panel 3 - gasoline direct injection: heiko weller, bosch

Gasoline Systems | GS/NE-NA | 09/13/2016 © 2016 Robert Bosch LLC and affiliates. All rights reserved.

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THE GDI REVOLUTION Presented to: Driving Automotive Innovation Workshop, September 13, 2016 Presented by: Heiko Weller, VP of Gasoline Systems Engineering, Robert Bosch LLC


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World-Wide Powertrain Sales Forecast

1) Estimation Bosch

Results based on NEDC; WLTP not yet considered CNG incl. bifuel

The GDI Revolution

The GDI Revolution


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Why GDI? Why Now? Turbo Charging

Variable Valve Timing

Gasoline Direct Injection

Around since the 1960’s. Recuperates exhaust gas energy to boost intake air pressure, resulting in increased power. Remained a niche technology through 2010 primarily due to turbo lag

Became common equipment in the mid-90’s. Allows precise control of airflow in/out of the cylinder

First applied by Bosch in the 1950’s, industrialized from 2000 onwards. Allows precision injection of gasoline directly into the cylinder and optimization of the combustion process

SCAVENGING Air is swept through the combustion chamber to spool up the turbo charger even at low RPMs

The GDI Revolution


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Why GDI? Why Now?

Downsizing Fuel Economy More power from a smaller package…

•  Fewer cylinders

•  Less friction

•  Less loss at idle

•  Lower engine weight

•  Lower vehicle weight

Cylinders

Time

8

6

4

3

Turbo Charging

Variable Valve Timing

Gasoline Direct Injection

SCAVENGING

Fuel economy improves despite…

•  More CUVs/SUVs/Pick-ups

•  Larger footprint

•  Increased horsepower

Change in Adjusted Fuel Economy, Weight, and Horsepower for MY 1975-2015

Source: EPA LD Trends 1975-2015, Dec. 2015

The GDI Revolution


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Picking up the Pace of ICE Technology Mio. Vehicles/Year

GDI GTDI

2nd Gen GTDI

PFDI

CVO

350 Bar

Cooled EGR?

6 Speed AT

8 Speed AT

10 Speed AT

CVT

Water Injection?

GD

I Eng

ine

Pro

duct

ion

in N

A

10  -

8 -

6 -

4 -

2 -

12 -

Powertrain Technology Milestones: 14 -

Direct Injection System

Source: Bosch Internal Estimate (AMPI 2016}

Optimizing the Powertrain The GDI Revolution


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Background: •  Overall goal is to operate engine at high fuel efficiency

regions as frequently as possible. Best fuel efficiency normally at high load/low engine speed conditions

•  Traditional PFI engines generally operated at higher engine speeds and lower loads

Powertrain Optimization:

•  GTDI enables downsizing, which moves the operating point into the higher load area

•  High speed transmissions enable downspeeding, which keeps the engine speed low

Load

– B

ME

P (b

ar)

Engine Speed (RPM)

Fuel Economy Strategy:

The GDI Revolution


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CO2 Reduction Roadmap

ɛ = Compression Ratio FR = Friction Reduction DI = Direct Injection DZ = Downsizing w/ Turbo SGDI = Stratified Lean Burn CDA = Cylinder Deactivation high ɛ = High Compression BRS = Boost Rec. System CVT = Continuous Variable Tra. cEGR = Cooled Exhaust Gas AT8+ = 8/9/10 speed Simulation for FTP75 test cycle

Powertrain Measures Engine Measures

Sources of Particles System Approaches to Increase Efficiency and Reduce Particulates

The GDI Revolution


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Next Steps in GDI – Meeting the Emissions Challenge

Increased Pressure:

Laser Drilling:

Spray Targeting:

Reduced penetration

0mm

10mm

20mm

30mm

40mm

50mm

60mm

70mm

80mm

0mm

10mm

20mm

30mm

40mm

50mm

60mm

70mm

80mm

Advanced Combustion: Optimized Calibration, CVO, & Multi-Injection:

Diffusion Combustion: �  1. Piston surface wetting �  2. Combustion chamber roof wetting

�  3. Injector tip fuel deposits �  4. Droplets in combustion zone

Inhomogeneous Mixture: �  5. Fuel vapor phase (l<1) �  6. HC in crevices (l<1)


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Thank you for your attention! Questions?

panel 3 - gasoline direct injection: heiko weller, bosch

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