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The Advanced Internal Combustion Engine Report

2013 edition supplierbusiness.com

Sectoral Report

IHS Automotive

2013 edition 2 © 2013 IHS

IHS Automotive SupplierBusiness | The Advanced Internal Combustion Engine Report

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ContentsIntroduction ..................................................................................................................................................................... 7Market drivers ................................................................................................................................................................. 9

Emissions regulations ................................................................................................................................................. 9The United States ......................................................................................................................................................... 9The European Union ...................................................................................................................................................11Japan ..........................................................................................................................................................................11China ..........................................................................................................................................................................11Other countries .......................................................................................................................................................... 12

Fuel costs .................................................................................................................................................................... 13Criterion emissions ................................................................................................................................................... 14

The United States ....................................................................................................................................................... 14Japan ......................................................................................................................................................................... 15Europe ....................................................................................................................................................................... 15China ..........................................................................................................................................................................17Other countries ...........................................................................................................................................................17

Powertrain design ...................................................................................................................................................... 18Powertrain technology ................................................................................................................................................. 22

Engine downsizing and down-speeding ................................................................................................................. 22Combustion cycles .................................................................................................................................................... 26Altered combustion modes ...................................................................................................................................... 27Variable valve actuation ............................................................................................................................................ 29

Variable valve timing and lift ........................................................................................................................................ 30Camless valve actuation ........................................................................................................................................... 35

Electro-hydraulic valve actuation ................................................................................................................................ 35Electromagnetic valve actuation ................................................................................................................................. 35

Cylinder deactivation ................................................................................................................................................ 37Direct injection technology ...................................................................................................................................... 40

Spray-guided injection ................................................................................................................................................ 42Diesel injection technology ......................................................................................................................................... 43

Advanced ignition systems....................................................................................................................................... 45Laser ignition systems ................................................................................................................................................ 47

Compression-ignition engine technologies .............................................................................................................. 50Combustion cycles .................................................................................................................................................... 51Downsizing ................................................................................................................................................................. 51Material development................................................................................................................................................ 52

Forced induction ........................................................................................................................................................... 57Compressors .............................................................................................................................................................. 57

Screw compressors ................................................................................................................................................... 58Centrifugal compressors ............................................................................................................................................ 58

Bearing systems ........................................................................................................................................................ 59Micro turbocharging ................................................................................................................................................. 60Waste-gated turbochargers ..................................................................................................................................... 61Twin-scroll turbochargers ........................................................................................................................................ 61



Variable geometry turbochargers ........................................................................................................................... 63Multi-stage turbocharging .......................................................................................................................................... 66Sequential twin turbocharging .................................................................................................................................... 66Regulated twin turbocharging .................................................................................................................................... 67Three-stage turbocharging ......................................................................................................................................... 68

Twin vortices supercharger ...................................................................................................................................... 68Multi-speed superchargers ...................................................................................................................................... 68Electric superchargers ............................................................................................................................................. 69

The Future of Turbocharging ..................................................................................................................................... 70Charge air coolers (intercoolers) ............................................................................................................................. 73

Exhaust and emissions control ................................................................................................................................... 75Gasoline engine emissions control ......................................................................................................................... 76

Three-Way Catalytic converter (TWC) ......................................................................................................................... 77Exhaust Gas Re-circulation (EGR) .............................................................................................................................. 79

Diesel engine emissions control .............................................................................................................................. 81Diesel oxidation catalyst ............................................................................................................................................. 81Selective catalytic reduction ....................................................................................................................................... 83Lean NOx trap or NOx adsorber catalyst.................................................................................................................... 86CRT Process .............................................................................................................................................................. 87Diesel particulate filter ................................................................................................................................................ 87Catalyst Poisoning ..................................................................................................................................................... 90The SCR versus EGR debate ..................................................................................................................................... 90SCR plus EGR for Euro 6 ........................................................................................................................................... 92

Thermal management ............................................................................................................................................... 93Alternative compression-ignition technologies .................................................................................................... 94

