Transient Simulation of a 2007 Prototype Heavy-Duty Engine · • Crankshafts • Aftertreatment...

Copyright © 2004 Caterpillar Engine Research

Heavy Truck Clean Diesel (HTCD) Program

Transient Simulation of a Transient Simulation of a 2007 Prototype Heavy2007 Prototype Heavy--Duty EngineDuty Engine

PI’s: Kent Rutan, Josh Driscoll, Maarten Verkiel

Prog. Mgr.: David Milam

DOE Contract DE- FC05- 00OR22806

DOE Team Leader: Gurpreet Singh Prog. Mgr.: Roland GravelTech. Mgr.: Carl Maronde

2004 DEER ConferenceCoronado, CA

Caterpillar


Presentation Overview

n HTCD Program Background

n Simulation Tools Overview

n Test Cell Model Contents

n Transient Test Cell Results

n Truck Model

n Summary

n Truck Model Movie


Heavy Truck Clean Diesel Goalsn Funded by HTCD CAT/DOE programn Phase 1 goal 2007 emissions, 45% efficiency

NOx + NMHC (g/hphr)

PM

(g

/hp

hr)

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo

NOx + NMHC (g/hphr)

PM

(g

/hp

hr)

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo

47% identified in analysisn 2007 In-chassis demonstration

DEER 2003

n Phase 2 goal 2010 emissions, 50% efficiencyn 2010 In-chassis demonstrationnn Simulation critical to achieving HTCD goalsSimulation critical to achieving HTCD goals


More with Less – High Fidelity Simulation

Steady-statePerformance

Multi Cylinder Steady State

Develo

pm

ent C

ycle

Simulation World <$Objectives Test World $$$

Transient/SystemPerformance

Multi Cylinder Transient

Detailed Comb.+ Emissions

Single Cylinder Test Cell

Real-worldSystemPerformance

2007 DemonstratorTruck



In-cylinder 3DCombustion



Develo

pm

ent C

ycle

Simulation World <$Objectives




Test World $$$





More with Less – High Fidelity SimulationCaterpillar 3D Combustion Simulation Software






Develo

pm

ent C

ycle





Test World $$$




EngineAftertreatment (A/T)(Separately)


More with Less – High Fidelity SimulationCaterpillar Engine Cycle Simulation Software

n Thermodynamicsn Heat Transfern Fuelingn Combustionn Air systemsn Components






Develo

pm

ent C

ycle





Test World $$$





Engine + A/T+ Test Cell

Engine + A/T+ Vehicle

(Coupled Together)

(Coupled Together)



Caterpillar Dynasty™

“for toolbox of components to simulate the whole system”

Engine Simulation Software+

Caterpillar Confidential: YellowKent Rutan 8 Apr 2004

Caterpillar Engine ResearchDiesel & Emissions Technology

Tool Development

n Tool development funded 100% by Cat

n Tool application for HTCD 50/50 cost share


Dynasty Components and Applications

Drivelines• Transmissions• Clutches• Final drives• Wheels & Tires• Gear dynamics

Linkages & Structures• 2D & 3D rigid bodies• Flexible body dynamics

Controls & Electronics • Component & full vehicle

simulation• Algorithm development• User programming• Co-simulation

Fluid Systems• Fuel• Hydraulic• Lube • Brake• Steering

Engine Systems• Cycle simulation• Valve trains• Crankshafts• Aftertreatment

Cooling Systems• Radiators• ATAAC• Fans• A/C• Parasitics

Component-based architecture supports diverse modeling applications






Develo

pm

ent C

ycle





Test World $$$







(Coupled Together)

(Coupled Together)

Focus of presentation


Heavy Truck Clean Diesel Goalsn Funded by HTCD CAT/DOE programn Phase 1 goal 2007 emissions, 45% efficiency

NOx + NMHC (g/hphr)

PM

(g

/hp

hr)

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo

NOx + NMHC (g/hphr)

PM

(g

/hp

hr)

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo

47% identified in analysisn 2007 In-chassis demonstration

DEER 2003

n Phase 2 goal 2010 emissions, 50% efficiencyn 2010 In-chassis demonstrationnn Simulation critical to achieving HTCD goalsSimulation critical to achieving HTCD goals


NOx + NMHC (g/hphr)P

M (

g/h

phr )

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo

NOx hphr)P

M (

g/h

phr )

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo


M (

g/h

phr )

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo

NOx hphr)P

M (

g/h

phr )

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo


M (

g/h

phr )

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo

NOx hphr)P

M (

g/h

phr )

