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Conferenza del Dipartimento DIITET
26 e 27 maggio 2014
Carlo Beatrice (c.beatrice@im.cnr.it)
DIITET nel settore dei veicoli a basso impatto ambientale
CONSIGLIO NAZIONALE DELLE RICERCHE
Pisa, November 17th, 2015
Convegno del Dipartimento di Ingegneria,
ICT e Tecnologie per l’Energia e i Trasporti
The next-generation powertrains for 2050 mobility
1
Smart & Environmental friendly vehicles
Powertrain Technologies (hybrids, sensors, control, devices, etc.) Alternative fuels
Storage SystemsThermo-fluidynamic & vibroacoustic
Vehicle & Environment(incl. LCA)
ICT/ITS Infrastructures, Smart Grids, …..,
Materials
2
3
Scenarios / The indicative evolution of passenger road transport energy source and propulsion technology, towards 2050
[Source: ERTRAC - European Road Transport Research Advisory Council]
2050
Conferenza DIITET
Pisa, November 17th 20157
Series Parallel
Parallel-series Hybrid Split configuration
IC engine and electric drive connected to separate axles
Electric vehicle with super-capacitors and batteries
Hybrid vehicles classification: Architecture typologiesToyota Prius
Opel Ampera
Peugeot 3008
8
H2020 calls 2016-2017
Smart, green and integrated transport 2016 - 2017
1. GV-02-2016: Technologies for low emission light duty powertrains;
2. GV-03-2016: System and cost optimised hybridisation of road vehicles;
3. GV-06-2017: Physical integration of hybrid and electric vehicle batteries at pack level aiming at increased energy density and efficiency;
4. GV-07-2017: Multi-level modelling and testing of electric vehicles and their components;
Conferenza DIITET
Pisa, November 17th 2015
9
The Hybrid Powertrain
Looking at the ICE technology roadmap
Conferenza DIITET
Pisa, November 17th 2015
10
The ideal Diesel cycle
Max thermodynamic efficiency of the Diesel cycle
Conferenza DIITET
Pisa, November 17th 2015
With a compression ratio of 18 the efficicency of the ideal cycle is 62%
11
The energy balane in the internal combustion engine
Diesel Heavy-Duty case (e.g. Truck engine)
Conferenza DIITET
Pisa, November 17th 2015
13
Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_1: Diesel and Liquid fuel spray studies
Different approaches: X Ray / tomography Laser / LED
• 3D spatial and temporal analysis of liquid sprays from injection systems for ICE
Reference: L. Allocca, A. Montanaro
14
Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_2: Fuel spray & combustion studies in optical engines
Optical diesel engine Optical GDI engine
Reference: E. Mancaruso, S. Merola
15
Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_3: Fuel spray & combustion studies in optical engines
Reference: P. Sementa
Direct Injection CNG spray Direct Injection CNG combustion
Gasoline-PFI
Injector
DI-GAS
Injector
16
Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_2: Advanced research engines for downsizing studies
Advanced engine test laboratory @ IM-CNR
Reference: C. Beatrice
17
Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_3: Fully dynamic & transient engine test benches
Reference: C. Guido, S. Iannaccone, M.V. Prati
6-cylinder HD NG engine on 315 kW transient test bench
Chassis dynamometer for vehicle testing
18
Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_4: Design and development of advanced components
Reference: A. Di Gaeta, V. Giglio
Electromagnetic actuation of engine valves
Rivestimenti superidrofobici per ridurre l’attrito da strisciamento
19
Sample CA with ARNICA 46(°) st. dev.
