Diesel Engine Development TENERGY

TENERGY
Diesel engine development

Achievement & experience of TENERGY
World Best of Energy Conversion Technology

28. September 2013
TENERGY
Contents
1. Diesel engine development of TENERGY
2. Process of diesel engine development
3. Design
4. CAE analysis
5. Combustion development
6. Mechanical & Functional test
7. ECU calibration of diesel engine

8. Resources of TENERGY for diesel engine
1. Diesel engine development by TENERGY
A2300T IDI Engine (Kukje Machinery)

Cylinder Head Design & development
Mechanical & Function development
Vehicle cooling system development
D2400T DI Engine (Kukje Machinery)

Turn-key Project : Concept Design,
Test and development
Production Development support
D3400T DI Engine (Kukje machinery)

Turn-key Project : Concept Design,
Test and development
Production Development support
3
www.tenergy.co.kr
Denso Piezo 2,000 & 2,200 bar FIE Application to HMC R-Engine
R-Engine based EMS
Denso FIE system application
2.4L
(TCI, TC, NA)
CRDI Tier 4 Engine
Combustion development
Mechanical & Functional development
Engine & Vehicle calibration
Engine calibration & EMS application
1.8/2.4L
(TC, NA) CRDI Tier 4 Engine
4
www.tenergy.co.kr
3.4L
TCI CRDI Tier 4
Engine
Combustion Development
Mechanical & Functional
Development
Engine & DPF calibration
2.0L
CRDI Euro 5 Engine
C150 Vehicle calibration
(with CDPF)
CRDI Euro 4 Engine
V12 30L TCI CRDI

Diesel Engine
1 MW Power plant engine design
2.0L
CRDI Euro 5 Engine
A150 Vehicle calibration
(with CDPF)
CRDI Euro 4 Engine

A150 Vehicle calibraiton
1.9L / 2.5L
3 / 4 cylinder TCI
CRDI engine
C150 Vehicle calibration
5
www.tenergy.co.kr
2. Process of development of diesel engine

1) 4V Port and Combustion Chamber
Target
Objectives
Performance
Emission
Fuel
Regulation
Economy
(Tier4)
Durability
Cost
Max. Power
Max. Torque
Fuel Consumption
Emission Strategy
Reliability & Durability
NVH
Engine Dimension
Engine Weight
Machine Application
Common-use of Parts
6
www.tenergy.co.kr
2. Process of development of diesel engine

2) Design Process
Analysis
Engine Target
Design
Valve System
Gas Exchange
Simulation with
T/C Matching
Valve Train Kinematics

Camshaft
In-Cylinder Motion /
1-D Cooling
: Cooling Circuit
Piston
Injection Targeting /
Combustion
Cylinder Head
1-D Lubrication
: Oil Circuit
Belt Drive Layout
Timing Drive Layout
FIE System
Cooling Circuit CFD
Head Cover
Cylinder Block
Oil Pan
Head & Block FEA

Intake Manifold CFD
Intake Manifold
Ex/Manifold CFD & FEA
Exhaust Manifold
Crankshaft TV & FEA
Crankshaft
Con Rod FEA
Con Rod
Brackets
Modal Analysis
Bearing Load Analysis
Concept
Definitive & Detail

7
www.tenergy.co.kr
3. Design
1) Typical Design Feature of Diesel engine
FIE System
With Common Rail
Center Injector,
Glow Plug in Cylinder Head
4 Valve , OHV,
Rocker Arm Valve Train
Skewed Intake Port

(1-Tangential & 1-Helical )
6 Cylinder
Head Bolt Pattern
EGR & Oil Cooler

Application
Timing Gear Drive System
2nd Mass Balancing System

(Lanchester Type)
PTO Application
Rigid Bottom End Construction
(Half Skirt Cylinder Block + Bed
Plate + Structural Oil Pan)
8
www.tenergy.co.kr
3. Design
2) Engine Layout Major functional components
Intake
Exhaust
O/filter & cooler, F/pump, O/pump, O/level gauge, O/filler cap, EGR valve
EGR cooler, Start-motor, PTO, Alternator, Cam shaft
EGR Cooler
EGR
Valve
Oil Filter
& Cooler
Water Pump
Starter
Crank Pulley
Fuel Pump
Alternator
PTO Gear
Oil Pump
Bal. SHF Gear
(Drive Ratio 2/1)
Bal. SHF Gear

(Drive Ratio 2/1)
Cam Gear
(Drive Ratio 1/2)
9
www.tenergy.co.kr
3. Design
3) Lubrication system
T/charger
(Thru main bearing & cam shaft journal groove)
Rocker Shaft
Piston Cooling Jet

