Engine Optimization.

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Automotive Research Center
NAC
Engine Optimization Methodologies: Tools and Strategies for Diesel Engine Design
George Delagrammatikas Dennis Assanis, Zoran Filipi, Panos Papalambros, Nestor Michelena
The University of Michigan May 24, 2000
Diesel Engine Optimization Methodologies
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Automotive Research Center BACKGROUND: VEHICLE AND ENGINE FUNDAMENTALS
NAC
ENGINE TUNING
INVERSE DESIGN
NOVEL TECHNOLOGIES
CVT, INJECTION TIMINGS
MAP SHAPING AND MATCHING
ENGINE FLEXIBILITY: COMPRESSION RATIO, CVT,HYBRID
TARGET CASCADING Diesel Engine Optimization Methodologies
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Motivation
Federal Regulations
Fuel economy (CAFE) Emissions (NOx, smog, and other pollutants)
Public Awareness
Green movement Global warming scare
Decrease Dependence on Foreign Oil

Avoid another oil crisis
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Objectives
Develop an engine optimization framework
21st century conventional and hybrid heavy truck
Implement techniques to conventional vehicle

Define a problem analytically Apply suitable driving cycle(s) Investigate location of use on engine map
Extend lessons learned to hybrid vehicle

How different are demands on engine and transmission? Need for a systems approach
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Euro III Steady State Test Procedure
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Power Demands on Engine
WHEEL
Torque, Speed at Wheel
Torque, Speed at Engine
ENGINE
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HEV System Simulation Framework

Matlab-SIMULINK environment
FUEL (g/s)
ADVISOR
TORQUE
RPM
ENGINE FUEL DELIVERY LOOK-UP TABLE Parallel HEV Diesel Engine Optimization Methodologies
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Baseline Vehicle Parameters

Cummins M11-330 (246 kW) Diesel Engine Wheel/axle assembly for heavy truck Kenworth T400 Vehicle Standard heavy vehicle accessory loads Standard catalyst for CI engine Eaton Fuller RTLO-12610B 10-Speed Transmission Generic 10-spd constant efficiency gearbox Heavy Vehicle Powertrain Control Eaton Fuller RTLO-12610B 10-Speed Transmission Generic 10-spd constant efficiency gearbox
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Baseline Cummins Engine Map
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Driving Cycles Investigated

US06 REP05
FUDS
FHDS
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Engine Use Points for Various Cycles

US06 REP05
FUDS
FHDS
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Power Frequency for Each Cycle

US06 REP05
FUDS
FHDS
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Ideal BSFC Line Generation
Output Torque
Engine Speed
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Benefits of Flexible Engine Designs Actual Transmission Case

Determine cumulative fuel throughput for each cycle investigated
Interpolate BSFC from engine map for every torque/speed combination for that given cycle Integrate all BSFCs from above step Find the total time that engine is producing power Mean effective BSFC = total BSFC/engine on time
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Ideal BSFC vs. Power Level
BSFC (g/kW-hr)
Power
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Benefits of Flexible Engine Designs Ideal Transmission Case

Find ideal BSFC transmission line on engine map used for a given cycle
Interpolate BSFC for every visited power level on the BSFC vs. Power graph Sum of all BSFCs is cumulative fuel throughput Mean effective BSFC = numerical average of total fuel throughput during time steps when engine is active
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Potential Benefits of Ideal CVT Design

140
Increase in Mean BSFC Per Cycle
120 100
4*BSFCmin
80 60 40 20 0 US06
2*BSFCmin
REP05
FUDS
FHDS
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Optimum Injection Timing Method

Using an optimization framework
Vary injection timing for every torque/speed combination (over 200 map points, ~100 executions per point) Computationally prohibitive
Parallel computer framework

Run as many maps as you want at different injection timings Coalesce data with a Matlab-based routine One map = ~5 minutes
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Injection Timing Maps
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Output Torque
Engine Speed
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Optimum Injection Timing Map
Fueling Rate
Timing
RPM
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Variable Compression Ratio Engine

Hypothetical investigation of novel engine design
Find the ideal fuel consumption benefit Apply ideal transmission techniques from previous slides
Determine how BSFC can be optimized at various power levels

