acc symposium held on september 28 · pdf filemazda skyactiv-g engine with new boosting...

Mazda SKYACTIV-G Enginewith New Boosting Technology

Reiji Okita Mazda Motor Corporation

- ACC Symposium held on September 28 -

28, Sep. 2016

1. Mazda’s approach for environmental improvement

2. SKYACTIV-G Development Process

3. SKYACTIV-G 2.5L TC development

4. End message

CONTENTS

2© Mazda Motor Corporation │ Strictly Confidential │

3

Mazda’s Long-term Vision “Sustainable Zoom-Zoom“

© Mazda Motor Corporation │ Strictly Confidential │

Provide all the customers with driving pleasure, Also, Mazda considers the best contribution to the environment is to

incorporate superior and fairly valued technologies into every car modelrather than expensive eco technologies to limited models

a b c d e f g h i j

Vehicles

CO2

100%

0%

CO2

100%

0%a b c d e f g h i j

Vehicles

Small number

of expensive

eco-vehicles

Mazda’s approach

1. Mazda’s approach for environmental improvement

Why we believe so ?

1) Market forecast

2) Difference between Well-to-Wheel

CO2 emissions of EV and ICE

4© Mazda Motor Corporation │ Strictly Confidential │

CO2CO2

Well Tank Wheel

CO2CO2CO2CO2

Wheel

Tank to Wheel Well to Wheel

5

ICEInternal Combustion Engine

BEV

PHEV

・・・ GE/DE

1. Mazda’s approach for environmental improvement

250

200

150

100

50

0

202020102000 2030 2040 2050

Vehicle Sales Volume by regionRef. Marubeni Research Institute

Non-OECD

: Others

Non-OECD

: ASIA

OECD

Sales volume /year (m

illion)

Vehicle Sales by typeRef. BP Energy Outlook 2035

Most of power source of a car which will increase in future are internal combustion engines. It will not be possible to make a contribution for environment without improving internal combustion engines.

- Market forecast-

France IndiaEnglandItalyCanada USGermanJapan China

6© Mazda Motor Corporation │ Strictly Confidential │

0.5kg-CO2/kWh

1. Mazda’s approach for environmental improvement

- Well to Wheel -

We assume that global average of specific CO2 emission in electric power generation is 0.5kg-CO2/kWh

CO2排出原単位（発電端）の各国比較

Nuclear

Water

New energy, others

Well to Tank CO2 emission of Electricity(without transmission efficiency)

CO2

emis

sion

sby

bas

ic u

nit

Brea

kdow

n of

non

-fos

sil

ener

gies

0.37kg-CO2/L

Well to Tankof Fuel in Japan

7© Mazda Motor Corporation │ Strictly Confidential │

C car EV Real World Electricity Consumption : 21.2kWh/100kmC car SKYACTIV-G Real World Fuel Consumption： 5.2L/100km

Electricity Consumption and Fuel Consumption

A carB car

15%

30%

45%

0%

10 12 14 16 18 2010

12

14

16

18

20

22

24

26

28

30

Specific electricity consumption at NEDC (kWh/100km)

A car

B car

C car

21.2kWh/100km

Specific electricity consumption

at ADAC ECO test (kWh/100km)

C car average

3

4

5

6

7

3 4 5 6 7

I2 0.9L

I3 I.0L

I3 0.9L

1.4L

I3 1.0L

1.2L

1.4L

A 1.8L1.6L

1.4L

1.6L1.6L

1.2LI3 1.0L

1.4L

1.6L

1.2L

1.6L

2.0L

1.4L

1.6L

1.4L

*Source : ADAC EcoTest

NEU ab März 2012

1.4L

1.2L

Mazda3

2.0L SKYACTIV-G

Note I3

I.2L

1.2L

F/E at NEDC (L/100km)

15%

0%F/E ADAC ECO test

(L/100k)

- Well to Wheel -

1. Mazda’s approach for environmental improvement

5.2L/100km

8© Mazda Motor Corporation │ Strictly Confidential │

Well to Wheel CO2 emission 〜Mazda EstimateC car EVElectricity Consumption: 21.2kWh/100kmSpecific CO2 emission : 0.5 CO2-kg/kWh+ LCA considering Li-ion Battery: 1.0kg/100km

If the fuel consumption could be improved by 20%-30%, CO2 emission level of the vehicle powered by ICE could be equal to that of EV.

