MAN CNG Bus Technology Guide

MAN CNG Buses
MAN Nutzfahrzeuge AG
SRN
MAN CNG Buses
May 2009
MAN CNG Buses

Content
1. 2. 3. 4. 5. 6. 7. 8. 9.
MAN CNG bus history Actual CNG bus & engines portfolio MAN CNG buses sales worldwide Actual CNG technology Concept Comparison New developments Advantages of CNG technology (compared to Diesel) Cost comparison Summary
SRN
MAN CNG Buses
May 2009
MAN CNG Buses

Content
1. 2. 3. 4. 5. 6. 7. 8. 9.
SRN
MAN CNG Buses
May 2009
MAN Gas Buses

History History
1943 - First MAN Gas Bus, Augsburg
SRN
MAN CNG Buses
May 2009
MAN Gas Buses

History
1972 LNG Bus for Munich Olympic Games
2001 CNG Bus for Zwickau, Germany
1988 SL 202 CNG Bus
2003 CNG Bus for Frankfurt/Oder, Germany
SRN
MAN CNG Buses
May 2009
MAN CNG Buses

Products
SRN
MAN CNG Buses
May 2009
Milestones in the Development of MAN Natural Gas Engines

E 2866 DUH01 E 2866 DF01 E 2866 DUH03 Euro 2-engines Euro 3-engine EEV-engine
naturally aspirated engines stoichiometric
E 2866 DOH01 turbocharged engines lean-burn lean-burn/mix
E 2866 DUH02
E 2866 LUH02
E 2876 LUH02
E 2866 LUH01
E 2876 LUH01
1990
MAN Nutzfahrzeuge AG SRN
1995
2000
MAN CNG Buses May 2009
2005
7
MAN CNG Buses

Content
1. 2. 3. 4. 5. 6. 7. 8. 9.
SRN
MAN CNG Buses
May 2009
MAN CNG-Buses and CNG-Buses with MAN-Natural Gas Engines
SRN
MAN CNG Buses
May 2009
MAN CNG Buses

Content
1. 2. 3. 4. 5. 6. 7. 8. 9.
SRN
MAN CNG Buses
May 2009
10
MAN gas engines

Technology
MAN gas engines are based on the mass produced MAN Diesel engine type D 28 Most parts are identical to the Diesel engines especially the expensive ones as crankcase, crankshaft connection rods etc. Gas engines are dedicated engines with a lot of special features
SRN
MAN CNG Buses
May 2009
11
Engine cross section Gas engine Diesel engine
Otto-cycle Gas engine

Spark plug and special combustion chamber with lower compression ratio
TVA-N,MAN Nutzfahrzeuge AG 01.02.00
SRN
Diesel engine
Diesel injector and combustion chamber with high compression ratio
MAN CNG Buses May 2009 12
Features of MAN gas engines I

Cylinder heads with armored valves and armored valve seats for low abrasion Optimized cylinder head cooling, especially good cooling of the spark plug Inlet valves with shaft sealing for minimized oil consumption Outlet valve guides made from special material with self lubricating quality for low abrasion Valve tappets with hard metal plates for low abrasion of the cams Special pistons and piston rings for low oil consumption Piston rings with special coating for low abrasion
SRN
MAN CNG Buses
May 2009
13
Features of MAN gas engines I I

Bearing shells for con rods and crankshaft with non abrasive surface Water cooled exhaust gas manifold for naturally aspirated engines Turbo charger with water cooled bearing house Turbo charger equipped with waste gate Engine management system Bosch Motronic GAS 1 Long life Platinum/Iridium spark plugs (60000 km) Exhaust gas aftertreatment with a three-way catalyst (at lean operation oxidation only)
Summary: the number of differences indicate it makes no sense to convert Diesel to CNG engines !
SRN
MAN CNG Buses
May 2009
14
CAN-structure of gas vehicles
ABS/ ASR
Accelerator pedal
Gearbox control
Driveline CAN
Vehicle management computer (FFR)

MASTER
Engine CAN
Motronic ME7-Gas1 engine management

SLAVE
SRN
MAN CNG Buses
May 2009
15
Components of the Engine Management System Motronic ME7-GAS1

