交通运输国三国四排放发动机用涡轮增压器概述课件

1、Technical summarize of turbocharger meet euro 3 euro 4 engine emissions standard 国三、国四排放发动机用涡轮增压器技术概述 Shouguang Kangyue Turbocharger Co., Ltd寿光市康跃增压器有限公司2009.04.18第1页，共51页。2022/8/41康跃增压器Euro III was the start of serious emissions reductions. Initial reactions from European engine manufacturers in th

2、e 1998-1998 timeframe was that they would need to implement EGR. EGR was seen as effective at NOx reduction, but the impact on engine life was extremely concerning. A lot of experience was gained by European manufacturers with EGR, but they were all able to meet Euro III without EGR. Basic combustio

3、n improvement was sufficient to meet the requirements.欧3标准是更严格排放的开始。在1998年至1998年期间欧洲发动机制造商最初意识到需要实施废气再循环。废气再循环能有效减少氮氧化物的排放，但与发动机的寿命是极为相关。一些有丰富的经验，获得废气再循环技术的欧洲制造商，他们都能够满足欧洲III无废气再循环。基本燃烧改善足以满足发动机的需求。第2页，共51页。2022/8/42康跃增压器Serious research on alternative combustion schemes such as Homogeneous Charge C

4、ompression Ignition (HCCI), Pre-mixed Charge Compression Ignition (PCCI), Low Temperature Combustion (LTC) began at this time. In addition, NOx reducing after-treatment research was significantly increased resulting in significant improvement in Lean NOx Traps (LNT), Selective Catalytic Reduction (S

5、CR), and Lean NOx Catalysts.认真研究替代燃烧的计划，如均质充气压缩点燃方式（ HCCI燃烧） ，预混合混合燃烧（ PCCI ） ，低温燃烧（中校）开始使用。此外，处理后氮氧化物减少有了很大的改善，氮氧化合物捕集器 （ LNT ） ，选择性催化还原（ SCR ） ，氮氧化物和精益催化剂。第3页，共51页。2022/8/43康跃增压器At about the same time, the Department of Justice in the U.S. determined that the advanced electronic controls that U.S.

6、 manufacturers had implemented to meet 1998 standards violated the intent of the law. Many manufacturers were sued and reached an out-of-court settlement with the EPA (referred to as the Consent Decrees) which required them to meet 2004 standards in 2002, AND without any transient controls that coul

7、d be viewed as “cycle-beating”. This shortened time-frame combined with a required switch in strategy caused significant upheaval in the industry. Most engine manufacturers launched EGR systems for the first time in this period. They learned to control the pressure differential across the engine to

8、control EGR flow, as well as learned about the effects of EGR on engine life. They learned the boundaries where condensation could occur in the exhaust and EGR systems forming nitric and sulfuric acid within the engine resulting in corrosion.与此同时，美国制造商已经实施了先进的电子控制，并能达到1998年标准，但是美国司法部提出， 该系统违反法律。许多制造

9、商被起诉，并达成了庭外和解与EPA （称为同意法令） ，要求他们在2002年能够达到2004年的标准，被认为是“周期挫败”的发动机行业并没有做出任何的控制措施。在这个如此短的时间内，需要有一项体系来结合，成为业界的一个重要事宜。在那个时机初期，大多数发动机制造商推出废气再循环系统。他们学会了控制压差，他们学会控制横跨引擎的压力差控制来达到对EGR废气再循环流量的控制，以及了解EGR对发动机寿命的影响。他们的经验教训表明，在哪里可能发生的排气系统和废气再循环形成硝酸和硫酸的发动机造成腐蚀。第4页，共51页。2022/8/44康跃增压器Euro IV was not as severe in NO

10、x reduction, but more substantial in particulate reduction. Many manufacturers launched diesel particulate filters (DPF) in this period and learned to deal with the problems of active regeneration, soot load modeling and sulfur poisoning. 欧IV并不是使氮氧化物减少，但大量减少了的微粒的排放。在此期间许多制造商推出柴油微粒过滤器（柴油机微粒过滤器），并了解了如

