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Fiat 1.4L CNG performance - Presentation contents

Fiat 1.4L CNG performance - Presentation contents. Engine tests at bench : 1 st phase with base engine Engine characterization with CR 9.8 (full load + Willans) Engine improvements : CR = 11:0 + Turbo matching Engine tests at bench : 2 nd phase with new hardware

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Fiat 1.4L CNG performance - Presentation contents

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  1. Fiat 1.4L CNG performance - Presentation contents • Engine tests at bench : 1st phase with base engine • Engine characterization with CR 9.8 (full load + Willans) • Engine improvements : CR = 11:0 + Turbo matching • Engine tests at bench : 2nd phase with new hardware • Engine characterization with CR 11 + VGT (full load + Willans)

  2. Engine tests at bench : 1st phase with base engine • Compression ratio : 9,8:1 • Turbocharger : IHI 150 CV

  3. Engine tests at bench : 1st phase with base engine • Partial load characterisation • Willans lines

  4. Engine tests at bench : 1st phase with base engine • Full load characterisation • Constraints : max temperature inlet turbine = 950 °C • max cylinder pressure (Pcyl max + 3s) = 105 bars Max torque : IFP : 226 N.m @ 2500 rpm CRF : 218 N.M @ 2040 rpm Max power : IFP : 90 kW @ 5000 rpm CRF : 94 kW @ 5000 rpm

  5. Engine improvements : CR = 11:0 + Turbo matching Turbo matching : Simulation of 4 turbocharger configurations : Pressure loss models :

  6. Turbo matching 2000 rpm Compressor IHI RHF3 BRL315 04 (Base TC) Compressor C224(46) 55 Trim 0.46 A/R > 3000 rpm 1 3 2 4 Compressor C224 (44) 60 Trim 0.44 AR (associated with VGT) 4750 rpm Compressor C224(38) 60 Trim 0.38 A/R

  7. Turbo matching VGT turbocharger simulation : Allowed max. BMEP taking into account surge line Target 60 % 80% 30 % ? 100 % 40 % • VGT is the best competitor to improve the full load engine performances. • VGT offers the potential to improve the low speed engine performance, in spite of the surge line of the compressor from 1000 to 1500 rpm • For engine speed higher that 2500 rpm, the VGT turbine also offers an higher efficiency than a fixed geometry turbine with an opened waste gate.

  8. Engine tests at bench : 2nd phase with new hardware • Compression ratio : 11:1 • Turbocharger : VGT Garrett GT1444

  9. Engine tests at bench : 2nd phase with new hardware • Partial load characterisation • Willans lines

  10. Engine tests at bench : 2nd phase with new hardware • Differences observed at partial load could be due to : • New compression ratio • New turbine permeability • New engine parts (piston rings, crankshaft bearings, …)

  11. Engine tests at bench : 2nd phase with new hardware • Full load characterisation : Torque • Constraints : max temperature inlet turbine = 850 °C • max cylinder pressure (Pcyl max + 3s) = 105 bars • Max torque : • IFP CR 9.8:1 : • 226 N.m @ 2500 rpm • IFP CR 11:1 + TGV • 227 N.m @ 2250 rpm • (limited by Tin turb = 850 °C)  Max torque at lower rev

  12. Engine tests at bench : 2nd phase with new hardware • Full load characterisation : Power • Constraints : max temperature inlet turbine = 850 °C • max cylinder pressure (Pcyl max + 3s) = 105 bars • Max power : • IFP CR 9.8:1 : • 90 kW @ 5000 rpm • IFP CR 11:1 + TGV (l=1) • 76 kW @ 4500 rpm !! •  strongly limited by • Tin turb 850 °C, not WOT • IFP CR 11:1 + TGV (l opti) • 92 kW @ 5000 rpm • limited by Tin turb = 850 °C

  13. Engine tests at bench : 2nd phase with new hardware • Full load characterisation : Thermomechanical constraints Turbine inlet temperature Pcyl4 + 3s Performation limitation due to turbine inlet inlet temperature

  14. Engine tests at bench : 2nd phase with new hardware • Full load characterisation : Turbochargers duty zones IHI 150 CV VGT Garrett GT1444 Compressor of Garrett TC presents better efficiency than IHI one In return, surge limit is dramatically reduced

  15. Conclusions • New hardware configuration (VGT + CR 11:0) • offers similar performances regarding maximum torque and power. No improvement was obtained because the lower maximum turbine inlet temperature (850°C vs. 950°C) • reduces maximum torque engine speed (VGT effect) • does not reduce the fuel consumption because the turbine is undersized • GT 1444 compressor works with a better efficiency … • … but the safety margin regarding surge is not sufficient with the GT1444

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