Homogenous charge compression ignition ................................................................................................................ 94Reactivity controlled compression ignition .................................................................................................................. 94Gasoline direct-injection compression ignition ............................................................................................................ 95

Alternative engine technologies ................................................................................................................................. 97Achates Power opposed-piston engine ...................................................................................................................... 97EcoMotors OPOC ...................................................................................................................................................... 97RadMax Rotary Turbine Engine .................................................................................................................................. 98Tour Engines ............................................................................................................................................................. 99Axial Vector ...............................................................................................................................................................101

Variable compression ratio engines ...................................................................................................................... 101FEV ...........................................................................................................................................................................101MCE-5 ......................................................................................................................................................................101Gomecsys GoEngine ................................................................................................................................................101Lotus Engineering .....................................................................................................................................................101Ilmore five-stroke ...................................................................................................................................................... 102Ricardo 2/4SIGHT engine......................................................................................................................................... 102Scuderi .................................................................................................................................................................... 103Transonic Combustion ............................................................................................................................................. 103Pinnacle Engine ........................................................................................................................................................ 103Wave Disk Generator................................................................................................................................................ 104Cyclone Power Technologies ................................................................................................................................... 105

Alternative fuels .......................................................................................................................................................... 106Alcohols ....................................................................................................................................................................107Algal biofuels ............................................................................................................................................................ 109Bacterial biofuels .......................................................................................................................................................110Biogasoline ...............................................................................................................................................................110Dimethyl ether ...........................................................................................................................................................110Hydrogen ..................................................................................................................................................................110Hythane ....................................................................................................................................................................111



Liquefied petroleum gas ............................................................................................................................................111Natural gas ................................................................................................................................................................111Coal to liquid fuels .....................................................................................................................................................112Biodiesel ...................................................................................................................................................................113Dimethyl ether ...........................................................................................................................................................114Natural gas ................................................................................................................................................................114

Powertrain market outlook .........................................................................................................................................116North America ...........................................................................................................................................................116Europe ......................................................................................................................................................................117China ........................................................................................................................................................................118

FiguresFigure 1: Global CO2 (g/km) progress normalised to NEDC test cycle .................................................................... 8Figure 2: CO2 (g/km) performance and standards in the EU new cars 1994 - 2011 ................................................ 9Figure 3: Global CO2 (g/km) progress normalised to NEDC test cycle .................................................................. 10Figure 4: US Regular Gasoline prices $/gallon, January 2011 to June 2013 .......................................................... 11Figure 5: WTI crude oil prices (US$ per barrel, monthly average 2010 dollars), 2001 – March 2012 .................. 12Figure 6: NOx limits in the EU, Japan and the US, 1995 – 2010 (g/kWh) ................................................................ 14Figure 7: PM limits in the EU, Japan and the US, 1995 – 2010 (g/kWh) .................................................................. 15Figure 8: Aluminium/ magnesium lightweight design 6 cylinder engine .............................................................. 16Figure 9: Engine weight and performance for aluminium and cast iron blocks ................................................... 17Figure 10: Active engine mount technology .............................................................................................................. 17Figure 11: Cumulative sales of Ford’s EcoBoost engine family .............................................................................. 18Figure 12: 1.0L EcoBoost cylinder head with integrated exhaust manifold .......................................................... 18Figure 13: Progress through powertrain technologies ............................................................................................ 20Figure 14: The effects of downsizing on fuel consumption ..................................................................................... 21Figure 15: Comparison between downsized turbocharged diesel and non-turbocharges gasoline (Volvo) and turbocharged gasoline and non-turbocharged gasoline (Opel) performance ...................................................... 21Figure 16: Performance evolution through downsizing and turbocharging for the Volkswagen Golf .............. 22Figure 17: Low-end torque versus mid-high speed brake specific fuel consumption for gasoline engines from MY2005 to MY2012 ....................................................................................................................................................... 23Figure 18: Low-end torque versus mid-high speed brake specific fuel consumption for gasoline engines from MY2005 to MY2012 ....................................................................................................................................................... 23Figure 19: Atkinson versus Otto cycle operation ...................................................................................................... 24Figure 20: A schematic of homogenous and stratified charge modes .................................................................. 26Figure 21: General classification of variable valve actuation technology ............................................................. 28Figure 22: Honda i-VTEC system ................................................................................................................................ 29Figure 23: BMW Valvetronic system ........................................................................................................................... 30Figure 24: Comparison of airflow with VVT on a diesel engine .............................................................................. 31Figure 25: Variable valve actuation on 6.7-litre Cummins diesel ............................................................................ 32Figure 26: Valeo electromagnetic valve actuation.................................................................................................... 34Figure 27: LaunchPoint’s electromechanical valve actuator system ..................................................................... 35Figure 28: Variable cylinder management ................................................................................................................ 36Figure 29: Pattern of variable cylinder management operation ............................................................................. 37Figure 30: A6 cylinder on demand system ................................................................................................................ 37Figure 31: Direct injection operation .......................................................................................................................... 39Figure 32: Measures to improve fuel economy ......................................................................................................... 40Figure 33: A comparison of wall-guided and spray-guided direct injection ......................................................... 41Figure 34: Comparison of piezo-actuated and servo-hydraulic-actuated injector spray patterns .................. 42Figure 35: BorgWarner’s Dual Coil ignition system .................................................................................................. 43Figure 36: Federal Mogul’s Corona Ignition System ................................................................................................ 44Figure 37: Schematics of ignition using conventional spark and laser technology ............................................. 44



