3-Cylinder Turbocharged Gasoline Direct Injection: a High Value Solution for Euro VI Emissions

Home , Cylinder (engine), Engine downsizing

3-Cylinder Turbocharged Gasoline Direct Injection: A High Value Solution for Euro VI Emissions

John E. Kirwan

Presented at DEER 2009 Conference August 5, 2009

DEER 2009 Slide # 1 Delphi Powertrain Outline

• Global Emissions and CO2 Challenges

• Technology Overview for 3-Cyl Boosted GDi Engines

• Value Analysis

• Summary and Conclusions

DEER 2009 Slide # 2 Delphi Powertrain The Emission Legislation Global Drive Global emission legislation are evolving toward fuel neutral standards, with emerging countries adopting European legislation.

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Europe Euro 4 Euro 5 Eu5+ Euro 6 USA (federal) Tier II bin 8 Tier II bin 5 India (nationwide) Euro 2/BSII Euro 3/BSIII Euro 4? China Euro 2 (w/o OBD) Euro 3 Euro 4 (nationwide) (w OBD)

NEDC Cycle FTP Cycle 300 250 SI Engine 250 Diesel Engine 200 180

150 NOx relief is disappearing 124 124 for EU diesel engines mg/km mg/km 100 80 80 60 60

43 43 50

NOx Emissions Standard, Emissions NOx 0 DE ER 2009 Slide # 3 Euro 4 Euro 5 / 5+ Euro 6 Tier2 Bin8 Delphi Tier2 Powertrai Bin5 n CO2 Regulations Globally Introduced

Fuel Consumption Gasoline: 35miles/gallon is 6,7lt/100 or 161g/km CO 300 2

275g/km CAFE LDT <3,8t

254g/km 250 Obama Admin. (May 2009) Truck Status Germany Combined Pass. Car CAFE PC <12 Pers. 205g/km

200 Gasoline Vehicles 30 MPG Average Senate Bill CAFÉ Diesel Vehicles Plan (2007) 15 7g/km 150 35.5 MPG ACEA 140g/km 39 MPG 130g/km

CO2-Emission CO2-Emission [g/km] 100 Vehicle/Engine EU Comission 02/2007

50 1990 1995 2000 2005 2010 2015 2020 2025 Year

o Powertrain/Vehicles will change significantly: - Dramatic Downsize and Boost +++ 3-cyl. Turbo GDi - Hybrids/Electrification required to meet future targets

DEER 2009 Slide # 4 Delphi Powertrain Outline

• Global Emissions and CO2 Challenges

• Technology Overview for 3-Cyl Boosted GDi Engines

• Value Analysis

• Summary and Conclusions

DEER 2009 Slide # 5 Delphi Powertrain Fuel Economy Benefits from Engine Boosting Downsizing and Downspeeding • Reduced Engine Displacement and Decreased Engine Speed Increase Engine Load for Reduce Fuel Consumption - Good low end torque is essential

Downsizing B1*V1*N = B2*V2*N BSFCBSFC BMEP BMEP P = f(B*V*N)

B2 BSFC1 Spe S BSCF2 ed = co Load Load Load peed nst. B1 , Power for VV2 IncreaseIncreaseIncrease = con st. Reduction Reduction Sp Consumption Consumption eed = const. for V1

VV22 V11 DDiissppllaacceemmeenntt BB11 B22 BBMMEEPP

Downspeeding B1*N1 = B2*N2 BSFCBSFC BMEPBMEPBMEP P = f(B*V*N)

B2 BSFC1

Load Load Load Load V, B1 Power = BSCF2 V = con IncreaseIncreaseIncreaseIncrease const. st. ReductionReduction Consumption Consumption

NNN222 NNN111 EEEnnngggiiinnneee SSSpppeeeeeeddd BB11 B22 BBMMEEPP DEER 2009 Slide # 6 Delphi Powertrain Gasoline Direct Injection Boosted Engine Systems • Gasoline Direct Injection is a Key Enabler to Improve Low End Torque in Boosted Engines - Improved Volumetric Efficiency - Direct injection with cam phasing allows scavenging with fresh air to reduce residual gas fraction - Reduced knock propensity - In-cylinder fuel vaporization reduces charge temperature - Improved combustion phasing - Charge motion increases burn rate

