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INGAS INtegrated GAS Powertrain
INGAS Sub Project A3
„Boosted Lean Burn Gas Engine“
Review Meeting
07/04/2011 Brussels
RWTH, Martin Müther
M. Müther, RWTH
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INGAS INtegrated GAS Powertrain
Face to face meeting SP A3 – Brussels, 7 April 2011
Time
Item
Name (company)
14:30
Preamble with background
Motivations of face to face meeting
Coordinator Massimo Ferrera (CRF)
PM Stefania Zandiri (CRF)
14:40
FEV: executive summary of activities done in Period
1 and Period 2 versus effort planned and claimed
(main engine project vs side engine project)
Christoph Bollig (FEV), Bertold Hüchtebrock
(FEV), Michael Wittler (FEV)
15:00
OPEL: executive summary of activities done in
Period 1 and Period 2 versus effort planned and
claimed (main engine project vs side engine project)
Winfried Hartung (OPEL)
15:20
RWTH: executive summary of activities done in
Period 1 and Period 2 versus effort planned and
claimed
Martin Müther (RWTH), Philipp Simm (RWTH),
Sandra Glück (RWTH)
15:40
Discussion
All
16:30
End of reviewers meeting
17:30
Feedback of the reviewers & PO
M. Müther, RWTH
2
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
MM allocation RWTH
WP
Task
Start Dur.
End
[month [month [month Plan
]
s]
]
Y1
Y2
Y3
Open
MM
Compl
etion
[%]
Concept phase and design
specifications
WP A3.1
WP A3.1
A3.1.1
WP A3.1
WP A3.1
A3.1.2
A3.1.3
WP A3.1
A3.1.4
WP A3.1
WP A3.1
A3.1.5
A3.1.6
Definition of base engine and vehicle
with fuel consumption and performance
0
4
4
1.6
1.6
0
0
100
Design specifications of the power train
and draft lay out
0
12
12
9.6
9.6
0
0
100
Support for gas storage system
Draft packaging of power train and fuel
system
5
31
36
0
0
0
0
3
10
13
0.8
0.8
0
0
Definition of the aftertreatment system
4
5
9
0
0
0
0
First lay out of the control strategy
0
12
12
2.4
2
0.5
-0.1
100
7
9
16
8
4
4
0
75
7
6
13
0
0
0
0
7
12
19
3.2
1
3
-0.8
7
9
16
0
0
0
0
100
Components, Engine Design
and Procurement
WP A3.2
WP A3.2
A3.2.1
WP A3.2
A3.2.2
WP A3.2
A3.2.3
WP A3.2
A3.2.4
M. Müther, RWTH
Description
Modelling, design, procurement and rig
test of the boosting device
Modelling, design and rig testing of the
aftertreatment system
Modelling, design and rig testing of lean
burn combustion
Design of the power train and gas
system packaging
100
3
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
MM allocation RWTH
WP
Task
Description
WP A3.3
A3.3.1
WP A3.3
A3.3.2
Testing and improvement of the
boosting system on a test rig
Testing and improvement of the
aftertreatment system
A3.3.3
Single cylinder testing of the lean burn
combustion process for DI stratified
charge and port fuel
injection w/o EGR, decision of the
combustion chamber design
WP A3.3
A3.3.4
WP A3.3
A3.3.5
WP A3.3
A3.3.6
Y2
Y3
Open
MM
Compl
etion
[%]
Multicylinder testing under steady state
and transient conditions on a test bench
and improvement
of the engine
Design of the power train control
strategy
Testing of the influence of NG / H2
mixture an combustion
13
8
21
0
0
0
0
13
12
25
0
0
0
0
12
7
19
0
0
0
0
17
14
31
12.6
0
9
3.6
12
19
31
0
0
0
0
28
7
35
0
0
0
0
24
29
5
5
29
34
0
2.4
0
0
0
0
0
2.4
33
4
37
0
0
0
0
75
Vehicle Testing and Potential
Evaluation
WP A3.4
WP A3.4
WP A3.4
A3.4.1
A3.4.2
WP A3.4
A3.4.3
M. Müther, RWTH
Y1
Component, Engine and
Power Train Testing
WP A3.3
WP A3.3
Start Dur.
End
[month [month [month Plan
]
s]
]
Vehicle procurement
Vehicle calibration and testing
Potential evaluation and comparison
with state of the art technology
0
4
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
Task-No.
A3.1.1
Title
Definition of base engine and vehicle with fuel
consumption and performance
Main Activities
Simulation work: Process calculation (engine decision 
focus on peak firing pressure)
Main Result
A3 approach requires base diesel engine (pmax>150 bar!)
Engine: OPEL Z19DTH (diesel)
Vehicle: OPEL ZAFIRA
WP
Task
Description
WP A3.1
A3.1.1
Definition of base engine and vehicle
with fuel consumption and performance
M. Müther, RWTH
Start Dur.
