1. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 1 Continental Automotive GmbH Advanced development (AD) at INGAS SPA2 Meeting 2009-11-05 Naples

2. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 2 Continental Automotive GmbH WPA2.1 + WPA2.3 First half year ECU / IO – Box development Integration of additional components and signals and implementation of functionality Transfer of functionality from 16Bit platform (Project NICE) to 32Bit platform Preparation of basic calibration data for engine operation Procurement of ECU + IO Box + delta wiring harness 8 Systems were built up 2x car system 1x engine test bench 1x HIL 4x spare parts Support of DAI / AVL for engine operation at the engine test benches

3. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 3 Continental Automotive GmbH WPA2.4 Combustion system development Planned objectives Development of a DI combustion system, Optimizing the mixture formation with methodologies like transparent engine and 3D-CFD simulation. Operation strategies for starting capability, catalyst heating strategies, part load fuel consumption and full load capabilities. From CONTI, ECU functionalities have to be developed in order to realize the different combustion strategies achieve the emission targets realize a good drivability of the demo car

4. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 4 Continental Automotive GmbH WPA2.4 Combustion system development Fuel injection functionality start of injection angle (SOI) or the injection duration (TI) dependent of the desired end of injection angle (EOI) the cylinder charge, the necessary fuel amount, the opening and closing behaviour of the injector and the counter pressure in the cylinder pcyl

5. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 5 Continental Automotive GmbH Cylinder pressure characteristic due to injected fuel Increase of cylinder pressure of ca. 7% due to injected gas Cylinder pressure w/o fuel Cylinder pressure with CNG All fuel in for λ=1 11bar

6. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 6 Continental Automotive GmbH Cylinder pressure characteristic due to injected fuel

7. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 7 Continental Automotive GmbH Mass fuel flow dependent of crank angle For CNG χ ≈ 1,3 Ψ = 0,47 p critical at Π = 0,55  at p rail of 20 bar  p critical ≈ 11bar Π crit Mass fuel flow is constant supercritical independent of cylinder pressure Mass fuel flow is sub critical dependent of cylinder pressure

8. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 8 Continental Automotive GmbH Evaluation of NICE measurements EOI / load variations in the EU NICE project at MB-TECH in Munich 30 measurements EOI variation of -160... -80 °CRK in 20° steps Load variation from MAP 400.... 1400 hPa corresponds to pmi approx. 3... 12bar Engine speed N = const = 2500 rpm Test program: Change load and EOI in dedicated steps Varies TI until lambda = 1 Objective Is there a dependency of TI from EOI and MAP ?

9. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 9 Continental Automotive GmbH Evaluation of NICE measurements lower load at late EOI longer injection times at late EOI

10. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 10 Continental Automotive GmbH SOI calculation EMS requires time based trigger EOI is calibrated TI 1+2+3 = f (MAP, MAF, A/F, MFF) TI = TI_ADD_DLY + TI 1+2+3 SOI = f (EOI, TI, N) = EOI – 360 / 60 x N x TI TI opening behavior of the injector

11. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 11 Continental Automotive GmbH Evaluation of NICE measurements Without further corrections

12. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 12 Continental Automotive GmbH Evaluation of NICE measurements Mass flow correction

13. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 13 Continental Automotive GmbH Summary of fuel injection investigations We always consider supersonic conditions TI = f(MFF,mass fuel flow FAC_MFF_STND, fuel flow through the injector = constant FAC_TI_1_PRS_HOM, pressure correction = f(PGAS_L, MAF) FAC_TI_1_TGAS_HOM, temperature correction = f(TGAS_L) TI_TUN_ADD_IV[x], injector individual correction = f(injector number), slope correction VB ) voltage battery correction = f(VB) but neutral calibrated because of seperate piezo injector drivers TI_ADD_DLY (x)= f(injector number) offset correction

14. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 14 Continental Automotive GmbH New functionality for pressure low side control Problem: Unstable pressure at transient to fuel cut off and vise versa

15. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 15 Continental Automotive GmbH New functionality for pressure low side control

16. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 16 Continental Automotive GmbH New SW for pressure low side control Problem Unstable pressure at transient to fuel cut off and vise versa Solution Establish of a new interface form interface box to the ePCD control unit ->PWM signal 0... 100% = 0... 180V Advantage IB is connected to the main ECU via CAN -> Engine operation state and load info is transmitted to IB -> Pre control of fuel pressure at transient conditions.

17. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 17 Continental Automotive GmbH New SW for pressure low side control State Pressure control functionality integrated in the IB Problems occurred due to ALTERA compiler version mismatch for the ePCD electronic –> PWM frequency wasn't synchronal –> Modification of interface box SW for 400Hz PWM frequency Dataset was calibrated First tests were carried out in a CNG car Pressure stabablity better in transient conditions at PUC phases But controller needs some improvements –for adaptation –at start conditions

18. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 18 Continental Automotive GmbH WPA2.6 Vehicle Demonstrator Outlook Integration of DI engine into vehicle Adaptation of wiring for new ECU, IO – Box, CNG interface box, ePCD electronic, Piezo injector driver Unit Adaptation of ECU functionality for the use in the car

19. INGAS meeting, Naples, 05-06 Nov. 2009 INGAS INtegrated GAS Powertrain 19 Continental Automotive GmbH Thank you for your attention! For further information please contact: Harry Schuele Continental Automotive GmbH Siemensstr. 12 93055 Regensburg, Germany Telefon/Phone: +49 941 790-4291 Mobile: +49 160 97292958 E-Mail: Harry.Schuele@continental-corporation.com