Roadmap to Energy Conversion Efficiency at Cummins · PDF fileRoadmap to Energy Conversion Efficiency at Cummins ... Contribution of Future Engine Technology ... Roadmap to Energy

Roadmap to Energy Conversion Efficiency at Cummins

2013 ERC SymposiumJune 5, 2013

Wayne Eckerle-VP Corporate Research & Technology

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� Technology Integration Process

� Key Technologies for Diesel Engines

� GHG Reduction Potential for On-Highway Applications

� Key Technologies for Natural Gas Engines

� Summary

Topics

2

Low Initial Cost

Low Maintenance

Electronic

Integration

Low

Emissions

Reliable and Durable

High Performance

Fuel Efficient

Our Products Must Meet Customer Requirements

Improve

Alt Fuels

Understanding

Mechanical

Components

Analysis

Led

Design

Achieving Very Low

Engine Out

Diesel

Emissions

Catalyst

Technology

Development

System

Integration

Controls

R&T Product Preceding Technology Research Areas

Keys to Successful Analysis-Led Design

� Cultural Change

� Effective Tools

� Documented Processes

� Skilled Analysts

� Continuous Improvement

� Analysis Must Deliver

10-Year Combustion Research ALD Funnel

Active Projects(Exploratory) Active Projects

(Near Term) Baseline

Technology

2011 - 2012 < 20112012 - 2016

> 2016

Hopper

KIVA (Old CFD Tool)• RIF Diesel and G-Equation

NG Combustion Model

• Full NOX

• Soot Moment Model

• KH-RT Spray Model

• Single CPU

Block Structured Grid• Hand-built/semi-automated

mesh generation

Calibration/Optimization• DOEs

• Pre-defined bowl geometries

In-Cylinder Charge

Motion• Bessel Function (standard)

• Fluent imposed flow field

(for 360o grids as needed)

Modeling Enhancements• Fully-Coupled LES with

Sprays and Chemistry

• Improved Combustion &

Emissions Models

• Injector Internal Flow/Spray

Routine Coupling

• Flow/Structure Heat Transfer

Routine Coupling

• Massively Parallel Computing

New CFD Tool• Detailed, Flamelet, and Flame-Area Chemistries

• Improved Emissions Modeling

• Spark Ignition Engine Modeling, including Knock

• Improved Spray Modeling, including Liquid Films

• Improved RANS Turbulence Modeling

• Integrated Port Flow Modeling

• Full Parallelization

• Improved Pre-/Post-Processing Tools

• Improved Support and Documentation

New Chemistry Tool• Detailed Mechanism Calculations

• Reduced Kinetics Mechanism Generation

• Flamelet Model Support/Library Generation

• One-dimensional Engine Model, including Knock

New Optimization Tool• Fully integrated Mesher, Solver, and Optimizer

• Automated Grid Generation/Mesh Refinement

• Detailed Chemistry Solver (RIF to be added)

• Genetic Algorithms Optimization

Advanced Simulation• Turbulence and Spray DNS

• Full Chemistry

• Advanced Numerical

Methods

• Advanced Computing

Technology

�

�

�

�

�

�

�

�

�

Technology

Development

(Sub-system Level)

Platform

Integration/

Product

Development

(System Level)

Technology

Integration

(System Level)

Invent /

Innovate Develop Optimize Certify

Value Package

Introduction

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Technology Workflow

2020 HD Technical

Prioritized List

Adv. Combustion

Friction/Parasitic

Hybrid

Waste Heat Rec.

Low T. Aftertreatment

Increased PCP

2020 HD Technical

Prioritized List

Adv. Combustion

Friction/Parasitic

Hybrid

Waste Heat Rec.

Low T. Aftertreatment

Increased PCP

Implement

as Required

in VPI

Arrange Technologies

in Customer

Benefit Order

Illustrative Example

Payback

Regulation

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Integration Approach

Vehicle Energy LossesSuperTruck Baseline

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Analysis of 27 Drive Cycles for Class 8 Vehicles

with a Variety of Seasons (Summer, Winter, etc.)

