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8144 8JUNE99P1CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
“A High Mileage Extended Duration Fleet Trial ofOrbital’s Direct Fuel Injected Automotive
2-Stroke Engine”
David Shawcross
8th June 1999
Hamburg Germany, 8-10th June 1999
Thank you for this opportunity to present to you today.
My name is David Shawcross and I am Commercial Engineering Managerwith the Orbital Engine Corporation based in Perth, Western Australia.
It is my objective to present to you today, the preliminary results of a highmileage extended fleet trial that was based in Australia over the last 3 yearsand comprised 100 vehicles fitted with an Orbital air assisted direct fuelinjected 2-stroke engine.
I will attempt to show an automotive 2-stroke engine can be made durableand consumer acceptable and is a commercially viable opportunity that yetremains unexploited.
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8144 8JUNE99P2CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
• Up to 40% Reduced Packaging Volume
• Up to 40% Fewer Parts
• Up to 30% Lighter Weight
• Up to 30% Greater Power Density
• Up to 30% Lower Manufacturing Cost
• Reduced maintenance requirements
INHERENT ADVANTAGES of2-STROKE ENGINES
Compared to a conventional 4-Stroke, a 2-Strokeengine can have:
I think most people here would be aware of the inherent advantages of two-stroke combustion engines.
If I had to condense these it would be:
•Size,
•Weight,
•Cost.
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8144 8JUNE99P3CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
FOUR-STROKEFOUR-CYLINDER
434132248735861811852542840060
3871434331123561610193204271525614
OCP TWO-STROKETHREE-CYLINDER
BLOCK ASSEMBLYHARNESSIGNITION
CRANKSHAFTPISTON AND RODS
FLYWHEEL AND RING GEARENCODER
INLET /THROTTLE BODYWATER PUMPFRONT DRIVE
OIL PUMP AND LINEFUEL SYSTEM
FUEL AND AIR PLUMBINGEXHAUST MANIFOLD
EGR VALVECYLINDER HEAD / COVERBALANCE SHAFT / DRIVEEXHAUST VALVE / DRIVE
ALTERNATORAIR COMPRESSOR
SUBASSEMBLY
AP
PR
OX
. 560
CO
MP
ON
EN
TS
340
CO
MP
ON
EN
TS
THE 2-STROKE ENGINE PARTS BENEFIT
This slide shows the substantial parts count advantage a two-stroke enginecan have over a conventional multi-valve four-stroke engine.
The cylinder head is the most graphic example and yet these days cylinderheads are becoming much more sophisticated and complex with variablevalve timing, cylinder valve deactivation and the like.
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8144 8JUNE99P4CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
• Exhaust gas scavenging by fresh air
• Injection of fuel after port closure
TRADITIONAL DEFICIENCIES
Conventional 2-Stroke engines have:
• High fuel consumption
• Excessive exhaust emissions
OCP Direct Fuel Injection Enables:
Most people would be well aware of the traditional deficiencies of two-strokeengines, namely: high fuel consumption and excessive exhaust emissions.
Orbital has overcome these problems by the application of the OrbitalCombustion Process.
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8144 8JUNE99P5CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
INJECTIONSYSTEM
CONTROLSYSTEM
• Lean-Burn Stratified-Charge Combustion System
COMBUSTION SYSTEM
OCP: More than just a Fuel System
• Engine Management & Control System
THE ORBITAL COMBUSTION PROCESS
• Air-Assist Low-Pressure Direct Injection System
The Orbital Combustion Process, simply abbreviated “OCP”, contains threeessential elements:
•An air assisted low-pressure direct fuel injection system
•An engine management and control system
•A lean burn stratified charge combustion system
The application of OCP gives both fuel consumption and exhaust emissioncontrol benefits.
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8144 8JUNE99P6CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
THE GENESIS FLEET PROGRAM
A 100-vehicle fleet trial, fitted with the OCP1200cc 3-cylinder 2-stroke engine:
• Environmentally friendly
• Sporty responsiveness
• Representative of production
To demonstrate the maturity of the OCP 2-stroke engine, Orbital undertook aUS$15m, 3-year engineering development and sign-off program, culminatingin the release of 100-vehicles into the Australian market.
The purpose of this trial was to demonstrate:
•In-field durability
•Production feasibility
•Market acceptance
•Automotive applicability of a two-stroke engine.
It was also intended to build an information-database on
•Mechanical durability
•Oil consumption
•Fuel consumption
•Emission durability
•Any unknown in-field issues associated with a 2-stroke in anautomotive application.
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8144 8JUNE99P7CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
International Allocations:China, hot humid summer, cold dry winter.USA, hot humid summer, cold dry winter.Asia, hot humid summer, wet winter. Europe, warm damp summer, cold wet winter.
GENESIS VEHICLE DISTRIBUTIONDarwinHire Car Fleet . High mileage,open road, high speed countrydriving. Hot humid summerWarm dry winter
AdelaideHot dry summer,Cool wet winter.
BrisbaneMedium/low mileage city
& country driving.Single driver conditions.