Cam-Shaft Journal
(Thru main bearing
journal groove)
Main Gallery
Main Journal
Oil-Filter & Cooler

Oil-Pump
(Indirect driven)
Cooled Oil
Hot Oil
Oil Strainer
10
www.tenergy.co.kr
3. Design
4) Intake Port (1 tangential + 1 helical) : Layout
4
25
2
3
1
[ Port Layout ]
Items
[ Skewed Angle ]
Features
Separated (1 tangential + 1 helical) + Swirl chamfer
Intake port
- Tangential port : Rectangular shape entrance

- Helical port : Oval shape entrance
Exhaust port
Siamese
G/plug
Mounted on intake side
Injector
Center in cylinder head
11
www.tenergy.co.kr
3. Design
5) Intake Port (1 tangential + 1 helical) : Cross-sectional Area
Tangential port
Helical port
Position
Tangential port
Helical port
Port entrance
(Intake manifold)
55%
45%
Middle
50%
50%
Escape
(Combustion chamber)
45%
55%
Cross-section
Little tapered
Constant
Entrance
Middle
Escape
[ Cross-sectional Area ]
12
www.tenergy.co.kr
3. Design
6) Combustion Chamber Layout
Intake valve dia.
: Improvement of volumetric efficiency at high speed
- Maximum size under layout restriction while considering
cooling performance
(Performance matching at low speed : low capacity T/charger)
Exhaust valve dia.

: A little smaller size considering exhaust gas temperature
: Decrease of friction => improvement of fuel economy
In-valve dia.
(mm)
Ex-valve dia.
(mm)
Valve seat ~
Injector hole
(mm)
Valve seat~
G/plug hole
(mm)
Injector hole~
G/plug hole
(mm)
35
29
8.0
5.0
8.0 (angle 48)
13
www.tenergy.co.kr
3. Design
7) Cooling Concept : Individual Cross Flow
W/pump
OUT
Individual Cross Flow Cooling

: Water duct on the upper intake side of cylinder block
[ Top View ]
: Individual cross flow from intake side to exhaust side
in cylinder head
- Injector & G/plug cooling
- Valve bridge cooling

: W/pump outlet on exhaust side of cylinder head
W/pump
IN
[ Intake Side View ]
Water duct
14
www.tenergy.co.kr
3. Design
8) Valve Train Layout
Rocker Arm
Rocker Shaft Spring

(Spacing spring)
: Lash adjustment screw & ball joint with elephant foot
: Applied spring for rocker-arm position fixing

Ball Joint
Push Rod
: Sphere-socket type, Hollow pushrod
15
www.tenergy.co.kr
3. Design
9) Water Pump
Water Pump Rig Test
Heat Rejection
for middle & heavy duty engine,
Heat rejection 75~85% of engine power
Water Pump
- qradiator = * Q * Cp * T,
: Density of coolant
Cp : Specific heat of coolant
T : temp. difference between in & outlet
16
www.tenergy.co.kr
3. Design
10) Oil Pump
Oil Flow Rate Calculation

Main
Bearing
Con-rod
Bearing
Cam
Bearing
Cooling
Jet
R/Arm &
Shaft
Turbocharger
Bal.
Shaft
Qtotal
Pm
Journal dia. (mm)
Bearing width(mm)
Detail Design Data
Clearance (mm)
Orifice dia. (mm)
(l/min)
2600rpm
7.21
1.48
5.78
9.20
4.43
3.00
1.63
32.73
3.5bar
1000rpm
3.08
0.59
2.47
6.03
1.85
1.25
0.69
15.96
1.5bar
Oil Distribution
Oil Pump Capacity
: Focused at low speed (1000rpm)
Primary
point
: At rated rpm, oil pump has additional relief

margin of about 10%.
17
www.tenergy.co.kr
3. Design
11) High Pressure Common Rail System
High injection pressure needed for both

emission feasibility and reasonable
performance
At least 1600bar system needed
18
www.tenergy.co.kr
3. Design
12) Injector Nozzle Optimization
Nozzle layout optimization
Number of Hole
Hole dia (Hydraulic Flow Rate),
Conical nozzle
Spray cone angle
SAC volume(VCO or minisac)
NTP(Nozzle Tip Protrusion) optimization
Injector nozzle gasket thickness
Spray target point optimization
Nozzle tip max temperature limit
I4-2.0L Diesel EU5 Ref.
A company
B company
Type
Bosch Piezo 1800 bar
Delphi Sol. 1800bar
Power level
184PS
150PS
Hole no.
Cone angle
156
156
HFR(cc/min@100bar)
940
800
19
www.tenergy.co.kr
3. Design
13) Turbocharger Matching
Turbocharger can not be matched efficiently around whole operating area.