106 〜 116 CO2-g/km

C car SKYACTIV-GFuel Consumption : 5.2L/100km

148 CO2-g/km

20% - 30%

- Well to Wheel

1. Mazda’s approach for environmental improvement

（Well to tank + Tank to Wheel)

9© Mazda Motor Corporation │ Strictly Confidential │

Potential of the improvementWell to Wheel CO2 emission with ICE

Current efficiency of Tank-to-Wheel

� EV : 80%-90%

� ICE: max. 30% - 40%

1. Mazda’s approach for environmental improvement

There is still Large potential of improvement in ICE, also hybridization gives further improvement on ICE

10© Mazda Motor Corporation │ Strictly Confidential │

1. Mazda’s approach for environmental improvement

How do we let the aim accomplish ?“F/C improvement 20%〜30%”

CONTENTS

1. Mazda’s approach for environmental improvement

2. SKYACTIV-G Development Process

3. SKYACTIV-G 2.5L TC development

4. End message

11© Mazda Motor Corporation │ Strictly Confidential │

12© Mazda Motor Corporation │ Strictly Confidential │

2. SKYACTIV-G Development Process

Innovative High Thermal EfficiencyThe energy of the fuel is converted to power that

moves the vehicle.

� Improvement of driving force� Improvement of fuel economy� Decrease of poisonous substance in

exhaust gas

Maximize

13© Mazda Motor Corporation │ Strictly Confidential │

Effective work

Exhaust loss

Heat

En

erg

y B

ala

nce (

%)

Heat energy balance vs. load

0

20

60

80

100

20 40 60 80 100

Load (%)

40

Radiation, Misfiring loss

Cooling loss

Compression ratio

Specific heat ratio

Control factor

Combustion period

Combustion timing

Heat insulation

Pressure differenceb/w intake and exhaust

Mechanical loss

High-efficient Engine ← Minimize Losses

2. SKYACTIV-G Development Process

14© Mazda Motor Corporation │ Strictly Confidential │

2. SKYACTIV-G Development Process

Gasoline engine Diesel engine

Further reduction

LeanHCCI

adiabatic

Higher CR

LeanHCCI

Roadmap to the goal of ICE Distance to idealFar Close

Specific

heat ratio

Heat transfer

to wall

Compression ratio

Combustion

period

Control factors

Combustion

timing

Pressure diff.

Btw IN. & Ex.

Mechanical

frictionFurther reduction

friction reduction

More homogeneous

World lowest CR

TDC combustion

TDC combustion

World highest CR

friction reduction

Miller cycle 1

stste

p S

KY

AC

TIV

-G

1stste

pS

KY

AC

TIV

-D

2n

dste

p S

KY

AC

TIV

-G

2n

dste

p S

KY

AC

TIV

-D

3rd

ste

p=

Go

al

current current

Better mixing

Gasoline and diesel engines will look similar in the future.

15© Mazda Motor Corporation │ Strictly Confidential │

Alternative delivering torque higher than 400Nm on a large SUV is, V6 Natural Aspirated or Boosted I4 downsized.

Power Source for CD-SUV

TIME-LINE

TORQUE

Nm2.0L

2.0L/1.8L

1.3L

1.6L/1.5L1.5L

1.3L

2.5L

2.3L_T/C

3.7L_V6

200

400

Previous

Generation

New

Generation

2.5L

I4 Boostedor

HIGH CR NA

Inline four (4)

V6

3. SKYACTIV-G 2.5L TC development

CONTENTS

1. Mazda’s approach for environmental improvement

2. SKYACTIV-G Development Process

3. SKYACTIV-G 2.5L TC development

4. End message

16© Mazda Motor Corporation │ Strictly Confidential │

Scenario we selected I4 boosting,not V6 NA.

17© Mazda Motor Corporation │ Strictly Confidential │

18© Mazda Motor Corporation │ Strictly Confidential │

Compared to V6 3.7L, boosted I4 2.5L achieves:- 30% less mechanical friction with fewer cylinders (6 to 4) and less displacement

Mechanical Friction ～Calculation by Mazda

Effect of Downsizing V6 3.7L ⇒⇒⇒⇒ Boosted I4 2.5L

3. SKYACTIV-G 2.5L TC developmentAdvantage of I4 boosted

19© Mazda Motor Corporation │ Strictly Confidential │

Compared to the V6 3.7L, the boosted I4 2.5L achieves:- 30% less pumping loss with less displacement.