13 1 5 2 12 4 16 1 2 3 4 5 6 7 11 8 9 10 11 3 7 14 6 17 12 13 14 15 16 17 Butterfly valve actuator Injection valves Control unit Phase sensor Speed sensor Boost air temperature sensor Boost pressure sensor Coolant temperature sensor Natural-gas pressure sensor Natural-gas temperature sensor Igniting stages Spark coils Hot film air mass sensor Knock sensors Proportional valve for wastegate Broad-band lambda sensors Exhaust gas temperature sensor
10
9
SRN
15
May 2009 16
MAN CNG Buses
Functions of the Motronic ME7-GAS1

Output control by means of electrically driven butterfly valve actuator and boost pressure control via waste gate control Fuel control using a completely electronic sequential gas injection system and an air mass measurement system Ignition control using a map transistor ignition system with open-circuit high voltage distribution Safety functions as self surveillance and diagnostic of sensors and actuators Engine starter control Lambda = 1 control for naturally aspirated engines by means of a broad band Lambda sensor Lambda = 1 or Lambda > 1 control for turbo charged engines by means of a broad band Lambda sensor Cylinder individual anti-knock control with the help of two knock sensors Idle speed filling control
MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 17
Gas Mixer Unit of the Natural Gas Engines E 2866 DUH03 and E 2876 LUH02
gas pressure sensor throttle valve
gas inlet
gas injectors (12 x) gas temperature sensor
SRN
MAN CNG Buses
May 2009
18
Evaluation of the Central Gas Mixer Unit
8 excellent homogenity of the natural gas/air-mixture,

very important for lean-burn operation 8 very compact component 8 very good accessibility of the gas mixer unit for service 8 good dynamic behaviour during transient engine operation 8 many identical parts of the gas mixer unit for the naturally aspirated and the turbocharged engine version
SRN
MAN CNG Buses
May 2009
19
MAN CNG Buses

Content
1. 2. 3. 4. 5. 6. 7. 8. 9.
SRN
MAN CNG Buses
May 2009
20
EEV- Gas Engines for Buses

EEV = Enhanced Environmentally friendly Vehicle
Fuel
Engine type E 2866 DUH03
Engine concept naturally aspirated three-way-catalyst turbocharged and aftercooled three-way-catalyst naturally aspirated three-way-catalyst naturally aspirated reduction -catalyst
Mixture stoichiometric lean-burn / mix stoichiometric stoichiometric
Installation horizontal horizontal horizontal horizontal
Power [kW] 180 228 200 150
Exhaust gas standard EEV EEV *) EEV EEV**)
CNG LPG H2
E 2876 LUH01 /02 G 2876 DUH01 H 2876 UH01
*) gas grup limitation e **) not jet certified
SRN
MAN CNG Buses
May 2009
21
Evaluation of Concepts for turbocharged Natural Gas Engines

Lean-Burn Concept acceptable emissions suitable for Euro 3 also Euro 4 with restriction to the driveability good Stoichiometric Concept excellent emissions fulfil Euro 5 and EEVstandard suitable for Euro 6 high (in relation to lean-burn) Lean-burn/Mix-Concept very good emissions fulfil Euro 5 and EEVstandard acceptable ( between lean-burn and stoichiometric) acceptable thermal stress exhaust gas temperatures slightly higher to these of a Diesel engine
Emissions
Fuel consumption
Thermal Stress
low thermal stress exhaust gas temperatures comparable to these of a Diesel engine
very high exhaust gas temperatures (> 900 C)
Costs
acceptable costs
high costs expensive materials are needed heat protection in the engine compartment is necessary
MAN CNG Buses
acceptable costs
SRN
May 2009
22
Differences between Leanburn and Lean-burn/Mix Concepts
Lean-burn Concept
Lean-burn / Mix Concept
8 Operation of the engine in the complete operation map with high excess air 8 Lambda value between 1,3 and 1,65 depending on engine load
8Stoichiometric operation of the engine in a part of the operation map 8 Switch over to operation with high excess air depending on the load and the speed of the engine 8 Lambda value between 1,0 and 1,65 depending on the engine load
SRN
MAN CNG Buses
May 2009
23
The Way from an Euro 3- towards an EEV-Natural Gas Engine with Turbocharger
NOx [g/kWh]
Lean-Burn Concept
4,20 4,0
Lean-Burn/Mix Concept
Euro 3-Natural Gas Engine E 2866 LUH02 2,0
EEV-Natural Gas Engine E 2876 LUH02
CH4 [g/kWh]
1,00
1,80
0,65
0,30 0,005
0,02
Particles [g/kWh]
EEV-Limits
0,10
0,50
0,40 NMHC [g/kWh]