Hot humid summerWarm dry winter.
PerthMedium/low mileagecity/country driving.Multi/single driver vehicles.Hot dry summerMild wet winter.
Canberra/ACTMedium mileage city &
freeway driving. Multi driver vehicles
Hot dry summer,Cold dry winter.
HobartMild summer,
Cool wet winter.
Sydney/MelbourneMedium/low mileage
Multi/single driver vehicles.Hot summer Cold winter.
The vehicles were distributed across Australia, based around the capital citiesfor ease of maintenance and control:
•approximately 25% were sold to private buyers/general public
•approximately 25% were sold to Government fleets
•approximately 20-40% were sold to a commercial car rental fleet and
•the balance were mixed between Orbital Australia and overseascustomers
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8144 8JUNE99P8CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
-8%
19%
25%
21%25%
15%
1200cc
56kW
125Nm
12.3 sec15.5 sec
6.1 l/100km(AS2877)
ADR Compliant (USA Tier 1/Euro II hardware)
Displacement
Power
Torque
Acceleration 0-100km/h50-100km/h
Urban Fuel Economy
Emissions System
IMPROVEMENTOVER BASELINEECOSPORT
GENESIS VEHICLESPECIFICATION
The vehicle platform used was the readily available Ford Festiva as it isknown in Australia, the Kia Avella in Europe or the Ford Aspire in the USA.
This comparison shows the difference the OCP equipped 1.2L 3-cylinder 2-stroke engine made to the vehilce performance.
The standard Festiva at that time had a 3-valve SOHC 1.3L 4-cylinder 4-stroke engine.
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8144 8JUNE99P9CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
0
25,000
50,000
75,000
100,000
125,000
150,000
175,000
Vehicle
Dis
tanc
e (k
ilom
etre
s)GENESIS ACCUMULATED DISTANCE
Over 5.15 million kilometres as of June ‘99
• 50% of fleet over 50,000 km• 20% of fleet over 80,000 km
This plot shows the spread of accumulated distance the vehicles in the fleetwere experienced and reflects the diverse range of drivers and operatingconditions.
Some vehicles are well over 100,000 km and almost half the fleet hasexceeded 50,000 km. Some vehicles are apparently in pristine condition!
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8144 8JUNE99P10CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
GENESIS FUEL and OIL CONSUMPTION
AVERAGE FUEL 7.2 L / 100 km AVERAGE OIL 5.3 L / 10,000 km
0
1
2
3
4
5
6
7
8
9
10
Vehicle
Con
sum
ptio
n
This plot shows the spread of fuel consumption. Average in-field fuelconsumption is approximately 7.2 L/100 km.
As a large percentage of the fleet was based with a car rental fleet in Darwinwhere there a open roads and no speed limits, the fuel economy is generallybiased upwards.
Similarly with the spread of oil consumption. Some vehicles are driven quitehard resulting in additional lubrication demands.
Average oil consumption is comparable to the typical service change intervalof the average 4-stroke vehicle with the exception that the service operationis significantly simplified. There is no filter to replace and no used oil todispose of. Only a simple oil bottle top is required, just like fuel.
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8144 8JUNE99P11CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
GENESIS IN-FIELD ENGINE EMISSIONS• 10 vehicles tested at 20,000 km intervals• Statistical database relatively small / low km’
0
1
2
3
4
0 20000 40000 60000 80000Distance (kilometres)
Eng
ine
Out
Em
issi
ons
(g/m
ile, F
TP C
ycle
)
NOx (g/mile, FTP)
HC (g/mile, FTP)
At the start of the fleet, 10 vehicles were identified for periodic emissionsmonitoring. Unfortunately the majority of these vehicles tended toaccumulate distance very slowly and we were left with a poor statistical base.
As we are currently in the process of reducing the vehicle fleet are we aretaking the opportunity to test those vehicles that have achieved nominally80,000 km or more and we expect to have these results by the end of thisyear.
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8144 8JUNE99P12CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
• 180 hour high speed tests• Engine and ancillaries at max speed
• Urban cycle tests• Simulates cold city driving
• Jogging cycle tests• Dynamic component durability
• Thermal shock tests• Durability under extreme weather conditions
GENESIS ENGINE VALIDATION
• 600 hour transient durability tests• Core engine and ancillaries durability
A significant part of the design validation program was a focus onmechanical durability.
A suite of standard industry tests were performed and successfully completed.
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8144 8JUNE99P13CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
ENGINE BLOCK and CRANKSHAFTTRANSIENT DURABILITY
A CD
B5
12
12
7
7
12
12
7
FRONT
INLET
REAR
EXHAUST
CYLINDER BORE WEAR AT TDC (um)
D
ABC
600 hrs 1000 hrs
E
F
G
H
J
K
L LKJH
EF
REAR MAIN 0 2.2
CRANK PIN #3 5.4 3
MAIN #1 2.6 0
CRANK PIN #1 5 0
MAIN #2 1.1 4
CRANK PIN #2 2.3 3
FRONT MAIN 1
G
8
CRANKSHAFT JOURNAL WEAR (um)
1000 hrs 1600 hrs
These results show the wear observed on the key components of engine blockand crankshaft.
