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TRANSCRIPT
Innovative Approaches to
Improving Engine Efficiency
Deer Conference August 14, 2007
Wayne Eckerle
Agenda
Needs for Diesel Engine Efficiency Increase
Roadmap for Increasing Heavy Duty Diesel EngineEfficiency
Novel Engine Concepts
Challenges
Conclusions
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1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025 2030
Mill
ion
barr
els
per
day
Marine
Rail
Cars
Air
Light Trucks
Heavy Trucks
U.S. Production Off-Road
Sources: Transportation Energy Data Book: Edition 25 and projections from Annual Energy Outlook 2006.
U.S. Petroleum Production and Consumption, 1970-2030
Light and Heavy Duty Trucks
Account for Increasing
Highway Transportation
Energy Use
Petroleum Consumption
Surface Transportation Fuel Use
Diesel engines are involved directly in 40% of all surface transportation fuel consumption
Off Road 13%
LT/SUV 28%
4.4 MBPD
3.3 MBPD
2.5MBP D
1.5 MBPD Passcar 38%
Heavy Truck & Bus
21%
Total U.S. Surface Transportation Diesel + Gasoline Fuel Use
= 11.7 MBPD (Million Barrels Per Day)
Source: Trans. Energy Data Book, Edition 25, 2006
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Truck Fuel Use
Source: 21st Century Truck Technical Roadmap – 2001, 1993 VIUS data
Heavy duty trucks are best early market entry for new fuel saving technologies
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Innovation You Can Depend On Source: Philip Patterson, Department of Energy projections.
0.0%
10.0%
20.0%
30.0%
2005
2010
2015
2020
2025
2030
2035
2040
2045
2050
Year
Pet
role
um S
avin
gs, %
Hybrid (Med. Trucks)
Aerodynamic Load Reduction
Vehicle Weight Reduction
Engine Efficiency/WHR
Auxiliary Load Reduction
Heavy Duty Truck Technologies for Energy Efficiency
Engine Efficiency is the Biggest Opportunity
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Historical Perspective of HD Brake Thermal Efficiency
Bra
ke T
herm
al E
ffici
ency
(%)
35
40
45
50
55
60
1985 1990 1995 2000 2005 2010 2015
2002 CEGR Technology
• Cummins Turbo Technology – VGT Improvements • Combustion System Development • EGR Cooling System
HDT DoE Effort - Cummins Fuel System Technology (HPI EUI) - Cummins Turbo Technology (VGT) - Cummins Emissions Solution (DPF) - Advanced Low Temperature Combustion (CEGR)
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1998 HD Architecture
CA
C Ambient
WG Turbo-charger
Exhaust
Control Volume
1998 HD Engine Energy Balance
Fuel Energy 100%
Indicated Power Heat Transfer Exhaust 50% 20% 30%
Gas Exchange Friction Accessories Brake Power2.5% 1.5% 2.5% 43.5%
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2007 HD Architecture
EGR
-Coo
ler
CA
C
Mixer
Ambient
VGT Turbo-charger
DOC
Diesel Particulate
Filter
Fuel Injection
Engine
EGR Valve
Control Volume
2007 HD Engine Energy Balance
Fuel Energy 100%
Indicated Power 50%
Heat Transfer 26%
Exhaust 24%
Gas Exchange 4%
Friction 1.5%
Accessories 2.5%
Brake Power 42%
Advanced Combustion Improvements
with CEGR and FIE
Increased Coolant Heat Rejection with CEGR
Increased back pressure to drive EGR
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Potential Advanced HD Engine Energy Balance
Fuel Energy 100%
Indicated Power Heat Transfer Exhaust 58% 22% 20%
Gas Exchange Friction Accessories Brake Power 2% 1.0% 2.5% 52.5%
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PCCI
Lifted FlameDiffusion Controlled
SmokelessRich
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Fuel Energy 100%
Indicated Power 58%
Heat Transfer 22%
Exhaust 20%
Gas Exchange 2%
Friction 1.0%
Accessories 2.5%
Brake Power 52.5%
Enabling Technology for Efficiency Improvement
Advanced Combustion • Early PCCI • Lifted Flame • Stoichiometric • Mixed Mode
SPEED (rpm)
TOR
QU
E (ft
-lbs)
SPEED
PCCI
Lifted Flame Diffusion Controlled
Smokeless Rich
( rpm)
TOR
QU
E (ft
-lbs)
Enabling Technology for Efficiency Improvement
Fuel Energy 100%
Advanced Combustion Indicated Power
58%
• FIE (Inj. Pressure, Multiple Injection) • CEGR Cooling Systems Heat Transfer Exhaust • Air Handling (Electrically assisted turbo) 22% 20% • Increased Peak Cylinder Pressure • Closed Loop Combustion Control
Gas Exchange Friction Accessories Brake Power 2% 1.0% 2.5% 52.5%
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Enabling Technology for Efficiency Improvement
Fuel Energy 100%
Indicated Power 58%
Heat Transfer 22%
Exhaust 20%
Gas Exchange Friction Accessories Brake Power 2% 1.0% 2.5% 52.5%
Gas Exchange • Electrically assisted turbo • EGR pump • Variable valve actuation
