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					Clean Diesel Program
Technical Program Overview

 •   Partnership, Cummins and U.S. Department of Energy
 •   Focus
     – Light Truck Market, Pickups and SUV’s
     – Development of technologies that will result in a product in the
       near term
     – Emissions Goal
         ~ U.S. Tier 2 6000-8500 lb GVW
             » NOx = 0.07 g/mi
             » PM = 0.01 g/mi
     – Fuel economy - 50 percent MPG improvement over 1997
       gasoline powered vehicle it replaces


                                                                      2
                           Engine Design Proposal


                            Diesel Attributes:
                            Power                250 - 350 HP
                            Torque               335 -440 ft lb @ 2000 RPM
                            Speed                5000 RPM maximum             Light Truck
Fuel Economy, Durability




                            Fuel Economy         30 MPG
                            Durability           >200,000 miles               Diesel Vision
                            Image                High Technology



                                                                              Gasoline Attributes:
                                                                              Size
                                                                              Weight
                                                                              Noise/Vibration/Harshness
                                                                              Serviceability
                                                                              Quality/Reliability
                                                                              Cold Weather Characteristics
                                                                              Transient Response
                                                                              Sociability


                                                           Performance, Sociability
                                                                                                             3
Light Truck Diesel
Subsystem Description

Subsystem              Description
Configuration          90 V
Displacement           4.2 L V6 5.6 L V8
Bore and Stroke        94 X 100 mm
Valvetrain and Drive   Single overhead cam, chain-driven
Valve System           Four valves per cylinder with hydraulic lash adjustment
Fuel System            High-pressure common rail (HPCR)
Control System         Full electronic
Emissions Control      Modulated-cooled EGR plus Oxidation catalyst (Interim)
                       4-Way Catalyst (Tier 2, Bin 5)
Aspiration             Wastegated turbocharger
Intercooling           Vehicle mounted air-to-air
Block                  Cast iron, thin-walled
Head                   High temperature alloy aluminum
NVH Control            Deep skirted block, with bedplate, HPCR fuel system
Accessories            Common automotive V-8 gasoline
Accessory Drive        Single serpentine belt, self-adjusted
                                                                            4
Light Truck Diesel
Advanced Diesel Technology
 •   Cold weather characteristics
      – In-Cylinder Glow Plug
          ~ Fast warm up, full temp in less than 2 seconds
          ~ Vehicle integration reduces wait time to ZERO!
      – Fast warm up
          ~ Thin wall casting, reduced coolant capacity
          ~ Exhaust Gas Recirculation
 •   Transient Response
      – Full authority electronic controls
          ~ Engine and transmission controls working together
          ~ Mass Air Flow sensor for precise A/F control
          ~ Small, low inertia turbocharger

                                                                5
Light Truck Diesel
Advanced Diesel Technology - Performance
Land Speed Record Holder
730 HP, 1300+ Ft-Lb, 5.9 ltr displacement




                 Top speed - 222 mph
                 Two way average - 213 mph
                 city + highway combined fuel economy 21 mpg
                                                         6
Light Truck Diesel
Advanced Diesel Technology
                      Serviceability
                             Top mounted fuel filter
                             Standard automotive acc. Drive
                             Familiar user serviceable labeling
                             Hydraulic lash adjusters
                                no adjust valves
                                 Weight
                                 Thin wall castings
                                 Aluminum cylinder heads
                                 Integrated functions
                                     reduced bracketing
                                     cast in passages
                      Size
                        Fit within current gas V8 package
                        No major vehicle modifications

                                                            7
Light Truck Diesel
Advanced Diesel Technology
                      Noise
                          HPCR - pilot injection
                          Hydraulic lash adjusters
                          Chain driven overhead cam

                              Vibration and Harshness
                                  Deep skirted block
                                  Bedplate design
                                  Dampened covers




                                                        8
Noise Vs Gasoline Engines

                                            2000 RPM, Full Load

                                           Diesel       Gas       Cummins/DOE V6           1 Top Cover
                                                                                           2 Pan Encl.
                         100
   Noise, 1M SPL - dBA




                          95                                                       2


                                                              2
                          90                            1
                                                              2

                          85

                          80

                          75
                               1   2   3            4             5     6      7            8            9
                                              Displacement - Liters                Est. Eng/Eng SD = 0.6 dBA




                                                                                                               9
Light Truck Diesel
Advanced Diesel Technology




Sociability
    Ultra low sulphur fuel - low smell
    Soot filter - no visible soot emissions




                                              10
Light Truck Diesel
Advanced Diesel Technology
       V6, Automated Controls
                                                          Full Life Emissions, g/mi
                            Condition
                                                          NOx       PM          NMHC
    Regulations




                  Tier 2 Bin 8 (Max Bin)           Tier   0.20      0.02        0.125
                  2 Bin 5 (Fleet Neutral)                 0.07      0.01         0.09




                  Vehicle Results, Full FTP-75, Nov 02    0.46     <0.01            0.15
    Results




                  Test Cell, Full FTP-75, Jan 03          0.07     <0.01            0.40a


                                                                      a. Total HC



                                                                                            11
Light Truck Diesel
Advanced Diesel Technology
                  City,      Highway, Combined, Combined                 CO2
                  mpg*       mpg*     mpg*      gal/mi                   g/mi **

Typical SUV
- Gasoline        12         17          13.8             0.072          640
- Diesel          20.3       25.0        22.1             0.045          450
                                     +60% Improve         37% Reduction 29% Reduction
Typical 1/2 Ton Pick-up
- Gasoline        12         16          13.5             0.074          650
- Diesel          19.8       24.6        21.7             0.046          460
                                     +61% Improve         38% Reduction 29% Reduction


*Adjusted values for vehicle labeling (10% city, 22% highway)
** Based on discounted combined fuel economy
                                                                               12
Light Truck Diesel
Goals and Status
                                     Target                             Actual (status)
        Description
                           V6                    V8                V6                     V8
                             EPA Tier 2 in 2008
                             CA LEV II in 2007
  Emissions                  NOx,PM,HC focus                   Tier 2 Interim Demonstrated


                                 69 Hood Open,             68.7 Interior,      65.0 Interior,
  Noise, dBa                      Equal to Gas             Cruise @ 65 mph     Cruise @ 65 mph
                                                                               21.7 Combined,
                                                           22.1 Combined,      Pickup Truck
  Fuel Economy, MPG         50 % Better than Gas           SUV (+60% )         (+60% )
                               Equal to Gas
                             <2 RPH First Year
  Quality/Reliability       <10 RPH Five Years                       Not yet evaluated.

                                                            6400 hr Total Development Testing
  Useful Life, mi                B10 >200,000                    (estimated 960,000 CEU)

                                                           11.9 sec, 0-60      9.95 sec, 0-60
  Performance                    Gasoline-Like             mph, SUV            mph, 4x4 P/U

                                                                                    300 @ 4000
  Power, hp @ rpm       250 @ 4000            350 @ 4000      250 @ 3600        Interim target met.

  Torque Peak, ft-lb       335                   440              350                     460

  Weight, lb               650                   750              663                     835

                                                                                                  13
Conclusions

 • Advanced Diesels are capable of meeting the current,
   customer driven market demands


 • Advanced Diesels do not require major changes to vehicles
   (design and application), end users (care and operation), or
   infrastructure (fuels - based on 2007 fuel specifications)


 • Advanced Diesels offer nearly a 30% reduction in CO2
   emissions while meeting current and future emissions
   requirements



                                                             14

				
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posted:10/28/2011
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