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Junichi Ishii OVERVIEW: The amount of CO2 emission from the transport sector
Minoru Osuga (including cars) accounts for about 20% of total CO2 emissions. Accordingly,
from the viewpoint of preventing global warming, reducing that proportion
Takashi Okada
is a key issue. In regard to CO2 emissions from cars, fuel economy standards
Hideki Miyazaki are getting tougher all over the world, so improving fuel economy of cars is
Mitsuru Koseki strongly desired. From now onwards, it is considered that fuel economy of
Koichiro Tanikoshi engines will be further improved by boosting engine efficiency and by
hybridization (electrification) of cars. Whats more, improving fuel economy
by improving driving operation (i.e. the operation in which a car is driven)
and by smoothing traffic flows will come into the picture in the near future.
Under these circumstances, with concern for the environment from the
viewpoint of reducing CO2 and other exhaust emissions, the Hitachi Group
is comprehensively promoting a broad range of technical developments for
reducing CO2 emissions from cars.
of control
amount (g/km) in Japan
220 retor
Boosting engine efficiency High-efficiency engines
Gasoline direct injection Homogeneous-charge
200 compression ignition
Diesel Variable valves
180 Electrification Hybrid electric vehicles (motor, inverter, battery)
Auxiliary electrification (pumps, power steering)
160
ITS application
140
Fuel Ethanol fuel,
120 diversification bio-fuels, etc.
1980 1990 2000 2010 2020
CAFE: corporate average fuel economy mpg: miles per gallon Based on data from Japan Automobile Manufacturers Association, Inc.
ITS: intelligent transport systems
Engine
Fuel-
Piston
control unit
Variable valves Internal EGR Piston
Air control by VEL
Variable-
Exhaust
valve
heat release
chamber
Rate of
Rate of
Stabilization
Crank angle Crank angle Fuel spray Air-fuel mixture Combustion flame
EGR: exhaust gas recirculation CAD: computer-aided design
Fig. 4Concept Called Homogeneous Charge Compression Fig. 5Simulation and Analysis Technology.
Ignition and a Prototype Engine Based on that Concept. The engine-combustion simulation technique achieves high-
By means of high compression ratio and multipoint-auto- speed mesh generation by the voxel method and accuracy
ignition combustion with even and lean fuel-mixture improvement by modeling of unsteady flow. Based on this
distribution, it is possible to attain both low fuel consumption analysis technique, specifications of product components and
and low emission. The prototype engine is composed of an in- combustion concepts are being proposed.
line four-cylinder direct injection system and a variable-valve
system, and stable operation is achieved by variable-valve and
injection control.
technology is based on an unsteady and compressible-
flow analysis program used for analyzing gas-liquid
two-phase flow in pipe work of nuclear plants. This
for the direct-injection and variable valves (VEL and technology is being developed with focus on
VTC) has been prototyped, and technical development shortening TAT (turnaround time) and accurately
for comprehensively controlling combustion of the reproducing phenomena occurring in the cylinders. As
HCCI engine is continuing(5). As for this prototype regards TAT, a voxel method that can create meshes
engine, stable combustion under internal EGR control directly from a CAD (computer-aided design) drawing
using variable valves and precise split-injection control was developed, and the man-hours needed for mesh
of fuel is being experimentally demonstrated. creation was reduced. In regard to recreating in-
Moreover, according to test data and simulation results cylinder phenomena, through development of a method
concerning the prototype engine, compared to a that directly simulates turbulent flow, accuracy of
conventional engine, the engine is forecast to reduce recreation of the airflow (which strongly affects spray
fuel consumption by 20%(6) (see Fig. 4). formation and combustion) was improved(3).
An example of applying this simulation technology
Simulation and Analysis Technology to development of a direct-injection engine is shown
Presently, as for continuing development of in Fig. 5. The conditions regarding the fuel-air mixture
injectors for direct injection engines, variable valves, formed and its combustion flame can be calculated in
and homogeneous charge compression ignition, accordance with the flow of air and fuel in a cylinder.
analysis technology making use of simulation is being In the case of a direct-injection engine, from the
applied. The engine-combustion simulation viewpoint of assuring ignitability, the fuel-air-mixture
Reduction of CO2 Emissions for Automotive Systems 188
CO2 emission reduction (%) at home, development is pushing ahead. CO2 emissions
(conditions: from well to wheel; from conventional gasoline-engine cars, HEVs,
running distance: 100 km)
PHEVs, EVs (electric vehicles), and FCVs (fuel cell
0 20 40 60 80 100
vehicles) are compared in Fig. 6. The calculation of
Conventional Refining Fuel consumption of gasoline engine
CO2 emissions uses total well-to-wheel efficiencies
Fuel consumption 50% (i.e. from refining at the oil well to combustion in the
vehicle) published by various organizations(7)(9).
