BMW Group

Detlef Hiemesch BMW Diesel.

DEER 2008
Page 1
14th DEER Conference, 4th-7th of August 2008
Detroit

BMW Diesel - Engine Concepts for Efficient

Dynamics

Detlef Hiemesch
BMW Group
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 2
Contents.

Evolution of Diesel Performance

Diesel Motivation

Efficient Dynamics

US Market Introduction

Future Trends

Summary
 BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 3
Evolution of Diesel Performance.

BMW 535d

BMW 524td
2007
- 3rd generation
Common Rail
(2000 bar)
2004 - Piezo injectors
- Variable Twin Turbo
2001 - Diesel Particulate
- 2nd Gen.
1999 Common Rail
Filter of 2nd Gen.
1998 - First V8 Diesel (1600 bar)
1987 1990 - Introduction of Sedan in Torque:
1983 - First Digital
- First BMW DI Technology Premium
+ 170 %
- 1st BMW 6Cyl. Diesel Diesel with at BMW Diesels Segment
Inline Diesel Oxy-Cat. - BMW 320d wins offered by BMW
Electronics
- 524td fastest (DDE) “24 Hours of Power:
diesel vehicle
in it´s segment
Nürburgring” + 147 %

100 %
Consumption:
- 20 %

Emissions:
- 99 %
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 4 Evolution of Diesel Performance.

BMW Market Share Europe

600 5 Series

550 Mini
500 80%
3rd Generation
450
until End 2006 7 Series
400
Engines 1000/a

2.821.000
350
73%
300
250 X5
2nd Generation
200
635.000
150 93%
1st Generation
100
262.000
50
67%
0 total
Year of Production
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 5
Diesel Motivation.

Souvereign Pleasant
Performance Acoustics
Low Fuel
Consumption

High Range
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 6
Diesel Motivation.

Diesel vs. comparable Gasoline Vehicle: Max. Load

„Acceleration at 4th Gear“ Diesel Engine
Engine Power

Max. Load
Gasoline Engine

Available Power for

acceleration Gasoline
Vehicle

Available Power for

Acceleration Diesel Power for const. Speed
Vehicle

35 60 85 110
Vehicle Speed [mph]
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 7
Diesel Motivation.

5series Sedan 3.0l Diesel

Comparable Gasoline Vehicle
(Automatic Transmissions)
35%
Fuel Consumption

32%

26%

20%

Min. Fuel Cons. MVEG Standard Overall Test Max. Fuel Cons.
„Vehicle Dynamic“ Source: Test Reports
BMW Group
Detlef Hiemesch BMW Dieselengines.
DEER 2008
Page 8
Diesel Motivation.

Average noise inside vehicle at 30 mph - BMW 5series

2 dB
Diesel -7,5 dB
Noise [dB]

Petrol -5 dB
Diesel

Petrol

1992 1994 1996 1998 2000 2002 2004 2006 2008

Year of Production
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 9
Efficient Dynamics.

Increased
Power

Reduced Low Fuel

Weight Consumption
and Emissions
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 10
Efficient Dynamics.

Increased
Power

Reduced Low Fuel

Weight Consumption
and Emissions
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 11
Variable Twin Turbo.
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 12
Variable Twin Turbo.

Small Turbo

Compressor
Bypass

Turbine Bypass

Large Turbo

Waste Gate
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 13
Variable Twin Turbo.

26
VNT + Mech. Compressor

Variable
Effecitve Mean Pressure [bar]

22
Twin Turbo

18
VNT

14
EAT / E-Boost

10

0
1000 2000 3000 4000 5000
Engine Speed [rpm]
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 14 Variable Twin Turbo.

Large T/C Small T/C

Æ pre-charging Æ post-charging
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 15 Variable Twin Turbo.

Large T/C Small T/C

Æ pre-charging Æ post-charging
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 16 Variable Twin Turbo.

Large T/C Small T/C

Æ main charger Æ standby
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 17 Variable Twin Turbo.

Large T/C Small T/C

Æ main charger Æ standby
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 18
Variable Twin Turbo.

460 300

430 270

400 240

370 210
Torque [ft lbf]

Power [hp]
340 180

310 Variable Twin Turbo 3.0l

150
280 hp at 4200 rpm
430 ft lbf at 1750 rpm
280 120
Single Turbo Engine 3.0l
250 230 hp at 4000 rpm 90
380 ft lbf at 2000 rpm

220 60
1000 2000 3000 4000 5000
Engine Speed [rpm]
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 19
Combustion.

4 Valves per Cylinder

Central Position of Injector
Symetrical Combustion Chamber
Variable Air Control

Cylinder Displacement: 499 cm³

Bore / Stroke: 84 / 90 mm
Max. Combustion Pressure: 180 bar
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 20
Piezo Common-Rail System.

Very quick Needle

Opening and Closing for
Effective Combustion
Up to 5 Shots per
Combustion Stroke
Very low Tolerances for
Injection Quantities
Long term Learn Algorithm
for Injection Control
High Pressure Pump with
Feed Volume Control
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 21
Efficient Dynamics.

Increased
Power

Reduced Low Fuel

Weight Consumption
and Emissions
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 22
Aluminium Crankcase.

80
65 kg
70
59 kg

60
Cast Iron
Weight [ kg ]

50
Cast Iron 37 kg
„optimized“
40

30
Aluminium
3.0l 6-Cylinder

20
175 200 225 250 275 300
Engine Power [ hp ]
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 23
Aluminium Crankcase.

