GLOBAL AUTOMOTIVE REGULATION & PROTON’S ...staff.iium.edu.my/aniliza/Proton Powertrain 1 August 2008...1 2 3 1992 1994 1996 2000 2005 EURO 5? Direct-injection diesel passenger cars

Date: 1st August 2008 Revision 0 Page 1

GLOBAL AUTOMOTIVE GLOBAL AUTOMOTIVE REGULATION & PROTONREGULATION & PROTON’’S S

ENGINE DEVELOPMENTENGINE DEVELOPMENT

1st AUGUST 20081st AUGUST 2008SUHAIZI HASSANSUHAIZI HASSAN

POWERTRAINPOWERTRAIN


WHAT IS HOMOLOGATION?

Approval, accreditation, certification.


REGULATORY TREND WORLDWIDEREGULATORY TREND WORLDWIDE

ADR

ECE/ECFMVSS

ECE/EC

ECE/EC

FMVSS

ECE

Integrated ECE

ECE-base

Switch to ECE

Switch to ECE

Switch to ECE

GB JISGS AIS


REGULATORY STANDARDREGULATORY STANDARD

ENVIRONMENTENVIRONMENT

ACTIVESAFETYACTIVESAFETY

PLATES & LABELS

PLATES & LABELS

REGULATORYSTANDARD

REGULATORYSTANDARD

PASSIVESAFETY

PASSIVESAFETY

GENERAL SAFETY & SECURITY

GENERAL SAFETY & SECURITY


Radio suppression / EMC

Exhaust emissionNoise

Re-use, recovery & recycling

ENVIRONMENTENVIRONMENT

CO2 emission

Fuel consumption


Defrost / demist

Lightsinstallation

Tyres

Brakes

Horn

Mirror

Steeringequipment

Speedometer

Identification of control

ACTIVE SAFETYACTIVE SAFETY

Forward vision Washer / wiper


Seatbelt

Door latches & hinges

Steering

Seatbelt anchorages,

ISOFIXSeats strength& anchorages

Interior fittings

Headrestraint

Glass

PASSIVE SAFETYPASSIVE SAFETY


Wheel guard

Masses & dimensions

Anti-theft devices

GENERAL SAFETY & SECURITYGENERAL SAFETY & SECURITY

Fuel tank / rear underrun

protective devices

Exterior projections

Flammability


VIN

Tyre pressure

Build-date

Jack

PLATES & LABELSPLATES & LABELS

Convex mirrorCO2 & Fuel

consumption

Airbag

Spare wheel max speed warning

Brake fluid

Luggage net

ISOFIX

VisibleVIN


• R&D Center – Officiated on 20th April 1993 • Launched on May 15th, 1999 by the Y.A.B Former Prime Minister

Tun Dr. Mahathir Mohamed

• The most advanced Automotive R & D facilities in Asia Pacific outside of Japan.

• The facilities are: - Clay Modelling- Powertrain Design and Development- Advanced Prototype Center- Rapid Prototype- Vehicle and Component Testing- Engineering Design Development and Service- Virtual Reality - Chassis Engineering- Catia Version 5

COMMERCIAL BREAKCOMMERCIAL BREAK

PROTON R&D FACILITIES


PHASE - 0 PHASE - I PHASE - II PHASE - III

• Technology & Concept Development• Product Development• Process Development• Prototype Validation

• Process Validation• Product Confirmation

• Production• Continuous

Improvement

DEVELOPMENT EXECUTION

LIFECYCLE

• Enhancement• Phase-out

ENGINE DEVELOPMENT PHASESENGINE DEVELOPMENT PHASES

48 MONTH


Future Goals for EnginesFuture Goals for Engines

The main challenges for modern drives are :

Further considerable reduction of toxic exhaust products like carbon monoxide (CO), unburned hydrocarbons (HC), nitrogen oxides (NOx) and particulate matters (PM).

Drastic reduction of fuel consumption as well as carbon dioxide (CO2).


Trends in Gasoline Engine DevelopmentTrends in Gasoline Engine Development

The main principals, characteristics and their positive impacts :

Charge dilution and variable in-cylinder charge motion.

Gasoline direct injection with homogeneous charge or charge stratification.

Variable valve activation for load control.Displacement on demand.Downsizing by super charging.Homogeneous charge compression ignition.

A great number of patents and inventions have been published for avoiding these pumping losses.


Development of European emission Development of European emission regulations since EURO 1regulations since EURO 1

0

1

2

3

1992 1996 2000 2005

Carbon Monoxide - COHydrocarbons - HCNitrgen Ovides - NoxSum of HC+NoxParticulate Matter - PM

0

1

2

3

1992 1994 1996 2000 2005 EURO 5?