SuperTruck Program

50% Drive Cycle

Freight Efficiency

Demonstration

68% 24hr Cycle

Freight Efficiency

Demonstration

50% BTE

Demonstration

55% BTE

Demonstration

SuperTruck Program

Dec 2012

50% Drive Cycle

Freight Efficiency

Demonstration

Dec 2013

68% 24hr Cycle

Freight Efficiency

Demonstration

Dec 2012

50% BTE

Demonstration

Apr 2014

55% BTE

Demonstration

Contribution of Future Engine Technology

6.3 MPG 10 MPG

TM

Engine50%

Truck50%

Contribution to Improvement

Subsystem Technology Palette

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Air Handling & EGR

Aftertreatment (AT)

Electronic Controls

EnergyRecovery

TransmissionIntegration

Combustion &Fuel Systems

TM

Sources of Heat on Current EngineF

uel E

nerg

y (

100%

)

Brake Power

(42%)

Friction/Misc Losses

(8%)

Heat Transfer

(24%)

Exhaust Energy(26%)

Hig

hW

aste

Heat

Qu

ali

tyH

igh

Cooled EGR

Tailpipe Exhaust

200-600o C 200-600o C

200-750o C 200-750o C

Charge Air Cooling

Engine Cooling

20-60o C20-60o C

80-100o C80-100o C

Lo

wW

aste

Heat

Qu

ali

tyL

ow

TM

Current WHR Architecture

� Low GWP Refrigerant

� Turbine Expander

� Heat exchangers

–EGR Heat Exchanger

(replaces EGR cooler)

–Exhaust Heat Exchanger

–Recuperator

� Mechanical power to crank

Waste Heat Recovery Trucks on Road

WHR Exhaust

Heat Exchanger Exhaust

AftertreatmentWHR Expander

Drive Module

WHR

Recuperator

WHR

EGR Heat Exchanger

WHR

Condensor

Technologies for 50% Engine Thermal Efficiency

Combustion & Air Handling� Piston bowl size and shape

� Injector specification

� Calibration optimization

� Turbocharger efficiency

� Aftertreatment optimization

Parasitic reductions� Shaft seal

� Variable flow lube pump and viscosity

� Geartrain

� Cylinder kit friction

� Cooling and fuel pump power

WHR system� EGR, exhaust, recuperator

� Turbine expander

� Low GWP refrigerant

SuperTruck Efficiency Improvement Results

Inn

ovati

on

Yo

u C

an

Dep

en

d O

n™

Fuel Energy

100%

Indicated Power58%

Heat Transfer

17%

Exhaust

18.5%

Gas Exchange

2%

Friction

1.0%

Accessories

1.0%

Brake Power

60.5%

EGR Source

(ORC)

5%

EGR + Exhaust

Source1.5%

Energy Balance for Advanced HD Engine

with Electrification of the Vehicle

Electrified Vehicle

Hybrid Technology

Accessory Loads

Power to Driveline

Motor Battery

Hybrid Spectrum

Basic

Start stop

Start stop with braking energy capture

Integrated power source (super alternator)

Integrated starter generator

Parallel full hybrid

Increased functionality

Hig

her

init

ial co

st

Affordable Today

Research efforts in

place to pull these down.

� Technical feasibility has been demonstrated

� Performance competitive

� Customer interest growing

BUT

� Market penetration continues to be hampered by persistent high costs

� Aggressive cost reduction at ALL levels essential for commercial viability and mass market acceptance

Hybrids and EVs in the 2012 Marketplace

� Energy Storage Systems

� Power Electronics (Inverter, Converter, Charger)

� Electric Machines

� System Integration

Key HEV Technologies Driving Vehicle Performance and Cost

DoE Traction Drive Technical & Cost Targets

ATLAS Program Technologies for High Efficiency Pickup Truck Application

Light Weighting

On-Engine/

Close coupled

aftertreatment

Low Pressure

EGR

Direct NH3 Gas

Delivery

Low Thermal

Mass Exhaust

Manifold

Cold Start Catalyst

By JMI

Down Sizing

Reduced

Displacement

Base ATLAS

City MPG 15.6 23.5

Highway MPG 24.5 34.3

SCRF

Natural Gas Technology

Aftertreatment

Air Handling

Friction and Parasitics

Waste Heat Recovery

Natural gas produces 5-10% less

mass of exhaust CO2/hp

(less CO2/energy but worse BTE)CH4 GWP = 25 x CO2 GWP

Diesel Engine

Technologies

Most

Technologies

Transfer

Ignition Systems

Nat Gas Aftertreatment

Nat Gas Combustion

Air Handling

Friction and Parasitics

Waste Heat Recovery

Combustion

Natural Gas

Technologies

Advanced Lean

Burn

Stoichiometric

Higher Detonation Limit

for “EGR diluted” mixture

λλλλ = (Airin + Diluant*)/Airstoich Ratio

* CO2 + H2O

Simple

Lean Burn

Spark Ignition ArchitecturesALB w/SCR

Stoichiometric

Cooled EGR

Ghourshal, Bangladesh – 146 QSK60 Gas Aggreko gensets

Summary

� Engine and powertrain technology can provide significant GHG benefits going forward

� Technologies are applicable to a wide range of energy sources

� Simulation capability is a significant enabler

� System Integration is the discriminator

Acknowledgements

� DOE

� Partners on the DOE programs

– Peterbilt, Eaton, Nissan

� Researchers in Cummins R&T group

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