1 

un Zhang, Yury Kalish, Marc Allain, Guangsheng Zhu, and Zhiping Han 

August 6, 2008 
Daimler Trucks 2 

Overview 

Details 

ced Fuel Injection System 

ustion Optimization 

ced Next Generation Control 
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 Objectives 

vancements in engine combustion systems using high-efficiency 

ustion (HECC) techniques to minimize cylinder-out emissions while 

engine fuel economy 

hermal efficiency with integrated engine and DPF+SCR 

ent system while meeting 2010 emission regulations 

n Enabling Sub-system 

es 

ed combustion system 

ogies 

 precise fuel injection 

EGR system technologies 

ed multiple input multiple output 

echnologies 
Daimler Trucks 4 

evelopment Approach 

Evaluation on truck operation for overall

 technology assessment and refinement 

 Conditions

outes

Tailpipe DPF 

SCR 

perating 

Integrated Analytical

 Simulation Tools 

Component Optimization

Steady State and Transient

 Dynamometer Testing

Integration of aftertreatment

 systems

Focus on integrated engine and DPF+SCR system, 

maximizing thermal efficiency 

while meeting 2010 emissions 
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Production engine Demo engine 

Current project: Combustion focus • High efficiency clean combustion • Dual-mode combustion • Variable fuel injection • Basic energy recovery • Advanced control 

ous project: 

 engine system

rovements 

Future project: complete engine system • Next gen. variable fuel injection • Multi-mode combustion • Variable breathing technologies • Advanced control • Advanced Energy recovery • Engine + DPF+SCR integration • Powertrain integration 

al Efficiency 

map 
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ed Fuel Injection System 

el injection with full flexibility of injection events 

d and being evaluated. 

ombines unit injectors and an accumulator rail 

ressure rail (up to 1000 bar) to provide early / late 

events 

or to provide high pressure short duration main 

d rail / unit injector operation for boot shape and close 

t injections 

ors to act as rail pressure source (no rail pump 

Delphi 
Daimler Trucks 7 

Nozzle Technology 

ed variable fuel injection technology into the program with high 

 to significantly enhance high efficiency clean combustion. 

tentials have been demonstrated analytically throughout different 

and loads 

ficant fuel economy improvement, ranging from 5% to 12% 

tantial NOx and soot emission reductions, ranging from 50% to 

 

nozzles have been procured, and assembled with advanced fuel 

 system. 

nch tests are underway, and the engine tests will follow soon. 
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p. 

riable Circular Orifice (MVCO) 

ction with conical spray 

y angle produced by 

Second phase injection with multi-jet spray and wide spray angle produced by MVCO Nozzle 
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Baseline

Optimum

d Combustion Development 

Automated selection of engine operating parameters for optimal emissions reduction 

combustion optimization 

injection and piston bowl 

mization 

mbustion concept exploration 

-mode combustion with advanced 

njection system and variable 

e technology 

e combustion control 

linder pressure sensor 

ation sensors 
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Combustion Optimization on PCCI 

t NOx gisfc Fuel economy 

improvement 

f g/kgf g/kW-hr % 

 3.24 233.3 -  5.27 201.1 13.8  7.76 223.0 4.4 

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

 1.98 212.9 8.7 

 3.72 208.1 10.8 

ve is to achieve similar soot and NOx emissions to that of the

ase but with a ~10% fuel consumption improvement 

10.8% fuel economy improvement was obtained while maintaining the same emission level as baseline. 

ting is just under way and preliminary results show 5.03% 

ovement. More tests will be reported soon. 
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CONTROLLER 

Model Based 

Controller 

Engine 

Model 

Engine 

Actuators 

Engine 

Sensors 

Position 

Feedback 

+ 

- 

Aftertreatment 

Model 

+ 

- + 

- 

Adaptation 

Emissions 

Model 

Real-Time 

Optimizer 


	
	


	


Physical and Virtual 
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 of Transient Calibration Optimization to FTP Cycle 

r designates one 

et point 

fficiency Improvement 

neration Model Based Controller 

And 15% NOx and 25% PM Reduction Simultaneously 
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 Calibration Optimization (FTP Tests) 

neration Model Based Controller breaks traditional BSFC

de-off Curve toward more Fuel Economy Improvement 
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Challenges 

allenges with variable nozzle technology are enormous 

t control 

sitivity to needle position – design may not be robust to tolerances 

 precision required in manufacture 

mode transition 

ust controls methodologies 

ion model based control 

tional power and speed in engine control unit 

egration complexity with real time engine, aftertreatment, and 

model that must be adaptive, robust, and precision 
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y 

ogressing well and aggressively. It is toward meeting the program 

 10% thermal efficiency improvement by 2009. 

enabling technologies with high potential returns 

 fuel injection system coupled with variable fuel injection nozzle 

ombustion system optimization 

control optimization 

nefits with advanced fuel injection system and variable nozzle 

ve been demonstrated. A new combustion strategy covering the 

ng range is emerging. 
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ledgements 

 of Energy Headquarters 

t Singh 

Gravel 

ergy Technology Laboratory 

onde 

Kooser