TNO AutomotiveDiesel Emission Control
Introduction
New Concepts
Tools
Testing
14-okt-09 2
Presentation Content
1. Introduction
2. TNO Powertrains Roadmap
3. Proposition
4. Track record
5. Wrap-up
14-okt-09 3
Presentation Content
1. Introduction
2. TNO Powertrains Roadmap
3. Proposition
4. Track record
5. Wrap-up
14-okt-09 4
About TNO
Key Figures
○ TNO is the Netherlands Organization for Applied Scientific Research
○ Independent Research & Technology Development
○ Founded by law in 1932
○ 4,600 employees world-wide
○ HQ in Delft, the Netherlands
○ Annual turnover approx. 400 m€
Mission StatementTo apply scientific knowledge with the aim of strengthening
the innovative power of industry and government
14-okt-09 5
Automotive Campus / Location TNO Automotive
High Tech Automotive Campus:– High tech automotive companies– Facilities– Education programmes– Knowledge institutes– Engineering companies
14-okt-09 6
Offices PT & IS
Vehicle HiLtesting (VEHiL)
Homologations
Crash Testing
Powertrian Test Center (PTC)
Automotive Facilities
14-okt-09 7
TNO Automotive Global Presence
Livonia, MI, USA
Seoul, Korea
Yokohama, Japan
Wheelers Hill,Vic. Australia
Helmond The Netherlands
Nogent / Marne,France
Stuttgart & FrankfurtGermany
Coventry, United Kingdom
Shanghai, China
Bangalore,India
14-okt-09 8
– Focus area’s:Integrated Safety and Powertrains
– Over 35 years of automotive experience
– Close to 200 employees
– Over 65% Master or PhD
– Located in Helmond, the Netherlands
– International customers
– Annual turnover approx. 30 m€
– Multiple expertises in one location
http://www.automotive.tno.nl
Business Unit Automotive
14-okt-09 9
Automotive(Helmond)
Automotive(Helmond)
PowertrainsPowertrains
Diesel Emission ControlDiesel Emission Control
Future Automotive FuelsFuture Automotive Fuels
Powertrain TestingFacilities
Powertrain TestingFacilities
Integrated SafetyIntegrated Safety HomologationsHomologations
Science and IndustryScience and Industry
Diesel Emission Control within TNO
Defense, Security and Safety
Defense, Security and Safety
Quality of LifeQuality of Life
Built Environment and Geosciences
Built Environment and Geosciences
Information and Communication Technology
Information and Communication Technology
Advanced PowertrainsAdvanced Powertrains
14-okt-09 10
Science and IndustryScience and Industry
Connections within TNO
Defense, Security and Safety
Defense, Security and Safety
Quality of LifeQuality of Life
Built Environment and Geosciences
Built Environment and Geosciences
Information and Communication Technology
Information and Communication Technology
Monitoring SystemsMonitoring Systems
Environmental Sust.Transport (Delft)
Environmental Sust.Transport (Delft)
– Legal requirements– Test procedures– Traffic studies
Oil & GasOil & Gas
Separation technologies(Delft)
Separation technologies(Delft)
Thermal processes(Apeldoorn)
Thermal processes(Apeldoorn)
Case examples
– SCR chemistry– CFD modelling
Food & BiotechnologiesFood & Biotechnologies
– 2nd gen. Biofuels
Advanced concepts & productsAdvanced concepts & products – Plasma assisted gas cleaning
engine
aftertreatment
Limit
– Injector technology
Automotive
(Helmond)
Automotive
(Helmond)
TTAITÜV Rheinland TNO
Automotive International(Helmond)
TTAITÜV Rheinland TNO
Automotive International(Helmond)
– Vehicle safetyand crash testing
Crashbarrier
14-okt-09 11
TNO Role & Position
Automotive
Industrialisation&
CertificationEngineering
Research&
Adv. Eng.