Figure 38: Schlieren photographs for early stage of ignition in a constant-volume chamber ignited by spark plug and micro-laser in a stoichiometric mixture .................................................................................................... 45Figure 39: New diesel car registrations, EU15 + EFTA, 1991 - 2010 ....................................................................... 48Figure 40: Total cost of ownership, diesel versus gasoline US over 3 years/ 45,000 miles ................................ 49Figure 41: Case study for downsizing versus de-rating for a 1460kg curb weight passenger car ..................... 50Figure 42: A polyamide air intake manifold ............................................................................................................... 51Figure 43: Ultra-thin steel coated cylinder bores in aluminium crankcases (LH image) compared with con-ventional grey cast iron (RH image) ........................................................................................................................... 52Figure 44: Federal Mogul’s DuraBowl technology for piston crown strengthening ............................................. 53Figure 45: Material properties comparing CGI 400, Gray Iron 250 and AlSi9Cu alloy .......................................... 54Figure 46: Global supercharger/ turbocharger fitment by type, 2011 – 2017 ........................................................ 55Figure 47: An Eaton roots-type supercharger with integrated bypass .................................................................. 56Figure 48: Compressor map of a turbocharger for passenger car applications .................................................. 57Figure 49: Fiat two-cylinder MultiAir engine ............................................................................................................. 58Figure 50: Volvo D12D 500hp Euro 3 engine turbo-compound set up ................................................................... 59Figure 51: Multi-scroll turbine housing design.......................................................................................................... 60Figure 52: A schematic of a twin scroll turbocharger .............................................................................................. 60Figure 53: Deflection through a dual-volute-turbine housing with VTG guide vanes .......................................... 61Figure 54: Twin volute VTG with optimised exhaust manifold design .................................................................... 62Figure 55: Holset VGT™ Turbocharging Technology ................................................................................................ 64Figure 56: BMW bi-turbo .............................................................................................................................................. 65Figure 57: Exploded view of a Rotrak variable-speed supercharger ..................................................................... 66Figure 58: Antonov dual-speed supercharger .......................................................................................................... 67Figure 59: Valeo’s electric supercharger ................................................................................................................... 68Figure 60: Turbocharging technologies for high-pressure charging .................................................................... 69Figure 61: GM’s LF3 twin turbocharged V6 engine with integral manifold mounted intercooler ....................... 71Figure 62: A comparison of exhaust systems 1975 and 2009 .................................................................................. 73Figure 63: Tenneco’s technology road map for exhaust systems .......................................................................... 74Figure 64: A 2012 exhaust system including emissions control, CO2 reduction and acoustic design .............. 75Figure 65: Three-way catalytic converter .................................................................................................................. 76Figure 66: The effect of temperature on catalytic converter operation ................................................................ 76Figure 67: The effect of fuel-air mixture on catalytic converter operation ........................................................... 77Figure 68: Exhaust gas recirculation with cooler ..................................................................................................... 77Figure 69: The construction of an electrically heated TWC .................................................................................... 78Figure 70: Denso’s compact EGR cooler for gasoline engines ............................................................................... 79Figure 71: The construction of a diesel oxidation catalytic converter ................................................................... 80Figure 72: Selective catalytic reduction .................................................................................................................... 80Figure 73: Selective catalytic reduction schematic ................................................................................................ 81Figure 74: Delphi’s on-board reformer ....................................................................................................................... 82Figure 75: Faurecia ASDS unit ..................................................................................................................................... 82Figure 76: A schematic of Faurecia’s ASDS system ................................................................................................ 84Figure 77: NOx trap system with ECU control ........................................................................................................... 84Figure 78: Mercedes Benz E Class DPF ..................................................................................................................... 86Figure 79: A schematic of a wall-flow DPF ................................................................................................................ 87Figure 80: Acicular Mulite process effects in DPF substrate .................................................................................. 87Figure 81: A comparison between EGR and SCR technology ................................................................................. 89Figure 82: Schaeffler’s Thermal Management module ............................................................................................ 91Figure 83: Criterion emissions from RCCI engine by % gasoline ........................................................................... 93Figure 84: GDICI emissions results for single, double and triple injection ........................................................... 94Figure 85: Achates opposed piston engine ............................................................................................................... 95Figure 86: EcoMotors OPOC engine ........................................................................................................................... 96Figure 87: RadMax RTE engine driving a pump ........................................................................................................ 96Figure 88: The Tour engine .......................................................................................................................................... 97Figure 89: The Tour engine cutaway ........................................................................................................................... 97