11、何处理处理烟尘负荷建模和硫中毒等问题。U.S. 2007 and 2010 are extremely stringent. US07 could be meet with either EGR+DPF or SCR+DPF. US10 requires either massive EGR or EGR+SCR for NOx reduction. US10 cannot be met by SCR alone.美国2007年和2010是非常严格的。 US07标准可满足带有废气再循环+柴油机微粒过滤器或可控硅+DPF 。 美国07要求要么使用大量废气再循环系统要么使用废气再循环+晶闸管的NO

12、x还原系统。 美国10不能与SCR独立使用第5页，共51页。2022/8/45康跃增压器过去10年柴油机在减少排放方面做得工作Courtesy of Tim Johnson, Corning, Inc.NOx & PM是焦点对美国来讲2010年也是困难的第6页，共51页。2022/8/46康跃增压器Euro Heavy-Duty Emission Regulations欧洲重型排放规则Euro I standards were introduced in 1992, Euro II regulations in 1996, both using the steady-state engine

13、test ECE R-49 In 1999, the EU introduced Euro III standards (2000), as well as Euro IV/V standards (2005/2008) 欧I标准开始使用是在1992年，欧II是在1996年开始使用，两个标准被欧洲经济文员会 R-49用作发动机稳定测试 在1999年欧洲引进欧III标准（2000年），同时连同欧IV/V标准（2005/2008）With Euro III, ECE R-49 was replaced by the European Stationary Cycle (ESC) and the E

14、uropean Transient Cycle (ETC). Smoke opacity is measured on the European Load Response (ELR) test.欧III,ECER-49 被欧洲固定式周期(ESC)和欧洲瞬变周期(ETC)替代，烟雾的不透明性被作为欧洲装载反应(ELR)测试的标准。第7页，共51页。2022/8/47康跃增压器In 2001, the European Commission prohibited the use of emission “defeat devices” and “irrational” emission cont

15、rol strategies在2001年，欧共体禁止使用“受损装置”和不合理“排放等控制战略In 2005 Directive 2005/55/EC introduced durability and OBD requirements2005/55/EC指令， 2005年推出的耐用性和车载诊断系统的要求In December 2007, the Commission published a proposal for Euro VI emission standards COM(2007) 851. The new emission limits, comparable in stringenc

16、y to the US 2010 standards, would become effective from 2013/2014. 在2007年12月，委员会发表了一份提案，欧VI排放标准COM （ 2007 ） 851 。新的排放限度，与US2010标准同样严格，该提案会从2013/2014年开始正式生效第8页，共51页。2022/8/48康跃增压器Emissions TechnologiesMany New Emission Technologies Have Been Developed:许多新的排放技术已经被应用New Combustion Processes新的燃烧过程: HCCI

17、均质充气压缩点燃方式, PCCI预混合混合燃烧, LTC低温燃烧Higher Injection Pressures高压喷射, Rate Shaping调整速率, Multiples Injections 混合喷射Exhaust Gas Recirculation (EGR)排气再循环High Pressure Loop 高压循环Low Pressure Loop 低压循环Selective Catalytic Reduction (SCR) 选择性催化还原Lean NOx Traps (LNT)降低氮氧化物的捕集器Diesel Particulate Filters (DPF) 柴油颗粒过滤

18、器Diesel Oxidation Catalysts 柴油氧化催化Variable Valve Actuation (VVA)可变气门第9页，共51页。2022/8/49康跃增压器Advanced Combustion Technologies第10页，共51页。2022/8/410康跃增压器Many advanced combustion modes have been invented which produce almost no NOx and Particulate Matter. They are similar when looked at with regards to Lo

19、cal Equivalence Ratio (Stoichiometric air/fuel ratio divided by the actual air/fuel ratio), and the Local Combustion Temperature.许多先进的燃烧方式已经发明，这些燃烧方式几乎没有产生氮氧化物和颗粒物质。这些方式非常相似， 如，地方量比（计量空气/燃料比除以实际的空气/燃料比） ，当地燃烧温度。In general, these combustion modes can be made to work in a limited operating range, usua