End
[month [month [month Plan
]
s]
]
0
4
4
1.6
Y1
1.6
Y2
Y3
0
Open
MM
0
Compl
etion
[%]
100
5
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
Performance prediction referenced to 1.9 l (Z19DTH)
Cyl. Pressure
160
1
Mass Fraction Burned [-]
Intake Valve
140
Cyl. Pressure [bar]
Exhaust Valve
120
Ign. Timing
100
Compression
80
60
40
20
0
0
Engine Speed
60
120
180
240
Crank Angle [°]
4000 rpm
Rel. Air-Fuel Ratio
1,60
BMEP
17 bar
Efficiency (eff.)
37,1 %
Pmax @ CA
139 bar @ 191°CA
M. Müther, RWTH
300
360
0.8
0.6
0.4
0.2
0
120
150
180
210
Crank Angle [°]
240
Ignition Timing
157 °CA
Ignition Delay (0%-5%)
14,5 °CA
Combustion Duration (5%-95%)
31,5°CA
Combustion Centre (50%)
187 °CA
270
6
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
Task-No.
A3.1.2
Title
Design specifications of the power train and draft lay
out
Main Activities
Spark plug application using manufacturer CAD data and
investigation of base hardware. Spark plug dimensioning. Layout of
the fuel metering system and intake manifold modification. Specific
conversion work (dieselNG). Determination of CR and piston
design. Application of cylinder pressure indication device. Definition
and adaption of throttle. Definition of ignition system.
Main Result
Initially CR of 13. Squish height 0.8 mm. Spark plugs M12x1.25
(mm). Fuel injectors close coupled to intake ports via „spacer“construction. Pressure indication with KISTLER 6041 (8 mm). Throttle
from OPEL GT (2 l Turbo). Twin-coil ignition system (BOSCH).
WP
Task
Description
WP A3.1
A3.1.2
Design specifications of the power train
and draft lay out
M. Müther, RWTH
Start Dur.
End
[month [month [month Plan
]
s]
]
0
12
12
9.6
Y1
9.6
Y2
Y3
0
Open
MM
0
Compl
etion
[%]
100
7
INGAS INtegrated GAS Powertrain
Basic Diesel engine (Z19DTH): CAD-Data
 Spark plug application
 Analysis of CAD-Data
M. Müther, RWTH
8
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
Task-No.
A3.1.4
Title
Draft packaging of power train and fuel system
Main Activities
Constructional data exchange with OPEL.
P1: Integration of PFI system („spacer“).
Main Result
Definition of spacer-length. Integration of PFI is feasible
considering a spacer-length below 40 mm.
WP
Task
Description
WP A3.1
A3.1.4
Draft packaging of power train and fuel
system
M. Müther, RWTH
Start Dur.
End
[month [month [month Plan
]
s]
]
3
10
13
0.8
Y1
0.8
Y2
Y3
0
Open
MM
0
Compl
etion
[%]
100
9
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
Task-No.
A3.1.6
Title
First lay out of the control strategy
Main Activities
Definition of EMS. Definition of required sensors and
actuators. Definition of necessary functionalities (l-control
(lean!); EGR; SCR; …).
Study (recherche) on possible SCR strategies (NH3 dosing 
NH3 storage modelling).
P1: 2 MM‘s; P2: 0.5 MM.
Main Result
Input for EMS documentation supervised by FEV.
WP
Task
Description
WP A3.1
A3.1.6
First lay out of the control strategy
M. Müther, RWTH
Start Dur.
End
[month [month [month Plan
]
s]
]
0
12
12
2.4
Y1
Y2
2
0.5
Y3
Open
MM
-0.1
Compl
etion
[%]
100
10
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
Task-No.
A3.2.1
Title
Modelling, design, procurement and rig test of the
boosting device
Main Activities
Setup and matching (measurementcalculation) of GT
Power engine model for 1.9 l diesel based NG engine.
Performance calculation using TC maps from rig testing
delivered by FEV.
Main Result
High power/torque-targets linked with high air excess
(efficiency target) requires 2-stage TC in A3 approach.
WP
Task
Description
WP A3.2
A3.2.1
Modelling, design, procurement and rig
test of the boosting device
M. Müther, RWTH
Start Dur.
End
[month [month [month Plan
]
s]
]
7
9
16
8
Y1
Y2
4
Y3
4
Open
MM
0
Compl
etion
[%]
75
11
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
serial / serial
System specific actuators
•
HPC-BP
HPT-BP
High-Pressure-Turbine bypass
– low speeds -> controlled wastegate
function for High Pressure Turbine
– from mid speed on complete mass
flow bypassed toward Low Pressure
Turbine
•
High-Pressure-Compressor bypass
– back pressure valve
– on/off bypass (not active)
LPT-WG •
Low-Pressure-Turbine wastegate
– conventional function of turbine control
M. Müther, RWTH
12
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
Task-No.
