Documente Academic
Documente Profesional
Documente Cultură
Contents
Background
System Description
Thermodynamic Analysis
NEDC Results
On Engine Application
Conclusions
2
Motivation
1.0
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0.6
Eu Kor
Eu ro II ea
ro I 20
IV
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20 5
10
0.4
s
ate 7
St 200
d
ite n 5
Un II Bi
r
Tie
Japan
Japan 2005
Japan 2009
India
Bharat II 200
5
Bharat III 20
10
ina 07
Ch 3 20 0
1
20
ro
Eu r o 4
Eu
Eu Euro
Eu r o 3 p e
Eu ro 4 2000
ro
2
5 2 005
00
9
Exhaust
Throttle
VTG
DPF
HP-EGR
Valve
HPEGR
Cooler
LPEGR
Cooler
LP-EGR Valve
Intake
throttle
EGR Mixer
EGR-system:
cooled HP-EGR, cooled LPEGR
Boosting system:
1-stage VTG
100%
LP
75%
55%
VTG
Open
Development Process
Modeling of Production Baseline
Full GT-Power Model
Real time capable mean value model (MVM)
Speed
EGR-Boost
optimization
Temperature
HP EGR
Control
Map
High
Pressure
LowFeed
Pressure
Forward
Loop
Controls
Loop
Controls
Loops
HP EGR Valve
HPL
Split
Engine
State
Intake Throttle
EGR TOTAL
set-point
Feedback
Controller
LP EGR
Control
Map
Engine
State
Total EGR
frac
estimator
Boost Pressure
Set Point
LP EGR &
Exhaust Throttle Module
Sensor(s)
Boost
Controller
Turbo VTG
Sensor(s)
Turbo
Controls
9
10
12
Torque
40/60
High pumping
loss with LP
20/80 EGR
0/100
Fast
reaction
time
40/60
75/25
40/60
75/25
100/0
Combustion temperature
Optimizing
VTG
position
Engine speed
13
50
EGR rate setpoint
EGR rate actual
40
30
Production ECU
Control
20
10
0
200
230
290
320
350
380
410
Maintains
requested rate
during cycle
50
40
EGR Rate (%)
260
440
470
500
BorgWarner
Control
30
20
10
0
200
230
260
290
320
350
380
410
440
470
500
14
120
80
40
250
0
Base HP EGR calibration / Daimler ECU controller
HP+LPHP
EGREGR
V0 calibration
/ BWES
controller
V0 / ECU
Control
HP+LP EGR V5 calibration / BWES controller
200
NOx Peaks
reduced
150
100
50
Significant NOx
reduction
0
780
880
980
1080
1180
15
16
17
Km/hr
NOxmg/km
ProdECUHPEGR25%
72%
Reduction in
NOx
-72% Increased
EGR to
Obtain
Equivalent
BWDualLoopEGR35%
Fuel
Consumption
Seconds
& PM
18
System Summary
System
EGR System
Fuel
Consumption
reduction (%)
NOx
Reduction (%)
Baseline
High Pressure
loop w/ cooler
25%
NA
NA
BorgWarner
coordinated
controls
High Pressure
loop w/ cooler
20%
BorgWarner
coordinated
controls
24
BorgWarner
coordinated
controls w/
increased EGR
72
19
175
+ 15
EGR
+15% EGR
Actual
CO2 g/km
Theoretical
Line +15% EGR
+15% EGR
Actual
180
ECU Control
HP EGR
170
165
+ 15%
EGR
+
BW
+BorgWarner
Air
Controls
Path Controls
160
+ LP
EGR
155
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
NOx g/km
20
Conclusions
Dual Loop EGR offers significant advantages to
reduce emissions and fuel consumption to meet future
emission requirements
21
rczarnowski@borgwarner.com