3,0 CO [g/kWh]
The Way from an Euro 3- towards an EEV-Natural Gas Engine with Turbocharger
0,50
SRN
MAN CNG Buses
May 2009
25
Natural Gas Engine E 2876 LUH02, turbocharged and intercooled, EEV

Number of cylinders: Displacement: Power output: Torque: Exhaust gas standard: 6 12,8 l 228 kW/2000 rpm 1250 Nm/1000 - 1700 rpm EEV
Concept features: central gas mixer unit gas injection system Motronic ME7-GAS1 lambda 1 -control three- way catalyst
SRN
MAN CNG Buses
May 2009
26
Function Chart of Natural Gas Engine E 2876 LUH02

gas cylinders pressure regulator intercooler throttle valve air by-pass
air mass sensor
sensors wastegate
gas mixer unit spark coils
turbocharger
silencer with three-way-catalyst
Lambda sensors
engine control unit
vehicle management controller

SRN
Performance diagram of Natural Gas Engine E 2876 LUH02

240 230 220 210 200 190 180 Leistung [kW] Drehmoment [Nm] Verbrauch [g/kWh] DAEQ 170 160 150 140 130 120 110 100 90 80 70 1400 1300 1200 1100 1000 900 800 700 280 270 260 250 240 230 220 210 200 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100
Motor-Typ.: Leistung : Drehmoment : Kraftstoffverbrauch : Nenndrehzahl : Abnahme nach 80/1269 EW G
E 2876 LUH01 228 kW bei 2000 1/min 1250 Nm bei 1000 - 1700 1/min 208 g/kW h DAEQ 2000 1/min
Drehzahl [1/min]
Leistungsdiagramm E2876LUH01
SRN
MAN CNG Buses
May 2009
28
MAN CNG Buses

Content
1. 2. 3. 4. 5. 6. 7. 8. 9.
SRN
MAN CNG Buses
May 2009
29
New developments
Small CNG engine E08
SRN
MAN CNG Buses
May 2009
30
Performance diagram of the Turbocharged Gas Engine E 0836 LOH01
Highlights: Euro 6 & OBD 2 compliant 206 kW (280 bhp) 1000 NM (900-1900 1/min) New optimized ECU
SRN
MAN CNG Buses
May 2009
31
MAN CNG Buses

Content
1. 2. 3. 4. 5. 6. 7. 8. 9.
SRN
MAN CNG Buses
May 2009
32
Exhaust-Gas Emissions of EEV-Natural Gas Engines in the ETC

Homologation values, rounded
6,00
5,45
Euro 3 Euro 4 Euro 5 EEV E 2866 DUH03, Lambda =1, EEV E 2876 LUH02, lean-burn/mix, EEV
3,50 5,00
EEV
Enhanced Environmentally friendly Vehicles European Transient Cycle
Gaseous emissions [g/kWh]
5,00
ETC =
4,00
4,004,00
3,00
3,00
0,30
Range of variation depends on the composition of the test gases
2,00
1,60 1,101,10
2,002,00
1,90
0,16 1,60
0,20
1,00
0,25 0,15
0,78 0,550,55 0,40 0,000,05
0,65 0,40 0,050,10 0,3 0,30 0,03 0,20 0,02 0,050,05 < 0,005
0,10
0,00
0,00
CO
NMHC
SRN
Methane
NOx
Particles
May 2009 33
MAN CNG Buses
Particles [g/kWh]
Exhaust-Gas Emissions Euro 3 to Euro 6

ETC Overview: legal requirements for heavy duty vehicles Euro 3 to Euro 6
ETC: European Transient Cycle MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 34
Specific Fuel Consumption and CO2Emission in the European Transient Cycle (ETC)
140 132 Spec. fuel consumption CO2-emission 100 100 80 60 40 20 0
D 2876 LF with SCR E 2866 LUH02 E 2866 DUH03 E 2876 LUH02
[%]
120
121 101 93
125
100
96
EEV
Specific fuel consumption = Diesel equivalent
EURO 3
EEV
EEV
MAN CNG Buses
May 2009
35
Particle Size Distribution in the Exhaust Gas of Diesel and Natural Gas Engines
Test cycle: ESC
1,00E+15 1,00E+14 1,00E+13 1,00E+12 1,00E+11 1,00E+10 1,00E+09 1,00E+08 1 10 100 1000
Diesel-engine, Euro 2, raw exhaust gas Diesel-engine, Euro 2, after CRT CNG-engine, EEV indoor air
dN/dlogDp [1/kWh]
electrical mobility diameter [nm]