Tal Quale 16.7 2.3
Coated 123.8 11.8
20
T= 150s T= 350s
T= 700 s T= 1500s
T= 700s
D1) 1500x2
D3) 2000full
D2) 2000x5
D4) 2500x8
A)
B)
Engine combustion improvement for high efficiency and low pollutant emissionsExamples of CNR activities_4: 3D CFD of spray and engine combustion
Reference: M. Costa, V. Fraioli, M. Migliaccio
21
Mitigazione degli effetti degli agenti fisici sugli operatori e sull’ambiente (NHV)
Analisi sperimentale e gestione delle caratteristiche del campo acustico mediante tecniche intensimetriche ed verifiche in camera anecoica
Sistema di analisi automatica delle analisi intensimetriche su componentistica
Noise emission qualification and control
High Performance Computing (HPC) per la simulazione vibroacustica
Simulazione integrata BEM - FEM
Interventi nel cofano motore.
Interventi di tipo passivo per la riduzione dirumore e vibrazioni
Reference: E. Carletti IMAMOTER, D. Siano IM
22
The Hybrid PowertrainLooking at the E-Motor technology roadmap
Conferenza DIITET
Pisa, November 17th 2015
24
100 kW DynamicTest Bench
Analisi sperimentale delle prestazioni di sistemi di accumulo in condizioni di funzionamento stazionarie e dinamiche
Valutazione delle strategie di gestione dell’energia on board per sistemi di propulsione elettrici su cicli di guida standard, al variare dei parametri della strada e del veicolo
High Specific Energy Storage Devices
Lead Acid
Studio Sperimentale di Sistemi di Propulsione Elettrici per Veicoli Elettrici ed Ibridi
DC
DCVsc VDC
SC +
SC -
DC +
DC -
Control System Supervisor
LiFePO4 ZEBRA Li[NiCoMn]O2
Super-Capacitor Li-Ion Capacitors
High Specific PowerStorage Devices
Strategie di gestione dell’energia elettrica in sistemi di accumulo di tipo ibrido (batterie+supercondensatori)
Test bench di laboratorio per azionamenti elettrici da 3 a 100 kW, comprensivi di moduli software e volani per la simulazione delle forze di inerzia.
10 kW Eddy Current Brake
30 kW Eddy Current Brake
Energy Storage Modules Test Bench
I V
CYCLE
TESTER
P
+-Data
Battery
TEMP.
SENSOR.
TEMPERATURE
Reference: O.Veneri, C. Capasso
25
Architetture per sistemi di propulsione ibridi di tipo Termico-Elettrico
Attività di Ibridizzazione del sistema di propulsione della
Nave Oceanografica del CNR G. Dalla Porta
G
6-CYLINDER
THERMAL ENGINE
Tra
ns
mis
sio
n G
ea
r
HYDRAULIC
SYSTEMS
SISTEMA DI
ACCUMULO
WINCH
M AC
DC
DC
AC
MOTORUOTE
ELETTRICHE
+
FRESA
HYBRIDIZATION
Strategie di gestione dei flussi energetici finalizzate all’incremento dell’efficienza complessiva ed alla riduzione delle emissioni
Architetture Ibride di Propulsione per Veicoli Cingolati
Ibridizzazione del sistema di propulsione mediante
Operazioni di Retrofit su configurazioni preesistenti
Analisi architetture di potenza per la generazione elettrica e la propulsione ibrida in applicazioni navali
Modellazione e simulazione di Architetture Ibride diPropulsione per Pescherecci, su cicli di pesca prestabiliti,con approccio systems engineering e modelli 3D - Catia v6
Reference: O.Veneri (IM), P. Paoluzzi (IMAMOTER)
26
AC/DC Bidirectional
Converter
DC/DC Unidirectional
Converter
DC Bus
Electric Connections
to Battery Packs
I/O Control Signals
Main Switch
Room for Future
Extensions
Voltage and
Current Sensors
DC/DC Bidirectional
Converters
Architetture di potenza per l’integrazione di veicoli elettrici e fonti rinnovabili in contesti di tipo smart grid
Analisi sperimentale e gestione dei flussi energetici su sistemi di ricarica rapida con pacchi batteria di diversa tecnologia
Dimostratore di laboratorio di micro-grid in corrente continua per operazioni di ricarica rapida per veicoli PEV
Sitema di Accumulo Buffer basato su tecnologia LiFePO4
Valutazione sperimentale di strategie di gestione per l’integrazione ottitmale in architetture di potenza in corrente continua di sistemi di generazione di energia ellettrica da fonti rinnovabili e sistemi di accumulo
0 0.2 0.4 0.650
55
60
65
70
Time [h]
EV
Ch
arg
ing
Vo
ltag
e [
V]
0 0.2 0.4 0.60
0.75
1.5
2.25
3
EV
Ch
arg
ing
Po
wer
[kW
]
0 0.1 0.2 0.3 0.4 0.5 0.60
20
40
60
80
Time [h]
EV
So
C [
%]
Architetture di tipo micro-grid in DC e AC per la ricarica rapida di veicoli elettrici ed ibridi plug-in
Architetture di potenza per l’integrazione di fonti rinnovabili in contesti di tipo smart grid
High efficiencyHetero-Junction HIT Modules
Sito di
installazione
SUD
Sito installazione impianto fotovoltaico.
