Heavy Truck Engine Developme

DE-FC05-00OR22805

Houshun Zhang, Ph.D.

Detroit Diesel Corporation

May 21, 2009

This presentation does not contain any proprietary, confidential, or otherw
Overview

• Project start: February 2007• Project end: March 2010• Percent complete: 75%

• Limitations of fue• Lack of cost-effe

management and techniques;

• Inadequate integ

engine and aftert

• Total project funding

– DOE: $5 million– DDC: $5 million

• Funding received in FY08

• $1.45 million

• Funding received in FY09

• $0.2 million

Timeline

Budget

Barri

• Oak Ridge Natio• Delphi: Fuel inje• Atkinson: Contro• WERC: Combus• Quantlogic: Fue• Continental/Woo

sensors

Partn
Objective

• Explore advancements in engine combustion systems u

clean combustion (HECC) techniques to minimize cylindwhile optimizing engine fuel economy

Multi

• Emphasis on Enabling Sub-system 

Technologies

- Advanced combustion system 

technologies 

- Flexible, precise fuel injection - Air and EGR system technologies - Advanced multiple input multiple 

output control technologies 
Milestones

Month/Year Milestone or Go/No-Go DecisionAugust - 2008 Go/No Go Metric – Successfully complete d

necessary individual subsystems to meet thMilestone: 5% thermal efficiency ImprovemStatus: Completed and accepted by DOE in 

Sept - 2009 Milestone - Complete engine systems integ

controls and effective synergies with aftertr

Status: On schedule
System Development Approach

Example Operating Conditions 

Over Truck Routes

RPM

LOAD (%)

Tailpipe

DPF

SCR

Selecting road-load operating conditions

Integrated Analytical 

Simulation Tools 

Compo

Steady Sta

Dyna

Evaluation on truck operation for overall 

technology assessment and refinement 
Performance and Accomplishments

• Advanced fuel injection system with variable nozzle• Innovative combustion system optimization• Next generation control logic• Real time combustion control
DDC engine at ORNL

Advanced Fuel Injection System

• Demonstrate potential of advanced injection system for ac

clean combustion (HECC) mode operation for engine conHD drive cycles.

• Characterize emissions/efficiency for multiple high efficien

strategies.

Delphi

Bosch’s ACRS 
Micro-Variable Circular Orifice (MVCO)

First phase injection with conical sprayand narrow spray angle

Second phase inand wide spray a

• Early analytical simulations demonstrated substantial thermal eff

dual combustion mode realized by this variable nozzle technolog

• More flow bench tests of Quantlogic nozzle are underway to simu

operation 

• Significant challenges exist in machining precision and needle co

Initial feasibility evaluated on successful fuel bench test o
Multi-Stage Model Combustion

• Use of dual injectors is made to explore 

multi-mode combustion concept based on University of Wisconsin’s extensive research and development

• Each injector is controlled by its own 

advanced flexible fuel injection system. 

• Each injector system will be operated 

based on individual combustion mode requirements, such as spray angle, timing, phasing, fueling split in order to achieve optimal combustion efficiency

• The combustion analysis using KIVA on a 

production engine is being conducted

• Key technical challenge is whether two 

injector configuration can be fitted into the production engine cylinder head. Comprehensive CAD for feasibility study is being conducted.

Two injector design study initiated, to ensure continuation of tcombustion development independent of MVCO nozzle maturit
Combustion Optimization on PCCI

run Soot NOx gisfc Fuel economy 

improvement

g/kgf g/kgf g/kW-hr

%

base 0.23 3.24 233.3 -

1 0.12 5.27 201.1 13.8

2 0.41 7.76 223.0 4.4

----- ----- ----- ----- -----

11 0.33 1.98 212.9 8.7

12 0.19 3.72 208.1 10.8

• Advanced combustion simulation tool (KIVA) is used for PCCI 

wide range of injection timing, phasing, EGR rate, and boost.

• Analytically demonstrated potential for 10.8% fuel economy im

low load and low speed point while maintaining the same emis

• These analytical results provide immediate guidance to explore 

experimentally for optimal thermal efficiency while maintaining tlevels.

