avl india private limited (head office)avl+india+sem… · all the vehicle manufacturers or vehicle...
TRANSCRIPT
Manoj Kusumba
AVL India Private Limited (Head Office)
Confidential
EAS development challengesAVL M Seminar, May 22-25, 2018
Manoj Kusumba | | 20 May 2018 | 2Confidential
Author(s): Manoj Kusumba
Co-Author(s):Josef KoenigNeil Jason KunderAnuj Goel
Approved by:
Project Leader:
Version: 1.0
Release date: 20.05.2018
Security level: Confidential
Customer:
Project:
Task ID:
Department:
Copyright © 2018, AVL India Private Limited (Head Office)
Manoj Kusumba | | 20 May 2018 | 3Confidential
Contents
� BS VI development overview
� EAS Hardware screening, selection and
development
− NH3 uniformity
− Urea deposit testing
� Thermal Management
� Fuel economy norms – overview
� Electrification overview @ AVL ITC
Manoj Kusumba | | 20 May 2018 | 4Confidential
Contents
� BS VI development overview
� EAS Hardware screening, selection and
development
− NH3 uniformity
− Urea deposit testing
� Thermal Management
� Fuel economy norms – overview
� Electrification overview @ AVL ITC
Manoj Kusumba | | 20 May 2018 | 5Confidential
Development process
� Design, layout simulation
− Design changes (Combustion system, fuel injector, turbo, intake throttle, exhaust flap,….)
− EAS layout simulation
− Sensor layout and specification
− Software gap analysis
� Procurement of new and modified parts
� Test bed development and calibration
− Performance and emission development (Engine Out Emission)
− EAS development
� NH3 Uniformity (UI measurement)
� Deposit formation testing
� EAS hardware checks and screening
− Thermal Management
− EAS (SCR, DPF) Calibration (Tail Pipe Emissions)
� Vehicle level development and calibration
� Design validation (DVP)
� Engine emission certification
Manoj Kusumba | | 20 May 2018 | 6Confidential
Development process
� Design, layout simulation
− Design changes (Combustion system, fuel injector, turbo, intake throttle, exhaust flap,….)
− EAS layout simulation
− Sensor layout and specification
− Software gap analysis
� Procurement of new and modified parts
� Test bed development and calibration
− Performance and emission development (Engine Out Emission)
− EAS development
� NH3 Uniformity (UI measurement)
� Deposit formation testing
� EAS hardware checks and screening
− Thermal Management
− EAS (SCR, DPF) Calibration (Tail Pipe Emissions)
� Vehicle level development and calibration
� Design validation (DVP)
� Engine emission certification
Manoj Kusumba | | 20 May 2018 | 7Confidential
EAS layout overview
CO/HC
PM
NOx
Exhaust Emissions
PN
Manoj Kusumba | | 20 May 2018 | 8Confidential
Contents
� BS VI development overview
� EAS Hardware screening, selection and
development
− NH3 uniformity
− Urea deposit testing
� Thermal Management
� Fuel economy norms – overview
� Electrification overview @ AVL ITC
Manoj Kusumba | | 20 May 2018 | 9Confidential
NH3 uniformity
Manoj Kusumba | | 20 May 2018 | 10Confidential
BS VI EAS layout overview
CO/HC
PM
NOx
Exhaust Emissio
ns PN
Manoj Kusumba | | 20 May 2018 | 11Confidential
NH3 Uniformity - Introduction
Manoj Kusumba | | 20 May 2018 | 12Confidential
Objective
Manoj Kusumba | | 20 May 2018 | 13Confidential
Installation on the engine test bed
Manoj Kusumba | | 20 May 2018 | 14Confidential
Minimum required instrumentation of EAS
Manoj Kusumba | | 20 May 2018 | 15Confidential
Assessment of uniformity
Manoj Kusumba | | 20 May 2018 | 16Confidential
Deposit formation testing
Manoj Kusumba | | 20 May 2018 | 17Confidential
Objective
Manoj Kusumba | | 20 May 2018 | 18Confidential
Robust dosing areas
Manoj Kusumba | | 20 May 2018 | 19Confidential
Engine test bed installation
Manoj Kusumba | | 20 May 2018 | 20Confidential
Instrumentation of EAS
Manoj Kusumba | | 20 May 2018 | 21Confidential
Contents
� BS VI development overview
� EAS Hardware screening, selection and
development
− NH3 uniformity
− Urea deposit testing
� Thermal Management
� Fuel economy norms – overview
� Electrification overview @ AVL ITC
Manoj Kusumba | | 20 May 2018 | 22Confidential
BS VI EAS layout overview
CO/HC
PM
NOx
Exhaust Emissions
PN
Manoj Kusumba | | 20 May 2018 | 23Confidential
Thermal management
� Dosing release temperature
� Cold start
− SCR heat up
− Keep warm
� DPF regeneration
� DeSOx
Manoj Kusumba | | 20 May 2018 | 24Confidential
Max S
oot
Loadin
g g
/l
RGN Trigger
DPF Life Cycle
DPF Loading DPF Regeneration
DPF Loading
Regeneration Intervall
DPF regeneration
