POWERTRAIN STRATEGIES FOR THE 21ST CENTURY
July 22, 2015
Paul Whitaker
AVL Powertrain Engineering Inc.
AVL
“Anstalt Fuer
Verbrennungskraftmaschinen
List” (Institute For Combustion
Engines)
Expertise
Three Divisions …
One Globally Unique
Company
Powertrain
Engineering
Integrated
Powertrain Solutions
Advanced
Simulation
Technologies
Instrumentation
&
Test Systems
2
AVL POWERTRAIN ENGINEERING AT A GLANCE
3750
7500
3
Increased Powertrain Diversity:
The Five Basic Elements of the Future Powertrain
• Storage capacity
• Energy density
• Recharge time
• ...
• Gasoline/diesel
• Valvetrain
• PFI/GDI
• NA/Boosted
IC Engine • …
Battery
• CVT
• DCT
• 8/9/10 Speed
•…
Transmission
• Torque output
• Voltage requirements
• Efficiency
•…
Electric Motor
Control
System
• ECU Complexity
• TCU Complexity
•…
4
Increased Powertrain Diversity:
The Five Basic Elements of the Future Powertrain
• Storage capacity
• Energy density
• Recharge time
• ...
• Gasoline/diesel
• Valvetrain
• PFI/GDI
• NA/Boosted
IC Engine • …
Battery
• CVT
• DCT
• 8/9/10 Speed
•…
Transmission
• Torque output
• Voltage requirements
• Efficiency
•…
Electric Motor
Control
System
• ECU Complexity
• TCU Complexity
•…
5
Increased Powertrain Diversity:
The Five Basic Elements of the Future Powertrain
NA PFI Engine with
9 Speed Automatic Transmission
IC Engine
Battery
Transmission
Electric
Motor
Control System
6
Fuel Economy Improvement By Transmission
Measures
NA PFI
6 speed AT
Traction Force - N
BSFC < 240 g/kWh
Energy consumed
(WLTC)
7
7
Traction Force - N
Fuel Economy Improvement By Transmission
Measures
NA PFI
6 speed AT
NA PFI
9 speed AT
BSFC < 240 g/kWh
BSFC < 240 g/kWh
Energy consumed
(WLTC)
Increased no. of gears
8
8
Increased Powertrain Diversity:
The Five Basic Elements of the Future Powertrain
Turbo GDI Engine with
6 Speed Automatic Transmission
IC Engine
Battery
Transmission
Electric
Motor
Control System
9
Regional Market Share
of Turbocharged Gasoline Engines
• Share of boosted
Gasoline engines will
dramatically increase
especially in Europe
Share of Charged Engines - %
• China higher share
than US
Europe
China
North
America
Japan
Korea
Source: IHS Q2/2013
• Various GDTI
launches also in
Japan
Downsizing / downspeeding based on
boosted engines is
already the mainstream technology
for FE improvement
10
Regional Market Share
of GDI Engines
Share of GDI Engines - %
North
America
Europe
Korea
• Share of GDI will
significantly
increase in most
major markets
• In Europe and US
GDI will become
dominating
Japan
China
• China, Korea and
Japan expected to
gain app. 40% by
2020
Source: IHS Q2/2013
11
Fuel Economy Improvement With Gasoline
Engines - Turbocharging
BMEP
limit of
NA
BSFC
CHARGING
State-of-art
Charged
NA
Turbocharged
Engines
Extending area
of low BSFC by
Boosting and
Downsizing
Schematic
BMEP
12
Traction Force - N
Fuel Economy Improvement With Gasoline
Engines - Turbocharging
NA PFI
6 speed AT
Gen 2 TGDI
6 speed AT
BSFC < 240 g/kWh
BSFC < 240 g/kWh
Energy consumed
(WLTC)
CHARGING
13
Increased Powertrain Diversity:
The Five Basic Elements of the Future Powertrain
Turbo GDI Engine
+ 6 Speed Automatic Transmission
IC Engine
Battery
Transmission
Advanced Turbo GDI Engine
+ 9/10 Speed Automatic Transmission
+ BSG with start/stop
IC Engine
Battery
Electric
Motor
Control System
NA PFI Engine with VCT
+ 9 Speed Automatic Transmission
IC Engine
Battery
Transmission
Electric
Motor
Control System
Transmission
Electric
Motor
2015
Control System
2020 and beyond
14
Evolution Of Turbocharged GDI
BSFC < 240 g/kWh
260
30
0
0
0
12
10
33
300
14
27
BMEP
BMEP 4 cyl [kPa]
BSFC
80
75
70
65
60
55
50
45
40
35
30
25
0
16
240
250
8
260
270
2
6
4
300
360
2
0
500
BMEP
20
27
18
4
Miller Cycle
Schematic
20
270
6
Gen 3 TGDI
22
8
Gen 2 TGDI
15
Next generations
of TGDI significantly extend
sweet spot area
10
24
330
400
500
700 1000
BSFC
[g/kWh]
1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
N [1/min]
Engine Speed
15
Miller TGDI Democar
Golf 7 HiEff
1,6l TGDI; 104 kW/4500 rpm
Cooled Exhaust Manifold
Increased Compression Ratio
Miller Cycle
Cooled Forced EGR (HP)
Engine min. BSFC <210 g/kWh
