Research & Technology, New Propulsion Systems (TR-S)
New propulsion systems for non-road
applications and the impact on combustion
engine operation
London, 14th March 2014, Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
Content
1
Incentive
1.1 Non-road-applications / MTU products
1.2 Trend of reducing CO2 emission
1.3 Technological challenges of ICE & propulsion system
2
Electrical enhanced propulsion systems
2.1 E-Drive system
2.2 E-Drive components
2.3 Functional benefits
3
Railcar E-Drive propulsion system
3.1 Application
3.2 System layout & fuel savings
3.3 Impact on internal combustion engine
4
© MTU Friedrichshafen GmbH | All rights reserved
Summary
01
Incentive
Page 3
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
01 Incentive
Non-road applications / MTU products
Page 4
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
01 Incentive
Trend of reducing CO2 emissions
A significant step towards future CO2-targets and reduction in life cycle cost will be
achieved only by optimising both, internal combustion Engine and propulsion system
Recuperation
Effective
Energy
~15 - 25%
Primary Energy
= CO2 -Emissions
~5 - 10%
Waste Heat
Recovery
Losses
Benefits of new propulsion systems:
 Optimised engine operation  reduction of real life exhaust gas emissions (NOx, PM, HC)
 Functional enhancement (e.g. boost capability, temporary silent operation, strong on-board
electrical grid)
Page 5
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
Time
Power Demand
Fuel Energy
01 Incentive
Trend of reducing CO2 emissions
The IC engine is able to deliver maximum power at any time and at short notice
 power-oriented rating and dynamics-optimised operating strategy
Page 6
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
Time
Time
Power Demand
Time
Engine power
Fuel Energy
01 Incentive
Technological challenges of ICE & propulsion system
Time
Power ESS
Electric motor /
generator
Time
Energy Storage System (ESS)
Future IC engine delivers the energy for a specified mission within a mean power range
 energy-oriented rating with efficiency-optimised operating strategy
Page 7
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
02
Electrical enhanced propulsion systems
Page 8
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
02 Electrical enhanced propulsion systems
E-Drive system
Propulsion control unit
External Information
Application
control
BMS
DC-Link
Power
Battery
Power
Electronics
Aux drives
Power
electronics
ECU
GCU
IC engine
Page 9
Electric motor /
generator
Gear box
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
02 Electrical enhanced propulsion systems
E-Drive components
Controls
 Power and Energy
Management
 Interface to the
Application
 Safety
Functionality
Page 10
E-Machine
Power Electronics
 Electric motor for
propulsion
 Generator
 E-Motor for
Auxilliaries
 Traction Converter
 Geno Rectifier
 Filter element in
the DC- or AC-Bus
 Auxiliary Supply /
Battery Charger
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
Battery System
Source & Sink:
 Energy Storage
 Power Buffer
02 Electrical enhanced propulsion systems
Functional benefits
Page 11
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
03
Railcar E-Drive propulsion system
Page 12
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
03 Railcar E-Drive propulsion system
Application
Drive cycle:
Vehicle:

Distance 37 km

Mass: 78t

13 Stops

2 x MTU 6H1800R75 (2 x 315kW)

43min

Electric motors: 2 x 400kW peak

speed limit 120kph

Li-Ion-Battery

Diesel-mechanical / parallel hybrid
Page 13
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
03 Railcar E-Drive propulsion system
System layout & fuel savings
Implemented features:
 Regenerative braking
 Load point shifting
 Partially electrified auxiliary drives
 Fuel consumption optimized drive strategy
Page 14
Cumulated fuel consumption [l]
Measured fuel savings over time
(test bench / real track data)
ca. -20%
Driving time along a railway track [min]
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
03 Railcar E-Drive propulsion system
Impact on internal combustion engine operation
Diesel only
consumption optimized drive strategy
E-Drive
consumption optimized drive strategy
+55%
58% fuel
conversion
90% fuel
conversion
32%
9%
Impact on combustion engine:
 Increase of 55% of fuel conversion at
high engine loads
 Still 9% fuel converted at idle speed
Page 15
9%
Further potential:
 Decoupling auxiliary drives from
combustion engine
 Engine shutdown during idling
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
04
Summary
Page 16
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
04 Summary
New propulsion systems for non-road applications:
 New propulsion system concepts are capable of significant fuel savings heavily
dependent on the application
 Fuel savings result from optimized operation of internal combustion engine and
auxiliary drives
 Fuel savings result from energy recovery
Impact of future propulsion system design on internal combustion engine:
 Increased fuel conversion at high engine loads
 Increased frequency of engine starts
 Engine shutdown during vehicle operation
Page 17
 mechanical / thermal fatigue?
 main bearings, starter lifetime?
 effect on main bearings?
 effect on exhaust aftertreatment?
New propulsion systems for non-road applications and the impact on combustion engine operation | Benjamin Oszfolk
© MTU Friedrichshafen GmbH | All rights reserved
Thank you very much for your attention.
© MTU Friedrichshafen GmbH | All rights reserved

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