Heavy-Duty-, On- und Off-Highway-Motoren 2018

Frontmatter

Why I love my diesel so much – … and nevertheless flirt with other drives

Zusammenfassung

To approach the subject we should take the time to look what is behind the term “nonroad mobile machinery (NRMM)”.

Werner Seifried, Marion Schmid

How do you define the best powertrain solution for your off‑highway customers?

Zusammenfassung

The optimum powertrain configuration for future machines will vary from BEV to improved efficiency ICE and everything in between including mild and full hybrid systems. The best solution will be the one that delivers the lowest costs (total cost of ownership and capital cost) while meeting customer performance goals, and legislative and ethical requirements for emissions including pollutants and greenhouse gases.

William Missions, Ben Dexter, Andy Skipton-Carter, Pascal Revereault, Matthew Maunder

Next generation high-speed engines paving the road for the highest engine efficiency

Zusammenfassung

High-speed engines are set to be the main power source for decentralized power generation, commercial and high-performance marine, Oil&Gas service, Rail as well as for construction equipment (C&I). Considering the projection, that next generation highspeed engines will be operated much more in integrated systems and hybridized applications, the thermal efficiency of the combustion engine will still be in the main focus of new engine developments.

Günter Figer, Kurt Schmidleitner, Thomas Kammerdiener, Mathias Schönbacher

Efficiency improvements for commercial vehicles through dynamic electronic horizon

Zusammenfassung

It is well established that greenhouse gas emissions must be reduced to combat climate change. To realise this, many countries and regions around the world are setting greenhouse gas reduction targets. The European Union has defined a timeline for the phased reduction of greenhouse gas emissions, 20% by 2020, 40% by 2030 and 80% by 2050, all relative to 1990 levels.

Gareth Milton, Fabien Fiquet, Anuradha Wijesinghem, Andy Noble, Peter Fussey

Layout and integration of a range extender in a medium‑duty truck

Zusammenfassung

The non-disputable global climate change has led to challenging goal setting with respect to reduction of anthropogenic greenhouse gas emissions in the 2015 Paris Agreement of the United Nations Framework Convention on Climate Change [1.1]. One major contribution to achieve this goal is expected from fuel economy improvements in the field of transportation. In addition to the already established legislative regulation of fuel consumption for Light- and Heavy-Duty in the United States, China and Japan [1.2, 1.3, 1.4], the European Commission published its proposal for CO2 standards for Heavy-Duty truck applications in May 2018 [1.5].

Stefan Wedowski, Markus Ehrly, Korbinian Vogt, Farouk Odeim, Bastian Holderbaum, Christopher Marten, Johannes Moritz Maiterth

Improving the quality of in‑service emission compliance based on advanced statistical approaches

Zusammenfassung

For Heavy-Duty (HD) as well as for Non-Road Mobile Machinery (NRMM) applications, legislative requirements regarding in-use emission compliance have been introduced in recent years. The in-use compliance needs to be fulfilled under real-world boundary conditions for different engine applications with partly very large load profile differences in HD trucks and NRMM machineries. Moreover, the driver/operator influence and the operation under various ambient conditions (hot/cold temperatures, various altitudes) must be considered.

Daechul Jeong, Maurice Smeets, Henning Gero Petry, Markus Netterscheid, Imre Pörgye, Matthias Kötter, Sung-Yong Lee

Emission simulation as a tool for the evaluation of future CV emission concepts

Zusammenfassung

The tightening of the emission regulation over the last decades has a significant influence on the size as well as on the complexity of the exhaust systems for heavy duty vehicles. Starting with the introduction of a diesel oxidation catalyst (DOC) to reduce hydrocarbons (HC) and carbon monoxide (CO) emissions according to emissions legislation, with the introduction of EU4 emission limits for heavy duty commercial vehicles the more complex SCR technique took place within Europe. The application of the SCR technology provides an excellent potential for reducing NOx emissions of commercial vehicles.

Heike Többen, Philipp Weinmann, Lisa Zimmermann, Markus Henzler

DEUTZ G2.2 – the new 3-cylinder gas engine for non‑road mobile machinery

Zusammenfassung

Beginning of 2019 DEUTZ will launch its first gas engine for non-road mobile machinery. The G2.2 is based on the new Diesel engine platform D/TD/TCD 2.2 which is a 3-cylinder version of the existing D/TD/TCD 2.9 engine family. The G2.2 is developed primarily for LPG, but operation with CNG is also possible with light modifications.

This article describes the commonalities with the Diesel engine as well as the specific properties needed for a monovalent robust gas engine for industrial applications. It will focus on the adaptation of the mechanical system of the engine, the combustion, the mixture formation and the specific control system. This includes a safety concept needed for the utilization of gas.