MAN Nutzfahrzeuge AG SRN MAN CNG Buses May 2009 36
Advantages of CNG technology

Focus: Biogas
Overview: environmental performance of buses
SRN
MAN CNG Buses
May 2009
37

Focus: Biogas
SRN
MAN CNG Buses
May 2009
38
MAN CNG Buses

Content
1. 2. 3. 4. 5. 6. 7. 8. 9.
SRN
MAN CNG Buses
May 2009
39
Cost comparison
Source: MAN NL
SRN
MAN CNG Buses
May 2009
40
MAN CNG Buses

Content
1. 2. 3. 4. 5. 6. 7. 8. 9.
SRN
MAN CNG Buses
May 2009
41
CNG/LPG Exhaust gas emissions are significantly better than Diesel emissions CNG/LPG engines are quieter than Diesel engines (up to -2 dB(A) less) Worldwide known resources for natural gas expected to last up to 300 years Biogas provides the optimal fuel reference greenhouse effect and local air quality CNG as fuel provides a higher safety standard than Diesel !
SRN
MAN CNG Buses
May 2009
42
SRN
MAN CNG Buses
May 2009
43
Thank you for your attention.
Author
Title of presentation
DD Month YYYY
44

MAN CNG Bus Technology Guide

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

MAN CNG Bus Technology Guide

Încărcat de

Drepturi de autor:

Formate disponibile

MAN CNG Buses

MAN CNG Buses

MAN CNG Buses

MAN CNG Buses

MAN CNG Buses

MAN CNG Buses

MAN Gas Buses

1943 - First MAN Gas Bus, Augsburg

MAN CNG Buses

MAN Gas Buses

1972 LNG Bus for Munich Olympic Games

2001 CNG Bus for Zwickau, Germany

1988 SL 202 CNG Bus

2003 CNG Bus for Frankfurt/Oder, Germany

MAN CNG Buses

MAN CNG Buses

MAN CNG Buses

Milestones in the Development of MAN Natural Gas Engines

naturally aspirated engines stoichiometric

E 2866 DOH01 turbocharged engines lean-burn lean-burn/mix

MAN CNG Buses

MAN CNG Buses

MAN CNG-Buses and CNG-Buses with MAN-Natural Gas Engines

MAN CNG Buses

MAN CNG Buses

MAN CNG Buses

MAN gas engines

MAN CNG Buses

Engine cross section Gas engine Diesel engine

Otto-cycle Gas engine

Features of MAN gas engines I

MAN CNG Buses

Features of MAN gas engines I I

MAN CNG Buses

CAN-structure of gas vehicles

Vehicle management computer (FFR)

Motronic ME7-Gas1 engine management

MAN CNG Buses

Components of the Engine Management System Motronic ME7-GAS1

MAN CNG Buses

Functions of the Motronic ME7-GAS1

gas pressure sensor throttle valve

gas injectors (12 x) gas temperature sensor

MAN CNG Buses

Evaluation of the Central Gas Mixer Unit

8 excellent homogenity of the natural gas/air-mixture,

MAN CNG Buses

MAN CNG Buses

MAN CNG Buses

EEV- Gas Engines for Buses

Engine type E 2866 DUH03

Mixture stoichiometric lean-burn / mix stoichiometric stoichiometric

Installation horizontal horizontal horizontal horizontal

Power [kW] 180 228 200 150

Exhaust gas standard EEV EEV *) EEV EEV**)

E 2876 LUH01 /02 G 2876 DUH01 H 2876 UH01

*) gas grup limitation e **) not jet certified

MAN CNG Buses

Evaluation of Concepts for turbocharged Natural Gas Engines

very high exhaust gas temperatures (> 900 C)

Differences between Leanburn and Lean-burn/Mix Concepts

Lean-burn / Mix Concept