DC
DC
MPPT
DC
DC
MPPT
DC
DC
MPPT
DC
AC
PV1
PV2
PVnBattery
Pack
DC
DC
MPPT
DC
DC
MPPT
DC
DC
MPPT
DC
AC
PV1
PV2
PVnBattery
Pack
A B
Smart PV Panels with distributed MPPT controller
2
Vehicle Battery Pack
DC
DC
DC
DC
Po
we
r F
lux
Po
we
r F
lux
AC
DC
Energy Storage Buffer
2
Reference: O.Veneri, C. Capasso
Conferenza DIITET
Pisa, November 17th 2015
CONCLUSIONS I
27
• Even if pure electrical and Fuel Cell powertrains are the long term solution for sustainable surface transport, 2050 estimations indicate a predominance of thermal and hybrid engines;
• From the ICE side, while pollutant emission will be controlled mainly from exhaust-after-treatments in order to fulfill the future worldwide regulations, improvement of fuel efficiency (and CO2 reduction) will be the main target of the ICE R&D activities;
• Such targets can be achieved through several areas of investigation like, engine downsizing, waste heat recovery, friction loss reduction, advanced engine control, new renewable clean fuels etc., based on both fundamental and applied studies;
• Both of them can be found in the CNR institutions, while a increase of the synergy between fundamental and applied research has to be pursued;
• The cooperation between IM and ITAE in the study and testing of new renewable fuels (MIPAAF Project “TERVEG”) is an example. Other examples can be found in the possible cooperation on the use of new materials for friction and heat losses reduction (e.g. engine component coating or new lubrication/cooling fluids employing nanoparticles)
Conferenza DIITET
Pisa, November 17th 2015
CONCLUSIONS II
28
• From the E-motor side, there are available technologies on the market for hybrid vehicle diffusion, and a lot of them are under development;
• Anyway, the limiting points to the large diffusion of the hybrid vehicles are the increase of the capacity of the batteries and their recharging process through advanced Battery Management Systems (BMS) (the fast recharging systems represent the core of this item);
• Another crucial point that requires additional relevant research effort lies on the on-board energy management system (intelligent energy fluxes control and breaking energy recovery), from which depends the mileage range of the vehicle.
• As for ICE, the synergy between fundamental and applied researches are the key point for the development of robust and long-range hybrid vehicles. The cooperation between IM and IMAMOTER in the study of the hybridization of a snow groomers is an example.
• Several CNR Institutes could be involved in IM activities relatively to the design and development of specific components of the electric powertrain that could be tested and validated in demonstrator vehicles at IM laboratories.
Conferenza DIITET
Pisa, November 17th 2015
Thanks for the attention
29
Tavolo di lavoro AP Veicoli a basso impatto ambientale:Carlo Beatrice IMMichele Gambino IMGiorgio Dispensa ITAEElena Ciappi INSEANSandro Ianniello INSEANAlessio Ferrari ISTIGianpaolo Vitale ISSIAPietro Marani IMAMOTERPasqua d’Ambra ICARCésar de Julián Fernández IMEM
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