Heiner Bülte, Carsten Funke, Klaus-Peter Bark, Kai Tedsen

A high efficiency lean-burn mono‑fuel heavy‑duty natural‑gas engine for achieving Euro VI emissions legislation and beyond – part 2

Zusammenfassung

Engine development for road haulage transportation is facing several major challenges relating to the reduced minimum payload for in-service emissions conformity and future limitations on CO2 emissions that will require improved fuel economy. Currently in the European Union (EU), Diesel engines dominate the market share of Heavy-Duty Vehicles (HDVs), with this category of vehicles accounting for one quarter of the total CO2 emissions emitted in the transportation sector. To address the significant CO2 production within the sector, the European Commission has recently announced the intention to implement a legislative proposal to regulate CO2 emissions from new HDVs [1].

André Barroso, Andrew Auld, James Manuelyan, Matthew Keenan, Paolo Ferrero Giacominetto, Rhys Pickett

Improving fuel flexibility: new Jenbacher gas engine versions with high power density for gases with high carbon dioxide content

Zusammenfassung

Due to the constantly growing world population and the associated energy demand, along with increasingly stringent environmental regulations, the use of alternative gas fuels is becoming more attractive and more widely used. These gases historically have been considered waste gases and burned using flares but there are significant financial, social and environmental benefits from their use in internal combustion engines to produce heat and power. Modern gas engines will play a significant role in future world-wide decentralized energy supply by delivering high power density, efficiency and reliability with low emissions levels under challenging operating conditions around the globe.

Stefan Prankl, Robert Böwing, Herbert Schaumberger, Robert Wilson, Dietmar Heintschel, Thomas Elsenbruch

The effective use of ethanol for GHG emissions reduction in a dual‑fuel engine

Zusammenfassung

Regulations have been established for the monitoring and reporting of greenhouse gas (GHG) emissions and fuel consumption from the transport sector, including heavy-duty vehicles. Low carbon fuels combined with new powertrain technologies have the potential to provide significant reductions in GHG emissions while decreasing the dependency on fossil fuels. In this study, advanced combustion control strategies have been used as means to improve upon the efficiency and emissions of a lean-burn ethanol-diesel dual-fuel engine.

Vinícius B. Pedrozo, I. May, T. Lanzanova, W. Guan, H. Zhao

Real‑time capable combustion simulation of a dual‑fuel engine for hardware‑in‑the‑loop application

Zusammenfassung

Due to increasing restrictive legislation, modern DF-engines become more and more important, especially in marine application to meet the IMO Tier III limits in coastal areas, without using complex exhaust gas after-treatment systems. Compared to conventional combustion processes in diesel or gas engines, the characteristics of the Dual-Fuel process are not fully understand and the increased degree of freedom leads to a demanding application and test effort. To handle the resulting complexity for the development of engine control functions, it is essential to support the development process with suitable simulation methods.

Stefan Kraft, M. Moser, C. Büskens, M. Echim

Formulating to meet the lubrication challenges of modern gas engines to prolong oil life and maximize engine protection

Zusammenfassung

Over the past few decades the world’s population has grown considerably, and continues to do so. Combined with an overall increase in standards of living the global demand for energy has increased and is expected to continue to rise. Natural gas is increasingly being seen as one of the solutions to cater for this increased energy demand. As a fuel it is readily available, flexible and affordable.

Jonathan M. Hughes

Integration of manufacturing aspects into the development of heavy-duty engine cast components

Zusammenfassung

Grey iron cast components were introduced for their lightweight and functional integration potential in steam engines already 70 years before the first combustion engine driven automobiles appeared about 130 years ago. Since that time there was a parallel development of engine design, performance, iron casting processes and iron metallurgy and alloy performance. It is clear and fair to say, that the demands from engine developers and the capabilities of metal casting grew together and profited from each other all the time.

Johannes Heger, Götz Hartmann, Mathias Bodenburg

Flow-optimized cooling gallery concept for laser welded steel pistons to enable reduction of oil flow

Zusammenfassung

Der Muldenrand von Stahlkolben ist grundsätzlich der thermomechanisch am höchsten belastete Bereich, so dass der Kühlung mit über Düsen zugeführtem Motoröl in Kombination mit einem Muldenrandnahem Kühlölkanal eine besonders hohe Bedeutung zukommt. Das Ziel weiterer Steigerung der thermischen Effizienz erhöht die Anforderungen an das Bauteil unter Druck- als auch Temperaturbelastungen. Da die üblichen Werkstoffe für Stahlkolben den Einsatzbereich in Nfz- und Industriemotoren hinsichtlich der maximalen Temperaturen begrenzen, sind optimierte Kühlungskonzepte ein entscheidender Beitrag. Zukünftige Abgasvorschriften in allen Regionen der Welt werden den bisherigen Fokus auf optimierte Betriebskosten, z.B. durch lange Ölwechselintervalle und niedrige Kraftstoffverbräuche, um den Anspruch niedriger CO2-Emissionen noch erweitern, so dass Maßnahmen zur Erhöhung des Gesamtwirkungsgrades und die Reduzierung der Reibleistung die wichtigsten Ziele darstellen.

