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diesel applications

As a result of lower global standards for particulate and NOx emissions, and customer demands for increased performance and refinement, the complexity of diesel powertrain systems has grown. This includes more complex DPF, NOx after treatment and EGR systems with advanced boosting solutions.

These are only the visible changes. New and more sophisticated control strategies are being developed to control these systems, and other fuel injection control features are constantly being developed to provide a better optimisation of refinement, performance and emissions under all operating conditions.

IP has recent production experience on EU5 and EU6 applications on a wide range of EMS systems and engine types, and a specialist team with experience of DPF and NOx after treatment systems. IP has the capability and all the right tools to successfully deliver your diesel calibration project on the latest technology systems.

capability 

  • Concept definition of powertrain system hardware, including fuel injection system, EGR system and emission after treatment package. Complete system layout.
  • Experience of a wide range of Tier 1 EMS and OBD systems latest advanced torque and imep based control strategies.
  • Capability with latest technology emission control systems:
    • DOC systems and their integration with DPF systems
    • DPF system specification, development, validation and ageing. Calibration of supervisor and manager functions
    • SCR system specification, their interaction with EGR systems, and calibration
    • NOX storage system specification and calibration
  • Optimisation of EGR system configuration and capacity. Experience in the configuration and development of HP and LP systems and their interaction with boosting systems. Development of coolers and bypass systems.
  • Capability in light and medium / heavy duty applications, including off road applications. Knowledge of the different market legislative and market requirements for industrial engines and other applications.
  • On board diagnostics, including strategy design and development of monitors for new emission control systems

technology

  • IP defined and documented calibration procedures and sequence for turnkey calibration programmes. These can be combined with OEM and EMS supplier procedures as required.
  • Engine dyno based calibration using Design of Experiments methods and MBC toolbox. Advanced dyno and vehicle instrumentation (eg on board combustion and torque measurement).
  • Specific powertrain application toolsets - rapid calibration with reduced testing requirement using control strategy modelling.
  • Emission cycle modelling, including catalyst warm up and modelling of NOx emissions.
  • Pressure loss and soot accumulation modelling for DPF regeneration optimisation, to assist with calibration optimisation and control of DPF during thermal transient conditions.
  • In-house CFD toolsets for EGR flow simulation, catalyst / DPF flow distribution and SCR system vaporiser design and development.

references

  • 2 turnkey production progammes to EU5 standards, including installation system development, emission concept definition, full engine calibration and OBD.
  • >5 production driveability and emissions projects with EU5 emissions, on C and C/D passenger & light commercial vehicles.
  • Engine and system concept design and development for off road applications, including combustion system, fuel injection system specification, DOC / DPF definition and EGR system design /development.
  • Emission concept design on 2013 MY complete engine family for German OEM. This included DPF and SCR system definition / specification, package study, HP EGR system layout
  • Boosting system and EGR system modelling and concept definition for selection of HP, LP or combined system.