Figure 90: Axial Vector engine .................................................................................................................................... 98Figure 91: 2/4SIGHT engine concept ........................................................................................................................ 100Figure 92: Wave Disk Generator ............................................................................................................................... 102Figure 93: Wave Disk Generator principles ............................................................................................................. 102Figure 94: SunEco algal fuel production ponds ...................................................................................................... 107Figure 95: GDICI emissions compared to a conventional diesel ...........................................................................111

TablesTable 1: US emissions standards for light-duty vehicles, to five years/50,000 miles (g/mile) ............................ 15Table 2: Japan emissions limits for light gasoline & LPG vehicles (g/km) ............................................................. 15Table 3: Japan emissions limits for light diesel vehicles (g/km) ............................................................................. 15Table 4: Euro 5 emissions limits for light gasoline vehicles (g/km) ........................................................................ 15Table 5: Euro 5 emissions limits for light diesel vehicles (g/km) ............................................................................ 16Table 6: Emissions standards timetable in selected countries, 2012 - 2021 ......................................................... 17Table 7: Fuel economy improvement and costs for powertrain .............................................................................. 18Table 8: Emissions control strategies ........................................................................................................................ 76Table 9: Reactions in a three- way catalytic converter ............................................................................................ 78Table 10: Cost comparison EGR vs SCR in Europe .................................................................................................. 92Table 11: Energy input versus output for alternative fuels .................................................................................... 106Table 12: Global powertrain technology penetration: 2012/2019 ...........................................................................116Table 13: North American technology penetration: 2012/2019 ..............................................................................117Table 14: European technology penetration: 2012/2019 .........................................................................................117Table 15: Chinese technology penetration: 2012/2019 ............................................................................................118

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