Daniel Hrdina, Weiping Yang, Geno Marinov, Adam Loch

Development methodology for valves spindles and seat ring tailored for future large bore engines

Zusammenfassung

Currently, the large bore engine itself is facing challenging requirements. Ambitious emission legislations worldwide and next level of efficiency at peak firing pressures more than 250 bar cause novel operating conditions. Furthermore, in the rising age of hybridization and electrification of the powertrain a new operating behaviour occurs. Peak on demand, increasing number of shutdowns in hybrid mode with solar or wind power plants characterize a new trend of stationary large bore engine applications in recent years. From the field it can be observed that still working solutions are pushed to their limits and are subjected to high wear. One of these solution is the system valve spindle/seat ring.

Oliver Lehmann

Combined LP / HP EGR system for HD diesel engines for optimum fuel consumption and lowest raw NOX emissions

Zusammenfassung

In commercial vehicles, a high technical level is reached today in terms of emissions abatement and fuel consumption reduction. The emission levels according to EURO VI are currently fulfilled via a combination of DOC, DPF and SCR system.

Simon Schneider, Carsten Koolmann, Rainer Lutz, Jorge Curras-Guede

Electrically assisted turbocharging – enhanced engine agility for off-highway applications

Zusammenfassung

As with drives for passenger vehicles, the development of propulsion systems for off-highway applications involves an intricate interplay between fuel consumption, transient load response capability and the reduction of all kind of emissions. This means that an innovative approach to technical solutions is essential if optimum results are to be achieved.

Rudi Rappsilber, J. Thiesemann, J. Kech

Holistic design process for new commercial application engine concepts

Zusammenfassung

New legislation and the demand to increase the effective efficiency of the propulsion, require an always far-reaching optimization of the complete powertrain. In addition, nitrogen oxide emissions from internal combustion engines have recently been subject to strong public perception and discussion, which has put additional pressure on legislation.

Sören Franke, Uwe Parsche, Carsten Schreiter, Tom George

Dynamic rate shaping – one diesel common-rail injector for all combustion strategies

Zusammenfassung

With Diesel engine emission targets stabilising, the focus is now shifting towards CO₂ reduction and fuel economy improvements. This is especially true for the heavy duty truck engine, where legislation is already in place in the United States, and is being proposed in Europe, that sets challenging new targets for CO₂ reduction. Of course, for any heavy duty engine, fuel costs also constitute a major part of the total cost of vehicle ownership, adding to the pressure on engine manufacturers to reduce fuel consumption.

David Needham, Dan Mellors, Tony Williams, Thomas Cawkwell, Simon Tullis

The new Liebherr LI1 common-rail injector platform

Zusammenfassung

Liebherr, a family owned company in the third generation, launches a new platform of common rail injectors for light-, medium- and heavy- duty engines. The LI1 (Liebherr Injector) platform was developed for large volume production and maximum customer application freedom. Proven series materials from our applications in heavy duty construction machinery were taken over and show outstanding resistance to contaminated fuels compared to other injectors on the market.

Norbert Schöfbänker, Richard Pirkl, Dennis Herrmann, Verena Kögel

Next generation of smart injectors for future diesel and dual-fuel applications

Zusammenfassung

Common Rail fuel injection systems had a remarkable success since their first introduction in 1997. Today, they dominate all Diesel engine segments from passenger car to large two-stroke engines. Woodward L´Orange has been at the forefront of Common Rail system development and introduced several milestone products with improved emission performance or other functional capabilities.

Andreas Lingens, Clemens Senghaas, Michael Willmann, Hartmut Schneider

eWHR box approach: from component development to system testing in the real world and synergies with future drive train

Zusammenfassung

Modern long haul trucks utilize about 40% of the fuel energy for propulsion, the remaining is dissipated into the environment as waste heat. Increasing the vehicle overall efficiency is of high importance – for OEMs due to upcoming CO2 legislation [1] and for end customers to reduce the total cost of ownership. Harvesting the waste heat by means of a Rankine cycle is considered as the biggest single measure to fulfill these targets.

Hannes Marlok, Jana Mertens, Michael Bucher, Klaus Irmler, Richard Brümmer

Development of an ORC turbo pump for waste heat recovery from the coolant of an HD truck

Zusammenfassung

Waste heat recovery (WHR) will shortly become a necessity to improve engine efficiency and provide significant reduction in fuel consumption of trucks and passenger cars and reach ambitious CO2 emissions.

Pascal Smague, Pierre Leduc, Philippe Pagnier, Gaël Leveque, Norman Holaind, Gabriel Henry, Arthur Leroux

Challenges for the power pack system from the perspective of a global agricultural machinery producer

Zusammenfassung

CLAAS is a family business founded in 1913 and one of the world’s leading manufacturers of agricultural engineering equipment and among the top 10 in the German mechanical engineering sector.

Thomas Böck

Tagungsbericht

Zusammenfassung

Die 13. Internationale MTZ-Fachtagung „Heavy-Duty-, On- und Off-Highway- Motoren“ fand am 6. und 7. November in Köln statt. 164 Teilnehmer aus 12 Ländern diskutierten unter anderem über zukünftige Antriebskonzepte, Abgasnachbehandlung und alternative Kraftstoffe.

Marc Ziegler