• It can significantly reduce development efforts with proper use o

Combustion modeling leads the way to experimental eval
PCCI Testing with Help of Combustion Analyses 

• Flexible fuel injection system allows to follow up analytical set 

timing, fueling, phasing, and multiple injection events, thus optperformance and emissions simultaneously toward the program 

• Preliminary engine tests demonstrate 5% thermal efficiency be

maintaining about the same or lower emissions (NOx and PM)

• More engine testing is still underway in the hope to achieve the 

efficiency benefits as analytical work predicted

Analytically developed roadmap allowed to meet August 2008 
Uses feedback frfidelity engine mtime optimizerCalibration inherOptimization captime Æ Reduced engineering effor

Next Generation Controller

• Next Generation Controller (NGC) consists of sophisticated forward and i

real time optimizer and model based engine model

• Inverse controller produces ‘optimized’ control inputs for any engine spee

given the instantaneous engine operating parameter feedback, as well as history of the engine and the trajectory of the control inputs.

• Engine model produces fully transient engine performance and emissions 

that are then used by the Real-Time Optimizer to produce optimal time-ba
0.9951.0001.0051.0101.0151.0201.0251.030

0.60 0.65 0.70 0.75 0.80 0.85 0.90 0

Integrated Normalized Brake Specific NOx Emission

Integrated Normalized Brake Thermal Efficiency MCM Baseline NGC Baseline NGC with real time opti

NGC with real time optiNGC with real time optiNGC with real time optiNGC with real time optiNGC with real time opti

Immediate impact on engine performance with 37% NOx reduction and over 1% thermal efficiency improvement TE optimization

Next Generation Controller Optimization Transient Cycle 1 

CO optimization

NOx optimization

• Next Generation Controller (NGC) can easily set optimization objectives ta

application needs

• Advanced forward and inverse controllers plus real time optimizer and sop

based engine model provide multi-task optimization with multi-objectives s
Next Generation Controller Optimization Transient Cycle 2 

Immediate impact on engine performance with 75% NOx reduction and over 1% thermal efficiency improvement

Continuous thermal efficiency improvement with different real time optimizer strategies

• Next Generation Controller (NGC) can specifically target thermal efficiency 

toward program goal while simultaneously reducing emissions significantly

• 75% NOx reduction and 2.7% thermal efficiency improvement are obtained

B

NGC is still in the early development, but already shows pro
Comparison of FTP NOx Emissions for Baseline Control and 

• NGC shows significant reductions in NOx over the FTP cycle.

• PM maintains similar level

MCM – Motor Control Module
Real Time Combustion Control

• Real time combustion control

- Objective is to use closed loop control of 

combustion to achieve the necessary level of combustion timing control

- Start of Ignition detection (SOI) is one of 

approaches

• Implementation of SOI determination

- The third derivative can be calculated or 

determined by a simple circuit

- To speed up the control loop, a hardware 

implementation was selected

- Each functional group implements one 

differentiation on the input signal

- The maximum value of the final output 

provides the SOI

• Validation and tests are underway

+

-

+

-

+

-

in

out

MCM

Integration of sensors on the engine cylinder head is com
Future Work

• Advanced next generation fuel injection system

- Fully explore and validate all potential features of fuel i

• Variable injection nozzle technology 

- More flow bench validations are underway- Quantify the technical barriers before moving to the ne

• Multi-mode combustion mode exploration with enabled an

injection for optimal thermal efficiency

• Next generation control development 

- Consolidate and validate the current developed contro

efficiency optimization

- Develop more robust and more reliable control system

• Transient combustion and control development

- Real time combustion control using cylinder pressure s
Summary

• Program is progressing well toward meeting the program 

efficiency improvement.

• Experimentally demonstrated 5% thermal efficiency impro

guidance of advanced combustion analysis

• Advanced analytical tools, if used properly, can play signif

shortening development cycle. 

• Significant progress was made in next generation control 

substantial benefits in both thermal efficiency and emissio
Acknowledgements

• Department of Energy Headquarters

- Gurpreet Singh- Roland Gravel

• National Energy Technology Laboratory

- Carl Maronde- Jeffrey Kooser