Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, T i Lingotto Li tt Fiere Fi 22 aprile 2015 Diesel Passenger Car : Target 2020 Ing. Francesco MONTEAMARO Logo presentatore Diesel Passenger Car: Target 2020 1 Drivers & Megatrends for Powertrain 2 System Strategies Diesel 3 E l ti off electrification Evolution l t ifi ti 4 Quality Requirements & Challenges 5 Summary Turin, 22.04.2015 Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 2 Logo presentatore Diesel Passenger Car: Target 2020 Drivers for Powertrain Development Legislation Market Soft Factors Emission/Diagnosis Legislation Crude Oil reserves ⇩ Annual Mileage ⇩ CO2 / Green House Gases Legislation Fuel Price ⇧ EV Incentives Battery Price ⇩ Willingness to pay Fuel Economy Incentives & Taxation EV Infrastructure I f improvements New Technology B i Business f Green for G Image I E-Motion Need for further IC Engine improvements and alternative Powertrain Technologies will lead to increased Powertrain diversification Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 EV: Electric Vehicle 3 Logo presentatore Diesel Passenger Car: Target 2020 Megatrends affecting Diesel Systems Energy Efficiency CO2 fleet targets for PC, fuel efficiency for CV Connectivity & Web3.0 New business models Powertrain P t i Competition and diversification, TCO, mobility concepts, concepts Downsizing Market Growth in Asia Pacific Increasing growth of small vehicle segment Tightened Emissions and OBD RDE, WLTC and new sensors Innovations HPT, Diesel Hybrid, WHR G WHR, Gas, NSC NSC, … EGT Diesel business enabler, cost challenge Product Cost and Technology Competition High end / low end Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 4 Logo presentatore Diesel Passenger Car: Target 2020 Requirements & Challenges CO2 & E Emission i i L Legislation i l ti llead d tto increasing complexity of diesel systems Worldwide usage and different fuel quality add complexity for engineering Increasing focus on EU VI Development times Variant handling Cost $ RDE Technical and Economical Reasons require advanced Quality & Cost Effective Solutions Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 5 Logo presentatore Diesel Passenger Car: Target 2020 Diesel Engine System Optimization Strategy Compression ratio (≈16) optimized (Trade-off: CO2 Fuel consumption/HC,CO) CO2 Air system and turbocharger transient optimized improved TC efficiency @ part load optimized, HP- and LP-EGR system (flexible fraction) + efficient EGR cooling CRS 2200-2500 bar, in future up to 3000 bar for highest spec. power (PC Top) or part load BSFC CO2 optimization (with reduced HFR) Digital Rate shaping (DRS) for NVH and Fuel CO2 Consumption reduction CO2 Reduced HC critical nozzle volume SCR based NOx Aftertreatment to achieve Euro 6 + RDE depending on EU CO2 RDE and US Requirements Additional heat up measures (if required) HP-/LP-EGR: High/low pressure exhaust gas recirculation; TC: Turbo charger; CRS: Common rail system; HFR: Hydraulic flow rate; NSC: NOx storage catalyst; SCR: Selective catalytic reduction Holistic system optimization approach required to fulfill future norms Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 6 Logo presentatore Diesel Passenger Car: Target 2020 Di Diesel l 3% 1 2% 1-2 4-5 % low PFP D5 1-2 % 8-12% 2 3% 2-3 Dethrottl. Frict. red. CRP/ HF adapt. Downsized cyl.-# D5 93 Step 2 2020 NEDC EU6 ff D4 = Best-in-Class Diesel 2012 1.6l, 4 Cyl., 4V, FIE 2000 bar, t/c VNT SCR VNT, SCR, MT6 D5 = 1.6l, 4 Cyl., 4V, FIE <2200 bar, t/c VNT, Friction Reduction (engine), LP-EGR, De-throttling, CRP/HF-adaption, SCR, MT6 LPEGR Step 1 Compact Reference Base: CW 1400 kg, 100 kW, NEDC T/C frict. Option 1 4 cyll. 1.6l T/C, SCR R, EU6 Best-in-class Diese el, 2012 1-2 % D4 103 3% D6 12-17% Option 2 CO2 re eduction NEDC: CO2-Reduction Packages (Compact Class, 100 kW, 2020) D6 88 CRP/HF= common rail pressure / hydraulic flow | LP-EGR= low-pressure EGR system Frict. Red. = friction reduction | De-Throttl. = dethrottling engine | PFP= low-peak firing pressure | T/C = turbocharger | SCR = selective catalytic reduction D6 = 1.6l / 1.2l, 4V, FIE <2500 bar, t/ VNT, t/c VNT Friction F i ti Red.-Pack R d P k (engine, t/c), LP-EGR, De-throttl., CRP/HF-adaption, SCR, MT6, Opt. 1: Low-PFP, 1.6l ; Opt. 2: 3 Cyl., 1.2l w/ Bosch contribution in HW or SW Diesel powertrains offer further CO2-reduction potential of up to 17% Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 7 Logo presentatore Diesel Passenger Car: Target 2020 NEDC: CO2-Reduction Reduction Packages (Compact (C t Cl Class, 100 kW kW, 2020) Diesel 2% 10-12% 1-2 1 2% 5-10% Start Stop Friction reduction (e.g. beltdrive, …) D6 12-17% D4 103 Powertrain measures D7 15-21% Stop CRP/ HF adv. 3% SSC1 1-2% Start IDC1 BRS @ belt + SSC Stop SiG1 D6 88 Step 3 Compact 2020 NEDC EU6 ff Reference Base: IWC 1400 kg, 100 kW, EU6, NEDC driving cycle Start DRS-II 4 cyl. 1.6l T/C, S SCR, EU6 Be est-in-class Diiesel, 2012 CO2 reduction n Engine measures D6 = 1.6l/1.2l, 4V, FIE <2500 bar, t/c VNT, Friction Red.