thermal management – hot on the trail of emissions reduction · hot on the trail of emissions...

Thermal management –

Hot on the trail of emissions reduction

Alex Morein

Michael Weiss

Losses

Drive

Energy

Combustion energy

> 80% of energy lost

100%

?

Schaeffler Symposium 2014 Alex Morein 1


Usual suspects

Energy Requirements for Combined City/Highway Driving

US Dept. of Energy http://www.fueleconomy.gov/feg/atv.shtml

Engine Losses: 70% -72%

thermal such as radiator,

exhaust heat, etc. (60%-62%)

combustion/enrichment (3%)

friction (3%)

pumping (4%)

Parasitic Losses: 5% - 6%

Power to Wheels: 17% - 20%

Drive train Losses: 5% - 6%

Thermal management: why now?

• Global regulations

• Downsizing

• High heat output components

• Downspeeding

• Increased cooling system flexibility

• Lean assembly

Schaeffler Symposium 2014 3 Alex Morein

http://eofdreams.com/data_images/dreams/clock/clock-04.jpg


Shrinking ideal operation zone

Downsizing

Thermal Mass

Downsizing

Temperature

flexibility

Ideal Zone

Traditional

temperature

System

temperature limit

Nominal

temperature

Te

mpera

ture


Outdated thermostat

80

Oct. 1, 1934

Downsizing?

Flexibility?

X X


Schaeffler thermal management module

SOP

July 2011, Audi EA888 Gen.3

Function

Coolant control

Flow distribution

Advantages

shorter warm-up phase

increased thermal efficiency

CO2- and fuel consumption reduction

increased interior comfort

First on the market


video here

To block

To

radiator

Trans HX,

cabin return Radiator

return

Engine

oil HX

Block

return


Audi performance

Flexibility

Precision: +/-2°C

En

gin

e te

mp

era

ture

T in

°C

Ve

hic

le s

pe

ed

v in k

m/h

Time t s

2-4% CO2 Reduction


System flexibility

● Customizable

– Number ports

– Flow rates

– Diameters

Engine connection

Radiator feed

Interior heating

Bypass / EGR

Sensor & Drive

Commonized actuator components


CAFE demonstration vehicle

Base Engine

Zero-Flow

Zero-Flow + Oil Heating

Hot engine

Delta (fuel savings)

Warm-up

time

reduction

10%

Fu

el co

nsu

mp

tio

n in

hg

/h

Time t in s

Warm-up

time

reduction

30%

Test Point:

S. Grams, KIT

Comparing warm up strategies



Increasing cabin comfort

Time t in s

Pump pulsating

Seat

tem

pe

ratu

re T

in

°C

Pump on

Pump delayed 120s

Pump delayed 210s

70

60

50

40

30

20

10

0 100 300 400 500 600 800 700 200


System simplification

Head

Radiator feed

Block

(Turbo)

Interior

Heating

Bypass

1.0L Gasoline engine, split cooling

Main

Thermostat Split cooling

thermostat

14 Schaeffler Symposium 2014 Alex Morein

1.0L Gasoline engine, split cooling


Engine performance test bench setup


No thermal

management Zero flow Zero flow & oil heating

S. Grams, KIT

Exhaust valve bridge

Upper cylinder liner

Middle cylinder liner

Expectations


Exhaust Valve Bridge

Engine Oil Temp.

Cylinder Liner-top end

Cylinder Liner-center

Valve angle Zero-Flow

Head open

Block open

Radiator Control

Va

lve

an

gle

Engine performance test results


Exhaust temperature test results

• Higher exhaust gas temperature: faster catalytic converter light-off

300

320

340

360

380

400

420

440

0 100 200 300 400 500 600 700

Tem

per

atu

re T

in °

C

Time t in s

without TMM

with TMM



Retrofit and measurement of a 1.6L I4

130s

15°


Meaurement results-1.6L I4

Base engine

Retrofit

Time t in s

xy

Te

mp

era

ture

T in

°C

Zero flow Rapid warmup Hot operation Flexibility


Emission Benefit in NEDC (warm-up only)

Redu

ctio

n

Solving the puzzle

• Cooling systems growing in complexity

• Higher level of vehicle integration, including powertrain

• Push for lean assembly efforts

• System-level solution required


There is nothing more deceptive

than an obvious fact.

” ‟

Sherlock Holmes

per Sir Arthur Conan Doyle

1859-1930

thermal management – hot on the trail of emissions reduction · hot on the trail of emissions...

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