Therefore normally matched for high power before EURO 5
Efficiently matched for emission region together with reasonable power for EURO 6
THE MATCHING
PROCESS
BEST COMPRESSOR
BEST TURBINE
20
www.tenergy.co.kr
3. Design
14) Cooled EGR
Cooled EGR is effective measure to improve NOx-PM trade-off

Cooler by-pass is necessary to reduce HC & CO emission before warm-up
NOx
Smoke
EGR cooler with by-pass valve
21
www.tenergy.co.kr
3. Design
15) Emission potential of LP-EGR
Emission, Fuel con. 14-pts average
BSNOx
Smoke
BSFC
BSCO
BASE
(HP-EGR only)
1.07
1.01
389
6.51
LP-EGR
0.68
1.00
368
6.75
Improvement
35.8%
0.9%
5.2%
-3.6%
22
www.tenergy.co.kr
3. Design
16) Summary of Technology to meet EURO Legislation
EURO 2
EURO 3
EURO 4
EURO 5
EURO 6
Combustion
IDI
DI
(IDI)
Compression Ratio
20
18
17.5
16.5
FIE
Mech. Rotary
Electronic control
CRS 1350bar
CRS 1600bar
CRS 1600bar
CRS 1600bar
PFP [bar]
120
140
160
180
180
T/C (w/ I. Cooler)

Waste Gate
Wastegate or
VGT
Charging Device
NA
(or T/C)
VGT
(2 stage)
VGT or
2 stage TC
EGR
ON/OFF
EGR
Duty control
EGR
EEGR
w/ cooler
EEGR
w/ cooler
bypass
(LP-EGR)
Swirl Control
Exhaust Afer treatment
DOC
DOC(DPF)
DPF
LNT or SCR
23
www.tenergy.co.kr
4. CAE Analysis
1) 1D Performance Simulation
START
Developed using
CFD or flow bench
Build and calibrate air

induction system
Induction system
geometry & flow
data
Developed using
CFD or flow bench
Build and calibrate port

model
Port geometry &

flow data
Build and calibrate

intake & exhaust
manifolds
Manifold geometry
& flow data
Developed using
CFD or flow bench
For
naturally
aspirated
engines
For boosted
engines
Build and calibrate

exhaust system
Flow data
Pressure & drop
Build and calibrate

intercooler model
Efficiency Model
Build turbo charger

model
Gas Stand Maps
Exhaust system
geometry & flow
data
Build GT-Power
Setup engine model with
dyno inputs
Dyno test data

combustion data
heat transfer data
Execute Model
Verify results
GT-Power model results

mach dyno
Re-evaluate dyno inputs, assumptions, verify engine

hardware evaluated on the dyno (i.e. induct. sys, intake
manifold, cams, cylinder head, exhaust sys, etc.), engine
friction, CR, fuel type, etc.
GT-Power model results
DONT match dyno
24
www.tenergy.co.kr
4. CAE Analysis
1-D Engine Modeling (Diesel)
25
www.tenergy.co.kr
4. CAE Analysis
1-D Simulation Results
Corrected Break Torque
Location of Peak Pressure
Pressure per Crank Angle
P-V diagram
26
www.tenergy.co.kr
4. CAE Analysis
2) Hydrodynamic bearing analysis
Crank train design analysis with EXCITE-Designer
: Min. oil film thickness & max. oil film pressure
Minimum Oilfilm Thickness

Main Bearing - Uppershell: PSI_1
Minimum Oilfilm Thickness(micron)
16
14
12
10
8
6
4
2
0
1000
2000
3000
4000
5000
6000
7000
Engine Speed(rpm)
bearing 1
bearing 2
bearing 3
bearing 4
bearing 5
27
www.tenergy.co.kr
4. CAE Analysis
2) Hydrodynamic bearing analysis
Eccentricity Ratio(-)
: Oil hole positioning

1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0
90
180
270
360
450
540
630
720
Eccentricity Ratio
Relative to Shell
Eccentricity Ratio(-)
0
1
330
360
720
0
0.9
30
0.8
0.7
300
0.6
60
0.5
0.4
0.3
270
90
540
180
240
210
120
150
180
Shell Angle(deg)
28
www.tenergy.co.kr
4. CAE Analysis
3) 1D Torsional Vibration & FEA
: Torsional vibrations (TV amplitude & Dynamic torque)
- Max. 0.15deg at a specific order with the highest amplitude
- Max. 0.5deg at total TV amplitude

- Mass damper tuning
: Fatigue strength calculation (Safety factor)
- Safety factor for web cross-section
29
www.tenergy.co.kr
4. CAE Analysis
4) FEA crank-train & optimization
FEA of crank train