Pull
Push
Market&
StrategyConcepts
TNO within the value chain
14-okt-09 12
Value within the Development V-cycle
Requirements, properties, specifications
ModuleFuel system, urea
dosing system
ComponentSensor, injector
Design &
Developm
ent
Validated,certified product
Inte
grat
ion
& V
alid
atio
n
Componenttesting
Module Testing
System SimulationPowertrain, engine,
aftertreatment
Vehicle SimulationHD / LD
to be intensified…
Vehicle TestingLD dyno, HD climatic-
altitude chamber
Powertrain Testingengine, transmission
dynamometers
SiL / HiL
TNO = Focus and strong areas
= Supporting
14-okt-09 13
About Diesel Emission Control group
Mission StatementTo provide validated new concepts, tools & controls for meeting
future diesel exhaust emission requirementsby applied R&D
NSR map
T
SV
Open-loop control
NOx engine-out prediction
NOx prediction Torque
revs
Engine-out NOx prediction
Adaptation & cross-sensitivity compensation
NOx sensor feedback control
Desorption compensation
T urea correction
urea dosage
correction factor
NOx sensor
T
Tailpipe NOx target
Tailpipe NOx target
Torque
revs
NOx ref
Test FacilitiesModel Based Control
14-okt-09 14
About Diesel Emission Control group
Areas of expertise
• Combustion control research
• Emission targets feasibility study
• Model based control development
• System & control strategy
development
• Design of exhaust lay-outs
• Engine testing and calibration
• Pre-production programs
• Demonstration vehicles
• Vehicle field testing
• Homologation, certification
• Benchmarking, reverse engineering
NSR map
T
SV
Open-loop control
NOx engine-out prediction
NOx prediction Torque
revs
Engine-out NOx prediction
Adaptation & cross-sensitivity compensation
NOx sensor feedback control
Desorption compensation
T urea correction
urea dosage
correction factor
NOx sensor
T
Tailpipe NOx target
Tailpipe NOx target
Torque
revs
NOx ref
14-okt-09 15
Presentation Content
1. Introduction
2. TNO Powertrains Roadmap
3. Proposition
4. Track record
5. Wrap-up
14-okt-09 16
Major Challenges (1/2)
Stringent Emission Legislation
○ Standards: EURO VI / 6, US2010
○ Transient cycles: ETC, FTP, JE05
○ Cold start impact
Focus of TNO’s“Diesel Emission Control” group
PM [g/km]
Euro 4 (’05)25
5
25018080
Euro 5a(’09)
Euro 6(‘12) NOx
[g/km]
PM [g/kWh]
Euro IV (’05)0.02
0.01
3.52.00.4
Euro V (’08)
Euro VI (‘12)NOx
[g/kWh]
Passenger Car Heavy Duty
14-okt-09 17
Energy Demand & Climate Change
○ Upcoming CO2 legislation (LD)
○ Fuel costs increases
� Pressure to reduce fuel consumption
○ Diversification of fuels to bio’s, synthetics, gaseous
○ Electrification of mobility: hybrids, EV’s
Major Challenges (2/2)
See also TNO’s“Advanced Powertrains” group
Additional cost
CO
2em
issi
ons
[g/k
m]
Petrol (current)
Petrol (future)
Micro hybrid
Diesel (current) Diesel (future)
Mild hybridFull hybrid
Hybrid potentialsbased on currentpetrol engine
Oil
Pric
e$
14-okt-09 18
Presentation Content
1. Introduction
2. TNO Powertrains Roadmap
3. Proposition
4. Track record
5. Wrap-up
14-okt-09 19
Proposition Overview
�Calibration, validation
�Current technology application
�Next generation solutions
TNO PropositionCustomer Need
New Concepts
Tools
Testing
Research and Application
14-okt-09 20
New Concepts - OverviewNew Concepts
Tools
Testing
• Integrated Powertrain Control (IPC)Supervisory control of engine, aftertreatment and
driveline to optimize trade-off’s (fuel consumption vs. emissions vs. power output)
• Integrated Emission Management (IEM)Synergy between engine and aftertreatment to optimize trade-off’s (fuel consumption vs. emissions)
• Aftertreatment OBDModel-based OBD control for more robust performance and less calibration effort
• Closed-loop combustion control – C3
Apply in-cylinder pressure information to minimisevariations in power output and combustion phasing, avoiding misfires and knock and increasing stable operating range (HCCI/PCCI/fuels)
• TNO Euro VI SCR conceptFuture emission limits realized with limited EGR, based on maximized SCR efficiency for better fuel consumption at less costs