In contrast with 4-stroke manufacturing processes, the block used a nickelsilicone carbide coating and the crankshaft had nitride hardened journals.
The Genesis program took engines to a 600 hour test limit, however, we haveadditionally taken engines beyond this duration and these results have alsobeen provided for further information.
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8144 8JUNE99P14CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
CB
A
D
E
PISTON RING WEAR(weight loss in grams)
PISTON SKIRTDEFORMATION
PISTON SKIRTWEAR
PISTON PIN BORECLEARANCE
35
21
10
32
600 hrs
um
0.04Max
48
27
15
37
1000 hrs
um
PIN BORE RADIALCLEARANCE
27 - 29 25 - 29
BIG END RADIALCLEARANCE
20 - 22 20 - 27E
D
C
B
A
B PISTON SKIRTDEFORMATION
PISTON, PISTON RING and CONRODTRANSIENT DURABILITY
As with the previous slide the critical piston, ring and conrod componentshave demonstrated excellent durability.
These results presently show engine dynamometer running. As the fleet isreduced in-field measurements to be undertake. The engines that have beeninspected to date reflect the dynamometer results previously given.
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8144 8JUNE99P15CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
• Issues: • Resolutions:• Balance shaft timing belt
• Fuel regulator diaphragm
• Throttle potentiometer drift
• Exhaust valve actuator shaft
• Electrical harness earthing
• Occasional engine cut-out/stall
• EMS diagnostic sensitivity
• Compressor head gasket
• Oil replacement
• Connecting rod
• Exhaust valve carboning
• New FEAD layout
• Use Off-the-shelf regulator
• Implement adaptive software
• Shaft re-design
• Earthing re-design
• Software correction
• Improved software filtering
• Clamp force re-design
• Driver education
• Improve process control
• Modify cylinder flow rate
GENESIS FLEET IN-FIELD DURABILITY
In-field we have observed a range of different durability issues but otherwisethe durability performance was been very pleasing.
Early in the trial, a number of issues arose which were quickly assessed andcontained.
It is important to stress that Orbital is neither an engine nor vehiclemanufacturer and in launching such a fleet basically jumped on a rapidlearning curve which mainstream manufacturers have long since mastered.
Long term resolutions for these issues have been designed and in the majorityof cases re-verified with further dynamometer and/or in-field testing.
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8144 8JUNE99P16CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
• General response: Very positive
OVERALLRESULTSPOWER &ACCELERATION
NOISE CRUISE
NOISEACCELERATION
NOISE IDLE
OVERALLSATISFACTION
AVG
7.6
7.3
6.7
5.8
7.7
• Common themes:• Impressive torque
• Impressive power
• Engine is very flexible
• Sporty feel and sound
• “Where can I buy one ?”
• Industry Awards• SAE Australasia
• Far Eastern Economic Review
GENESIS CUSTOMER RESPONSE
The overall customer response has been very positive.
People are genuinely impress with the vehicle’s sporty responsiveness andperformance. Some drivers are not necessarily aware that they are driving a2-stroke engine.
A quantified engineering review of the vehicle has shown the weakest area tobe NVH at idle attributed to vehicle response to the 3-cylinder characteristic.
Very little change was made to the standard vehicle chassis to accommodatethe new engine and this consequently lead to compromises affecting theengine performance and feel. A new vehicle installation should not imposethe same level of constraints Genesis was subjected to.
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8144 8JUNE99P17CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
• City Car Applications Markets
• Hybrid Electric Vehicle Applications
• Emerging Automotive Markets
MARKET OPPORTUNITIES FOR ANAUTOMOTIVE 2-STROKE ENGINE
An OCP 2-stroke engine should be used where itmakes the most sense and gives maximum value:
In summary, the Genesis Fleet Trial has shown that a 2-stroke engine can beacceptable and viable in automotive applications.
Consumers enjoy the responsiveness of the technology and manufactures maytake advantage of the inherent and added advantages an air assisted directfuel injected 2-stroke engine offers - size, weight and cost.
A 2-stroke engine should be used where it makes the most sense and there area range of applications possible.
If you would like any further information or have any questions please do nothesitate to ask or see me after this session. We do intend to publish acomprehensive technical paper early next year once all the vehicle fleet datahas been obtained and processed.
In the short term you can see an Australian (RHD) ECOsport vehicle in theexhibition hall and I have a LHD vehicle briefly available outside for limiteddemonstrations during Engine Expo.
Thank you very much.
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8144 8JUNE99P18CONFIDENTIAL AND COPYRIGHT ORBITAL ENGINE COMPANY 1999
“A High Mileage Extended Duration Fleet Trial ofOrbital’s Direct Fuel Injected Automotive
2-Stroke Engine”
David Shawcross
8th June 1999
Hamburg Germany, 8-10th June 1999