: Stress & stiffness analysis
- Examination of the weakest points

Torsion
Bending
Calculation of torsional stress concentration factors
Calculation of bending stress concentration factors

30
www.tenergy.co.kr
4. CAE Analysis
FEA of crank train

: Fatigue strength analysis (safety factor) after stress analysis
[ Fatigue strength of crankshaft ]
[ Fatigue strength of connecting rod ]

31
www.tenergy.co.kr
4. CAE Analysis
FEA of connecting rod

: Bore deformation of connecting rod big-end
- Below 90% deformation of mean bearing clearance
con-rod = max ( 1 , 2 )
d_ratio = con-rod / clearance 100 (% )
Design optimization by numeric and FEA analysis
32
www.tenergy.co.kr
4. CAE Analysis
6) Crankcase _ Sealing performance
FE Model of Cylinder Block & Head & Gasket
Non-linear Behavior of Gasket
Load Condition
33
www.tenergy.co.kr
4. CAE Analysis
6) Crankcase _ Sealing performance
Pressure Line of Gasket
Surface Pressure on Full Bead
Surface Pressure on Stopper
Surface Pressure on Bead
34
www.tenergy.co.kr
4. CAE Analysis
7) Crankcase _ Bore Deformation
35
www.tenergy.co.kr
4. CAE Analysis
8) Crankcase _ Crankcase FEA & Optimization
Thermal Analysis of Bulkhead Inter Bore
36
www.tenergy.co.kr
4. CAE Analysis
9) Crankcase _ Crankcase FEA & Optimization
Fatigue Safety
37
www.tenergy.co.kr
4. CAE Analysis
10) Intake Port Design : Process
Database
Port Layout
Valve system
- 2V / 4V
- OHV / OHC
Valve(Port)
arrangement
Target
Cf & Swirl
Decision
Target Cf
Target swirl
- Consideration
of engine
performance
CAD 3D
Design
CFD
Analysis
Flow Bench
Test
Parametric
port design
Optimization
of port design
Measurement
of Cf & swirl
in flow bench
test
38
www.tenergy.co.kr
4. CAE Analysis
11) Intake Port Design
Major factor to influence performance of engine
Port Design
: Utilizing of benchmark data for initial layout
: Close collaboration with CFD analysis and flow bench tests
Diesel engine
Target
High flow coefficient & reasonable swirl
Features
Swirl(helical) port design considered
Shape
39
www.tenergy.co.kr
4. CAE Analysis
Port types for 4 valve pattern (for Diesel)
Helical / Tangential
2-Tangential
2-Helical
Interaction
Medium
Small
Strong
CF
0%
+3%
-8%
Geometry
Features
- Good compromise
between the flow and

Remarks
the swirl sensitivity

- Recommendation for
Daedong 3.5L engine
- Almost same direction

flow vectors
- More sensitive swirl
of the single cylinders
- Stronger interaction
of the two helical ports
of one cylinder head

40
www.tenergy.co.kr
4. CAE Analysis
Comparison of each port

Tangential port
Helical port
Geometry
Production of the swirling by impingement of

the air jet to the cylinder wall
Dependent upon the angle between cylinder
wall and air jet
Features
: Port positioning, direction, shape of the runner

More sensitive against casting displacements
(position of sharp edge)
Low swirl at small and medium valve lift,
very high swirl at large valve lifts
Production of the swirling air motion

inside the port
Independent from the valve positioning
Low sensitivity against casting displacements
A particular swirl number with high accuracy
Shorter development time and smaller

uncertainties during the design stage
41
www.tenergy.co.kr
4. CAE Analysis
Data base of swirl ratio vs. flow coefficient => Target Cf & swirl setting
42
www.tenergy.co.kr
4. CAE Analysis
Important geometry parameters for swirl port design
: Inlet & outlet position
: Port angle
: Sectional profile over port length
: Slope of spiral
: Eccentricity of spiral
[ Sectional Area of Helix ]

43
www.tenergy.co.kr
4. CAE Analysis
13) Intake Port CFD
CFD analysis
: CFD analysis
- Under same condition in flow bench test
: Computational Model
- CFD code : STAR-CCM+ v4.06
- No. of grids : about 5,900,000 cells
=> High Accuracy
- Steady state / cold flow condition

- Variable valve lift
- Boundary condition : Pressure boundary
[ Diesel engine port CFD model ]
44
www.tenergy.co.kr
4. CAE Analysis
13) Intake Port Flow Bench
Flow bench test
45
www.tenergy.co.kr
4. CAE Analysis
13) Intake Port Flow Bench
Flow bench test
46
www.tenergy.co.kr
4. CAE Analysis
14) CFD water jacket
STAR-CCM+ v4.06
Outputs
: Flow distribution
: Heat transfer coefficient
: Pressure drop
Guide Line Confirmation