14-okt-09 21
TNO Euro VI SCR conceptNew Concepts
Tools
Testing� TNO Euro VI SCR concept utilizes a close-
coupled SCR catalyst
� NOx conversion is maximized by smart control, thermal management and EGR/SCR balancing
� Reduced engine complexity compared to high volume EGR solution and better fuel consumption (CO2)
� Simulation and testbench validation show:
○ NOx conversion of 95% over a weighted cold and hot WHTC is possible
○ Engine out NOx emission of 7 g/kWh is low enough to meet Euro VI emission legislation
� Testbench program made possible by:
Close-coupled SCR catalyst
PM [g/kWh]
IV0.02
0.01
3.52.00.4
V
VI
NOx
[g/kWh]
0.03
7.0
Engineout
Tailpipeout
TNO Euro VI SCR concept
DPF
14-okt-09 22
Example project: SCR Development 2006-2008
initialdesign
catalyst &injector
system &componentcharacteri-
sation
geometry(cfd, cad)
catalystperformance
(fit tool,simcat)
controldevelopment
andprecalibration
(simcat)
SimulationTesting
rapidcontrol
prototyping(macs)
controlcalibration(winspecs)
vehicletesting
(roller dyno)
Testing
Design & Development
Integration & Validation
• Complete design & validation of SCR system (hard- and software) from concept to vehicle
• European LD OEM, US market
• Base MY 2005, Euro 4, 2.2litre turbo diesel
• Budget ~ 1.5 m€
• Issues tackled: Euro6 catalyst performance, homogeneity of urea distribution, crystallization, catalyst aging characterization for OBD
23.9°C
249.4°C
100
200
Inte
grat
ion
& V
alid
atio
n
�T
estin
g
PowertrainSystem
Vehicle
Module
Component
Module
VehicleDesign &
Developm
ent
�S
imulation
EURO 4 EURO 6
14-okt-09 23
Tools - OverviewNew Concepts
Tools
Testing• SIMCATExhaust aftertreatment modeling based on physical models
• Fit ToolAutomatic fitting of testbench data towards a validated SIMCAT model
• Model Based Supported CalibrationSIMCAT supported calibration of aftertreatment and OBD control strategies
• DYNAMO+Control oriented dynamic engine model to predict mechanical and thermal power output and emissions
• MACS 565Flexible and cost effective rapid control prototyping system consisting of controller and calibration tool
Tools Objective
Fue
lEff
icie
ncy
R&D&E time/costs
Potential within emission boundaries
Achieve more in less time at less costs
Tools
14-okt-09 24
SIMCATNew Concepts
Tools
Testing
Diesel Aftertreatment Modelling
� Diesel aftertreatment catalyst models buildusing actual physical models (instead of mathematical fitting) for increased resultrobustness
� Real-time capability
� Reduce time in development and calibration,especially in multi-configuration applications(e.g. different power ratings)
15 15
11
8
65
1616
0
2
4
6
8
10
12
14
16
18
Man-hours Dyno testing Man-hours Dyno testing
1st configuration 2nd configuration
Dur
atio
n [#
of d
ays]
Conventional SIMCAT based
31%
50%
60%67%
Simcat
14-okt-09 25
DYNAMO+New Concepts
Tools
Testing
Application examples:• Off-line calibration tool• Model-based control
development and OBD
Model-based combustion and aftertreatment control
Fuel injectionsettings
. . .
Intercooler Intake
Exhaust
Cooling
Valve
Compressor
Turbine
Exhaust gas
NOx, PM, temperature
Ambientconditions
IMEP, ISFC, CA50, pmax,dp/dca
EURO VI
NO
xan
d P
M
Aftertreat-ment
EURO IV/V
Combustionconcepts
Fuel Consumption
ConventionalDYNAMO+
DYNAMO+• Enabler of advanced
combustion concepts• Maximise combustion and
aftertreatment performance
14-okt-09 26
Calibration – Winspecs
Simulation – ADVANCE
I/O Modules:
• Analog/digital/timer I/O
• Otto engine Injection and /ignition
• Diesel engine Injection
• Electronic Throttle Control
• Client specific
Display & Control Panel
Analog I/O’s
Digital/timer I/O’s
Communication buses
• 3x hi-speed CAN
• Ethernet
CAN &
Ethernet
CAN
4 custom pins
MACS 565 RCP Controller
Modular Automotive Control System (MACS) is TNO’s in-house developed flexible controller for prototype systems, vehicles and small scale fleets
MACS saves time and cost in the early phases of the development proces.