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Enabling Technology for Efficiency Improvement
Fuel Energy 100%
Indicated Power 58%
Heat Transfer 22%
Exhaust 20%
Gas Exchange 2%
Friction 1.0%
Accessories 2.5%
Brake Power 52.5%
Friction Reduction • Piston and rings • Bearings • Surface treatment
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Fuel Energy 100%
Indicated Power 58%
Heat Transfer 22%
Exhaust 20%
Gas Exchange 2%
Friction 1.0%
Accessories 2.5%
Brake Power 52.5%
Enabling Technology for Efficiency Improvement
Exhaust Energy Recovery • Efficient PM Aftertreatment
• lower soot loading • low pressure drop • regen controls/strategy
• Exhaust Port Heat Transfer (liners)
Waste Energy Recovery for Advanced
Fuel Energy 100%
Indicated Power 58%
Heat Transfer 22%
Exhaust 20%
Gas Exchange 2%
Friction 1.0%
Accessories 2.5%
Brake Power 52.5%
Waste Energy Recovery
Hybrid
WHR
HD Engine
Frequent Start/Stop
Seldom Start/Stop
Cus
tom
erB
enef
it
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Fuel Energy 100%
Indicated Power 58%
Heat Transfer 17%
Exhaust 18.5%
Gas Exchange 2%
Friction 1.0%
Accessories 2.5%
Brake Power 59%
EGR Source (ORC)
5%
EGR + Exhaust Source
1.5%
Waste Energy Recovery for Advanced HD Engine
Waste Energy Recovery •Organic Rankine Cycle •Turbo compounding •Brayton Cycle
Comp
Turb
Exh.Manifold
Exhaust Out
Air In
Inta
ke M
anifo
ld
Turbine
Gen
erat
or
Ram Airflow
ISX Engine Rec
upe
DMG
Power Out
Condenser Cooler Pump
WHR Feedpump
Con
dens
er
NOT to scale
Superheate r
Boiler
EGR Valve
CAC
Power Conditioning
WHR Condenser Cooler
Engine Radiato
r Mechanical Fan
Energy Balance for Advanced HD Enginewith Electrification of the Vehicle
Fuel Energy 100%
Indicated Power 58%
Heat Transfer 17%
Gas Exchange 2%
Friction Accessories Brake Power 1.0% 1.0% 60.5%
EGR Source (ORC)
5%
Electrified Vehicle • HVAC • Water pump • Oil Pump • APU
Exhaust 18.5%
EGR + Exhaust Source
1.5%
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Historical Perspective of HD Brake Thermal Efficiency
Bra
ke T
herm
al E
ffici
ency
(%)
35
40
45
50
55
60
1985 1990 1995 2000 2005 2010 2015
Advanced Engine Concepts
Waste Energy Recovery - Waste Heat Recovery (EGR Derived) - Waste Heat Recovery (Exhaust Energy Derived) - Electrically Driven Accessories
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4
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BM
EP (p
si)
CRANK, PIS
TON, ROD
PUMPING
TURBO
FRONT END DRIV
EOIL
PUMPW
ATER PUMP
EXHMAN
INT MAN
FIEVALV
E TRAIN
3600RPM System Motoring BMEP Pareto
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Skirt (~22%)
Rod Bearing (~23%)
Rings (~26%)
Crank (~29%)
Pareto data normalized I6, V6, & V8 motoring friction test results
Lower Friction to Improve Fuel Efficiency
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2
4
6
8
10
12
14
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BM
EP (p
si)
CRANK,PISTON, R
OD PUMPIN
G TURBO
FRONT END DRIV
E OIL
PUMP
WATER
PUMPEXH
MAN IN
T MAN FIE
VALVE TR
AIN
3600RPM System Motoring BMEP Pareto
Just reducing piston skirt friction may reduce total friction torque by approximately 6%
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Piston Skirt Friction
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Alternative Engine Architecture
Hybrid pistons Hydraulic Linear alternator Air pump
Conventional pistons
� Axial, barrel-type piston configuration � Allows for integrated hybrid
Opportunities for New Engine Concepts
�Reduced Parasitics
�Power Density �Weight �Size
�Highly Integrated with Power Train System
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Advanced Concept Engines
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200
400
600
800
1000
1200
1400
1600
1800
2000
50 100 150 200 250 300 350 400 450 500 Power (HP)
Wei
ght (
lbs.
)
2010 Emissions Compliant Diesel Engine
Hybrid with Downsized 2010 Emissions Compliant Diesel Engine
Hybrid System
Hybrid with Advanced Concept Engines
Advanced Concept Engines
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Challenges
�Emissions
�Design Constraints
�Controls
�Total Cost of Ownership
Conclusions
�Diesel Engine efficiency improvements are a significant lever for controlling petroleum consumption
�Efficiency levels beyond 55% are feasible � System integration is critical to control cost and provide
additional system improvements• Waste energy recovery • Electrification
�New engine concepts are providing interesting possibilities
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