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Ace155 Wang 2021 O 2021 DOE Vehicle Technologies Office Annual Merit Review Project ID: ace155 Low-Mass and High-Efficiency Engine for Medium-Duty Truck Applications Qigui Wang/Ed Keating General Motors 6/24/2021 This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. This presentation does not contain any proprietary, confidential, or otherwise restricted information Overview Timeline Barriers/Technical Targets Project start date: 10/2019 Combustion Technology – Advanced gasoline stoichiometric dilute combustion Project end date: 12/2023 to achieve the target fuel economy requirement & Percent complete: ~30% deliver outstanding value to the customer Materials Technology Budget – Lightweight, high performance, and low cost Total project funding Partners – DOE share $7,007,878 Oak Ridge National Laboratory – Non-Federal Share $3,294,329 The Ohio State University Funding received in FY20 Michigan Technological University – $1,943,118 ECK Industries Inc Funding for FY21 planned Project lead: General Motors – $1,530,743 2021 DOE Vehicle Technologies Office Annual Merit Review (Project ID: ace155) 2 Relevance Objective: Develop a medium duty truck engine, compliant with EPA emission standards, utilizing advanced materials and combustion technologies capable of (relative to 2015 L96 VORTEC 6.0L V8 engine): ≥10% fuel economy improvement ≥15% engine weight reduction Impact: • The integrated R&D of advanced propulsion materials, manufacturing, and combustion strategies can not only expand engine operating efficiency, but also enable lighter weight engines for better performance and fuel economy. 2015 L96 6.0L V8 Engine (Baseline) • The technologies developed and demonstrated in this project will help bridge the technology gap between light and medium-duty engines. • The approach and methodologies developed and implemented in this project can be readily applied to other material/component systems to shorten development time and cost. Chevrolet Silverado 3500HD truck Reduce energy usage and CO2 emissions & increase energy security with the baseline engine 2021 DOE Vehicle Technologies Office Annual Merit Review (Project ID: ace155) 3 Approach Phase I - Research and Development Phase II - Validation and Demonstration 2020 2021 2022 2023 Task 1 Task 2 Task 3 Task 4 ❑ Simulate advanced ❑ Proof of concept ❑ Detailed design of ❑ Build and calibrate new combustion technology physical testing using new Phase 2 engine engine combinations “basis” engine ❑ Fabricate parts for ❑ Verify performance ❑ Simulate durability at ❑ Develop materials and new engine Key Key Tasks higher temperature and processes for Phase 2 ❑ Post test evaluation of pressure testing on new engine ❑ Verify feasibility of parts fabricated by new new material and material and process ❑ Choose best ❑ Select technologies for process innovations innovations combinations Phase 2 new engine Fuel Economy Engine Simulation & Concept Improvement Analysis Testing Design & Test & Build Final Validate Final Solution Solution Weight Engine Strategy & Strategy Reduction Simulation & Concept Work Streams Work Analysis Testing 2021 DOE Vehicle Technologies Office Annual Merit Review (Project ID: ace155) 4 Milestones Month/Year Description of Milestone or Go/No-Go Decision Status March 2021 Complete development and selection of lightweight high-performance materials (All) Completed June 2021 Develop advanced overcasting technologies (OSU) On Schedule Sept 2021 Complete development and optimization of materials and casting process for crankshaft (MTU) On Schedule Go/No Go Decision #2 - Selected Engine Technologies Demonstrated Potential to Achieve Performance and Dec 2021 On Schedule Mass Objectives (All) March 2022 Proposed medium duty truck engine hardware designed On Schedule June 2022 Key engine components produced with the developed material & manufacturing solutions On Schedule Sept 2022 Thorough process modeling and durability analysis using ICME completed On Schedule Go/No Go Decision #3 - An initial assessment is completed as to the capability of the new concepts to meet Dec 2022 On Schedule or exceed the project targets GM – General Motors, ORNL – Oak Ridge National Lab, OSU – Ohio State University, MTU – Michigan Technological University, ECK – Eck Industries Inc 2021 DOE Vehicle Technologies Office Annual Merit Review (Project ID: ace155) 5 Technical Accomplishments Fuel Economy