SAE2000-01-0251

Greater than 18bar achievable Source: Piock (AVL): 2002 SAE TOPTEC (Adv. in Dir. Inj. Eng. Sys.) DEER 2009 Slide # 7 at 1000rpm with GDi. Source: Schamel (Ford): 2008Delphi SAE Congress Powertrain Presenta tion Gasoline Direct Injection Boosted Engine Systems

• Gasoline Direct Injection is a Key Enabler to 1.8L engine downsized to 1.4L turbo (with down-speeding) Improve Low end Torque in Boosted •11% fuel consumption reduction Engines •Equivalent performance - Improved Volumetric Efficiency Source: Königstein et al (GM): 2008 Vienna Motor Symposium - Direct injection with cam phasing allows scavenging with fresh air to reduce residual gas fraction - Reduced knock propensity - In-cylinder fuel vaporization reduces charge temperature - Improved combustion phasing - Charge motion increases burn rate • Benefits BMW New Inline 6-cyl Engine - Fuel economy improvement 480 240 225 kW @ 5800-6400 min-1

- 9-15% for homogeneous systems 440 200

400 Nm @ 1200-5000 min-1 - 15-21% for stratified systems 400 160

- Improved fuel control and rapid catalyst light- 360 120 off with split-injection during cold start Output [kW] Torque [Nm] 320 80 TwinPower Turbo engine - Increased power and responsiveness with VALVETRONIC 280 TwinTurbo engine 40 without VALVETRONIC

240 0 0 1000 2000 3000 4000 5000 6000 7000 8000 DEER 2009 Slide # 8 Source: Schamel (Ford): 2008Delphi SAE Congress Powertrain Presentation Source: BMW Media Day (June 2009) Engine speed [1/min] Gasoline Direct Injection Boosted Engine System Mechanization

DEER 2009 Slide # 9 Delphi Powertrain Gasoline Direct Injection Boosted Engine System Mechanization

DEER 2009 Slide # 10 Delphi Powertrain Gasoline Direct Injection Homogeneous Systems • System Features - Inwardly-opening, multi-hole GDi Injectors, fuel rail and engine-driven high pressure fuel pump - Injection during the intake stroke focused on complete vaporization and mixing of fuel and air - Stoichiometric operation allows emissions control via traditional 3-way exhaust catalyst

Low Pressure Lines High Pressure Lines

Pressure Sensor

Fuel Rail

Injector

Wiring Harness and Connectors High Pressure Pump DEER 2009 Slide # 11 Delphi Powertrain Gasoline Direct Injection Homogeneous Systems Central mount • System Features Up to 190 mm long - Inwardly-opening, multi-hole GDi Injectors, Side mount fuel rail and engine-driven high pressure fuel pump - Injection during the intake stroke focused on complete vaporization and mixing of fuel and air - Stoichiometric operation allows emissions control via traditional 3-way exhaust catalyst • Key Requirements - Operation at fuel pressures up to 200 bar - Injector packaging for cylinder side mount and central mount - Spray generation for good vaporization and mixing without wetting in-cylinder surfaces Injector Linear Flow Range Comparison - Good linear flow range 22220000%%%% 11115555%%%% CompetitionBosch Ecotec 11110000%%%% DelphiDelphi Bravo 5555%%%%

0000%%%% ----5555%%%%0 Injector Linear Flow Range Comparison ----11110000%%%% ----11115555%%%% DeviationDeviationDeviationDeviationfromfromfrom from LinearLinearLinearLinear DEER 2009 Slide # 12 0 10 20 Delphi30 Powertrain40 50 Flow (mg/pulse) Gasoline Direct Injection Stratified Systems • System Features - Outwardly-opening, hollow-cone GDi Injectors, fuel rail and engine-driven high pressure fuel pump - Central mount injector near spark plug - Injection during the compression stroke for careful placement of fuel mixture in space and time