First maximize power density to find engines power upper bound Allow engine controller to change parameters that are not normally variable
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Problem Formulation
For each power level :
50, 100, 200, 300, 400, 500 kW
Minimize BSFC, subject to:

overall phi < 0.6 20% < percent premixed burn < 40% peak cylinder pressure < 150 bar
Variables:
Inlet manifold pressure Compression ratio Injection timing Fuel Engine speed
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Same Engine - Different Maps
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VCRE - Combined Map
TORQUE
RPM
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Ideal BSFC Line vs. Power Level

240 230
BSFC (g/kW-hr)
220 210 200 190 180 170 50 100 150 200 250 300 350 400 450 500
vcre_bsfc base_bsfc
Power (kW)
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Hybrid Powertrain Investigations
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Demands on Engine - CVT vs. 5-Speed
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Demands on Motor - CVT vs. 5-Speed
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Battery SOC - CVT vs. 5-Speed
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Zero Delta SOC - CVT vs. 5-Speed
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Additional Hybrid Clustering Scenarios
60 40 20
Power-Assist Battery Recharge
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Future Directions
How realistic is the variable compression ratio engine for the driving cycles and vehicles we are considering? How can we better quantify the benefits of increased flexibility in transmission parameters? What are the effects of injection timing and variable valve timing on engine map characteristics? Is it better to cluster points around optimum power levels on an engine map or disregard that an engine can be described by a single map?
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Integration with Target Cascading

Parameterize engine torque curve Maximize engine turndown ratio while meeting mobility constraints Match maximum torque curve with a real engine defined by high fidelity model Use engine visitation points in conjunction with control strategies to meet BSFC and emissions targets Send results back to top level for verification and subsequent iteration
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Parameterized Max Torque Curve - I
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Parameterized Max Torque Curve - II
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Sample Torque Curves
Min cluster area
Min rated torque
Min rated power
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Engine Matching Subproblem
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Conclusions
High fidelity engine model can be used at different levels in the design process Methods have been illustrated on a variety of different engines Continue feed-backward work with ADVISOR and extend methodology to VESIM

Engine Optimization.

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Engine Optimization.

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arc

Automotive Research Center

The University of Michigan May 24, 2000

Diesel Engine Optimization Methodologies

Automotive Research Center BACKGROUND: VEHICLE AND ENGINE FUNDAMENTALS

CVT, INJECTION TIMINGS

MAP SHAPING AND MATCHING

ENGINE FLEXIBILITY: COMPRESSION RATIO, CVT,HYBRID

TARGET CASCADING Diesel Engine Optimization Methodologies

Automotive Research Center

Decrease Dependence on Foreign Oil

Diesel Engine Optimization Methodologies

Automotive Research Center

Implement techniques to conventional vehicle

Extend lessons learned to hybrid vehicle

Diesel Engine Optimization Methodologies

Automotive Research Center

Euro III Steady State Test Procedure

Diesel Engine Optimization Methodologies

Automotive Research Center

Power Demands on Engine

Torque, Speed at Wheel

Torque, Speed at Engine

Diesel Engine Optimization Methodologies

Automotive Research Center

HEV System Simulation Framework

Automotive Research Center

Baseline Vehicle Parameters

Automotive Research Center

Baseline Cummins Engine Map

Diesel Engine Optimization Methodologies

Automotive Research Center

Driving Cycles Investigated

Diesel Engine Optimization Methodologies

Automotive Research Center

Engine Use Points for Various Cycles

Diesel Engine Optimization Methodologies

Automotive Research Center

Power Frequency for Each Cycle

Diesel Engine Optimization Methodologies

Automotive Research Center

Ideal BSFC Line Generation

Automotive Research Center

Benefits of Flexible Engine Designs Actual Transmission Case

Diesel Engine Optimization Methodologies

Automotive Research Center

Ideal BSFC vs. Power Level

Automotive Research Center

Benefits of Flexible Engine Designs Ideal Transmission Case

Diesel Engine Optimization Methodologies

Automotive Research Center

Potential Benefits of Ideal CVT Design

Increase in Mean BSFC Per Cycle

Diesel Engine Optimization Methodologies

Automotive Research Center

Optimum Injection Timing Method

Parallel computer framework

Diesel Engine Optimization Methodologies

Automotive Research Center

Injection Timing Maps

Automotive Research Center

Optimum Injection Timing Map

Automotive Research Center