2.5

0.1

1.2

0.01

0.2

2010 Demo

2007 Demo

n Feed into production process

Simulation Process Follows HTCD Goals

Emissions

Fuel Economy

Design Integration

Reliability & Durability

Val

ue

Timeline

Standar

d Com

mercial

ProgramDOE HTCD

Program

Emissions

Fuel Economy

Design Integration

Reliability & Durability

Cu

sto

mer

Timeline

Standar

d Com

mercial

Program

Production

DOE HTCD

ProgramDOE HTCD

Program

nModel validation on 2007 demo engine, truck

n Basis for 2010 system models






Develo

pm

ent C

ycle





Test World $$$







(Coupled Together)

(Coupled Together)


2007 Demo Builds on ACERT Technology

Electronics and Controls

CombustionAftertreatment

Air Systems

i=1

Exhaust Gas Volume

Catalyst Surface

,...),],NO([]NO[

PTxfdt

xd=

i=1

Exhaust Gas Volume

Catalyst Surface

,...),],NO([]NO[

PTxfdt

xd=

i=1

Exhaust Gas Volume

Catalyst Surface

,...),],NO([]NO[

PTxfdt

xd=

Integrated Integrated Engine SystemEngine System

®


Details Included in Simulation

Electronics and Controls

CombustionAftertreatment

Air Systems

i=1

Exhaust Gas Volume

Catalyst Surface

,...),],NO([]NO[

PTxfdt

xd=

i=1

Exhaust Gas Volume

Catalyst Surface

,...),],NO([]NO[

PTxfdt

xd=

i=1

Exhaust Gas Volume

Catalyst Surface

,...),],NO([]NO[

PTxfdt

xd=

Integrated Integrated Engine SystemEngine System

Multiple Injections

Same Control Code for Test or Simulation

Series Turbos

Variable Valve Timing

Particulate Filter

This project was undertaken pursuant to an agreement with the United States in connection with settlement of disputed claims in an enforcement action under the Clean Air Act


Engine + A/T + Test Cell Simulation

Transient Test CellTransient Test Cell

n Computer cycle command

n Dynamometer with speed/torque mode switching

n Transient torque controller

Engine & Engine & Aftertreatment SystemAftertreatment System


Next Slides: FTP Cycle Results20 minute Heavy-Duty Federal Test Procedure

Time (20 min. total)

Spee

d (%

)Lo

ad (

%)


Fuel consumption difference < 0.5% No transient performance

calibration for these results!

Measurement technique averages instantaneous fuel rate

System Performance Results(Test: Black Curves)(Simulation: Red Curves)


Note how integrated measured fuel lags then catches back up

System Performance Results – Zoomed In(Test: Black Curves)(Simulation: Red Curves)


FTP Cycle NOx

Dilu

te N

Ox

(pp

m)

n Modified PleeNOx model

n “Standard” coefficients with some transient matching

Test vs Simulated FTP Cycle NOxTest Point 4 Hot Run 7

Test NOx Sim NOx

NO

x(g

/hp.

hr)

Engine-Out NOx Results(Test: Black Curves)(Simulation: Red Curves)


FTP Cycle Engine-Out PM

PM

Rat

e

Test vs Simulated FTP Cycle PMTest Point 4 Hot Run 7

0

Test Est PM Sim PMP

M (g

/hp.

hr)

n Test-based steady-state PM map

n Transient A/F multiplier

n Transient match

Engine-Out PM Results(Test: Black Curves)(Simulation: Red Curves)

(test estimated from opacity)


Diesel Particulate Filter Results(Test: Black Curves)(Simulation: Red Curves)


Engine-Out PM Reduction – System Effect

n High engine-out PM rate to accelerate filter loadingn Red: baselinen Blue: ½ steady-state engine-out PM rate across board

For this particular system, 2X higher engine-out PMrate gives about 2.6X faster filter loadingdue to increasing backpressure on engine. Leads to increased fuel consumption and increased need for regeneration.

Filt

erP

ress

ure

Dro

p

So

ot

in T

rap

(g/L

)






Develo

pm

ent C

ycle





Test World $$$







(Coupled Together)

(Coupled Together)


2007 Demonstrator Truck Model

n Engine from test cell model drops into truckn Similar level of detail in truck modelnMore in video at end of presentation


Summary – Transient Simulation

n Need to model details – accuracy, relevancy

n Need to include more than just engine

n Caterpillar has been practicing this for years with the help of excellent simulation tools

n Need to improve modeling of measurements (measurement error and dynamics become even more significant for 2007/2010)

n Need to pay attention to engine-out PM for best engine/particulate filter system


Acknowledgements

n These results are built on the work of 100’s of Cat people over decades. Inventors of the basic computing tools are:

James R. Weber, Scott A. Leman, and Kem D. Ahlers, William L. Brown, and Eric C. Fluga.

n Cost share provided by the United States Department of Energy


Truck Simulation Movie

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