Spark Spray Spray plug

Recirculation Zone Piston

DEER 2009 Slide # 13 Delphi Powertrain Gasoline Direct Injection Stratified Systems

Spark Spray • System Features plug - Outwardly-opening, hollow-cone GDi Injectors, fuel rail and engine-driven high pressure fuel pump - Central mount injector near spark plug

- Injection during the compression stroke for careful Piston placement of fuel mixture in space and time • Key Requirements - Operation at fuel pressures up to 200 bar - Well-atomized and well-placed stratified mixture Stable spray under engine conditions under engine conditions 5 bar 10 bar 20 bar Backpressure - Multiple injections to confine the fuel mixture - High linear flow range

160 20% fp = 200 bar 140 15% 120 10%

100 5% 80 0% 60 -5%

Deviation (%) (%) Deviation 40 -10% Fuel Mass (mg/shot) (mg/shot) Mass Fuel 20 -15% 0 -20% 0.00 1.00 2.00 3.00 4.00 5.00 Injector Pulse Width (ms) DEER 2009 Slide # 14 Delphi Powertrain 3 Cylinder Engine Analysis Comparison with 4 Cylinder • 3 Cylinder Engine Offers Improved Engine Breathing at Full Load - Reduced firing frequency increases scavenging for improved full load torque

1500rpm, Full Load ]

abs 2.8 I4, twin scroll 2.4 p3 3cyl (Exhaust)

2.0 p2 (Intake) 1.6 1.2 L4, mono scroll 0.8 (Simulation AVL BOOST) 90 180 270 360 450 540 ºCA 630 Pressure Pressure at [bar valves (GE-TDC)

Area of Valve Overlap

DEER 2009 Slide # 15 Delphi Powertrain 3 Cylinder Engine Analysis Comparison with 4 Cylinder

• 3 Cylinder Engine Offers Improved Engine Breathing Source: Weinowski et al. (FEV) 2009 Vienna Motor Symposium at Full Load - Reduced firing frequency increases scavenging for improved full load torque • 3 Cylinder Engine Provides Reduced Fuel Consumption and Emissions - Reduced heat transfer surface area - Reduced quench layer and crevices - Lower friction Source: Heil et al. (Daimler) 2002 Vienna Motor Symposium

Tre T ndli Operation Point: 10kW CI E ne ngin Base 3.0lt 66-Cyl.- Cyl. NA Tren 2 es NA E dlin .0b at ngi e ar nes at 2. 0bar

2.2lt 6--Cyl. Cyl. Trend TCI TCI E line ngines a BSFCBSFC [g/kWh] [g/kWh] 10kW s at 2. 73bar 2.2lt 4- Cyl. TCI

Daimler, 2002 10kW

Cylinder Displacement [cm3] DEER 2009 Slide # 16 Delphi Powertrain 3 Cylinder Engine Analysis Comparison with 4 Cylinder • 3 Cylinder Engine Offers Improved Engine Breathing at Full Load - Reduced firing frequency increases scavenging for improved full load torque • 3 Cylinder Engine Provides Reduced Fuel Consumption and Emissions - Reduced heat transfer surface area - Reduced quench layer and crevices - Lower friction • 3 Cylinder Engine Increases NVH - Unbalanced 1st and 2nd order torque pulses require counterbalancing - Results in slight friction increase • Overall Conclusion: 3 Cylinder Engine is the Preferred Configuration for Displacements < 1.5L

Source: Colltman et al. SAE 2008-01-0138 DEER 2009 Slide # 17 (SABRE Engine) Delphi Powertrain Outline

• Global Emissions and CO2 Challenges

• Technology Overview for 3-Cyl Boosted GDi Engines

• Value Analysis

• Summary and Conclusions

DEER 2009 Slide # 18 Delphi Powertrain 3 Cylinder Engine Value Analysis

Comparison1.6lt - 4cyl vs. 1.2lt - 3cyl. 40 25Euro/% No electrification considered 35

30 Better 25 50Euro/%

15 CO2 Reduction [%] CO2 10