: Minimum flow velocity in critical areas at peak engine power
: Maximum flow velocity at peak engine power
: Minimum heat transfer coefficient in critical areas at peak engine power
: Total pressure drop(Program specific)
Velocity distribution
Heat Transfer Coefficient
Total Pressure Drop
47
www.tenergy.co.kr
4. CAE Analysis
15) Valvetrain kinematics (WINDAV)
Cam design
Kineto-Static Analysis (Spring load, inertia load, contact load, spring margin)
Cam/Tappet contact stress, contact ellipse
Valve Spring Design (Stress amplitude, Natural frequency)
HLA Load, Cam Torque.
Cam lift (Displ./Vel./Accel.)
Spring margin
Cam contact load & stress
48
www.tenergy.co.kr
4. CAE Analysis
15) CFD analysis of intake & exhaust manifold
Intake Manifold
Exhaust Manifold
49
www.tenergy.co.kr
4. CAE Analysis
16) FEA analysis of connecting rod
Stress Distribution for Each Step
1st Step
Cold Assembly
2nd Step
Inertia Load
3rd Step
Pressure Load
50
www.tenergy.co.kr
4. CAE Analysis
16) FEA analysis of connecting rod
Safety Factor Distribution
Big End Cross-In
51
www.tenergy.co.kr
5. Combustion Development
1) Diesel Engine Performance Development
Port swirl
Optimization
Port flow
BSFC
NVH
Performance
PM/NOx
Turbocharger
matching
Swirl Control valve
Valve timing
optimization
Combustion
Chamber
EGR cooler capacity
BypassEGR cooler
Throttle Valve
Breathing
Combustion
High Pressure Pump

& Rail
Injector nozzle
layout
Nozzle tip
protrusion
52
www.tenergy.co.kr
2) Intake Port and Development Process
Port Improvement by CFD Analysis
Correlation of Flow Bench & CFD
Cf
Swirl
Velocity
Cf Improvement by port flow

measurement
Correlation of flow box &

actual head flow
Actual Head Test

Measurement of Cf & swirl
(tumble) in flow bench
Torque & V.E of Engine performance
Head Prototype Manufacturing
Engine Performance Test
53
www.tenergy.co.kr
3) Combustion System Development
Both air motion and fuel spray energies contribute to mixture preparation
Significant effort is expended in matching the intake port and combustion bowl
CAD 3D
Design
CFD
Analysis
Flow Bench
Test
Parametric
port design
Optimization
of port design
Measurement
of Cf & swirl
(tumble) in
flow bench
Engineering
experience
Test
Simulation
Optimally
matched bowl
54
www.tenergy.co.kr
4) Intake port & variable swirl
Moderate swirl(1.5~1.8) is feasible for full load performance

Parallel arrangement with one tangential and one semi-helical port is optimal
for both performance and durability
Variable swirl is mandatory to comply with higher swirl demand at emission cycle
Parallel
Tandem
Twisted
Variable swirl by swirl control valve
Semi-helical port
Tangential port
55
www.tenergy.co.kr

1) Cooling System Evaluation
56
www.tenergy.co.kr

2) Lubrication System Evaluation
57
www.tenergy.co.kr

3) Ventilation System Evaluation
58
www.tenergy.co.kr

4) Engine Thermal Survey
59
www.tenergy.co.kr

5) Piston Marking test
60
www.tenergy.co.kr

6) Motoring Friction Test
61
www.tenergy.co.kr

1) Diesel EMS calibration - Overview
Items
Activities
Full load calibration
Emission optimization (DoE & Transient test)
Engine Dyno Calibration
Air model calibration (MAF, V/E, T/C model, PSE, TSE)

Torque model calibration (Friction model, MBT, Timing/Thermal efficiency)
DPF temperature control (Open loop model, Closed loop)

Soot mass estimation (Engine out soot model, Dp model)
Cold Startability (down to -25)
Driveability Calibration
Demand Torque Calibration

Normal & Hot/Cold Idle & driveability test
NVH Calibration
Chassis Dyno Calibration
Combustion noise check & improvement
Air model / control optimization

Emission & Fuel consumption optimization
62
www.tenergy.co.kr

1) Diesel EMS calibration - Overview
Items
Activities
EOBD regulation conformity
EOBD Calibration
EOBD threshold safety margin

Fail safe strategy and calibration
Regeneration strategy (Regeneration triggering/ Fail safe)

DPF calibration(Vehicle)
Temperature control calibration in all environment condition
Accuracy check & improvement of soot mass estimation