20、lly low load and low speed. Work is on-going to expand this operating envelope. Heavy-Duty emission requirements are quite stringent at all load/speeds, especially full load. Alternative combustion modes are of limited value when other full-scale systems need to be implemented for full load and spee

21、d.总的来说，这些燃烧的方式，可在有限的操作范围内工作，通常是低负荷和低速.及其持续运转。重型排放要求是相当严格的在所有负载/速度，特别是满载。替代燃烧模式的能量有限时，其他全系统必须执行满负荷和速度。第11页，共51页。2022/8/411康跃增压器Light-Duty (or passenger vehicle) emissions are generally only stringent at modest loads and speeds, with very little control required at full load. Alternative combustion mo

22、des are very valuable when developed to the point of covering the main operating points of the light-duty cycle.轻型（或客运车辆）排放量在负荷和速度上要求非常严格，很少要求满载。当轻型车辆发展到了覆盖该行业的时候，选择性燃烧模式会非常有价值。第12页，共51页。2022/8/412康跃增压器Dilution is Key to NOxAirAirDiluted with EGRThe EPAs research has shown that if the oxygen concent

23、ration can be reduced from 22% (normal air) to about 12%, NOx could be reduced to ultra-low levels.第13页，共51页。2022/8/413康跃增压器Exhaust Gas Recirculation废气再循环105210.50.2NOx g/kW-hrNOx is Formed Exponentially Combustion TemperatureNOx = f ( eT )氮氧化物形成指数燃烧温度Improved CombustionHigher Injection Pressure, Sp

24、lit Injection, Rate Shaping Lower NOx高级喷射压力，分流进样，速率整形下氮氧化物Exhaust Gas RecirculationDilution with “Inert” Exhaust Gas Lowers Combustion Temperature稀释的“惰性”尾气降低燃烧温度Increasing EGR is Highly Effective增加废气再循环是非常有效的Commercial Vehicle 商用车8-12 % at Full Load in 200218-22% at Full Load in 200726-35% at Full L

25、oad in 2010Passenger Vehicle 乘用车20-25% at Part Load in 200235-45% at Part Load in 200640-55% at Part Load in 2009Selective Catalytic Reduction第14页，共51页。2022/8/414康跃增压器SCR Requires Injection of Ammonia (on-board Urea) onto Catalyst for up to 80% NOx Reduction SCR选择催化还原装置，要求在装置上注入氨（车载尿素产生）还原剂，能达到NOX减少

26、80%的效果第15页，共51页。2022/8/415康跃增压器Impact of EGRThe impact of EGR on Turbochargers is the dominant Technology Requirement of the past 10 years增压基础的排气再循环技术在过去10年中是非常有优势的技术要求EGR increases the amount of gas flowing through the engine, which significantly increases the pressure ratio, and thus the required

27、turbocharger speed EGR增加了发动机气体流量，显著提高了压比，而且也因此要求增压器转速提高。EGR increases the flow range requirement of the compressor (surge to choke flow)EGR增加了增压器压气机的流量范围（从喘振到阻塞区）As EGR rates increase beyond 20% at full load, and 35% at part load, the required efficiency of the turbo increases significantlyEGR率在全负荷超

28、过20%，在部分负荷超过35%，对增压器的效率要求显著增加。第16页，共51页。2022/8/416康跃增压器Many turbocharger companies have had to go to multiple turbochargers to meet the requirements: Series, Series-Sequential, and Series Parallel许多增压器公司不得不采用种类繁多的增压器来适应新要求，包括系列化，顺序连续增压，顺序并列增压等。Some Turbo company has developed the Low Speed Turbo (LS

29、T) and the Series Sequential Turbo (SST) as single turbochargers with multi-turbo capability某些增压器公司曾开发过低速增压器和顺序连续增压作为单个增压器拥有多个系列增压能力。第17页，共51页。2022/8/417康跃增压器单个的低速增压器单个的连续增压器第18页，共51页。2022/8/418康跃增压器High Pressure Loop EGREGR must be pumped through the engine as is the airThe density at “4” must be h

