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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

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Page 1: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 2: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 3: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

Bosch: Automotive Technology business sector

C/CC | Sept 28 2012 | © 2012 Robert Bosch LLC and affiliates. All rights reserved. 3

Page 4: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 5: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 6: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 7: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 8: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 9: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 10: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 11: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 12: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 13: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 14: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 15: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 16: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 17: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 18: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 19: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 20: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 21: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 22: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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

Page 23: Bosch Powertrain Technologies - Department of Energyenergy.gov/sites/prod/files/2014/03/f8/deer12_yilmaz.pdf · DEER 2012 – Bosch Powertrain Technologies . ... Diesel Systems

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