GREEN - Green Heavy Duty Engine
Overview
Background & policy context:
The development of heavy-duty (HD) engines is undergoing a rapid evolution. Increased demand for fuel efficiency, emissions and global competition are driving forces. HD engines operate under constraints much more severe than those of passenger cars, such as:
- higher durability (> 600 000 km) of the engine and of the related after-treatment;
- higher mechanical and thermal stress of the engine (heavier load factor);
- higher pressure on reliability (up-time), investment and fuel economy.
The above constraints characterise the HD engines for their more general applications: not only trucks and urban vehicles but also the rail traction and the inland waterway vessels of the directive 2002/765.
New technologies will help in meeting future emission and fuel consumption targets by:
- a new combustion process enabled by variable components;
- new control strategies;
- considering the engine and the exhaust after-treatment as one system;
- considering sustainable fuels.
Objectives:
The main objective of the integrated project GREEN was to perform research leading to subsystems for a heavy duty powertrain based on the intelligent integration of a new engine concept, characterised by:
- flexible components;
- an improved combustion process;
- models for a model based closed loop emission control;
- high power density ;
- integrated exhaust after-treatment system with good reliability at low load in wide range of operating conditions;
- on a competitive cost base;
- with the highest fuel conversion efficiency of the Diesel cycle;
- near-zero real world pollutant emissions and significant reduction of CO2.
Methodology:
The work in GREEN was divided into sub-projects:
Subproject A1
Perform a gas engine with maximum thermal efficiency potential with:
- Electro-hydraulic variable valves motion management (EVMG)
- Very near to valves multipoint port-gas injection and experimental study of DI injection;
- Cooled EGR
- Gas quality assessment.
Subproject A2
Evaluate the potential of different variability in combination with tailored exhaust after-treatment systems based on novel fuel injection and variable valve actuation (VVA) system combined with:
- Functional particulate filter and catalyst
- New control strategies for filter regeneration and injection
- Assessment of different concepts.
Subproject A3
Develop the concept of a new combustion process and the first step to a model based closed loop powertrain control characterised by:
- High pressure engine with optimised combustion chamber
- Totally new amplified common rail (CR) system with variable nozzle
- Raw emission, thermodynamic and exhaust system models
- Assessment of the developed models in the context of a model based closed loop emission control.
Subproject A4
Investigate the potential of a high BMEP engine with development of:
- One- and two-stage turbochargers
- New engine design
- Variable compression ratio system
- An exhaust gas energy recovery system.
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