30、igher if the total flow is higherA pressure drop from “5” to “4” must exist for EGR to flow废气再循环泵必须通过发动机的空气，密度在“ 4 ”必须更高，如果总流量高压从“ 5 ”降到“ 4 ”，当中必须存在的废气再循环过程EGR does not flow through the compressor or turbine, but the turbine has to produce more power to pump the total gas flow through the engine废气再循

31、环不流经压缩机或涡轮机，但是涡轮必须产生更多的能量，促使所有气体流经发动机Good choice Heavy-Duty Engines重型卡车的选择第19页，共51页。2022/8/419康跃增压器(Point out the key elements of a high pressure loop EGR system指出在高压废弃再循环系统中的主要因素)Abbreviations缩写:A/C air cleaner 空气滤清器A/T after-treatment 后处理设备V valve 阀门M muffler 消声器At high loads and speeds, the negat

32、ive pumping work imposed by the necessary EGR pressures is less than what will be caused by a Low Pressure Loop EGR system, and thus HPL will have better fuel economy than LPL EGR.在高压和高速情况下，HPL比LPL废气再循环有更好的燃油经济性At low loads and speeds, high EGR rates require a large negative pressure differential ac

33、ross the engine, which is a severe fuel economy penalty. Low pressure loop EGR is more efficient at low loads and speeds.在低负荷和低速下，高废气再循环率在经过发动机时需要一个很大的负压差，这是一个严重的燃油经济性问题。在低负荷，低速情况下，低压回路废气再循环效率更高。第20页，共51页。2022/8/420康跃增压器Low Pressure Loop EGRLow Pressure Loop EGR 低压废气再循环Avoids the need for a negative

34、 dP across the engine避免负压经过发动机的需要Excellent choice for up to 50% load EGR (light duty cycle)是提高废气再循环功率50%的完美选择（轻型循环）Good choice for passenger vehicles, poor choice for H-D对乘用车是好的选择，对重型车是不好的选择第21页，共51页。2022/8/421康跃增压器For Heavy Duty, Problems Arise 对于重型，容易出现的问题：Contamination of air system w/ soot Acidi

35、c condensation in air systemTime lag in EGR controlMuch bigger turbochargerSignificant increase in pumping loop work resulting in fuel consumption penalty污染的空气系统W /烟灰空气中的酸性冷凝系统时间滞后的废气再循环控制更大的涡轮增压器大幅度增加循环泵的工作造成了燃料的消耗量增加第22页，共51页。2022/8/422康跃增压器Although the DPF is 99% efficient, running EGR through th

36、e intake system still has risks of contamination with soot, as well as acidic condensation.尽管柴油机微粒过滤器的效率高达99 ，但废气再循环通过进气系统仍然有烟尘污染，以及酸性冷凝的风险。第23页，共51页。2022/8/423康跃增压器Diesel engines run lean so EGR contains some excess O2柴油发动机废弃再循环包含过多的氧气Therefore, a lower “fresh-air/fuel” ratio will yield the same O2

37、/fuel ratio因此，较低的“新鲜空气 ”比率将产生同样的O2/fuel第24页，共51页。2022/8/424康跃增压器Effect of High Pressure EGR on the CompressorEGR shifts the operating line EGR 工作流程图Constant A/FKeeping Constant A/F significantly increases boost pressure (and turbo speed) A/F参数的稳定能提高压力和涡轮速度第25页，共51页。2022/8/425康跃增压器Options to Drive EG

38、RMany ways of driving EGR have been tried and put into production多种方式的废气再循环已经被试用并投入生产Variable geometry turbine 可变几何涡轮Closing the vanes raises the back pressure on the turbine producing more compressor power and also pushing the dP more negative关闭叶片能提高涡轮背压，生产出更多的压气机能量同时，也能推动Venturi文丘里管A venturi is us

39、ed to reduce the static boost pressure to allow the turbine gas to flow文丘里管是用来减少静态压力，避免涡轮废气流动Reed Valve簧片阀A highly dynamic one-way valve is used to allow the peak of the exhaust pulse to drive EGR during a portion of each cylinders exhaust stroke一个高度的动力阀是用来在每个气缸的排气冲程过程中，允许在排气脉冲的最高点推动废气再循环运转第26页，共51页