Manoj Kusumba | | 20 May 2018 | 25Confidential
Temperature [°C]
qu
alita
tive B
urn
-Rate
[-]
~550°C
Active RGNActive RGN
Kin
etic-L
imitation
Lo
w R
GN
-Eff
icie
ncy
NO
2-L
imitation
Typical operating rangefor passive RGN
650°C
Th
erm
al C
rack
Th
erm
al C
rack
Kin
etic-L
imitation
Lo
w R
GN
-Eff
icie
ncy
Typical operating rangefor active RGN
~250°C
Passive RGNPassive RGN
Temperature [°C]N
O2/N
Ox
%]
DOC
DOC 2DOC 2
DOC 1DOC 1
Providing NO2
DOCUnburned Fuel
Providing Heat
DOC 1DOC 1DOC 2DOC 2
C + NO2 → CO + NO C + O2 → CO2
DPF - Active & passive regeneration
Manoj Kusumba | | 20 May 2018 | 26Confidential
WHTC – Thermal management
Without thermal management
With thermal management
Dosing release temp
Dosing release temperature
Manoj Kusumba | | 20 May 2018 | 27Confidential
THERMAL ENGINE MANAGEMENT -AIR PATH
Intake throttle
� State-of-art technology route
� Electronically controlled mainly used for thermal EAS management in light load area and steady
state conditions
� Limited effect due to risk of lube oil sucking (intake valve shaft, TC, oil rings) caused by depression
in intake duct
Exhaust flap
� Electronically controlled in light load area and steady state conditions
� High potential for thermal EAS management w/ penalties in BSFC
Manoj Kusumba | | 20 May 2018 | 28Confidential
THERMAL ENGINE MANAGEMENT–FUEL PATH
Main injection timing
� Injection timing retardation for thermal EAS management by lower engine thermal
efficiency
Post injection
� Early post injection (close to main injection event) with lower effect as main timing
retardation
� Late post injection mainly for HC generation for exothermal reaction in DOC with
risk of lube oil dilution
Manoj Kusumba | | 20 May 2018 | 29Confidential
Intake throttle vs exhaust flap
Manoj Kusumba | | 20 May 2018 | 30Confidential
Contents
� BS VI development overview
� EAS Hardware screening, selection and
development
− NH3 uniformity
− Urea deposit testing
� Thermal Management
� Fuel economy norms – overview
� Electrification overview @ AVL ITC
Manoj Kusumba | | 20 May 2018 | 31Confidential
Overview – Passenger car applications
Source:- SIAM Website
� Source of information :- Amendment No-7 to MoRTH/CMVR/ TAP-115/116: Issue No.: 4
� The Fuel Efficiency Norms will be applicable on Motor vehicle having at least 4 wheels other than Quadricycles, used for transportation of passengers and there luggage.
� The maximum seating capacity of the vehicle shall not be more than 9 including driver and GVW < 3.5 tons (specified as Motor vehicle) for sale in India.
� Each Manufacturer of the said motor vehicle shall comply with energy consumption standard termed as Average Fuel Consumption Standard .
� In any fiscal year commencing from the 1st Day of April, 2017 onwards, the Average of Actual Fuel Consumption shall be less than or equal to Avg. Fuel Consumption Standard as specified in below slides.
� Compilation and Enforcement :- All Manufacturer and Importers shall comply with the said standards.
� The Ministry of Road Transport and Highway will enforce the same under the Central Motor Vehicle Rule, 1989.
Manoj Kusumba | | 20 May 2018 | 32Confidential
The Average Fuel Consumption standard
Formula for calculation of Limits of Avg. Fuel Consumption = a X (W-b) + c
Where as,
a = Constant Multiplier
b = Fixed Constant
C = Fixed Constant
W = Weighted Average Unladen mass of the Vehicle in Kg.
Average Fuel Consumption standard (Limit) of the manufacturer in Petrol Equivalent Liter per 100 Kilometer.
Where weighted average unladen mass of the manufacturer shall be calculated as follows
W = ∑ Ni Wi / ∑Ni , Where
Ni = Number of Vehicle manufactured or imported in India of a model ‘i’ in the respective fiscal year. Ni
Wi = Unladen mass in kg of Vehicle ‘i’ in the respective fiscal year.
Source:- Gazette Notification S.O 1072(E) Dated : - 23rd April, 2015 issues by MoP
Manoj Kusumba | | 20 May 2018 | 33Confidential
Table for Constant multiplier and Fixed constant
a 0.0024
b 1037
c 5.4922
Avg. Fuel ConsumptionStandard
= 0.0024 x (W – 1037) + 5.4922
Table 1.1 (for Fiscal Year 2017-18 to 2022-23)
a 0.002
b 1145
c 4.7694
Avg. Fuel ConsumptionStandard
= 0.002 x (W – 1145) + 4.7694
Table 1.2 (for Fiscal Year 2022-23 onwards)
Source:- Gazette Notification S.O 1072(E) Dated : - 23rd April, 2015 issues by MoP
Manoj Kusumba | | 20 May 2018 | 34Confidential
Summary
� From 1st April, 2017, Fuel Efficiency Norm is mandatory for M1 Category vehicle whose GVW is Less than 3.5 Tons.
