Gasoline Direct Injection – SIA / CNAM 2012turbo-moteurs.cnam.fr/publications/pdf/conference3_2012.pdf · Radial engine with 9 cyl. (BMW) Fuel injection pump (Boxer form) 7 Gasoline

1 Confidential | GS/EPC-EM | 21/03/2012 | P_12_0089 | ©

Robert Bosch GmbH 2012. All rights reserved, also regarding any

disposal, exploitation, reproduction, editing, distribution, as well as in

the event of applications for industrial property rights.

Gasoline Direct Injection –

SIA / CNAM 2012

Gasoline Systems

Paris, 27.03.2012

Georgis

Levée

Gasoline Direct Injection






SIA / CNAM 2012

Gasoline Systems

Gasoline direct injection: A long history

Electronic direct injection

Main components of the gasoline direct injection

New challenges with Euro 6 legislation

3

Gasoline direct injection: Historic

33


SIA / CNAM 2012

Confidential | GS/EPC-EM | 21/03/2012 | P_12_0089 | ©




Gasoline Systems

Gasoline direct injection introduced by Bosch in 1937 on engines

for aviation.

Advantages :

No impact of the negative G on the fuel supply in contrast with carburetor

No explosion risk of the intake manifold in case of «

back-fire

»

No risk of ice formation (venturi

of carburetor)

3

444


SIA / CNAM 2012





Gasoline Systems

Direct injection in aviation: historic

In-line fuel injection pump with 12 pistons for aviation engine (V12 Daimler, L=70 cm)

4

555


SIA / CNAM 2012





Gasoline Systems


Daimler engine

DB603 with

« inversed » V12 architecture (Mercedes Museum

in Stuttgart)

The fuel injection pump

is

placed

inside

the V

5

666


SIA / CNAM 2012





Gasoline Systems


6

Radial engine with 9 cyl. (BMW) Fuel injection pump (Boxer form)

777


SIA / CNAM 2012





Gasoline Systems

Direct injection in car: historic

After 2nd

world war, development of several economical cars with 2 stroke engine.

The direct injection allowed a reduction of consumption by removing the fuel losses through scavenging.

7

Gutbrod

Superior 600 Cabrio

(1950-

1954 ; direct injection from 1952)Goliath GP700E (1951-1957 ; direct injection from 1954)

888


SIA / CNAM 2012





Gasoline Systems

Direct injection in car: historic

8

Injection pump for 2 cyl. Engine (L=15cm)

Direct injection system for 2 stroke engine

999


SIA / CNAM 2012





Gasoline Systems

Direct injection: Sport car

9

In 1955, launch of Mercedes 300 SL with direct injection.

First serial application with 4 stroke engine.

Target: Increase of the maximum engine performance.

101010


SIA / CNAM 2012





Gasoline Systems

300 SL engine

Direct injection: Sport car

10






SIA / CNAM 2012

Gasoline Systems





121212


SIA / CNAM 2012





Gasoline Systems

Electronic

injection: historic

In 1967, first serial application of the indirect injection controlled by electronics (VW 1600).

First legislation for the emission in USA.

12

131313


SIA / CNAM 2012





Gasoline Systems

Evolution of the European legislation

13

Introduction ratio of catalytic converter on

passenger cars in Germany

Legislation

NMVEG

141414


SIA / CNAM 2012





Gasoline Systems

Evolution of the European legislation

14

151515


SIA / CNAM 2012





Gasoline Systems

Electronic Direct Injection

1996: First stratified gasoline direct injection on Mitsubishi Galant

1998: Toyota D4

1999: Renault IDE (Lambda 1 with high EGR rate)

2000: First Bosch gasoline direct injection VW «

FSI

»

engine

2000:

PSA HPI engine

2005: PSA Prince engine THP

Target: Consumption reduction by removing the suction losses at partial engine load (stratified mode).

Difficulty: Global

air-fuel mixture

lower than ignition readiness limit Necessity to create a stratified mixture with the condition to have enough fuel near to the spark plug.

Issue: Large NOx

generation

without any reduction possibility by three way catalytic converter due to

Lambda > 1. Necessity to have a NOx-Trap, but expensive and tricky (fuel without sulfur).

