GASTONE – Development of a New Powertrain Concept Based on the Integration of Electric Generation, Energy Recovery and Storage

Abstract

The new challenge in the reduction of CO2 emissions by heavy duty trucks is leading to a technological evolution in powertrain efficiency.Towards this objective, the EU has funded in the frame of the 7th framework program the project GASTONE: a collaborative project between several private and public companies and institutions: CRF, FTP, Continental, GENTHERM, MAGNA and U. Politécnica de Valencia, targeting the development of a new powertrain concept based on the integration of electric generation, energy recovery and storage with engine system and control strategies.The main features of this CNG engine concept are:•The energy recovery from the exhaust gases heat with a cascade approach thanks to the adoption of an advanced thermoelectric generator and a turbo-generator.•The integration of a smart kinetic energy recovery system to substitute the alternator with a smarter electrical machine.•The electrification of the main auxiliaries (coolant and oil pumps, auxiliary e-supercharger and air conditioning compressor).The electrification process is supported by an improvement of the performance of the CNG engine (the actual average value is about 38%): this number is expected to rise by 4% thanks to the engine control strategy improvement, by 1% due to the introduction of the water charge air cooler, by 2% from the reduction of the belt drive and gear losses, by 1% from the system strategy and management optimization and by 7% from the exhaust heat recovery (thermo-electric generator plus turbo-generator).This paper presents the details of the new powertrain concept design, the simulation tool developed to support the design and optimize the system and a cost per function tool to perform an economic analysis in the hypothesis to introduce the system in the market.The obtained benefits are expressed in terms of fuel saving for a target real driving cycle and effects related to the new devices are developed and tested.The project is in the design phase and the paper collects a first estimation of results based on the design, strategy and control improvement.