2. www.luisarimany.com Feasibility of the 3 litre per 100 Km small family petrol car with regular port injection Luis E. Arimany Supervisor : Matthew Harrison Supported by AVL, Austria

3. www.luisarimany.com Objectives of the thesis To use a structured approach to explore the feasibility of the 3 litre per 100 km fuel consumption car The project is focused in the alternative of a small gasoline engine with regular port injection

4. www.luisarimany.com Thesis structure Why 3 litre per 100 km? How ? Problems ? Assume a car Design the engine Calculate fuel consumption

5. www.luisarimany.com Why 3 litre / 100 Km? Global warming Agreements Economy CO 2

6. www.luisarimany.com Why 3 litre / 100 Km? Global warming Agreements Economy UNFCCC Kyoto Protocol 2153 rd Council Meeting

7. www.luisarimany.com Why 3 litre / 100 Km? Global warming Agreements Economy UNFCCC Kyoto Protocol 2153 rd Council Meeting

8. www.luisarimany.com

9. How ? Low weight Low rolling resistance Low aerodynamic drag Redesign gears Hybrid powertrain Fuel cells Alternative fuels EGR Lean burn. GDI Turbocharge Variable valve timing Variable lift timing Camless

10. www.luisarimany.com Problems of the 3 litre car target Technical problems Cost Customer expectation Drivability and NVH

11. www.luisarimany.com Target of the project Gasoline engine –Cancer risk –Diesel pollutes more –“A litre of diesel is not a litre of gasoline” Small engine –Optimum bsfc –Less friction –Less weight and improve packaging Regular port injection

12. www.luisarimany.com Assumed car

13. www.luisarimany.com Assumed car

14. www.luisarimany.com Engine designed

15. www.luisarimany.com Engine designed 2

16. www.luisarimany.com bsfc 0 50 100 150 200 250 300 350 010002000300040005000600070008000 rpm g/KWh Boost results Torque and Power 0 10 20 30 40 50 60 100020003000400050006000 rpm Nm 0 5000 10000 15000 20000 25000 30000 W

17. www.luisarimany.com Boost results

18. www.luisarimany.com Europeancycleprogram Why? Flexibility Calculates fuel consumption in ECE 15, EUDC and Combined Check engine capacity Sensitivity analysis

19. www.luisarimany.com Europeancycleprogram How?

20. www.luisarimany.com Results Importance of idle in the ECE and therefore in the Combined Importance of engine deactivation

21. www.luisarimany.com Results (2) Little change Mass more sensitivity Not possible to achieve 3 litre target with only this strategy Fuel consumption 3.85 3.9 3.95 4 4.05 4.1 4.15 4.2 4.25 -20-1001020 % parametre change L/100Km mass Cd Frontal area

22. www.luisarimany.com Validation of the results. 41.7 kW/ litre vs. 45 kW/litre 86.5 Nm/ litre vs. 90 Nm 243 g/kWh vs. 260 Torque and Power 0 10 20 30 40 50 60 100020003000400050006000 rpm Nm 0 5000 10000 15000 20000 25000 30000 W bsfc 0 50 100 150 200 250 300 350 010002000300040005000600070008000 rpm g/KWh

23. www.luisarimany.com Validation of the results. Comparison with MCC Smart 600 cc Turbocharged 6 gears Small 31% more power 34% more torque 19.8 % worst fuel economy 31% more power 34% more torque 19.8 % worst fuel economy

24. www.luisarimany.com Conclusions Weight, drag coefficient and frontal area reductions is not enough Engine deactivation is compulsory. Care with cool down and not additional fuel consumption Although 3.45 l/100km, the 3 litre car is possible, but low performance. 600 cc, 28 kW and 55 Nm It would be

25. www.luisarimany.com Work done Study of technologies which improve fuel economy Study of engine simulation, its advantages and its limitations Study valves and fmep Design an engine Write a fuel consumption program Derive important conclusions

26. www.luisarimany.com Future work Optimisation of gears for a very small engine. Study of the problems of using engine deactivation. Study of the implications to the catalyst and other non CO2 emissions Study of the tuning of a small engine. Study of the impact of the engine size in the fmep Study of the effect of introducing an ECU into the AVL Boost model in order to modify valve timing and spark timing. Study of the implication of running lean mixtures with a very small engine. Study the feasibility of increasing the compression ratio. Alternative fuels.

27. www.luisarimany.com Any question?

28. www.luisarimany.com Load

29. www.luisarimany.com Restriction Load defined as max_bmep/max_ max_bmep