15

161616


SIA / CNAM 2012





Gasoline Systems

NOx

after-treatment equipment

16

ECU

Temperature sensor NOX sensor

Oxygen sensor

NOX trap

Three way catalytic converter

VW –

Lupo

FSI 1.4

171717


SIA / CNAM 2012





Gasoline Systems

Electronic Direct Injection

Due to the technical issue and the costs associated to the stratified direct injection, the concept «

direct injection, homogeneous, Lambda=1

»

has emerged on the market in recent years.

Advantages:

Effective cooling of the combustion chamber (fuel evaporation) with the possibility to push the knock limit

Increase of the compression ratio of 1 point with consumption gain

Associated to supercharging controlled by electronics, new turbochargers (twin-scroll), possibility to enlarge the use of «

down-

sized »

engines Consumption reduction, torque increase

17

181818


SIA / CNAM 2012





Gasoline Systems

Electronic Direct Injection: The come back!

18

The Audi R8 4.2l FSI gained the victory in 2001 of the famous race “24 heures

du Mans”

with the gasoline direct injection technology!






SIA / CNAM 2012

Gasoline Systems





202020


SIA / CNAM 2012





Gasoline Systems


20

212121


SIA / CNAM 2012





Gasoline Systems

High Pressure Gasoline Injector (solenoid)

FlachsteckerTERMINAL

UmspritzungCONNECTOR MOLD

MagnetspuleCOIL

VentilsitzVALVE SEAT

DichtringSEAL RING

O-

RingO-

RING

SiebkorbFILTER

DeckelCOVER

StützscheibeSUPPORTING DISC

EinstellhülseADJUSTMENT SLEEVE

DruckfederSPRING

AusgleichsringCOMPENSATING RING

VentilnadelVALVE NEEDLE

MagnetankerARMATURE

AnschlaghülseSTOP SLEEVE

Druckfeder (AFW)SPRING (AFW)

FederaufnahmeSPRING -

LOCATOR

AnschlagringSTOP RING

VentilkugelVALVE BALL

VentilhülseVALVE HOUSING

InnenpolINTERNAL POLE

MagnettopfHOUSING

AnschlusshülseCONNECTING SLEEVE

SicherungsringC-CLIP

21

222222


SIA / CNAM 2012





Gasoline Systems

High Pressure Gasoline Injector (piezo)

22

Injection part

Coupler

Control unit

Fuel guide

Hydr. connection

Connector

232323


SIA / CNAM 2012





Gasoline Systems

HDP: High Pressure Pump

23

242424


SIA / CNAM 2012





Gasoline Systems

High Pressure Pump HDP5: Working

24

252525


SIA / CNAM 2012





Gasoline Systems

Pressure regulation by dosing fuel quantity

Rail

AuV

MSVcurrentless

deliverychamber

EiV

IMSV

Intake Stroke Delivery Stroke

MSVcurrentless

deliverychamber

MSVcurrent flows

deliverychamber

Rail

MSVcurrentless

deliverychamber

EiVEiVEiV

AuV AuV AuV

25






SIA / CNAM 2012

Gasoline Systems










SIA / CNAM 2012

Gasoline Systems

Major Drivers and Requirements

Advanced Spray Technologies for DI






SIA / CNAM 2012

Gasoline Systems

Major Drivers for Powertrain Systems

Driving comfort

Noise, vibration, harshness

Shift-

& launch quality

Easy driving

Image & Emotions

Fuel Economy Labeling

Willingness-to-pay for green image and emotions

Variants

Globalization

Powertrain & vehicle diversification

Fuel differences

Quality and Safety

Reliability, Robustness

ISO26262

Main market drivers are still emission legislations incl. CO2

which impacts fuel economy. Costs remain very important.

