A Hybrid Heavy Duty Diesel Power System for Off-Road Applications - Concept Validation

Chad Koci, Radoslav Ivanov, Jay Steffen, Jeremy Adams, R. Kruiswyk, Tim Bazyn, Lauren Duvall, R. McDavid, Marc Montgomery, Jason Keim, Tom Waldron
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Abstract

A multi-year power system R&D program was completed with the objective of developing an off-road hybrid heavy duty diesel engine with front end accessory drive-integrated energy storage. This system was validated to deliver 10.5 - 25.6% reduction in fuel consumption over current Tier 4 Final-based 18L diesel engines, over various off-road machine application cycles. The power system consisted of a downsized heavy-duty diesel 13L engine containing advanced combustion technologies, capable of elevated peak cylinder pressures and thermal efficiencies, thermal barrier coatings, exhaust waste heat recovery via SuperTurbo™ turbocompounding, and hybrid energy assisting and recovery through both mechanical and electrical systems. Following the concept definition, design, and analysis phases of the program, the final phase focused on building and validating the performance and efficiency in laboratory tests. While aspects of the system such as start/stop and reduced off-road cooling package energy losses were only analytically evaluated, the main 13L concept engine with full hybrid system was successfully built and tested in steady-state and in transient certification and real-world application cycles. Extensive simulations in Caterpillar's DYNASTY™ software environment utilized the validation test data to assess performance more fully and confidently over varied cycles and strategies. An average fuel consumption reduction of 17.9% was realized, and the majority (~13%) of the benefit stemmed from the core concept 13L engine. To conclude, a total cost of ownership analysis provides context to commercial viability and where adoption focus should be placed.
用于非公路应用的混合动力重型柴油机动力系统 - 概念验证
完成了一项为期多年的动力系统研发计划,目的是开发一种带有前端附件驱动集成储能装置的非公路混合动力重型柴油发动机。经过验证,与目前基于 Tier 4 Final 的 18L 柴油发动机相比,该系统可在各种非公路机械应用周期内降低 10.5 - 25.6% 的油耗。该动力系统由一个缩小的重型 13L 柴油发动机组成,该发动机采用了先进的燃烧技术,能够提高峰值气缸压力和热效率、热障涂层、通过 SuperTurbo™ 涡轮复合技术进行废气余热回收,以及通过机械和电气系统进行混合能源辅助和回收。在该计划的概念定义、设计和分析阶段之后,最后一个阶段的重点是在实验室测试中构建和验证性能和效率。虽然只对系统的某些方面(如启动/停止和减少越野冷却包能量损失)进行了分析评估,但还是成功地制造并在稳态、瞬态认证和实际应用循环中测试了配备全混合动力系统的 13L 概念主发动机。在卡特彼勒的 DYNASTY™ 软件环境中进行了大量模拟,利用验证测试数据对不同周期和策略下的性能进行了更全面、更可靠的评估。平均油耗降低了 17.9%,其中大部分(约 13%)来自于核心概念 13L 发动机。总之,总体拥有成本分析为商业可行性和应用重点提供了依据。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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