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Due to ever soaring fuel costs and even more stringent emission regulations which require more elaborate technical efforts and unfortunately lead to a negative trend on fuel economy as well, todays and future trucking business is extremely challenged. These facts create an urgent requirement for the engine manufacturer to offer an engine with an optimized cost-benefit-ratio for the trucking business. Mercedes-Benz, as the leader in the European commercial vehicle market - of which e. g. high fuel costs, long maintenance intervals and high engine power-to-weight ratios have always been key characteristics - has developed a new class 8 engine for the US market. The MBE 4000 is a 6 cylinder inline engine in the compact size and low weight category, but due to its displacement of 12,8 liters it offers high performance characteristics like heavier big block engines.

This paper investigates the potential of using FEA poro-elastic Biot elements for the modeling carpet-like trim systems in a simplified setup. A comparison between FEA computations and experiments is presented for two layer (mass-spring) trim systems placed on a test-rig consisting in a 510×354×1.6 mm flat steel plate clamped in a stiff frame excited at its base. Results are presented for a given heavy layer with two different poro-elastic materials: one foam and one fibrous material. The investigations included accelerometer measurements on the steel plate, laser-doppler vibrometer scans of the heavy layer surface, sound pressure measurements in free field at a distance of 1 meter above the plate, as well as sound pressure in a closed rectangular concrete-walled cavity (0.5×0.6×0.7 m) put on top of the test-rig. Computations were carried out using a commercial FEA software implementing the Biot theory for poro-elastic media.

The main objective of engine 3D CFD simulation is nowadays the support for combustion design development. New combustion concepts (e.g. Low Temperature Combustion, HCCI, multiple injection strategies …) could be analyzed and predicted through detailed thermodynamical computation. To achieve this aim many simulation tools are needed: each of them has to be capable to reproduce the sensitivities of combustion design parameters through physically based models. The adopted approach consists of the coupling of different models for 3D-nozzle flow, orifice-resolved spray formation in Eulerian coordinates and combustion. The advantages of the method will be proofed on an operative DI-diesel truck engine case, run with different nozzle geometries.

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).

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.

The Institute of Transportation Studies at the University of California, Davis (ITS-Davis) has brought together a group of public and industrial partners to demonstrate and evaluate the Siemens-Westinghouse Urea-Selective Catalyst Reduction System (SINOx™). The SINOx System has the potential to generate major reductions in nitrogen oxides (NOx) and the volatile organic fraction (VOF) of particulate (PM) from heavy-duty diesel engines, without increasing fuel consumption and carbon dioxide (CO2) emissions. This demonstration began with engine bench testing at Detroit Diesel Corporation to calibrate the system to attain 1 g/bhp-hr NOx emissions in the transient portion of the US-FTP on a 1999 Series 60 engine that has a 4 g/bhp-hr emission level. The second phase of the project entails an on-highway demonstration of a set of ten, Freightliner Class 8 heavy-duty diesel vehicles. These vehicles are part of the Valley Material Transport fleet based in French Camp, California.

The present paper describes the results of a joint development program focussing on a system approach to meet the EURO IV emission standards for an upper class passenger car equipped with a newly developed high displacement gasoline engine. Based on the well known catalyst systems of recent V6- and V8-engines for the EURO III emission standards with a combination of close coupled catalysts and underfloor catalysts, the specific boundary conditions of an engine with an even larger engine displacement had to be considered. These boundary conditions consist of the space requirements in the engine compartment, the power/torque requirements and the cost requirements for the complete aftertreatment system. Theoretical studies and computer modeling showed essential improvements in catalyst performance by introducing thin wall substrates with low thermal inertia as well as high cell densities with increased geometric surface area.

Prototype selective catalytic reduction (SCR) systems using urea have been demonstrated on diesel trucks in Europe in recent years. In view of upcoming stringent emissions control standards for US HD diesel engines, urea-SCR is being evaluated by US engine and truck manufacturers. The authors and their companies have worked jointly on a project to develop, test, and demonstrate urea-SCR on a US HD diesel engine and Class-8 truck. A prototype urea-SCR system was applied to a 12-liter HD diesel engine. The engine model selected is rated at 350 bhp and is common for highway trucks. The only engine modifications were changes to the injection timing control map in order to better suit the application of the urea-SCR system. This paper details two demonstration phases of the project as follows. The first phase includes recent emissions cell tests using a new compact SCR catalyst and an engine calibration optimized for lower NOX.

For the development of complex Man Machine Interfaces (MMI) we created an innovative development tool. With this system we gain significantly higher certainty in concept by earlier integration of the customer. Additional advantages are the reduction of development time and costs and an improvement of the MMI quality with regard to self-explaining operation for complex information systems.

Electronic control modules for engine control applications have an increasing number of power drivers. Most of them are switching in a PWM mode or synchronously with engine speed. Fast switching of load currents and voltages generates a noise in the lower AM band (150 kHz … 10 MHz) exceeding given limits for radiated emissions. The objective was to determine how the switching noise could be reduced by means of controlled current and/or voltage slopes. Finally ways were identified to implement appropriate voltage slope controls into a fully integrated quad low side driver ASIC. The paper will show results from practical measurements in the time and frequency domain as well as theoretical data to describe the switching behavior before and after implementation of the improvements A major result was that both current and voltage slope control are necessary to achieve best results. A special method of wave shaping was identified as the optimum.