HEV Fuel (42) Structure of
consumption G E HEV Under the assumption of a running distance of 100
70% W km, the HEV data is based on the Japanese 1015-
B M
PHEV40 Fuel (36)
mode test-drive cycle for fuel consumption, the PHEV
consumption
Structure of [i.e. PHEV40, which can run for 40 miles (64 km)
E G PHEV on one battery charge] data are drawn from US
EV (25)
B M W
governmental figures, and the EV and FCV data are
Same structure
from reference(9). Moreover, the electrical power
FCV (18)
as EV generation for the PHEV and EV used LNG (liquefied
Recharging natural gas). In the figure, two examples of system
at home
CO2 emission volume for CO2 emission volume for configurations are shown: the series-parallel hybrid
hydrogen generation electricity generation system for the HEV, and the series hybrid system
(in case of liquefied natural-gas
power plant) (using the engine to generate electrical power) for the
HEV: hybrid electric vehicle G: generator W: wheel PHEV. The arrows indicate the flow of power in each
PHEV: plug-in HEV E: engine
EV: electric vehicle B: battery configuration.
FCV: fuel cell vehicle M: motor
According to the figure, CO2 emission is reduced
Fig. 6Trends Regarding HEVs Aimed at Reducing CO2 by about 50% by switching from a conventional-engine
Emissions. vehicle to an HEV, and by subsequently switching the
Large-scale reduction of CO2 emissions is possible through HEV to a PHEV, it can be reduced by another 70%
vehicle electrification such as PHEV and EV. through improvement in single-battery-charge running
distance. In total, the CO2 emission ratios for the HEV
and the PHEV differ by only 6%, because it was
distribution is a key factor. By utilizing the simulation assumed that the electric-power generation for the
and analysis in the manner described above, we are PHEV was done by burning fossil fuel (i.e. LNG);
offering configurations for the combustion chamber however; if nuclear or wind power were assumed, this
and intake manifolds, in addition to combustion difference would be even bigger. In this way, it can be
concepts, from among an injector specification for considered that CO 2 emission volume can be
producing the optimum fuel-air mixture. significantly reduced by electrification from HEVs to
Utilizing this simulation and analysis technology, PHEVs and EVs. In accordance with the results
we are proposing solutions for reducing CO2 emission described above, as key technologies for handling the
such as system control for optimally driving various switch from HEVs to PHEVs and EVs that will allow
devices, reducing loss in accessories, and improving longer electric-running distance, R&D (research and
efficiency (especially for variable-valve systems and development) on boosting battery capacity, increasing
fuel subsystems for direct injection) and homogeneous motor and inverter power, and improving heat
charge compression-ignition systems aimed at the resistance is pushing forward.
vehicles of the future one after another.
Battery Technology for HEVs
CO2 REDUCTION BY HYBRID AND As a battery for HEVs, the Li-ion (lithium-ion)
ELECTRIC VEHICLES rechargeable battery which offers the advantages
Trends Concerning Hybrid and Electric Vehicles of high energy density, high power density (i.e. input/
In regard to reducing CO2 emission from individual output performance), and long life are drawing most
vehicles as well as lowering fuel consumption, much attention as the main battery of the future(11). Hitachi
hope is pinned on HEVs (hybrid electric vehicles). has been a driving force behind R&D on large-scale
Furthermore, aiming at commercialization of PHEVs Li-ion rechargeable batteries since the beginning of
(plug-in HEVs), namely, HEVs that can be recharged the 1990s. Accordingly, at the same time, a cell
Hitachi Review Vol. 57 (2008), No. 5 189
20 Direct-
water-cooled Improvement of direct water cooling
power module Attain low loss
Third-generation 15
(year 2010): High durability and compact packaging
Single-electric-cell power density (kW/kg)
5
Start full introduction and
4 10
3 Strong
5 HEV
Second-generation
(year 2005): Mild HEV
2 Application expansion