40、。2022/8/426康跃增压器Asymmetrical divided turbine 不对称分开涡轮A traditional divided turbine housing is used, but each passage has a different flow characteristic (A/r). EGR is driven from 3 cylinders and the other three do not have the high back pressure一般使用的是传统分开涡轮壳，但是每一个通道有不同的流动特征，废气再循环有三个汽缸推动，其他的三个并没有高背压Tu

41、rbo-compound 涡轮混合物Additional work is done by the turbine or by adding a second turbine. This work is used to add to the brake power of the engine or to add to the electrical output of the generator 涡轮或者增加的第二个涡轮做一些附加的工作，这项工作主要是增加发动机的制动能量，或者增加发电机的电力产能第27页，共51页。2022/8/427康跃增压器A-Symmetrical Divided Hous

42、ing 不对称分开涡壳EGR can be driven from one bank of cylinders using a different A/r 废气再循环能推动汽缸层使用不同的A/rThe non-EGR cylinders use a larger A/r, reducing the backpressure on those cylinders 非废气再循环汽缸用一个巨大的A/r,减少了在这些汽缸上的背压 Eliminates the VGT 排除VGTCan be combined with a venturi 能同文丘里管相连接Turbine Housing Cross-S

43、ection涡轮壳截面第28页，共51页。2022/8/428康跃增压器A divided turbine housing with different A/r for each side can result in different back-pressure for the front 3 cylinders than the back 3 cylinders. This method can be used to raise the backpressure for a bank of cylinders to the appropriate level to drive EGR. T

44、his type of system can be used to drive EGR without using a VGT. The level of EGR is limited compared to a VGT system.一个分开的涡轮壳在每边都有不同的A/r，这些能从前面的三个汽缸带来与后面的三个汽缸不同的背压。这种方式被用来提高气压的背压，使其适用于推动废气再循环达的需要。这种系统在没有用VGT的情况下依然可以推动废气再循环。废气再循环的水平与VGT系统相比是有限的。第29页，共51页。2022/8/429康跃增压器Electric Actuation 电动执行器Advant

45、ages 优势Closed Loop Position Control Within Actuator闭环位置控制驱动Fast Response 快速反应Position Fed Back to ECU for Diagnostics位置反馈到ECUZ诊断故障Standard Digital Control Interface (CAN)标准的数字控制接口High Accuracy of Actuator Position高精确度的驱动器位置 Self-Contained, No Additional Power Sources Required Other than 12V 自成一体的，超过

46、12V，不需要额外电源第30页，共51页。2022/8/430康跃增压器Disadvantages缺点Cost 费用高Electronics Exposed to Very High Temperature and Vibration电子接触非常高的温度和振动Control of Actuator Position, not VG Position (Error due to Mechanism Wear, Backlash, End Stop Variation) 控制驱动器的位置，而不是VG位置（由于机器磨损，反弹等造成的误差）Mechanical Elements Combined wi

47、th Electronics (Flexing and Distortion, Wear Particles, Self-Heating)机械元素结合电子（屈曲和畸变，磨粒，自加热） 第31页，共51页。2022/8/431康跃增压器The level of intelligence in the actuator can be low or high, depending on the choice of the turbo manufacturer and engine manufacturer. Control of the VGT can be delegated to the act

48、uator with only a desired position fed to the unit. The actuator can provide closed loop control of the vane position. The vane position can be fed back to the ECU as well as diagnostic information. The actuator can have software controlled end points, with learning by the actuator in service.执行器的执行

49、力可以高或低，这取决于所选择的涡轮增压器制造商和发动机制造商。VGT的控制可能会通过在适当位置的执行器反馈到产品中。该执行器可提供闭环控制的叶片位置。叶片位置可反馈到电控单元并诊断信息。执行器可以有软件控制端点，通过执行器的服务来了解。Alternatively, no intelligence can be included in the actuator and the full control function be accomplished by the engine ECU.相反的，没有良好执行力水平的执行器包括在执行器和控制发动机功能的ECU当中第32页，共51页。2022/8/4