Effect of Downsizing V6 3.7L ⇒⇒⇒⇒ Boosted I4 2.5L

Pumping loss

3. SKYACTIV-G 2.5L Turbocharged (TC) Engine Development

Advantage of I4 boosted

20© Mazda Motor Corporation │ Strictly Confidential │

I4 boosted concept has superior mechanical friction and pumping loss, while it is inferior fuel efficiency due to lowered compression ratio, and acceleration response.

3. SKYACTIV-G 2.5L TC development

21© Mazda Motor Corporation │ Strictly Confidential │

P: pressure (kPa)

T: unburned gas temp. (K)

X_EGR：EGR ratio

Ignition delay

Livengood-Wu integral

3. SKYACTIV-G 2.5L TC development

Key issue to realize I4 boosted with high compression ratio is

Knocking Resistance Improvement

Evaluation Toolfor calculation of knocking resistance

22

3. Breakthrough Point to Realize I4 Turbocharging Concept

© Mazda Motor Corporation │ Strictly Confidential │

To keep the advantage of I4 turbocharged engine for the mechanical friction and pumping loss, the compression ratio must be kept around 10.5.

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

0.5 1.0 1.5 2.0 2.5 3.0 3.5

LW

Inte

gra

l [-

]

Charging pressure [bar]

ε=13.0 ε=10.5

ε=9.0 ε=8.0

ε=7.0 ε=6.0

ε=5.0

LW integral value at BLD of 2.5L NA CR=13

ε=8

ε=10.5

Compression ratio setting

in the high load range

ε=6

（（（（2.5L）））） Displacement

2.5L TC

@2000rpm

ε=13

I4 2.5L

ε=10.5

BSFCImprovement

Anti-knocking technology

BS

FC

Mechanical Resistance

Pumping Loss

V6 3.7L

ε=13

V6 2.5L

ε=13

I4 2.5L

ε=13

I4 2.5L

ε=8

Maintain knock resistanceequivalent to NA

Compression ratio setting

in the light load range

Cascaded targets to realizecompression ratio, 10.5

23© Mazda Motor Corporation │ Strictly Confidential │

24© Mazda Motor Corporation │ Strictly Confidential │

The concept o improve knock resistance at high loads, encouraging “scavenging” for low speed and introducing EGR for mid/high speed.

3. SKYACTIV-G 2.5L TC development

ε=13

ε=10.5

ε=10.5

ε=10.5

EGR18%

EGR25%

(2.5L) ------ Displacement

@4000rpm

25

4. Setting Functional Targets and Appropriate Displacement

© Mazda Motor Corporation │ Strictly Confidential │

“Scavenging” at low rpm/high load

The follows are necessities for the turbo charged 2.5L engines(CR 10.5/boost pressure 2.0bar) to ensure the knock resistance equivalent to 2.5L NA engines(CR 13.0) .- low rpm/high load : TDC Temp.Δ75K, BGR* 7.0% →2.5%

- mid/high rpm & high load: EGR ratio 18%

-75K

(2.5L) ------ Displacement

ε=10.5BGR 7.0%

ε=10.5BGR 2.5%

ε=10.5BGR 0.0%

ε=13.0Heavy knocking area

“EGR” at mid/high rpm & high load

EGR18%

Heavy knocking area

*: BGR = Residual gas ratio

@1500rpm

Specific Measures to achieve cascaded specific targets

26© Mazda Motor Corporation │ Strictly Confidential │

27© Mazda Motor Corporation │ Strictly Confidential │

Exhaust Pulsation of a Turbocharged Engine

For strong scavenging, a large gap of pressure and long overlap interval are necessary, while the boost pressure exceeding over exhaust gas pressure.

