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A Mercedes E320 CDI vehicle has been modified for more optimal operation on Gas-To-Liquids (GTL) diesel fuel, in order to demonstrate the extent of exhaust emission reductions which are enabled by the properties of this fuel. The engine hardware changes employed comprised the fitment of re-specified fuel injectors and the reduction of the compression ratio from 18:1 to 15:1, as well as a re-optimisation of the software calibration. The demonstration vehicle has achieved a NOx emission of less that 0.08 g/km in the NEDC test cycle, while all other regulated emissions still meet the Euro 4 limits, as well as those currently proposed for Euro 5. CO2 emissions and fuel consumption, were not degraded with the optimised engine. This was achieved whilst employing only cost-neutral engine modifications, and with the standard vehicle exhaust system (oxidation catalyst and diesel particulate filter) fitted.

To fulfill future emission standards for diesel engines, combined after-treatment systems consisting of different catalyst technologies and diesel particulate filters (DPF) are necessary. For designing and optimizing the resulting systems of considerable complexity, effective simulation models of different catalyst and DPF technologies have been developed and integrated into a common simulation environment called ExACT (Exhaust After-treatment Components Toolbox). This publication focuses on a model for the NOx storage and reduction catalyst as a part of that simulation environment. A heterogeneous, spatially one-dimensional (1D), physically and chemically based mathematical model of the catalytic monolith has been developed. A global reaction kinetic approach has been chosen to describe reaction conversions on the washcoat. Reaction kinetic parameters have been evaluated from a series of laboratory experiments.

After-treatment systems (ATS) consisting of new catalyst technologies and particulate filters will be necessary to meet increasingly stringent global regulations limiting particulate matter (PM) and NOx emissions from heavy duty and light duty diesel vehicles. Fuels and lubes contain elements such as sulfur, phosphorus and ash-forming metals that can adversely impact the efficiency and durability of these systems. Investigations of the impact of lubricant formulation on the transfer of ash-forming elements to diesel particulate filters (DPF) and transfer of sulfur to NOx storage catalysts were conducted using passenger car diesel engine technology. It was observed that for ATS configurations with catalyst(s) upstream of the DPF, transfer of ash-forming elements to the DPF was significantly lower than expected on the basis of oil consumption and lube composition. Sulfur transfer strongly correlated with oil consumption and lubricant sulfur content.

BMW, DaimlerChrysler, Motorola and Philips present their joint development activity related to the FlexRay communication system that is intended for distributed applications in vehicles. The designated applications for powertrain and chassis control place requirements in terms of availability, reliability and data bandwidth that cannot be met by any product currently available on the market under the testing conditions encountered in an automobile. A short look back on events so far is followed by a description of the protocol and its first implementation as an integrated circuit, as well as its incorporation into a complete tool environment.

This paper describes the results of a joint development program focussing on the introduction of the new generation of Pt/Rh-technology for current and future emission standards as a cost effective alternative to the in serial Pd/Rh based exhaust gas concepts. In the initial phase of the program combinations of Pd- and Pt-based three-way catalyst technologies were evaluated on vehicles equipped with a 8 cylinder engine. One goal in this portion of the study was to achieve technical equivalence between a viable Pd-based technology and the new Pt/Rh technology in the underfloor position at lower precious metal loading. A combination of a close-coupled Pd/Rh technology and the new Pt/Rh in the underfloor position was able to meet the emission targets at significant lower costs of the system after a catalyst aging that resembles more than 100.000 km of vehicle German highway driving.

Suspension systems have a major effect on the handling characteristics of a vehicle, particularly ride comfort and handling safety, and thus substantially determine its character. Their increasing significance is reflected by the greater value that ever more demanding customers attribute to the properties ride comfort and handling safety. Now that the potential of conventional, passive systems is largely exhausted, adaptive and active systems open up new possibilities, e.g.: the suppression of rolling and pitching movements, handling and ride height independent of load, handling characteristics and ride height adaptable to situation and customer requirement. The DaimlerChrysler active suspension and damping system (Active Body Control – ABC) manages to resolve the conflict of aims between handling safety and ride comfort which afflicts conventional fixed suspension systems, and as a result offers greater freedom of layout whilst enabling optimization of both target criteria.