90 g/km CO2 in NEDC
High Pressure EGR
Non return valve
Electric
Supercharger
Boost pressure sensor
Air mass flow meter
Throttle
body
EGR valve
EGR
cooler
Turbocharger
Lambda sond
EGR / Air
Rail
EGR / air
feed pipe
AVL Patent Application
Throttle
body flange
EGR /
air rail
16
Evolution Of Turbocharged GDI
Miller TGDI
6 speed AT
BSFC < 240 g/kWh
Gen 2 TGDI
6 speed AT
BSFC < 240 g/kWh
Energy consumed
(WLTC)
refined engine
technology
17
Fuel Economy Improvement - Hybridization
+
Recharging
Hybridization allows
electric driving at low
power requirements
where the ICE would
otherwise operate
inefficiently
18
Development Trends TGDI
Specific Power vs. Production Volumes
GASOLINE Turbo DI – Global Engine Production vs. Specific Power
200
190
180
170
Spec. Power [kW/l]
160
150
1 Mio
Units produced
140
130
120
110
100
90
80
70
60
50
40
2007
2008
2009
2010
2011
2012
2013
2014
2015
19
Development Directions
Gasoline Engines
Gasoline Engine
“Image / Top
FE-Concepts
Performance“
Concepts
Miller+High CR+ext.EGR
BSFCmin  200*)g/kWh
P = 65 - 80 kW /l
BMEP = 17 - 20 bar
Mainstream 2013
BSFCmin
235*)g/kWh
P = 60 - 90 kW /l
BSFCmin >230*)
g/kWh
P = 110 - 180 kW /l
BMEP = 28 - 30 bar
BMEP = 17 - 25 bar
either - or
*) … 2l displacement
20
AVL 2013 High Performance TGDI R&D
200 hp/l Alfa Giulietta
1.75l GDI TC Fam B engine reinforced
Longer exhaust camshaft
K16 Monoscroll TC
Valeo Electric Supercharger (12V)
Flap Exhaust System
350 HP / 6500 rpm (148 kW/l)
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
1000
450
BMEP AMG
400
350
300
250
200
Boost
pressure
BMEP FPT E-Boost
BMEP FPT Low
Power
Power - HP
BMEP - bar
410 Nm / 3500 rpm
AMG
FPT E-Boost
FPT Low Power
150
2000
3000 4000 5000
Engine Speed - rpm
6000
100
7000
21
AVL 2015 High Performance TGDI R&D
200KW/L
1.75l GDI TC Fam B engine
Reinforced crankshaft, conrods, pistons
Revised valvetrain
Biturbo charging with dual compressor
Electric Supercharger (48V)
Flap Exhaust System
474 HP / 8000 rpm (200 kW/l)
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
1000
CAC aftercooling
-Air, water, iCAC:
tbd with package
500
BMEP
450
400
350
300
250
200
Main CAC
Power
interstage
CAC
Boost on demand (trans.)
Power - HP
BMEP - bar
416 Nm / 8000 rpm
-eSC (pre TC)
e-m
BlowBy / PCV
-Constant crankcase
pressure control valve
Bi-turbo
-1 stage expansion FG-turbine
-2 stage compressors
-Interstage cooling (LT-circ.)
Catalyst „RDE-safe“
-Small section / cat heating, low load
-Big section / high power & speeds
AVL patent
Flap controlled
EX-line „controlled flow“
-Acoustics vs. backpressure
AVL patent
2000
3000 4000 5000 6000
Engine Speed - rpm
7000
150
8000
PK 22
Variable Compression Ratio – Switchable Con Rod
AVL patent application
23
Light-Duty Diesel
U.S. application will only become tougher due to more stringent emissions!
Cooled
EGR
2000+ bar
FIE
VGT
Fuel
injection
Urea
solution
T
T

LEV III Fleet Average NMOG+NOx Standards
NOx
T
p
DPF
DOC
UREA
SCR
NOx
NH3
Cat
NH3
• Diesel has always been the
benchmark for efficiency
• Tier 3/LEV 3 emissions will
make diesel even more difficult
to implement in the US
− Costs will increase
− Efficiency may reduce
24
Increased Powertrain Diversity:
The Five Basic Elements of the Future Powertrain
Gasoline Powersplit Hybrid
Electric Vehicle
IC Engine
IC Engine
Battery
Battery
Transmission
Electric
Motor
Transmission
Electric
Motor
Control System
Control System
Range Extended Electric Vehicle
IC Engine
Battery
Transmission
Electric
Motor
Control System
25
CO2 Reduction – Sedan in WLTP
Base Engine: 1.4L, 4-cyl, TGDI, Start/stop, smart alternator control
120
116
115
CO2 – g/km
110
105
100
95
90
88
US 2025*
85
80
75
EU 2025**
75
70
65
1.4 TGDI 200 g/kWh 170 g/kWh
State of Art
*passenger car
**proposed upper limit
 Engine needs to
be operated as
close as possible
to BSFC min
 BSFC min needs
to be improved
 Additional
measures
required on the
vehicle side
 Significant
technical
challenges lie
ahead
26
Thank You
for Your
Attention
www.avl.com
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www.avl.com
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