-Pack (engine, LP-EGR, De(engine t/c), t/c) LP-EGR throttling, CRP/HF-adaption, NSC/SCR, MT6, Low-PFP D7 = 1.6l/1.2l, 4V, FIE 2500 bar, Friction Red.-Pack (engine, belt drive), digital rate shaping , D th ttli De-throttling, CRP/HF CRP/HF-adaption, d ti D7 84 CRP/HF= common rail pressure / hydraulic flow | LP-EGR= low-pressure EGR system | Frict. Red. = friction reduction | De-Throttl. = de-throttling engine | PFP= low-peak firing pressure | T/C = turbocharger | NSC = NOx storage catalyst | SCR = selective catalytic reduction | DRS = digital rate shaping | SiG = Start in Gear | IDC = Idle coasting | SSC = start stop coasting w/ Bosch contribution in HW or SW NEDC / Compact: Non HEV Diesel Cars have potential to stay below CO2 level of 80 g/km ! Evoluzione delle propulsioni 1 assumption: accepted as eco innovation Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 8 Logo presentatore Diesel Passenger Car: Target 2020 Segment Specific CO2-Strategies, Europe 2020 250 Market EU EU Q1/2014 2012 Market 230 Best-in-Market Gasoline 01/2014 210 Best-in-Market Diesel 01/2014 CO2 g/km 190 170 Dots show best in Diesel market vehicles in Gasoline EU Q1/2014 150 HEV 130 HEV BRS 90 BRS 70 50 800 Entry Class (A/B) 1000 1200 Standard Class (C/D) 1400 1600 1800 PHE EV PHE EV 110 Top /SUV Class (E/F) 2000 2200 2400 kg Entry (A/B): 1040-1100 kg, 60 kW; Standard (C/D): 1330-1400 kg, 100 kW; TOP(E/F): 1800-2000 kg, 150 kW (4 cylinder)-190 kW (6 cylinder); All: NEDC Segment specific solutions required to achieve CO2 targets in 2020: Entry Class w/o electrification, Standard Class w/ BRS and TOP/SUV Class w/ Diesel-PHEV BRS: Boost Recuperation System; (P)HEV = (Plug (Plug-in) in) Hybrid Electric Vehicle Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 9 Logo presentatore Diesel Passenger Car: Target 2020 Evolution of Electrification Innov vation line Bosch innovation line to support future market requirements! Start/Stop p Coasting Advanced Start/Stop 4 6 0 x 1000 / min 120 Start 4 Baseline: Start/Stop 2 6 6 Start 80 A 40 Stop0 0 A Stop 80 40 0 A Stop 0 80 40 Stop 80 40 x 1000 / min km/h 4 6 0 x 1000 / min A 80 Stop 20 80 40 160 200 x 1000 / min km/h Recuperation Recuperation Coasting 160 Boost 200 x 1000 / min km/h Boost e-drive 160 200 km/h 0 A Stop Recuperation 120 40 6 Coasting km/h Start 2 200 160 4 2 Coasting 160 200 x 1000 / min A 6 - - Start 4 4 2 - Start Start 48V Systems 2 2 PHEV sHEV Coasting e-drive Boost 120 160 200 km/h e-drive entry CO2 potential sHEV: Strong Hybrid | PHEV: Plug-In Hybrid | BRS: Boost recuperation system | St/St: Start/Stop Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 10 Logo presentatore Diesel Passenger Car: Target 2020 Quality Requirements & Challenges IInnovative ti technologies, t h l i P Powertrain t i diversification di ifi ti and d Word Wide usage lead to even higher attention on: • Product and System y Requirement q analysis y • Introduction of new and extended Mission Profiles for validation (system approach mandatory needed) Innovation by validation: introduction of virtual environment (e.g. Hardware in the Loop), Connectivity (Remote control) become requirements q for Quality y improvement p (not only y “efficiency measures”…) Safety Standards (e.g. ISO 26262) in combination with upcoming i new, even more complex l technologies t h l i represents t one of the main technical challenges for future mobility solutions Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 11 Logo presentatore Diesel Passenger Car: Target 2020 Summary Powertrain diversification will increase, but IC Engine remains still dominant on the WW market (Focus 2020) There will be solutions for the Diesel Powertrain to comply th Emissions the E i i and d CO2 challenges, h ll iimproving i th the ffuell economy of Diesel powered vehicles Success factor is a comprehensive system approach in order to ensure a proper and cost optimized solutions, matching t hi upcoming i legal l l and d quality lit requirements i t Evoluzione delle propulsioni Implicazioni su Qualità, Affidabilità e Sicurezza Torino, Lingotto Fiere 22 aprile 2015 12 Logo Header of section presentatore Thank You ! 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