After prototyping the hybrid control software can be developed into production code suited for a production controller
MACS 565New Concepts
Tools
Testing
14-okt-09 27
Powertrain Test Centre
Mission StatementTo provide R&D testing services in the field of combustion
engines, drivetrains and vehicles
New Concepts
Tools
Testing
14-okt-09 28
New Concepts
Tools
Testing
� Engine dyno’stransient, 20 - 700kW
� Transmissiontest bed with 2 transient dyno’s
� Chassisdynamometer for LD
� Digatronelectrical load simulator (750V, 300kW)
� Emissionsanalysis of both regulated (NOx, CO, THC, PM,…) and unregulated (NO, NO2, CH4, …) emissions by CVS, FTIR, PEMS, etc.
� Fuelsliquid and gaseous types, biofuels
� Climatic - Altitude Chamberengines, powertrains and complete HD vehicle testing at temperatures from –45 to +55 ºC and up to an altitude of 4000m
Powertrain Test Centre
14-okt-09 29
New Concepts
Tools
Testing
Powertrain Test Centre
Engine dynamometer& Emission measurement equipment
14-okt-09 30
New Concepts
Tools
Testing
Powertrain Test Centre
Climatic - Altitude Chamber
14-okt-09 31
ISC (EU)
Cold start,White smoke
Engine power,Turbo speed,Black smoke
Cooling,Engine-brake
DPFregen.
Temperature [°C]
Alti
tude
[met
ers]
NOx control OBD (EU)
NTE (US)
OBD (UN)
IUPR (EU)
0
1000
2000
3000
4000
-50 -40 -30 -20 -10 0 10 20 30 40 50 60
New Concepts
Tools
Testing
Powertrain Test Centre
Climatic chamber application examples
TNO climatic – altitudechamber range
14-okt-09 32
New Concepts
Tools
Testing
Powertrain Test Centre
Climatic – Altitude Chamber Specifications
� Temperature range-45 to +55 °C
� Altitude range0 to 4000 m
� Wind speed, nozzle area120 km/h, 1.25 x 0.7 m
� Dynamometer power, torque550 kW, 7000 Nm
� Regulated emissionsNOx, CO, THC, CO2
� Unregulated emissionsNO, N2O, O2, NH3
� Analysers: FTIR, particulate partial flow sampler, full flow CVS (at standard ambient conditions)
� Two direct emission lines at all ambient conditions
� Full transient hub-mounted dynamometers Veh
icle
tem
pera
ture
Duration
-45 °C
~ 2 hrs+ 55 °C
+ 21 °C
~ 8 hrs
Pre
ssur
e
Duration
~ ½ hrs
4,000 m
14-okt-09 33
Presentation Content
1. Introduction
2. TNO Powertrains Roadmap
3. Proposition
4. Track record
5. Wrap-up
14-okt-09 34
Track Record ExamplesTNO Internal Research
� First SCR project from 1993 to 1996 and first SCR demonstrator truck in 1999
� Euro VI testbench demonstrator
� Closed-loop combustion control engine demonstrator. Real-timemodel based control
Customer Projects
Commercial vehicle
� Development of DPF soot load predictor based on pressure drop and a regeneration strategy based upon this predictor
� Full engine and SCR calibration of two HD diesel applications for Tier 4i non-road emission standard
� Calibration and certification of Euro III common rail diesel engine
� Evaluation, calibration and certification of a complete aftertreatment system for a Euro IV truck application
Passenger car
� Multiple SCR research and application projects
� Evaluation of a DPF regeneration assistance system (HC doser) and development of a production-intent control strategy
� Impact analysis of HD test procedures on a LD vehicle (van) diesel engine and aftertreatment system
14-okt-09 35
Presentation Content
1. Introduction
2. TNO Powertrains Roadmap
3. Proposition
4. Track record
5. Wrap-up
14-okt-09 36
Summary
Next generation solutionsInnovative concepts for cost-effective modelling and control of advanced combustion and exhaust aftertreatment systems
Tools for current technologyTools to reduce time and effort in the application of available technology
TestingState-of-the art test facilities, including a full-sized climatic-altitude chamber, to support in a wide spectrum of testing needs
TNO Diesel Emission Control
New Concepts
Tools
Testing
14-okt-09 37
� Questions?
� How to continue…
Q & A
14-okt-09 38
Contact Information
TNO Science and Industry
BU Automotive
Steenovenweg 15708 HN Helmond
P.O. Box 7565700 AT Helmond
The Netherlands
T +31 40 265 2600F +31 40 265 2601E [email protected]
www.automotive.tno.nl