Test trip
Validation and fine calibration under Hot/Cold & High altitude condition
Lesson learned
Verification the lesson learned items
63
www.tenergy.co.kr

2) Engine calibration with DoE incl. DPF calibration
EMS parameters
Responses
SOI
Rail pressure
EGR, .
Fuel Consumption
Emission
etc
Model Based Calibration
DPF Re-gen calibration
NOx
PM
FC
SOI
EGR
64
www.tenergy.co.kr

3) Engine calibration (performance & emission)
PSE/TSE
MAF, Injector Q
calibration
Pilot Inj. Q
VGT model
Model based Boost

Control
Valve flow model
14 mode
selection
Full load
calibration
Structured
Eng cal.
Pilot Inj. timing

Main Inj. timing
14 mode
EM/FE cal.
Rail Pressure
Boost Pressure
(A/F ratio)
Volumetric Eff.
Smoothing
EGR
Model based
EGR control
Mapping
Swirl
Torque structure
65
www.tenergy.co.kr

4) Base map calibration : steady 14 mode point selection
Cycle
simulation
Steady 14 mode+Idle
Vehicle Parameters
400
350
1.25
Torque, Nm_ _
300
2.13
250
3.75
200
2.74
150
9.76 3.743.22
9.52
100
Replication
Vehicle modal data
1.01
32.23
4.04
4.58 8.2
50
5.83
4.65
0
0
Speed, Q
500
1000
1500
Speed, rpm
2000
2500
Speed, Torque
66
www.tenergy.co.kr

4) Base map calibration : steady 14 mode point selection
Cycle
simulation
Steady 14 mode+Idle
Vehicle Parameters
400
350
1.25
Torque, Nm_ _
300
2.13
250
3.75
200
2.74
150
9.76 3.743.22
9.52
100
Replication
Vehicle modal data
1.01
32.23
4.04
4.58 8.2
50
5.83
4.65
0
0
Speed, Q
500
1000
1500
Speed, rpm
2000
2500
Speed, Torque
67
www.tenergy.co.kr

5) Base map calibration : steady 14 mode point selection (DoE)
Measured
Variable
ECUVariable
Y
X
Engine
Z=a0+a1X+a2Y+a3XY+a4X2+a5Y2
Start of main injection
Rail pressure
EGR
Boost Pressure
Variable swirl
Quantity of pilot injection
Start of pilot Injection
Quantity of post injection
Start of post injection
Engine
Fuel Consumption
NOx
Smoke or PM
CO
HC
Combustion noise
68
www.tenergy.co.kr

6) Base map calibration
Steady 14 mode calibration(Test, Modeling)
Optimization & map manipulation
69
www.tenergy.co.kr

7) Base map calibration (Transient validation and refinement)
Transient test at engine bench provide quick refinement
in advance of vehicle calibration
70
www.tenergy.co.kr

8) DPF calibration
Regeneration mode calibration
Steady state base calibration with DoE

Open & closed loop temp. controller
Transient validation and tuning
Start of main injection

Rail pressure
Boost Pressure
Variable swirl
Quantity of pilot injection
Start of pilot Injection
Quantity of post injection
Start of post injection
DPF inlet temperature

O2 concentration
Oil Dilution
Fuel Consumption
Smoke
HC
71
www.tenergy.co.kr

8) DPF calibration
Soot load estimation
DP soot mass with clean filter model
Engine out soot mass model
O2 burn rate
NO2 burn rate
24
22
P_T_Dpf_dp_soot_mass
model_soot_mass
Real_soot_mass
20
Soot_mass
18
16
14
12
10
8
6
4
2
0
0
20000
40000
60000
80000
100000
time [s]
120000
140000
160000
180000
72
www.tenergy.co.kr

9) Driveability calibration overview
The basic drivability function need to be calibrated in an early phase,
and repeated as emission calibration status.

Due to the significant influence of the drivability functions & the emission
Low idle governor
Startability calibration
Driver demand torque map

Tip in/out filter & AOS
Smoke limit calibration

EGR controller
Boost pressure controller
73
www.tenergy.co.kr

10) Low Idle calibration
Target Idle setpoint calibration depend on external load and environment condition
Idle control parameter calibration depend on driving condition
TENERGY calibration check items for Idle calibration

Target Idle Setting(N/D, A/C On/Off, Temperature)
System Characteristic, Step Response measurement for every gear

Base PID Parameter selection
Control parameter selection validation
Idle control speed range selection
Idle stability validation with electric load
Idle stability validation with temperature variation(Hot/Cold)
Idle stability validation with A/C On Off
Speed drop - Clutch Engage after start (M/T)