The EU SPARC Project (Secure Propelled Vehicle with Advanced Redundant Control) has developed a new system architecture that enables effective application of driver assisted systems in an X-by-wire powertrain. A major challenge in the conception of such a system is development of a reliable electrical energy supply. A simulation is the most important tool for enabling the fundamental aspects to work, as for example, a dimensioning of the powernet. This article explains our approach in this SPARC simulation. We provide suggestions through examples of how to find simulation solutions for powernet dimensioning, as well as for the conception and validation of energy management strategies.

In this article model-based controller design techniques are investigated for the transient operation of a common-rail diesel engine in order to optimize driveability and to reduce soot emissions. The computer-aided design has benefits in reducing controller calibration time. This paper presents a nonlinear control concept for the coordinated control of the exhaust gas recirculation (EGR) valve and the variable geometry turbocharger (VGT) in a common-rail diesel engine. The overall controller structure is set up to regulate the total cylinder air-charge with a desired fresh air-charge amount by means of controlling the intake manifold pressure and estimating the fresh air-charge inducted into the cylinders. During varying engine operating conditions the two control loops are coordinated by a compensation of the EGR valve action through the VGT controller.

This paper describes work supporting the development of a new Diesel particulate trap system for heavy duty vehicles based on porous sintered metal materials that exhibit interesting characteristics with respect to ash tolerance. Experimental data characterizing the material (permeability, soot and ash deposit properties) are obtained in a dedicated experimental setup in the side-stream of a modern Diesel engine as well as in an accelerated ash loading rig. System level simulations coupling the new media characteristics to 3-D CFD software for the optimization of complete filter systems are then performed and comparative assessment results of example designs are given.

The oil ash accumulation on modern three way catalyst (TWC) as well as its influence on catalyst deactivation is evaluated as a parameter of oil consumption, kind of oil additive compound and additive concentration. The oil ash accumulation is characterized by XRF and SEM/EDX in axial direction and into the washcoat depth of the catalyst. The deposition patterns of Ca, Mg, P and Zn are discussed. The catalytic activity of the vehicle and engine bench aged catalysts is measured by performing model gas tests and vehicle tests, respectively. The influence of oil ash accumulation on the lifetime emission behavior of the vehicle is discussed.

The background for the development activities of the motor vehicle industry is strongly influenced by lawmakers, with engine development, in particular, coming under increasing pressure from the requirements of emissions legislation. Demands for CO2 reduction and thus corresponding savings in consumption contrast with regulations which call for compliance with extremely low emission levels, featuring the extreme of zero tailpipe emissions, and alternative low emission levels which make accurate measurement a problem even with current analysis technology. An example of such requirements are the SULEV limits of California law. These standards have given rise to a wide variety of emission control concepts, each of which, however, has certain limitations in its application. In the context of this general setting, the paper shows that the phase directly subsequent to cold start should be focused upon if these ambitious targets are to be reached.

The LEV II and SULEV/PZEV emission standards legislated by the US EPA and the Californian ARB will require continuous reduction in the vehicles' emission over the next several years. Similar requirements are under discussion in the European Union (EU) in the EU Stage V program. These future emission standards will require a more efficient after treatment device that exhibits high activity and excellent durabilty over an extended lifetime. The present study summarizes the findings of a joint development program targeting such demanding future emission challenges, which can only be met by a close and intensive co-operation of the individual expert teams. The use of active systems, e.g. HC-adsorber or electrically heated light-off catalysts, was not considered in this study. The following parameters were investigated in detail: The development of a high-tech three-way catalyst technology is described being tailored for applications on ultra thin wall ceramic substrates (UTWS).

In response to ever more stringent emission limits (EURO IV, SULEV), engine developers are increasingly turning their attention to engine start-up and warm-up phases. Since in this phase the catalytic converter has not yet reached its operating temperature, problems occur especially with regard to hydrocarbon emissions (HC) which are emitted untreated. Secondary air injection represents one option for heating up the catalytic converter more quickly. The engine is operated during the heating up cycle with retarded ignition angles and a rich mixture. Ambient air (secondary air) is injected close to the exhaust valve seat. During the spontaneously occurring post oxidation phase, the reactive exhaust components ignite and heat up the catalytic converter while simultaneously reducing HC. The various processes which affect the post oxidation, are not well known up to now. In order to achieve concrete improvements, detailed knowledge of its influences are necessary.