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Ford Motor Company 1ERC Low Emission Symposium
Low Emissions IC Engine
Development at Ford Motor Company
George Davis
Powertrain Research and Advanced
Engineering
ERC Symposium
University of Wisconsin at Madison
June 8-9, 2005
Research and
Advanced Engineering
Ford Motor Company 2ERC Low Emission Symposium
Presentation Overview
Emission Standards Evolution
PZEV PFI/DI Engine Development
Electric-Gasoline Hybrid Vehicle
HCCI Engine Development
H2ICE Engine Development
Summary
Ford Motor Company 3ERC Low Emission Symposium
0
2
4
6
8
10
'66 '70 '75 '77 '80 '93
0.41
40%
0.25
50%
0.125
40%0.075
0.04
0.01
46%
75%
Hydro
carb
ons (
gra
ms p
er
mile @
50K)
7 MODE FTP
1st CLEAN AIR ACT80 MODE FTP
C/H 110 MODE FTP
'93 Base Tier I TLEV LEV ULEV SULEV
HC REDUCED BY 96% 98% ADDITIONAL REDUCTION
99.9% REDUCTION OVERALL
100%
Evolution of Hydrocarbon Emission Standards - USA
HC Emission Standards
Ford Motor Company 4ERC Low Emission Symposium
Ox
ide
s o
f N
itro
ge
n (
gra
ms p
er m
ile
@ 5
0K
)
NOx REDUCED BY 90%
1st NOx STANDARDC/H 110 MODE FTP
0
1
2
3
4
5
'66 '70 '73 '75 '77 '80 '93
99.5% REDUCTION OVERALL
CAA
Base
TLEV LEV ULEV ULEV II SULEV
95% ADDITIONAL REDUCTION
100%0.4
50%
0.2
75%
0.05
0.02
60%
Evolution of Nitrogen Oxide Emission Standards- USA
NOx Emission Standards
Ford Motor Company 5ERC Low Emission Symposium
National Medal of Technology
• Haren Gandhi wins for his
work in automotive exhaust
catalyst technology
• Ford executives salute
Gandhi's breakthrough
accomplishment
• Today's automobiles are
more than 96 percent cleaner
– due in part to Gandhi's
efforts
• First time ever that auto
industry researcher has been
awarded Medal of Technology
• Past winners include Bill
Gates, Steve Wozniak, and
Edwin Land of Polaroid
Ford Motor Company 6ERC Low Emission Symposium
IC Engine Technology Roadmap
Gasoline
Diesel
Cost EffectivePerformance
Fuel Economy
Emissions
Time
Limited By Emissions C
onstraints
Ford Motor Company 7ERC Low Emission Symposium
Gasoline IC Engine Technology Spectrum
PFI DIFE, PBoosted/
Downsizing
FE, P
FE, P
FE, E
Now Future
Fixed
Cam
Cam lift
/phasingHCCI
High EGR
Ford Motor Company 8ERC Low Emission Symposium
Presentation Overview
Emissions Standards Evolution
PZEV PFI/DI Engine Development
Electric-Gasoline Hybrid Vehicle
HCCI Engine Development
H2ICE Engine Development
Summary
Ford Motor Company 9ERC Low Emission Symposium
Emissions ExampleC
umul
ativ
e E
mis
sion
s
Time (s)
HC
NOx
NMHC
Veh
icle
Spe
ed
0
2
4
6
8
0
2
4
0 200 400 600 800 1000 1200 1400 1600 1800 2000
0
20
40
60
80
100
120
140
•Minimize emissions before Cat light-off
•Minimize time to Cat light-off
•Maximize Cat efficiency (AFR Control)
Catalyst Light-off
0
2
4
6
8
0
2
4
0 200
Cum
ulat
ive
Em
issi
ons
Time (s)
HC
NOx
NMHC
Catalyst Light-off
Vehicle
Speed
40 80 120 160 200
Ford Motor Company 10ERC Low Emission Symposium
PZEV with Improved Aftertreatment
VCT
Close Couple
Catalyst
Underbody
Catalyst
DISI enables late
ignition for improved
CC catalyst light-off.