50、32康跃增压器Vacuum Actuation 真空脉冲Advantages 优势Inexpensive (if Vehicle has Vacuum Pump)廉价(如果车辆带有真空泵的话)Fast Response 快速反应Simple PWM Signal 简单的脉冲调制No Electronics Required on Engine 在发动机上没有电子需求Disadvantages 缺点No Vane Position Feedback 没有定位反馈Less Accurate 不准确No Diagnostic Information 没有诊断信息Requires Vacuum Pum

51、p 需要真空泵第33页，共51页。2022/8/433康跃增压器Vacuum Actuation with Position Feedback 带有定位反馈的真空脉冲Advantages 优势Inexpensive (if Vehicle has Vacuum Pump)廉价(如果车辆带有真空泵的话)Fast Response 快速反应Simple PWM Signal简单的脉冲调制第34页，共51页。2022/8/434康跃增压器Disadvantages 缺点Requires Vacuum Pump 需要有真空泵ECU Must Close Loop on Position ECU在位置上

52、必须靠近回线Multiple Wiring and Vacuum Connections 多重线路和真空连接Position Sensor Exposed to High Temperature and Vibration 传感器的位置容易引起高温和振动第35页，共51页。2022/8/435康跃增压器Basic Boost ControlSimple boost feedback system, but no vane position control简单的推动反馈系统，但是没有叶片位置控制第36页，共51页。2022/8/436康跃增压器The simplest VGT control,

53、an actuator moves the vanes more closed to raise the boost, more open to lower the boost. A boost table is created for all speeds loads, and a speed signal and a load signal is fed to the ECU. The load signal can be anything that is representative of loadaccelerator position, fuel flow, torque, etc.

54、最简单的VGT控制，执行器推动叶片.推动盘能产生所有的速度负荷， 速度信号和负载信号都会反馈到ECU, 这个负荷信号可以是任何具有代表性的负载-加速器位置，燃油流动，扭矩等 第37页，共51页。2022/8/437康跃增压器Very simple and effective, however, not robust to variation or tolerant of faults. Very little diagnostic information is available for troubleshooting非常简单和有效，然而，这些变化和误差并不稳定，对那些故障很少提供诊断信息。

55、第38页，共51页。2022/8/438康跃增压器Vane Position Control in ActuatorActuation controls vane position with internal feedback驱动控制叶片位置的内部反馈This control has the added functionality of controlling vane position as an intermediate variable. Unfortunately, very little value is derived from this.第39页，共51页。2022/8/439康

56、跃增压器Added DiagnosticsActuation controls vane position and passes signal to ECU驱动控制叶片位置和传送信号给ECU第40页，共51页。2022/8/440康跃增压器The vane position is controlled as an intermediate variable and the actual position passed to a diagnostic module. When the boost pressure does not meet the boost target, use of th

57、e vane position/vane position target can aid correct diagnosis of the fault. If changes to the vane position target do not result in a change in vane position, there is a fault with the VGT. If the VGT is at the end of its travel, when it should not be, or the vane position follows the target, the f

58、ault must be elsewhereboost connections, failed EGR valve, failed turbo CHRA, failed boost sensor, etc.叶片的位置是由可变数据和实际诊断的数据控制，当推动压力没有达到推动点时，叶片位置/叶片位置点也会发生不准确的诊断。如果叶片位置点的改变并没有带动叶片位置的改变，那么VGT肯定有故障，如果VGT随着变动，叶片位置随着叶片位置点变动，那故障发生在其他地方，如助推器连接点，EGR阀门，涡轮中间体，传感器等。 第41页，共51页。2022/8/441康跃增压器Advanced Control Sys

59、tem for VG TurboVG涡轮控制系统的优势Open Loop Function Acts as Integral Term in PID第42页，共51页。2022/8/442康跃增压器Turbo Speed LimitsSpeed sensor is cascaded in vane position control to increase stability and limit turbo speed速度传感器是叶片位置控制提高稳定性和涡轮限速的重叠第43页，共51页。2022/8/443康跃增压器When a speed is sensor is installed in t

60、he turbocharger and fed into the control system, it can be “cascaded” in the control function as an intermediate variable. Most of the time, the turbo speed functions as a dummy variable, with little impact on the overall control. However, limits on turbo speed can be used to prevent the control sys