Cooling Duct between

Cylinder Walls

Vertical armed Thermal fitted

„Deep Skirt“ Cast Iron (GG) Liners
Formed Threads
Deep Screw Linking

Diagonal Crankcase Embossed and shape-forced

Stiffening Bearing Caps („Sintermaterial“)
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 24
Specific Engine Weight.

350
Specific Weight [kg/kW]
Competitors 10-Cylinder
300
1,6
Engine Weight [kg]

8-Cylinder
1,4
6-Cylinder
250 1,2

1,0

200
VNT MJ´07
1,08 kg/kW VTT MJ´07
0,93 kg/kW
150
100 150 200 250
Power [kW]
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 25
Efficient Dynamics.

Increased
Power

Reduced Low Fuel

Weight Consumption
and Emissions
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 26
Engine Efficiency.

0.7
Operating Range
Diesel Engine = 2.0
Operating Range = 1.2
0.6 Gasoline Engine = 1.0
Efficiency [-]

= 0.9
0.5
= 0.8

0.4

0.3
4 8 12 16 20 24
Compression Ratio [-]
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 27
CO2 Emissions.

Gasoline -25%

CO2

Diesel

Vehicle Curb Weight Source: VDA

BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 28
Fuel Consumption.

24
Available 8-Cyl. Concept
Fuel Consumption NEDC [mpg]

26

28
„Downsizing“
+40%
30

32

34
6 Cyl. VTT (535d)
36
5,0 5,5 6,0 6,5 7,0 7,5
Acceleration 0-60 mph [sec]
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 29 Exceeding even today‘s Hybrid Concepts.

14
Hybrid #2 Competitor
BMW Hybrid
13
EU test cycle
12
Fuel Consumption [l/100 km]

BMW X3 3.0sd Customer

11 driving profile*
10
9
8
Hybrid #1
7
BMW X3 3.0d
6
BMW 120d BMW
5 118d
MINI Cooper D
4
3
5.5 6.5 7.5 8.5 9.5 10.5 11.5
Acceleration 0-60 mph [sec] * Source: An increasing number
of press test reports
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 30
Emissions.

NOx
g/mi
Tier 1 LDT3 0.98

SCR
Tier 2 Bin 10 (till MY 08) 0.60

0.10 0.08 0.05 0.075 0.23 0.32

PM NMHC
g/mi DPF DOC g/mi

Tier 2 Bin 5 (MY 09)

3.4

DOC
6.4

DPF . . . . . Diesel Particulate Filter CO

DOC . . . . Diesel Oxidation Catalyst g/mi
SCR . . . . . Selective Catalytic Reduction
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 31
Exhaust System Bin 5.

Particulate Filter Oxi Catalyst

Exhaust Gas
Temp. Sensor

SCR Catalyst AdBlue Injection

NOx-Sensor

NOx-Sensor
Rear Silencer
Mixer
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 32 Particulate Filter.

Particulates are being filtered

and frequently burned
Permanent Reduction of
Particulates
Additional positive Effect on
HC-/CO-Emissions
No Loss in Engine Power
No Increase in Fuel Consumption
No Maintenance necessary
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 33
SCR System.

High Efficiency
Good Long Term Stability
Urea Tank
No Increase in Fuel
Consumption
Maintenance (Urea Refill)
together with Oil Service

Dosing NOx-Sensor
Module

Oxidation Catalyst Particulate Filter Mixer SCR-Catalyst

Source: Bosch
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 34 EGR System.

Further NOx Reduction 30%

Reduced Charge Air Temperature
Higher Boost Pressure
and better Turbocharger
Efficiency
Improved Fuel Economy

Low pressure EGR

High pressure EGR

EGR…Exhaust Gas Recirculation System

BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 35
US Market Introduction.

X5 xDrive 35d
265 hp, 425 ft lbf
Emission Standard LEVII / Bin5
0-60 mph = 6,9 s
Fuel Efficiency City ≥ 25 mpg
(Test Figures) Hwy ≥ 36 mpg
USC ≥ 29 mpg

335d
265 hp, 425 ft lbf
Emission Standard LEVII / Bin5
0-60 mph = 6,0 s
Fuel Efficiency City ≥ 30 mpg
(Test Figures) Hwy ≥ 48 mpg
USC ≥ 36 mpg
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 36
US Market Introduction.

2-Stage-Turbo-System
(„Variable Twin Turbo“)
6 Cyl. Inline 3.0l
Diesel Engine
Piezo Common
Rail System

Aluminium
Crankcase
SCR System

Close Coupled Catalyst

and Particulate Filter
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 37
Future Trends.

Increased specific Power and Torque (>100 hp/dm3)

2-stage Turbocharging: NG Variable Twin Turbo – Technology
Common-Rail Injection System: Pressure >2000 bar
Improved Combustion
Further improved Fuel Consumption (>15%)
Reduced Engine Friction
Optimized Combustion
Downsizing
Advanced Energy Management: „Hybrid Functions“
Optimized Powertrain: Transmission
Reduced Engine Weight (>5 %)
Downsizing
Compact Design with high Intergration Level
Light Weight Materials
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 38
Summary.

Evolution of Diesel Performance is impressive

Good Reasons for a high Diesel Motivation exist
“Efficient Dynamics”-Philosophy is fundamental for all our
Engine Concepts
BMW´s US Market Introduction starts with X5 xDrive 35d and
335d, both featuring a 6 Cyl. 3.0l Variable Twin Turbo Engine
Modern Diesel Technology can contribute a lot to guarantee
Future Mobility
Medium- and long-term Potentials to further increase Power
and in parallel reduce Emissions und Fuel Consumption
exist
BMW Group
Detlef Hiemesch BMW Diesel.
DEER 2008
Page 39
Thank you for your Attention.