manufac-turing technologies
Mixture Preparation
• multiple injection
Adv. Injection Spread
• using ballistic range towards smallest quantities @ 200 bar
source: MTZ 12/2010 speed
torque build-upScavenging electrical
WG hybridization
knockingtumble design
active cyl. head cooling
comp. protectionintegr. exh. manifold
cooled EGR
high ignition voltagerobust ignition system
emissionsimproved mixture prep.
reduced penetration(e.g. soft spray, split inj.)
nominal powerturbo-charger
Pmaxto
rque
higher injection spread /multiple injection
controlled valve operation
15
GS/ECS | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
EU6 Requirements & Solutions
Gasoline Systems
Injector Engineering and Advanced Manufacturing Spray-Targeting Better mixture distribution Reduced wall wetting Optimize valve- spark plug interaction si
de m
ount
ed
cent
ral m
ount
ed
Laser drilling of spray holes Better spray break-up Increased air-entrainment Reduced penetration
Reduced penetration
0 mm
10 mm
20 mm
30 mm
40 mm
50 mm
60 mm
70 mm
80 mm
0 mm
10 mm
20 mm
30 mm
40 mm
50 mm
60 mm
70 mm
80 mm
Lase
r dr
illing
St
anda
rd
EDM
Laser drilling, opt. Standard
Individual spray beams Flexible hole design of single beams Improved homogenization Reduced wall wetting La
ser
drilli
ng
Stan
dard
ED
M
Laser drilling Standard
16
GS/ECS | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Small quantity injection w/ Controlled Valve Operation
Pressure increase up to 200 bar:
Improvement of mixture preparation with increased rail pressure
Multiple injection: Penetration reduction with twin- or
multiple injection.
Advanced Fuel Control for Gasoline Engines
Par
ticle
Num
ber
5 10 15 20 prail [MPa]
Inje
ctio
n tim
e
A B
single double triple
penetration decrease with multiple injection
B C
Tolerance requirements:
Increasing quantity tolerances with decreasing energizing time
Adjustment of qdyn tolerances for short energizing times with CVO (*Controlled Valve Operation)
tole
ranc
es Injection/energizing time
quan
tity
A B
C
ballistic non- ballistic
tolerance limit A
B C
single injection multi injection
17
GS/PJ-PT | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
US DOE & Bosch Collaboration in Powertrain
Gasoline Systems
Advanced FFV Project Targets
Timeline Partners
• US Department of Energy
• Robert Bosch LLC
• Ricardo, Inc
• University of Michigan, Ann Arbor
Targets: Fuel efficiency improvement with E85 ULEV level emissions with E85 Ethanol detection & combustion control
0 3 6 9 12 15 18 21 24 27 30 33 3610/07 01/08 04/08 07/08 10/08 01/09 04/09 07/09 10/09 01/10 04/10 07/10 10/10
Phase 1
Phase 3
T-2
T-6
Phase 2
Phase 4
T-3T-4
T-1
T-7
T-10
T-12
T-5
T-8T-9
T-11
T-12
K-Off M-1 M-2 M-3 M-4
1970 1980 1990 2000 2020 2040 2060
• ACEA-Selbstverpflichtung
2008: 140g/km (-25%)
Power / Comfort / Safety
Emissions (HC,CO,NOx, PM)
CO2-Emissions
Resources
From Fossil to renewable Fuels
Technological Challenges
18
Kick-off End of Project
October 2011
Febrruary2013
May 2014
October 2015
Phase I Phase II Phase III
GS/PJ-PT | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
US DOE & Bosch Collaboration in Powertrain
Objective Partners
Design a Thermoelectric exhaust waste heat recovery system (Thermoelectric Generator) that will provide at least a 5% fuel efficiency improvement for a light-duty vehicle platform.
Budget & Timeline Waste Heat Recovery
Total Budget: $11.3 Million DOE, National Labs, Academia, Industry
participation
19
GS/PJ-PT | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
US DOE & Bosch Collaboration in Powertrain
Gasoline Systems
DOE Awarded Project – REGIS
Structure Partners
Recirculated Exhaust Gas Intake Sensing
Objective of the REGIS project is to develop an Intake Air Oxygen sensor which directly and accurately measures the oxygen concentration in the intake manifold to estimate the external EGR rate in order to improve engine efficiency resulting in reduced fuel consumption while meeting the required U.S. EPA emission standards.
Timeline: 3-year project starting 2012 Budget: 4.75 Mio USD
US Department of Energy
Robert Bosch LLC
Oak Ridge National Lab
Clemson University
20
GS/ENS-NA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
US DOE & Bosch Collaboration in Powertrain
Gasoline Systems
ACCESS Partners
Concept Status
21
GS/ENS-NA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Gasoline Systems
Advanced Combustion Concepts – Enabling Systems and Solutions for High Efficiency Light Duty Vehicles $24.5 million investment (up to $12
million from Department of Energy) 4 year project started October 2010 25+% fuel efficiency improvement
compared to a baseline powertrain utilizing advanced combustion concepts complementing the downsizing trend
Prototype engines are operational with simultaneous testing First results show combustion concept feasibility Single ECU concept is successful
GS/ENS-NA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Bosch Powertrain Systems Technology Focus
Gasoline Systems
Engineering focus for 2016+ Fuel economy improvement 25% every five years
MY2016 -- US market Downsizing (DI with Turbo Charging) Vehicle size and weight reduction Start/Stop with automated transmission 8/9 speed transmission (cooled external EGR)
MY2020+ adds Advanced combustion features ‘Affordable electrification’ required to meet fuel efficiency targets. Revival of alternative fuels (driven by cost and availability)
The pressure from market and legislation to improve fuel economy accelerates the introduction of technology packages to the ICE. Optimization of the ICE still offers the best cost/benefit ratio over electrification.
22
Powertrain Architecture and Controls
GS/ENS-NA | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved.
Bosch Powertrain Systems Technology Focus
Gasoline Systems
Cha
ssis
Ele
ctric
Driv
e T
rans
mis
sion
Com
bust
ion
Powertrain Sub Domains System Engineering Powertrain
Target Optimized Powertrain Architecture with “Affordable Electrification”
Interlinked control concept for optimized powertrain operation.
Highly efficient combustion concepts
Optimized drive train control
Affordable Hybridization
Vehicle Information Management
Powertrain Control Strategy enhanced by awareness of vehicle environment and driver feedback.
23
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