Pre

ssure

Crank angle

EVO

IVO

Boost Pressure

Exhaust pressure

OverlapInterval

Pre

ss

ure

Ga

p

High Pulsationmakes high boost

3. SKYACTIV-G 2.5L TC development

- Scavenging -

28© Mazda Motor Corporation │ Strictly Confidential │

Dynamic Pressure Turbo (DPT) Structure

To realize scavenging concept, 4-3-1 exhaust was adopted so that the volume of four exhaust passages are minimized evenly. Each passage is divided into primary and secondary in order to encourage turbine rotation and scavenging effect.

A-A cross section

B-B cross section

3. SKYACTIV-G 2.5L TC development

29© Mazda Motor Corporation │ Strictly Confidential │

Dynamic Pressure Turbo (DPT) Scavenging Effect

3. SKYACTIV-G 2.5L TC development

30© Mazda Motor Corporation │ Strictly Confidential │

Dynamic Pressure Turbo (DPT) effect at low/high engine rev.

3. SKYACTIV-G 2.5L TC development

31© Mazda Motor Corporation │ Strictly Confidential │

EGR gas is pulled through EGR outlet placed at down stream of the control valve,and brought to EGR cooler.

EGR pipe

DPT Control Valve

EGR Cooler

HP-Cooled EGR Passage

3. SKYACTIV-G 2.5L TC development

32© Mazda Motor Corporation │ Strictly Confidential │

Function of EGR Pipe Location

EGR passage does not disturb “scavenging” effect when it is required, but able to provide sufficient amount of EGR with transient accuracy.

Valve : Close

Low pressure

Low pulsation

Scavenging condition

& no EGR required

High pulsation

Pre

ssure

No Scavenging condition

& enough EGR required

Valve : Open

Pre

ssu

re

EGR pipeEGR pipe

EGR

Low rpm

High loadMid/High rpm

3. SKYACTIV-G 2.5L TC development

33© Mazda Motor Corporation │ Strictly Confidential │

Scavenging and EGR Area

SKYACTIV-G with DPT achieved to enable high scavenging under low engine speed, as well as introduce high amount of EGR in wider engine operation range, led significantly low fuel consumption performance.

3. SKYACTIV-G 2.5L TC development

Achievements

34© Mazda Motor Corporation │ Strictly Confidential │

35© Mazda Motor Corporation │ Strictly Confidential │

Reduction in Fuel Consumption

SKYACTIV-G 2.5L with DPT improves the fuel efficiency over a whole range.

3. SKYACTIV-G 2.5L TC development

36© Mazda Motor Corporation │ Strictly Confidential │

SKYACTIV-G 2.5L with DPT achieved significantly higher torque than predecessor from low engine speed under 91RON, as well as much shorter turbo lag.

Acceleration CharacteristicTorque Curve

3. SKYACTIV-G 2.5L TC development

37© Mazda Motor Corporation │ Strictly Confidential │

0

50

100

150

200

250

300

350

400

450

500

0 1000 2000 3000 4000 5000 6000 7000

Torq

ue [

Nm]

Engine Speed [rpm]

180km/h

200km/h

220km/h

240km/h 6th

100km/h120km/h

140km/h

160km/h

5th

100kW

110kW

120kW

V6 3.7L WOT

SKYACTIV-G 2.5T

WOT

2.3L TC WOT

SKYACTIV-G 2.5L with DPT λ=1 window

1

2

SKYACTIV-G 2.5L with DPT achieved wider range of λ=1 window, real-world fuel consumption has been improved by 30% from the predecessor model.

3. SKYACTIV-G 2.5L TC development

38

Summary

© Mazda Motor Corporation │ Strictly Confidential │

Mazda 2.5L SKYACTIV-G Engine with “Dynamic Pressure Turbo” and “HP cooled-EGR” brought the following benefits:

2. Low fuel consumption at middle and high loads.

1. Acceleration response comparable to that of large-displacement naturally aspirated engine

3. The maximum torque of 420 Nm at low speed, 2000rpm

3. SKYACTIV-G 2.5L TC development

CONTENTS

39© Mazda Motor Corporation │ Strictly Confidential │

1. Mazda’s approach for environmental improvement

2. SKYACTIV-G Development Process

3. SKYACTIV-G 2.5L TC development

4. End message

� ICE has still enough potential to improve its thermal efficiency.

� Mazda continues to improve ICEperformance targeting to equalCO2 emission level as EV’s.

40© Mazda Motor Corporation │ Strictly Confidential │

Thank you for your kind attention