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.

For the measurement of exhaust emissions, Constant Volume Sampling (CVS) technology is recommended by legislation and has proven its practical capability in the past. However, the introduction of new low emission standards has raised questions regarding the accuracy and variability of the CVS system when measuring very low emission levels. This paper will show that CVS has the potential to achieve sufficient precision for certification of SULEV concepts. Thus, there is no need for the introduction of new test methods involving high cost. An analysis of the CVS basic equations indicates the importance of the Dilution Factor (DF) for calculating true mass emissions. A test series will demonstrate that, by adjusting the dilution and using state of the art analyzers, the consistency of exhaust results is comparable with those of LEV concepts, measured with conventional CVS systems and former standard analyzers.

In view of tight emission standards, injection strategies to reduce raw HC-emissions during the cold starting of port fuel injected engines are evaluated in this study. The relevance of spray targeting and atomization is outlined in the first part of this paper. The foundation and performance of different injector concepts with respect to spray characteristics are discussed. Laboratory experiments demonstrate that concepts relying on auxiliary energy, such as air-assistance, fuel heating and injection at elevated system pressures, are capable of producing spray droplet sizes in the SMD-range of 25μm. For future injection strategies aimed at the compliance of SULEV emission levels, this target value is considered to be essential. In the second part of this paper, emission tests of selected injector concepts are carried out using a V6-3.2I ULEV engine operated both in a vehicle and on a test bench.

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.

External Exhaust Gas Recirculation, EGR, is a central issue in controlling emissions in up-to-date diesel engines. An empirical model has been developed that calculates the EGR ratio as a function of the engine speed, the engine load and special characteristics of the heat release rate. It was found that three combustion characteristics correlate well with the EGR ratio. These characteristics are the ignition delay, the premixed combustion ratio and the mixing-controlled combustion ratio. The calculation of these characteristics is based on parameter subsets, which were determined using an optimization routine. The model presented was developed based on these optimized characteristics.

The NO distribution in a directly-injected Diesel engine with realistic combustion chamber geometry was investigated with laser-induced fluorescence (LIF) imaging with KrF excimer laser excitation. The highest possible level of selectivity has been ensured using spectrally resolved LIF investigations inside the Diesel engine. To minimize interference from both, oxygen and polycyclic aromatic hydrocarbon (PAH) LIF the NO signal was detected around 237 nm, blue-shifted compared to the excitation wavelength resulting in a background contribution below 10% at the earliest detection timing possible in the engine under study (20°ca after top dead center, TDC). The in-cylinder NO LIF intensities were compared for different injection systems and operating conditions and correlated to variations in pressure traces and soot temperature measurements.

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 view of limited crude oil resources, alternative fuels for internal combustion engines are currently being intensively researched. Synthetic fuels from natural gas offer a promising interim option before the development of CO2-neutral fuels. Up to a certain degree, these fuels can be tailored to the demands of modern engines, thus allowing a concurrent optimization of both the engine and the fuel. This paper summarizes investigations of a Gas-To-Liquid (GTL) diesel fuel in a modern, post-EURO 4 compliant diesel engine. The focus of the investigations was on power output, emissions performance and fuel economy, as well as acoustic performance, in comparison to a commercial EU diesel fuel. The engine investigations were accompanied by injection laboratory studies in order to assist in the performance analyses.

The improvement of DI diesel engines for passenger cars to fulfil pollutant emission limits and lower fuel consumption and noise is closely linked to continued development of the injection system. Today's injection systems demonstrate varying potential in terms of the flexibility of injection parameters for improving mixture formation and combustion. DaimlerChrysler evaluated the potential of different injection systems, looking particularly at the distributor pump, unit injection system and Common Rail system. Based on the results of these investigations, the Common Rail system was selected. The tests presented in this paper were performed on a single-cylinder engine with Common Rail system. They focused on increased rail pressure in combination with different nozzle geometries. The results show significant benefits in NOx/smoke trade off at part load conditions with high EGR rate.

In order to fulfill future emissions standards, there is a need for new exhaust-gas aftertreatment concepts, with NOx-emissions reduction in passenger car diesel engines being of particular importance. The NOx storage catalyst is one of the technologies currently under discussion with high NOx conversion potential, and which is under development at DaimlerChrysler for EURO IV standards. With this system, the nitrogen oxides contained in the diesel exhaust gas are stored under lean exhaust-gas conditions and are reduced in the catalyst through an enriched air-fuel ratio of the exhaust-gas and favorable thermal conditions. Hydrocarbons, carbon monoxide and hydrogen are used as reducing agents. DaimlerChrysler has analyzed the effect of sulphur contained in the fuel on the operation of various catalysts during laboratory and engine testing. The sulphur dioxide in the exhaust gas generates sulfates, which remain on the catalyst when nitrate compounds are regenerated briefly.