A3.2.3
Title
Modelling, design and rig testing of lean burn
combustion
Main Activities
close linked to Task A3.1.2 (design specifications)
Generation of CAD files regarding spark plug application, 1st
piston modification on base diesel piston (e=13), intake
manifold upgrading („spacer“) and other specific conversion
aspects (i.e. removal of diesel HP pump). Layout of 2nd CR
and corresponding piston design (1312).
Main Result
Transfer of CAD data  FEV regarding hardware machining.
WP
Task
Description
WP A3.2
A3.2.3
Modelling, design and rig testing of lean
burn combustion
M. Müther, RWTH
Start Dur.
End
[month [month [month Plan
]
s]
]
7
12
19
3.2
Y1
Y2
1
Y3
3
Open
MM
-0.8
Compl
etion
[%]
100
13
INGAS INtegrated GAS Powertrain
Piston design (CR=13CR=12 (Final))
CR=13.0
CR=12.0
 Increased bowl-diameter (‚open bowl‘)
 Increased pocket-width
 Unchanged Squish Height: 0.83 mm
M. Müther, RWTH
IMG_2592.jpg
K:\B_Technical_Status\04_Engine\044_Kolben\Fotos\20090605
IMG_0004.jpg
K:\B_Technical_Status\04_Engine\044_Kolben\Fotos\20100601
Reduced squish
area share
 Machining at FEV
14
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
Task-No.
A3.3.4
Title
Multicylinder testing under steady state and transient
conditions on a test bench and improvement of the engine
Main Activities
Definition of NEDC relevant operating points referenced to ZAFIRA (6
modes). Integration of DoE methodology into test planning and result
analysis. 3-dimensional experiment space (Inj.-Tim., Ign.-Tim., l).
Definition of constraints. Test bench measurements.
Setup and application of SW-tool for map-optimization assuming
predefined szenarios. Result analysis.
Main Result
Operation points in lower load area identified (6 modes). All
hypercubes for DoE testing created. Modified SW tool generates
accurate maps.
WP
WP A3.3
M. Müther, RWTH
Task
Description
A3.3.4
Multicylinder testing under steady state
and transient conditions on a test bench
and improvement
of the engine
Start Dur.
End
[month [month [month Plan
]
s]
]
17
14
31
12.6
Y1
Y2
0
Y3
9
Open
MM
3.6
Compl
etion
[%]
75
15
INGAS INtegrated GAS Powertrain
MCE-Testing
Definition of Operation Points
Steady-State-Replacement-Test (NEDC)
BMEP vs. Eng.-Speed
14.00
12.00
Reference:
ZAFIRA (1.9 CDTI)
6 Speed Gearbox
Modes
Punkte
10.00
S Idle: 326 s
S Push: 138 s
S Part Load: 716 s
8.00
6.00
Highest Relevance
Additional Points
4.00
 MAP-Completion
2.00
0.00
800
Breakdown (Modes)
Mode
1000
Urban: 3x
M. Müther, RWTH
1200
1400
1600
1800
Extra-Urban: 1x
2000
2200
Eng.-Speed
2400
[1/min]
BMEP
[bar]
Time Slice
[s]
1
1050
3.39
67
2
3
4
5
6
1378
1535
1754
1867
1960
1.44
3.21
6.19
0.86
11.06
129
140
157
202
21
16
14.00
12.00
10.00
8.00
6.00
INGAS INtegrated GAS Powertrain
Engine Testing / Procedure
Hypercube  3-dimensional experiment space (DoE-Methodic)
Due to the significant impact
of the NG-injection-window
on engine behaviour, this
parameter has been included
in the DoE-Testing !
Operation point (Mode 4):
n=1754 rpm
BMEP=6.2 bar
ZZP
Variables:
 Ignition Timing (ZZP)
 Rel. A/F-Ratio (LAM; l)
 End of NG-Injection (EOI)
 Hypercube-Parametrisation
is Mode-specific !
M. Müther, RWTH
17
INGAS INtegrated GAS Powertrain
MCE-Testing
MAP-Generation / Procedure
Setup of DoE-Modell for each defined operation point
considering operation limits
Testing
Stationary MCE-Testing ( DoE-Parameterisation)
Calculation
DoE-Analysis  Modell-Calculation / Generation of functionalities
Engine MAP-Generation assuming different szenarios




TExhaust > Limit value (presetting)
BSFC, NOx, HC min.
Ignition Timing (presetting)
…
(Weighted) Combination
possible
Projection on cycle (i.e. NEDC) (Presetting: Vehicle & gear box)
M. Müther, RWTH
18
INGAS INtegrated GAS Powertrain
Review meeting – Brussels, April 2011
BACKUP
 Slides concerning documentation of activities
M. Müther, RWTH
19