Ford Motor Company 11ERC Low Emission Symposium
Simulated S_Type98 Transient Test
MESIM CFD Injector Targeting Four Puddle Fuel Evaporation Model
10
11
12
13
14
15
16
17
18
19
20
0 50 100 150 200 250 300 350 400 450 500
Time (s)
AFR
Injector Targeting Process
1
2
3
4
PZEV PFI Engine: Improved AFR Control
Ford Motor Company 12ERC Low Emission Symposium
Injector Rotation
Injector
Up/Down offset
Cone Angle
Angle between Cones
Tricky
Spots
Injector Targeting Optimization for AFR Control
Ford Motor Company 13ERC Low Emission Symposium
Nominal
Design
Worst
Case
AFR Response Nominal Vs Worst Case
10
11
12
13
14
15
16
17
18
19
20
0 50 100 150 200 250 300 350 400 450 500
Time (s)
AFR
AF_Worst_cert
AF_Nominal_cert
Injector Targeting Optimization for AFR Control
Ford Motor Company 14ERC Low Emission Symposium
Direct Injection Engine For Low Emissions
Ford Motor Company 15ERC Low Emission Symposium
Reducing Smoke at Part-Load Operation
60 deg Injector 70 deg Injector
0
5
10
15
20
25
-80 -70 -60 -50 -40 -30 -20 -10 0
600 spray
700 spray
Normalized liquid fu
Crank angle (degree)
0
0.3
0.6
0.9
1.2
1.5
60 deg 70 deg
FS
N
Computed Piston
Wetting History
Measured Engine
Smoke Number
DI Engine
Ford Motor Company 16ERC Low Emission Symposium
Ford Focus PZEV
Ford Motor Company 17ERC Low Emission Symposium
Presentation Overview
Emissions Standards Evolution
PZEV PFI/DI Engine Development
Electric-Gasoline Hybrid Vehicle
HCCI Engine Development
H2ICE Engine Development
Summary
Ford Motor Company 18ERC Low Emission Symposium
Hybrid Vehicle Technology – Ford Hybrid Escape
High FE vehicle at low emission levels
Fuel efficient driving
Regenerative braking captures over 90% of braking
energy on EPA city cycle
2005 North American
Truck of the Year
2.3 L Atkinson2.3 L Atkinson
EngineEngine
E-CVT E-CVT
Ford Motor Company 19ERC Low Emission Symposium
Presentation Overview
Emissions Standards Evolution
PZEV PFI/DI Engine Development
Electric-Gasoline Hybrid Vehicle
HCCI Engine Development
H2ICE Engine Development
Summary
Ford Motor Company 20ERC Low Emission Symposium
HCCI Combustion System Concept
Compression
Ignition
(Diesel)
Spark
Ignition
(Gasoline)
Homogeneous Charge
Compression Ignition
(HCCI)
(Gasoline & Diesel)
Spark Ignition
Wall Guided
(Spray Guided)
Stratified
(Gasoline)
Flame
PropagationDiffusionKinetics
Requirements:
•Homogenization
•Temperature of ~1100 K
•Cycle-to-cycle control
parameter
Low temperature combustion…
Ford Motor Company 21ERC Low Emission Symposium
Gasoline HCCI Technology
Negative Valve Overlap and
pilot fuel injection is the key
for controlled ignition timing
Intake air heating &
fast intake T control
engine
heatexchanger
to radiator
air in
intake
to exhaust
heatexchanger
coolant out
TCV
exhaust
Controlled Auto Ignition
(CAI)
Optimized Kinetics Process
(OKP)
Ford Motor Company 22ERC Low Emission Symposium
HCCI Significantly Reduces CO2 Emission
1 2 3 4 5 6 7 8 9 10 11
NMEP (bar)
170
180
190
200
210
220
230
240
250
260
270N
SF
C (
g/k
Wh
)PFI 5.4L V8
PFI 4.0L V6
SC-DISI
CAI
OKP in HCCI
PFI
OKP (HCCI)
PFI CAI (HCCI)AVL
CSI
(HCCI)
1500 rpm Engine Speed
throttling(85 kPa)
(70 kPa)
Diesel
Ford Motor Company 23ERC Low Emission Symposium
Presentation Overview
Emissions Standards Evolution
PZEV PFI/DI Engine Development
Electric-Gasoline Hybrid Vehicle
HCCI Engine Development
H2ICE Engine Development
Summary
Ford Motor Company 24ERC Low Emission Symposium
Why Hydrogen Internal Combustion Engine?