Improvement TASK 1 - 2020 (Technology Research & Development) Potential engine architecture designs coupled with combustion system technology simulations ➢ Layout and Performance Simulation of Engine Architectures (#1 Large Displacement, Normally Aspirated and #2 (Small Displacement, Boosted) ✓ Determine approximate overall engine displacement, cylinder size and number of cylinders ✓ Execute basic layout of engine in medium-duty truck to understand packaging opportunities and challenges ✓ Establish approximate cost differential of engine assembly ✓ Employ 3D CFD analysis to create and evaluate potential combustion system design and technology enhancements ✓ Use 1D model to baseline and add projected benefits of proposed combustion system technology enhancements developed through 3D CFD analysis ✓ Select engine architecture for further development 2021 DOE Vehicle Technologies Office Annual Merit Review (Project ID: ace155) 6 Technical Accomplishments Fuel Economy Improvement TASK 1 - 2020 (Technology Research & Development) Potential engine architecture designs coupled with combustion system technology simulations ➢ Proposed Combustion System Technology Enhancements ✓ Advanced combustion system(s) OHV 2-Valve ✓ Optimal cylinder deactivation Combustion System ✓ Advanced valvetrain phasing and lift strategies ✓ Advanced fuel systems including “ultra” high pressure DI ✓ Advanced ignition systems including pre-chamber ✓ Advanced EGR dilution systems including E-EGR ✓ Atkinson or Miller cycle strategies DOHC 4-Valve Combustion System ✓ Variable induction system strategies ✓ Combustion chamber cooling strategies 2021 DOE Vehicle Technologies Office Annual Merit Review (Project ID: ace155) 7 Technical Accomplishments Fuel Economy Improvement TASK 1 - 2020 (Technology Research & Development) Potential engine architecture designs coupled with combustion system technology simulations ➢ Methodology: ✓ Engine Architecture proposals Weighted Fuel Economy Improvement were simulated using the PHASE Technology Specifics 6.6L NA V8 3.7L Turbo L6 2 GEM simulation software. PFI to DI V8 update from Baseline 1.9% base ✓ The speed-load points of high Basic Architecture 6.6L NA V8 / 3.7L T L6 base 7.5% fuel usage and impact on fuel Intake Valve Event Atkinson / Miller 2.5% 1.7% economy based on this drive cycle simulation were Cooled EGR Dedicated EGR/LPL 4.3% 2.1% established. Cylinder DEAC Full Authority 1.3% 0.1% UHPDI 1000 BAR Late Injection 1.8% 1.7% ✓ The top points, representing 90% Passive PC Mult-hole small volume 2.8% 2.1% of fuel energy used during the test cycle, defined the key operating points at which the fuel Total 14.6% 15.2% economy improvement potential was initially evaluated. 2021 DOE Vehicle Technologies Office Annual Merit Review (Project ID: ace155) 8 Technical Accomplishments TASK 1 (Technology Research & Development) MILESTONE 1.4 was completed in the 4th Quarter with the primary engine architecture selected Primary engine architecture selection criteria per plan SOPO is noted below: Milestone Type Description Engine architecture selected based on Primary Engine While both architectures show Technical potential to meet performance and weight Architecture Selected clear potential to meet the objectives cost effectively project objectives, our projection is that the large, Primary Engine Architecture Selection Milestones: normally aspirated V8 will do Requirement/Attribute Large NA V8 Downsized Boosted L6 so much more cost effectively. +10% Fuel Economy MEETS MEETS Therefore, this architecture has -15% Engine Weight MEETS MEETS been chosen for further Estimated Engine Cost BASELINE +37% development. Performance MEETS MEETS Packaging MEETS MEETS Primary Engine Architecture Selection Summary PUGH Chart 2021 DOE Vehicle Technologies Office Annual Merit Review (Project ID: ace155) 9 Technical Accomplishments Fuel Economy Improvement TASK 2 - 2021 (Technology Research & Development) Design and build hardware to further develop TASK1 simulation predictions ➢ Developed combustion system technology hardware to support test cell evaluation ✓ Advanced combustion system(s) ✓ Advanced fuel systems including “ultra” high pressure DI ✓ Advanced ignition systems including pre-chamber ✓ Advanced EGR dilution systems including E-EGR ✓ Atkinson cycle strategies ✓ Variable induction system strategies ✓ Combustion chamber cooling strategies
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