City Restrictions

Ban on driving

Specific traffic lane, parking

Costs

Affordable mobility (price, TCO)

OEM entry efforts (invest, E&A)

Incentives and taxation

Fuel Economy / CO2

CO2 fleet targetsW-EU: 130/95g CO2/km 2012/20,US CAFE: 34,1 mpg in 2016

Fuel availability (“Peak Oil”)

Fun to Drive

Power and low end torque

Response time (dynamics)

Emissions & Diagnosis

EU6 (PM/PN, ext. EOBD)

LEV III (SULEV20, PM)

Worldwide Driving Cycle

Real Driving Emissions

TCO: Total cost of ownership PM: Particle massE&A: Engineering and application PN: Particle number






SIA / CNAM 2012

EU6 Emissions Legislation Roadmap

“EU7”

no PN limit

EU6cEU6b

2013 2014 2015 2016 2017 2018 2019 2020 2021 2022

WLTCEmissions Test: NEDC

RDE: monitoring only RDE mandatory : compliance factors open

additional testing: RDE: stringent com.fact.

PN: 6*1011

1/km

PN: 6*1012

1/km

upon choice of manufacturer

Emissions: PN-limitsSource: 25. TCMV meeting; 19.12.11

CO2 Test:

NEDC

PN standards and RDE PN testing only for DI. RDE limits to be defined for 2017.

Challenge Gasoline: Robust solution to fulfill

PN-limits.

PN: 6*1011

1/km

no PN limitPFI

GDI

Diesel

PN: tbd

for new cycle, modified PN test procedure

NEDC WLTC

(CO2

-targets to be adapted)NEDC

WLTC: Worldwide harmonized Light duty driving Test Cycle, RDE: Real Driving Emissions, TCMV: Technical Committee -

Motor vehiclesGasoline Systems






SIA / CNAM 2012

Gasoline Systems

Major Drivers and Requirements

Advanced Spray Technologies for DI

31

Diffusion combustion

1. Wall wetting piston

2. Wall wetting roof/valves

3. Fuel deposits injector tip

Inhomogeneous gas phase

4. Local rich areas (stratified/HSP)

5. Fire land stored fuel






SIA / CNAM 2012

Gasoline Systems

real engine conditions

Sources of Particulate Emissions at DI Enginessources at DI formation / conditions

1

2

3

45

1

2

3

45

Fuel:

Cracking

Pyrolysis

Soot:

Precursors

GenerationPic

ture

:

DLR

, Ins

titut

für

Ver

bren

nung

stec

hnik

Ti

me

2500

2000

1500Tem

pera

ture

[K]

0.2 0.4 Lambda [-]

Soot formation region

• low O2• > 1500K

Com

bust

ion

Igni

tion

T[K]

O2[%]

°CA[BTDC]

-12

0-

20

>20

21

21-1

<1

400

500-

2500

~2000

Fuel

film

@

pis

ton






SIA / CNAM 2012

Gasoline Systems

Soot origin from wall film

1000

1500

2000

2500

3000

-

combustion finishedoxygen content < 1%

burn

ene

rgy

rele

ase

[%]

mea

n te

mpe

ratu

re [K

]

-20 -10 0 10 20 30 40 50 60

12°CA BTDC 9°CA ATDC

CA [°]

Very

small amountsof fuel film under:

• high temperature• low oxygen

conditionsresponsible for soot-emissions

0

25

50

75

100

Homogeneous2000 1/min5 bar pmiearly injection

Diffusive comb. fuel-

film @ piston

>> 20°CA ATDC

Combustion

~100 %

Ignition

2500

2000

1500

1000

Tem

pera

ture

[K]

0,2 0,4 0,6

Lambda [-]

Soot formation region






SIA / CNAM 2012

Gasoline Systems

Adv. Combustion Concepts: Challenge and Solution (Fuel Metering)

Downsizing / Displacement Reduction•

wetting (piston, valve)•

oil dilution•

mixture preparation (homogenization)•

spread (idling, catalyst heating, boosted full load)

Lean Burn Concepts (SGDI, HCCI)•

multiple injection >=3•

combustion concept robustness

Solution

Spray-Targeting

•

variable hole design

•

innovative manufac-

turing

technologies

Mixture Preparation

•

multiple injection

Adv. Injection Spread

•

using ballistic range towards smallest quantities @ 200 bar

source: MTZ 12/2010speed

torque build-upScavenging electrical

WG hybridization

knockingtumble design

active cyl. head cooling

comp. protectionintegr. exh. manifold

cooled EGR

high ignition voltagerobust ignition system

emissionsimproved mixture prep.

reduced penetration(e.g. soft spray, split inj.)

nominal powerturbo-charger

Pmaxto

rque

higher injection spread /multiple injection

controlled valve operation






SIA / CNAM 2012

Gasoline Systems

Contribution of innovative manufacturing technologies

Reduced penetration:

Better spray break-up and increased

entrainment of air due to enhanced

turbulence generation at sharp edged

nozzle inlet

standard inno. man. tech.

standard inno. man. tech.

