Thermal management – Hot on the trail of emissions reduction Alex Morein Michael Weiss Combustion energy Drive Energy 100% ? Losses > 80% of energy lost 1 Schaeffler Symposium 2014 Alex Morein Usual suspects Energy Requirements for Combined City/Highway Driving Engine Losses: 70% -72% thermal such as radiator, exhaust heat, etc. (60%-62%) combustion/enrichment (3%) friction (3%) pumping (4%) Parasitic Losses: 5% - 6% Drive train Losses: 5% - 6% US Dept. of Energy 2 Schaeffler Symposium 2014 Power to Wheels: 17% - 20% http://www.fueleconomy.gov/feg/atv.shtml Alex Morein Thermal management: why now? • Global regulations • Downsizing • High heat output components • Downspeeding • Increased cooling system flexibility • Lean assembly 3 Schaeffler Symposium 2014 Alex Morein Shrinking ideal operation zone Temperature System temperature limit Ideal Zone Nominal temperature Temperature flexibility Thermal Mass 4 Downsizing Downsizing Schaeffler Symposium 2014 Alex Morein Traditional temperature Outdated thermostat 80 Downsizing? Flexibility? Oct. 1, 1934 5 Schaeffler Symposium 2014 Alex Morein X X Schaeffler thermal management module First on the market SOP July 2011, Audi EA888 Gen.3 Function Coolant control Flow distribution Advantages shorter warm-up phase increased thermal efficiency CO2- and fuel consumption reduction increased interior comfort 6 Schaeffler Symposium 2014 Alex Morein To block Block return Engine oil HX video here To radiator Radiator return 7 Schaeffler Symposium 2014 Alex Morein Trans HX, cabin return Audi performance Flexibility Precision: +/-2°C Time t s 8 Schaeffler Symposium 2014 Alex Morein Vehicle speed v in km/h Engine temperature T in °C 2-4% CO2 Reduction System flexibility ● Customizable – Number ports Bypass / EGR Radiator feed – Flow rates – Diameters Sensor & Drive Engine connection Commonized actuator components Interior heating 9 Schaeffler Symposium 2014 Alex Morein CAFE demonstration vehicle 10 Schaeffler Symposium 2014 Alex Morein Comparing warm up strategies Base Engine Fuel consumption in hg/h Zero-Flow Zero-Flow + Oil Heating Hot engine Delta (fuel savings) Warm-up Warm-up time time reduction reduction 30% 10% Test Point: Time t in s S. Grams, KIT 11 Schaeffler Symposium 2014 Alex Morein Increasing cabin comfort 70 Seat temperature T in °C 60 50 Pump delayed 210s 40 30 Pump delayed 120s Pump on 20 Pump pulsating 10 0 100 200 300 400 500 Time t in s 12 Schaeffler Symposium 2014 Alex Morein 600 700 800 System simplification Radiator feed Interior Heating Head Block Bypass (Turbo) 13 Schaeffler Symposium 2014 Alex Morein 1.0L Gasoline engine, split cooling Main Thermostat Split cooling thermostat 14 Schaeffler Symposium 2014 Alex Morein 1.0L Gasoline engine, split cooling 15 Schaeffler Symposium 2014 Alex Morein Engine performance test bench setup 16 Schaeffler Symposium 2014 Alex Morein Expectations Exhaust valve bridge Upper cylinder liner Middle cylinder liner No thermal management Zero flow Zero flow & oil heating S. Grams, KIT 17 Schaeffler Symposium 2014 Alex Morein Engine performance test results Exhaust Valve Bridge Cylinder Liner-top end Cylinder Liner-center Block open Head open Zero-Flow Engine Oil Temp. 18 Schaeffler Symposium 2014 Alex Morein Valve angle Valve angle Radiator Control Exhaust temperature test results 440 with TMM Temperature T in °C 420 400 380 without TMM 360 340 320 300 0 100 200 300 400 500 600 700 Time t in s • Higher exhaust gas temperature: faster catalytic converter light-off 19 Schaeffler Symposium 2014 Alex Morein Retrofit and measurement of a 1.6L I4 20 Schaeffler Symposium 2014 Alex Morein Meaurement results-1.6L I4 Rapid warmup Temperature T in °C Zero flow Flexibility 15° 130s Retrofit Schaeffler Symposium 2014 xy Time t in s Base engine 21 Hot operation Alex Morein Reduction Emission Benefit in NEDC (warm-up only) 22 Schaeffler Symposium 2014 Alex Morein Solving the puzzle • Cooling systems growing in complexity • Higher level of vehicle integration, including powertrain • Push for lean assembly efforts • System-level solution required 23 Schaeffler Symposium 2014 Alex Morein ‟ There is nothing more deceptive than an obvious fact. ” Sherlock Holmes per Sir Arthur Conan Doyle 1859-1930