Speed drop/overshoot when P/N-R/D Shift after start
Combustion noise refinement at Idle
PID Parameter fine tuning
Creeping characteristic validation for every gear
Creeping Surge w/+A/C +Emergency Lamp +Electrical Load
M/T Creeping Surge w/ A/C, Electrical Load
74
www.tenergy.co.kr

11) Startability
Calibration under normal ambient conditions (+30 to -10C) on road.
Calibration under reproducible cold conditions (-15 to -25C) in cold chamber.
Validation and fine calibration under all environment conditions during test trip
TENERGY calibration check items for Startability

Start fuel Q/SOI/Rail pressure
Glow time setting, additional heater specification check
Startability check - engine oil characteristic

Crank'g speed check with temperature /Battery spec.
Idle speed set with temperature & characteristic of idle entering
Start & Smoke at cold condition
Idle stability during warm-Up period

Idle stability with EGR activation at cold condition
Combustion noise at cold condition
Fuel heater activation check
Idle speed characteristic with load change
75
www.tenergy.co.kr

12) Driver Demand torque map calibration
Torque Based Control

Vehicle Weight and
Drive Train Spec.
Target Vehicle
Acceleration g-value
Torque Transfer Function
Required Torque
Calculation
Torque Demand Map

Calibration
76
www.tenergy.co.kr

13) Tip in/out filter & AOS
Before
TENERGY calibration check items for Tip in/out
Sharp Shock
Step Response measurement for every gear
Base control Parameter selection
Control Parameter validation

Accel/Decel Fine Tuning for every gear (MT)
Accel/Decel Fine Tuning(AT) during D/C ON

Plausibility check of low speed region with Idle Control
After
Surge check during constant speed driving

No Shock
Drive Map Data validation
Clutch On/Off Tip-In/Out Shock & Surge check
gear change and Tip-In/Out Shock & Surge check
77
www.tenergy.co.kr

14) NVH Combustion noise review
Input
Main Injection
Pilot Injection
Rail pressure
Swirl
EGR
-
Output
Interior Noise
Floor Vib.
S/Wheel Vib.
What NVH response will be affected by Diesel EMS Calibration ?
78
www.tenergy.co.kr

14) NVH Combustion noise review
Combustion
Pressure Excitation
Mechanical excitation
Input Parameter
Main Injection
Pilot Injection
Rail pressure
etc
Transfer function
(Structure-borne & Air-borne path)
Vibration filtered by
PT dynamic characteristics
Output Response
Interior Noise
Floor Vib.
S/Wheel Vib.
etc
Noise Radiation by
Surface vibration
79
www.tenergy.co.kr

15) EM calibration procedure on C/dyno
Measuring the first available vehicle in NEDC on C/dyno
Analyzing the most emission relevant operating areas
with measured Engine speed/load and temp. profile
Optimization the most emission relevant operating areas
on E/dyno bench.
Evaluation engine test bench results on chassis dyno
Optimization EM relevant calibration on chassis dyno

Analyzing the effect of tolerances & aging of EM parts
80
www.tenergy.co.kr

16) Diagnostic & E-OBD calibration
Preparation of a system plan including fault path strategy: MIL/SYS, priority class, P-code
Mapping of plausibility checks for digital / analogue input signals

Calibration EOBD threshold
Fail safe strategy and calibration
TENERGY calibration check items for Startability
DTC/MIL/Freez Frame/LIMP-HOME configuration
Part Fail E/M check
Comprehensive Component
Catalyst EM verification with dummy caltalyst

Air Mass Sensor Monitoring
EGR Governor Deviation Monitoring
Rail Pressure Sensor Monitoring
Rail Pressure Sensor Drift Test

VGT Governor Monitoring
Coolant Temp Sensor Monitoring
Monitoring
IN-USE PERFORMANCE
OBD
81
www.tenergy.co.kr

17) DPF calibration (vehicle)
Regeneration strategy (Regeneration triggering/ Fail safe)
Temperature control calibration in all environment condition
Accuracy check & improvement of soot mass estimation
Driveability under regeneration & DPF related Diagnostics
TENERGY calibration check items for DPF calibration
Torque continuity, Combustion noise during transition
Regeneration coordinator
Regeneration interval calibration by regen strategy
Mileage regeneration trigger calibration
Possible mileage without ASH cleaning
Fuel consumption check (Min/Max DP sensor)

Temperature and pressure measurement
Emission confirm test after mileage accumulation
Temperature controllability check at COLD condition
High altitude & HOT condition correction

Driveability during regen at high alt./HOT/COLD
Visible smoke check during regen
DTI(Drop to Idle) check & uncontrolled burning check
82
www.tenergy.co.kr

18) Test trip
Calibration and validation of engine and vehicle behavior in special ambient conditions:
- Cold climate
- Hot climate
- High altitude condition