Sharp inlet edge

Reduced penetration

Optimization/adaptation of individual

spray pattern:

Flexible hole design of single beams

to avoid critical zones

Improvement of homogenization due to

improved capture of airBeam Flexibility

standard inno. man. tech.standard inno. man. tech.

Individual optimization of critical beams

35


SIA / CNAM 2012





Gasoline Systems

Spray examples: Eroded / inno. man. tech.

eroded

inno. man. tech.






SIA / CNAM 2012

Inno. Man. Technologies: Potential, Side Mounted

Gasoline Systems

•

Reduction of PN-emission, especially at higher loads•

Due to reduced penetration reduced oil dilution•

Widening of application area

Comparison Particle Emission

0,0E+00

1,0E+07

2,0E+07

3,0E+07

4,0E+07

5,0E+07

6,0E+07

2 5 8 11

Load, bmep

[bar]

PN

[N/m

s]

Oil dilution

0,0%

2.0%

4,0%

6,0%

8,0%

10,0%

12,0%

eroded

Oil

dilu

tion

%

IMT IMThole indiv.

erodedIMT IMT hole indiv.

2000 1/min, 280°bTDC

1000 1/minTmot=50°, 2h

bmep: brake mean effective pressureIMT: innovative manufacturing technologies

eroded

IMT

IMThole individual

37

Controlled Valve -

HDEV5 Operation






SIA / CNAM 2012

Gasoline Systems

Component

ti-co

rrec

tion

control-

algorithm

Software

ti

UBatt

UBoost

UBatt

UBoost

signal processing, A/D-control

Hardware

Current profileCurrentMotionInduced voltage

DGDI-S

CVO gains benchmark on small quantities with solenoid injector

Open loop Closed loop






SIA / CNAM 2012

Gasoline Systems

Optimized PN combining DI Advanced Spray

and Calibration

Start Calibration Catalyst Heating

Homogeneous Mode Overall Result in PN -

Reduction

06,0E+111,2E+121,8E+122,4E+123,0E+123,6E+124,2E+124,8E+12

series calibration

optimizedcalibration.

optimized calibration

and DI Advanced Spray

PN

[n/k

m]

discussed PN limit EU6c

Quick fuel pressure rise up

Multi injection in suction stroke to avoid wall wetting

Minimize wall wetting by minimized fuel quantity for turbulence injection

Minimize piston wetting by optimized start of injection

Multi injection (depending on combustion system)






SIA / CNAM 2012

Gasoline Systems

Summary

Drivers:

Main market drivers remain CO2/fuel economy and emissions

At least ‘til 2020 the ICE plays a major role for CO2 reduction

Advanced Fuel Metering as key feature for DI to fulfill the legislation requirements and gain the ultimate gasoline engine

DI solutions:

Innovative manufacturing technologies for optimized spray targeting and mixture preparation

Controlled Valve Operation for smallest quantities accurate @ 200 bar in combination of multiple injections

BOSCH offers DI Advanced Spray

Technologies to meet the worldwide market requirements






SIA / CNAM 2012

Gasoline Systems

Conclusion






SIA / CNAM 2012

Gasoline Systems

Conclusion

CO2/fuel economy and emissions are the main market drivers

The gasoline direct injection plays a major role in this technical context

The market share of the diesel engine is decreasing worldwide

The gasoline indirect injection remains at a high level worldwide

The gasoline injection will be the strong winner in 2020






SIA / CNAM 2012

Gasoline Systems

Thank you

Gasoline Direct Injection – SIA / CNAM 2012turbo-moteurs.cnam.fr/publications/pdf/conference3_2012.pdf · Radial engine with 9 cyl. (BMW) Fuel injection pump (Boxer form) 7 Gasoline

Documents