Ford Motor Company is dedicated to the realization of Fuel Cell
powertrains in mass produced consumer vehicles
Fuel cell powertrains are not ready for mass production in the
near term
H2ICE is regarded as a transition or “bridging” strategy to
stimulate the hydrogen infrastructure, and related hydrogen
technologies:
On-board hydrogen fuel storage
Hydrogen Fuel dispensing
Hydrogen safety sensors
Ford Motor Company 25ERC Low Emission Symposium
H2 Focus Breaks SULEV NOx Barrier
0.0080.00317<<< 0.02H2ICE – Test 2
0.0060.0036<< 0.02H2ICE – Test 1
0.0110.02SULEV Standard
NMHC(g/mi)
CO(g/mi)
NOx(g/mi)
Ford Motor Company 26ERC Low Emission Symposium
Hydrogen DI Provides Further Opportunities
Power density improvement
Air is not displaced by H2 during intake stroke
Elimination of backfire
H2 injection after intake valve closing
Higher CR & improved thermal efficiency opportunity due
to charge cooling
Optimized injection strategy may provide:
Reduced pre-ignition tendency
Reduced NOx
Increased fuel efficiency (less unburned H2)
Ford Motor Company 27ERC Low Emission Symposium
Volumetric Efficiency Comparison
125+%102%~115%
(Source:
HyICE)
70%Base
H2
PFI Positive
Displacement
Supercharger
H2
DI
H2
Cryogenic
PFI
H2
PFI
Gasoline
PFI
Fu
el
Vo
l. E
ffy.
Ford Motor Company 28ERC Low Emission Symposium
CFD-Based Engine Upfront Design Methodology
Design
Modeling
Up-front Design
Optimization
Optical Engine
Models/Design
Validation
Thermo Engine
Design Evaluation/
Confirmation
Modeling
Up-front Design
Optimization
Optical Engine
Models/Design
Validation
Thermo Engine
Design Evaluation/
Confirmation
Modeling
Up-front Design
Optimization
Optical Engine
Models/Design
Validation
Thermo Engine
Design Evaluation/
Confirmation
Ford Motor Company 29ERC Low Emission Symposium
Injector Included Angle Optimization
Cutting plane
90° 120° 150°60°
t
(ms)
Included angles
0.5
1.0
2.0
3.0
60
45
30
15
A/F
Ford Motor Company 30ERC Low Emission Symposium
H2ICE Vehicle/Application Programs
2001 - P20002003 – NAIAS Model U 2003 – H2ICE Focus
2003 – Centennial H2RV2004 – H2ICE C-Max
2005 – H2ICE Hybrid Bus(Designline)
2004 – H2ICE Rotary
(Mazda)
2.0L I4 2.3L Supercharged I4
6.8L Boosted V10
2006 – H2ICE Demo/Fleet
2004 – H2ICE Hybrid Bus (ISE)
2004 – H2ICE Generator(Generac)
2005 – Airport Tractor
4.2L V-6
Ford Motor Company 31ERC Low Emission Symposium
Summary
Ford has been recognized among
the leaders in environmental
stewardship.
Ford will continue developing a
spectrum of vehicle technologies to
meet and/or exceed environmental
regulations and customers needs.