TNO AutomotiveDiesel Emission Control

Introduction

New Concepts

Tools

Testing

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Presentation Content

1. Introduction

2. TNO Powertrains Roadmap

3. Proposition

4. Track record

5. Wrap-up

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Presentation Content

1. Introduction

2. TNO Powertrains Roadmap

3. Proposition

4. Track record

5. Wrap-up

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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

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Automotive Campus / Location TNO Automotive

High Tech Automotive Campus:– High tech automotive companies– Facilities– Education programmes– Knowledge institutes– Engineering companies

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Offices PT & IS

Vehicle HiLtesting (VEHiL)

Homologations

Crash Testing

Powertrian Test Center (PTC)

Automotive Facilities

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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

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– 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

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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

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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

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TNO Role & Position

Automotive

Industrialisation&

CertificationEngineering

Research&

Adv. Eng.

Pull

Push

Market&

StrategyConcepts

TNO within the value chain

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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

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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

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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

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Presentation Content

1. Introduction

2. TNO Powertrains Roadmap

3. Proposition

4. Track record

5. Wrap-up

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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

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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$

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Presentation Content

1. Introduction

2. TNO Powertrains Roadmap

3. Proposition

4. Track record

5. Wrap-up

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Proposition Overview

�Calibration, validation

�Current technology application

�Next generation solutions

TNO PropositionCustomer Need

New Concepts

Tools

Testing

Research and Application

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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

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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

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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

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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

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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

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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

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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

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Powertrain Test Centre

Mission StatementTo provide R&D testing services in the field of combustion

engines, drivetrains and vehicles

New Concepts

Tools

Testing

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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

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New Concepts

Tools

Testing

Powertrain Test Centre

Engine dynamometer& Emission measurement equipment

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New Concepts

Tools

Testing

Powertrain Test Centre

Climatic - Altitude Chamber

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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

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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

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Presentation Content

1. Introduction

2. TNO Powertrains Roadmap

3. Proposition

4. Track record

5. Wrap-up

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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

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Presentation Content

1. Introduction

2. TNO Powertrains Roadmap

3. Proposition

4. Track record

5. Wrap-up

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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

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� Questions?

� How to continue…

Q & A

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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 automotive@tno.nl

www.automotive.tno.nl