Test and fine-calibration of start and drive-off behavior
Test and verification of permitted component stresses:
- Coolant, engine Oil and exhaust gas temperatures
- T/C-speed under steady state and transient conditions
83
www.tenergy.co.kr

Lesson Learned check from field issues)
Items
Startability
Idle
Driving
(Accel & Decel)
The number of
detail items
3
2
18
Noise
Diagnostics
etc.
Total
45
Problem
No
1
(Phenomena)
2
(DTC)
Drive Condition
3
(Description)
Ambient Temp.
Warm-up
/cold
Road Condition
Driving
Condition
All
Warm-up
Mainly up-hill
Launch
Winter
Cold
High altitude
: 1000m above
Quick launch
Poor performance
No MIL / P0299
(When using scan tool,
No DTC)
Poor performance (cold

take-off)
No DTC
MIL on
Limp home mode
P244B
Turbocharger REA
noise
No DTC
All
All
MIL on
Limp home mode
P02E1
All
All
MIL on
P2453
Diesel particulate filter

differential pressure
sensor performance
All
White smoke @
regeneration
No DTC
Customer complaint
All
Starting Impossible @
cranking
No DTC
Engine stall
Mil on
10
No Cranking
Pending code
P0299
Diesel particulate filter

differential pressure too
high
Re-occurrence/ Measurement Condition
Engine rpm : Over 1750rpm

Fuel mass : PCR_qGvnrOn_CUR
. Cold & high altitude

. Quick launch
General driving mode
Key on/off
, deceleration
Deceleration state @DPF Regeneration
General driving mode
Regeneration
General driving
All
P0335
Crankshaft Position
(CKP) Sensor Circuit
All
P0633
Theft Deterrent Key Not

Programmed
All
Key off after running,

Tip out
DPF regeneration status
Cranking
General driving
Normal driving
Ignition On
...
...
84
www.tenergy.co.kr

1) Facilities
DoE Tool
Engine Dynamo
Vehicle Chassis Dynamo
CAMEO
On-line
CAMEO
Off-line
AC
EC
Emission
Calibration
1 (2WD)
1 (4WD)
Engine
Dynamo
Chassis
Emission
Dynamo
85
www.tenergy.co.kr

1) Facilities
Engine
Chassis
Emission
Emission
Analyzer
Analyzer
Cold
Chassis
Chamber
Mapping
(Ajou Motor
Dynamo
College)
86
www.tenergy.co.kr

Diesel Engine Development TENERGY

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Diesel Engine Development TENERGY

Uploaded by

Copyright:

Available Formats

TENERGY

Diesel engine development

World Best of Energy Conversion Technology

7. ECU calibration of diesel engine

1. Diesel engine development by TENERGY

A2300T IDI Engine (Kukje Machinery)

D2400T DI Engine (Kukje Machinery)

D3400T DI Engine (Kukje machinery)

1. Diesel engine development by TENERGY

Denso FIE system application

Engine calibration & EMS application

1. Diesel engine development by TENERGY

CRDI Euro 4 Engine

V12 30L TCI CRDI

CRDI Euro 4 Engine

C150 Vehicle calibration

2. Process of development of diesel engine

2. Process of development of diesel engine

Valve Train Kinematics

Timing Drive Layout

Cooling Circuit CFD

Head & Block FEA

Ex/Manifold CFD & FEA

Crankshaft TV & FEA

Con Rod FEA

Bearing Load Analysis

Definitive & Detail

Skewed Intake Port

EGR & Oil Cooler

Timing Gear Drive System

2nd Mass Balancing System

Bal. SHF Gear

Piston Cooling Jet

Oil-Filter & Cooler

- Tangential port : Rectangular shape entrance

Mounted on intake side

Center in cylinder head

Exhaust valve dia.

: Decrease of friction => improvement of fuel economy

8.0 (angle 48)

Individual Cross Flow Cooling

- Valve bridge cooling

[ Intake Side View ]

Rocker Shaft Spring

: Lash adjustment screw & ball joint with elephant foot

: Applied spring for rocker-arm position fixing

Oil Flow Rate Calculation

Journal dia. (mm)

Detail Design Data

Orifice dia. (mm)

: At rated rpm, oil pump has additional relief

High injection pressure needed for both

Nozzle layout optimization

I4-2.0L Diesel EU5 Ref.

Bosch Piezo 1800 bar

Delphi Sol. 1800bar

Turbocharger can not be matched efficiently around whole operating area.

Cooled EGR is effective measure to improve NOx-PM trade-off

EGR cooler with by-pass valve

T/C (w/ I. Cooler)

Exhaust Afer treatment

Build and calibrate air

Build and calibrate port

Port geometry &