Initial investigations showed that the fuel consumption can be reduced by up to 15% due to the global synergy between compression ratio, EGR rate and the fuel-air equivalence ratio. Based on these investigations, combustion concepts have been laid out for passenger car and LCV engines. After experimental assessment on a single cylinder engine and projection on different driving cycles, the expected gains identified at the very beginning of the project are not confirmed. The highest efficiency gain was reached for the LCV application which resulted in figures between 0.7% and 2.6% improvement, depending in the driving cycle. No improvement has been reached with the passenger car application. All the theoretical thermodynamic advantage that VCR combustions system could offer is overcame by its critical capacity to reach the pollutant targets, particularly the NOx/Soot trade-off. Besides of the thermodynamic topics modelling activities focused of the prediction of particle emissions.
Sub 23nm particle source analysis was carried out. PN measurements from dynamometer tests with the LCV baseline vehicle were made and analyzed. Low porosity substrates (for CSFs) and high porosity substrates (for SCRFs) have been selected to give a defined substrate for meeting best filtration, considering compromises with back pressure. Filtration efficiencies were investigated in detail also for special operating modes such as cold start and regeneration. All full size catalysts and filters were provided for both the demonstrator engines and lab size catalysts for lab investigations of ageing and robustness.
A new 2.0L Diesel engine for the RENAULT Espace was laid out and procured. This engine features a new air charging concept for improving the catalyst temperature management, a new fuel injection system (from partner CONTINENTAL) and advanced concepts for EGR and charging. Furthermore, a new aftertreament system has been laid out and an engine model has been developed which was used for extrapolation of the vehicle characteristics (calibration) to extreme environmental conditions (cold start, high altitude). The engine and aftertreatment system have been developed and calibrated on engine test bed. In the last project year, they have been installed in the demonstrator vehicle which initially was baseline tested with the MY2015 engine. After final calibration of the vehicle on the chassis dynamometer, the vehicle was delivered to partner ViF who managed its final independent testing. The targets were reached except a small exceedance of the CO2 in WLTC. One basic research topic investigated the use of thermal insulation coatings for specific engine components.
After procurement of the Iveco Daily demonstrator vehicle it was intensively baselined, primarily with respect to its particle emissions. This was partly carried out in the labs of partners. The analysis and design tasks enabled the specification and procurement of the new components. Aftertreatment hardware screening on engine test-bed showed most promising results with eDOC+SCRF+SCR and PNA+SCRF+SCR.
Initially, the baseline vehicle was tested by partner ViF. In the second period the advanced engine and aftertreatment system were integrated to the vehicle and again delivered to ViF who managed the final assessment. All project targets were reached with this demonstrator vehicle.
Development of calculation tools to determine the impact of the FIE on CO2 emissions, and to evaluate the deterioration of the EAS and its impact on pollutant emissions over useful vehicle life. Measurements of fuel injection systems were carried out on an advanced test rig. Various new catalysts were tested in the lab and their ageing characteristics have been determined. With the measured characteristics an engine model was correlated which was used to project the ageing and robustness characteristics (with respect of emissions and CO2) to the lifetime of vehicles.
Measurements with the base-configuration of the demonstrator vehicles have been carried out and all test procedures for the final assessment have been defined. Furthermore an LCA has been carried out which builds on the characteristics and final results achieved with of the demonstrator vehicles.