Direct-injection diesel passenger cars engine

Gasoline passenger cars

EURO 1

EURO 2

EURO 3

EURO 4

Exha

ust e

mis

sion

lim

its fo

r C

O, H

C, N

ox, (

HC

+Nox

) in

[g/k

m]

Exha

ust e

mis

sion

lim

its fo

r PM

in [g

/km

]

0.2

0.3

0.1

0


Malaysia Malaysia -- Proposal for Implementation of Euro 3 & 4Proposal for Implementation of Euro 3 & 4

Std 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12

Euro 1

Euro 2

Euro 3

Euro 4

Applies to model with new engine type

Applies to model with new engine type

New vehicle type

All vehicles

New veh. type

All


Test Procedure Checked Item Euro 1 Euro 2 Euro 3 Euro 4

Type I CO,HC.Nox

Type II Idling CO

Type IIINo emission of

crankcase gases

Type IV Evaporative

Type VDurability

80k/100k^or DF

Type VI CO, HC @ -7oC X X

OBD Show failure when exceed threshold limits

X X

Emission testEmission test


Load Control TechnologyLoad Control Technology

Active Valve Train (AVT)“Breakthrough Technology”

BMW Valvetronic

Variability's in valve timing are an excellent means for improvements at part and full load operation.


Fuel Economy Technology RoadmapFuel Economy Technology Roadmap

CDA

Hydrogen Fuel Cell Hybrid

Technical Challenge/Cost/Risk/Time to Maturity

GDI

% I

mpr

ovem

ent

in F

uel

Eco

nom

y

Petrol Hybrid(Parallel)

AVT

Energy Storage

Enhancement

Optimum Engine

Operating Point

Seamless Electric Motor Driveline

CAI+CDA

NGV20

80

40

60

100

120

140

160

180

200

Diesel Hybrid(Parallel)

Petrol Hybrid(Series)

Diesel Hybrid(Series)

Honda Civic IMA

Toyota Prius

Possible Upgrade to Fuel Cells

Energy Storage Enhancement

Base Engine Enhancement

Driveline Enhancement


ENGINE CALIBRATION

WHAT IS ENGINE CALIBRATION?

ECU

ENGINE

An integration of ECU data and hardware to optimize engine performance.


WHAT IS EMS?WHAT IS EMS?

SENSORSSENSORS ACTUATORSACTUATORSECUECU

•• EMS or Engine Management Systems is a system which controls EMS or Engine Management Systems is a system which controls and manage the engine efficiently.and manage the engine efficiently.•• The systems consists of an Electronic Control Unit (ECU) which The systems consists of an Electronic Control Unit (ECU) which integrates and control the sensors and actuators.integrates and control the sensors and actuators.•• The need of the system is to meet the ever increasing demand The need of the system is to meet the ever increasing demand of exhaust emissions regulations, allows better fuel economy, of exhaust emissions regulations, allows better fuel economy, without sacrificing the driveability and performance.without sacrificing the driveability and performance.

ENGINE MANAGEMENT SYSTEM



PROTON TECHNOLOGY WEEK

2nd and 3rd August 2008

• A favorable moment of 23 years Proton Anniversary.• In honor of 3 million roll out production of Proton cars.• Proton showcase Technology & Engineering Capability


BASE ENGINE CALIBRATION

BACK-UPMAP

TEMPCOMPENSA-

TION

SPARK

LOAD

LBT

A / F

BASE DYNO CALIBRATION


CPS VERSUS IAFM ENGINE


λ = 1

TOR

QU

ELBT POINT

λ=0.9 ~ 0.95

LEANEST FUEL FOR BEST TORQUE


strokeLbored

Ld

==

××=

41

air actual2π

η ν

air ltheoreticaair actual

=νη

densityair 10

1)(

21min601)flow(kg/hr fuel

63

=

××

××××=

a

a mkgcc

NFA

ρ

ρην

LOAD / VOLUMETRIC EFFICIENCY


VOLUMETRIC EFFICIENCY

densityair 10

1)(

21min601)flow(kg/hr fuel

63

=

××

××××=

a

a mkgcc

NFA

ρ

ρην


LOAD DATA


BTDC

TOR

QU

EMBT POINT

MINIMUM ADVANCE FOR BEST TORQUE


SPARK TIMING DATA


BASE ENGINE CALIBRATION

BACK-UPMAP

TEMPCOMPENSA-

TION

SPARK

LOAD

LBT

A / F

BASE DYNO CALIBRATION


VEHICLE CALIBRATION

• VEHICLE EMISSION• DRIVEABILITY• VALIDATION• EOBD


EMISSION TEST


0.970.5 0.35 0.18

2.2 2.3

1

2.72

00.5

11.5

22.5

33.5

44.5

5

1993 (EURO 1) 1996 (EURO 2) 2000 (EURO 3) 2005 (EURO 4)

Lim

its (g

/km

)

HC+NoxCO

EXHAUST EMISSION LIMITS


DRIVEABILITY

0

2

4

6

8City Driving

Hill Climbing

Launch

Highway drivingTrunk Road

Crawling

Acceleration

Target F5M41 CPS


ON BOARD DIAGNOSTIC (OBD)

• A system that identifies any malfunction which can cause the vehicle emissions exceeding the limits.

• When any malfunction detected and confirmed, Malfunction Indicator Light (MIL) or Check Engine is turned ON to alert the driver

• OBD system records relevant engine data such as RPM, temperatures and pressures, which is useful for fault diagnosis.

• OBD system monitor four main failure mode:1. Defective Catalytic Converter2. Engine Misfire3. Defective Oxygen Sensor4. Defective of any EMS component


Thank YouThank You

GLOBAL AUTOMOTIVE REGULATION & PROTON’S ...staff.iium.edu.my/aniliza/Proton Powertrain 1 August 2008...1 2 3 1992 1994 1996 2000 2005 EURO 5? Direct-injection diesel passenger cars

Documents