Turbocharged Spark Ignited Direct InjectionA Fuel Economy Solution for the USJune 10, 2009

Paul WhitakerChief Technologist, Gasoline EnginesAVL Powertrain Engineering Inc.

2PAW, JUN-09, © AVL 2009

Micro PC Engines < 1,0 l

Small PC Engines1,0 - 1,5 l

Medium PC Engines 1,5 - 2,4 l

Large PC LDT / MDT

Truck

Variable Charge Motion

Variable Valve Lift2 / 3 Step

Variable Valve Lift Continuous

NA Homogeneous SIDI

TC Homogeneous SIDI

SIDI Stratified

Controlled Auto Ignition

CylinderDeactivation

Engines> 4 cyl

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?

Technology

New /current Mainstream:

General Market Trends:

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Global Gasoline Technology Trends

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0

8

10

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24

1000 2000 3000 4000 5000 6000Engine Speed [rpm]

BM

EP [b

ar]

220

240

260

280

300

320

340

360

BSF

C [g

/kW

h]

RON 95

MY 2005

t turb = 950°C

MY 2012+ VGT

SIDI + TurbochargingLow End Torque versus Mid / High Speed BSFC

MY 2010 DVCPMY 2007 I-VCP

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High Tumble for Turbo SIDIOctane and Faster Burn Rate Benefits with High Tumble Improves Full-Load Fuel Consumption

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Optical Engine Supports Turbo SIDI ProgramsExample: 1500 rpm Boosted Full Load Optimization

Optimized System

Fuel spray direction

Flame Images Good Injector: flame intensity

NO soot flames!

Air intake flow

HEAVY soot flames!

Base SystemLIF

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Engine Speed [rpm]

10

20

30

1000 2000 4000 6000

Full LoadState of art 2007

Enrichment RON 98

Enrichment

RON 95

Measures to reduce enrichment requirement:

• High RON fuels

• Higher temperature turbine (e.g.: 950°C 1050°C)

• Cooled external EGR

• Active exhaust gas cooling

Enrichment Requirement for Turbocharged Gasoline Engines

Full Load, Ultra High Performance Concepts

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Showing The Potential Of Turbocharged GDI

GDI-Turbo Concept Carfor low Fuel Consumption

5.0

5.5

6.0

6.5

7.0

7.5

8.0

8.5

NEDC l/100km160

165

170

175

180

185

190

195

200

NEDC g/km CO2

0.08

0.09

0.10

0.11

0.12

0.13

0.14

0.15

0.16

NEDC $/mile*

2.0L VW FSI

NEDC $/mile* based on $3.55/gallon for premium gasoline & $4.15/gallonultra low sulfur diesel – US average prices 22-APR-08

2.0L AVL t-GDI2.0L VW Diesel

FTP 75: 32 mpgHWFET: 50 mpg

160

180

200

220

240

260

280

300

320

340

6000

Engi

ne T

orqu

e -N

m

360

380

1000 2000 3000 4000 5000Engine Speed – rpm

AVL 2.0l Turbo SIDI

2.0l Turbo SIDI(Production)

Increased full load performance allows longer final drive ratio for improved fuel economy

Ethanol Turbocharged Direct Injection

05

1015202530354045

Lower Heating Value (MJ/kg)

26.842.5

2/3

0

5

10

15

20

25

30

35

Heat of Evaporation (kJ/MJ)

33.8

8.0

4x

Regular GasolineEthanol

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Multiple Injection Strategy for E100 Cold StartTurbo SIDI

Injector

Fuel pressure 4 bar

Large droplets

Wall film

Intake valve

Single Injection

After SOI

After EOI

Significantly reduced wall film

Small droplets

Fuel pressure 40 bar

After SOI

EOI

New Multiple Injection

Fuel Pressure 40 bar

No wall film

Small droplets

Minimised Piston Wetting

Last Injection Late

First Injection Early

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Turbo SIDI - Benefits of E85 on Full Load Operation

E85RON91

2.5%

30°CA

150 bar

950°C

25%

MBT

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Dual Fuel Strategy

E85 provides significant octane benefit with DI due to high latent heat of vaporization and high octane rating

Allows knock-free operation at high CR and high BMEP with very high thermal efficiency

but…Low E85 heating value is a disadvantage

Dual fuel strategy uses E85 DI only as required to eliminate knock in a high CR gasoline engine.

Combines high load E85 octane benefit with part load gasoline heating value advantage

Provides maximum leveraging of available ethanol

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5

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1500 2000 2500 3000 3500 4000 4500 5000

Engine Speed [rpm]

BM

EP [b

ar]

10% E85

25% E85

50% E85

70% E85

0

5

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25

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1500 2000 2500 3000 3500 4000 4500 5000

Engine Speed [rpm]

BM

EP [b

ar]

10% E85

25% E85

50% E85

70% E85

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Dual Fuel Optimized E85 Engine vs. CompetitorsCycle Simulation Results Medium Duty Truck

+ 530 mpg E85+ 860 mpg Urea

0

2

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12

-25 -20 -15 -10 -5 0 5 10 15 20 25 30 35Metro Highway Fuel Economy Improvement (%)

Max

Gra

de in

6th

Gea

r at 6

5 m

ph (%

)

5.0l GTDI 91 RON5.0l GTDI FFV E855.0l Dual Fuel (gasoline mpg only)NA Gasoline Baseline 91 RONDiesel Target

Heating Value DisadvantageDownsizing/Downspeeding

Benefit

+3 Compression Ratio Increase, Advanced Combustion Phasing BenefitsGasoline Displaced By E85 At High Load

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Optical Engine - Split Injection for Catalyst HeatingComparison of Gasoline & E85 Flame Images

0

1001

100

FlameProbability

[%] Premixed Flame

Soot Flame

Gasoline DI

E85 DISignificantly

reduced smoke with E85

(oxygenated fuel) more calibration

freedom, increased efficiency

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Summary

Turbocharged SIDI is the most promising fuel economy technology for US:

Combines existing & proven technologies in a synergistic manner

Offers double digit fuel economy benefits

Much lower cost than diesel or hybrid

Can meet future emissions standards with inexpensive gasoline aftertreatment

Can be applied across an OEM’s entire engine portfolio in high volume

Provides benefits when operating on ethanol in Flex Fuel applications

Dual fuel (PFI gas + DI ethanol) concept new benchmark for SI fuel economy