� The FE will be measured at the time of TA as well as during COP.
� The same vehicle can be used for both Emission as well as FE Measurement.
During Test the system will measure the CO2
emitted by the vehicle during the test in grams/km. Using the CO2 Emission value, FE will be further calculated in liters/100 kms by dividing the CO2
Values by a constant factor 23.7135.
� The Manufacturer will have to keep record CO2 emitted by each model and its variant and maintain the data in an “Annual Fuel Consumption Report”.
� The Manufacturer will have to maintain “Fuel Consumption Integrated Passbook” also.
Manoj Kusumba | | 20 May 2018 | 35Confidential
Overview – HD Commercial Vehicle
� On and from 1st April, 2018, diesel vehicles of category M3 and N3 with gross vehicle
weight of twelve tonnes and above, complying with BS-IV emission norms, shall be tested
for constant speed fuel consumption as specified by the Ministry of Road Transport and
Highways, till the time Bureau of Indian Standards notify corresponding standards:
� Phase 01 norms effective from 1st April, 2018 and Phase 02 norms effective from 1st April,
2021.
� All other four wheel drive vehicles which are not covered in the norms shall be treated as
two wheel drive vehicles and shall conform to the norms of their two wheel drive category.
� In any fiscal year commencing on and from the 1st day of April, 2018, the fuel consumption
of each vehicle of a particular category shall be less than the fuel consumption value
derived from the equation of that category as specified in the preceding tables.
� The norms shall apply only for vehicles complying with BS-IV emission norms and for the
vehicles complying with BS-VI emission norms, the competent authority shall derive a
suitable correction factor to be used on above mentioned BS-IV norm values.Source :Draft notification dated 16 August 2017
Manoj Kusumba | | 20 May 2018 | 36Confidential
Overview – HD Commercial Vehicle
Compliance and enforcement
� All the vehicle manufacturers or vehicle importers selling the motor vehicles in India, as
specified in the Tables, shall comply with the energy consumption standards specified
� The Ministry of Road Transport and Highways shall implement the conformity of production
by constant speed fuel consumption method which shall be conducted once in every two
years;
� At least one conformity of production for the vehicle has to be conducted latest by 1st April,
2020
� The Ministry of Road Transport and Highways, shall enforce the norms along with provisions
relating to testing and calculation methodologies, reporting, consequence of non-
compliance and equivalent vehicle credits for electricity driven motor vehicles under the
Central Motor Vehicle Rules, 1989, in consultation with Ministries concerned.
Source :Draft notification dated 16 August 2017
Manoj Kusumba | | 20 May 2018 | 37Confidential
N3 vehicle category
Manoj Kusumba | | 20 May 2018 | 38Confidential
M3 vehicle category
Manoj Kusumba | | 20 May 2018 | 39Confidential
Suggested emission roadmap beyond BS VI
Draft National Auto Policy – Feb 2018
Manoj Kusumba | | 20 May 2018 | 40Confidential
Suggested emission roadmap beyond BS VI
Draft National Auto Policy – Feb 2018
Manoj Kusumba | | 20 May 2018 | 41Confidential
Contents
� BS VI development overview
� EAS Hardware screening, selection and development
− NH3 uniformity
− Urea deposit testing
� Thermal Management
� Fuel economy norms – overview
� Electrification overview @ AVL India Technical Centre
Manoj Kusumba | | 20 May 2018 | 42Confidential
AVL ITC: ElectrificationRoadmap
Ju
ly 2
01
8
• HV Battery Emulation• E-Vehicle Tests• E-Powertrain Tests• Durability Tests• Vibration Analysis
• Systems and Requirements Engineering
• Mechanical Design• Structural Simulations• Software Development
INDIA TECHNICAL CENTER
Dec. 2
01
8
• Calibration• Thermal Simulations• Vehicle Integration• Vehicle and Fleet Validation• End-of-Line Component
Testing• EV & E-PWT Benchmarking
DC Fast Charging Stations
Manoj Kusumba | | 20 May 2018 | 43Confidential
AVL ITC: Electrification Infrastructure Roadmap
� 160kW 800V Battery Emulator� Emulation on Chassis Dynamometer and Powertrain Testbeds� High level safety systems� Automation to enable efficiency and performance tests� Benchmarking capabilities
� DC Fast Chargers with CCS and ChaDeMo
Amit Arora
Associate Vice President - PTE Sales
Ph. No +91 98110 55044
Manoj Kusumba | | 20 May 2018 | 44Confidential
AVL ITC, Gurgaon
AVL-Graz
AVL Your Engineering Partner
We design, simulate, develop and validate new ideas and products
THANK YOUwww.avl.com