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pundir@iitk.ac.in
for
GreenpeaceIndiaSociety
Banglore-560025
November2008
Contents
Acknowledgements3
0.0Summary4
1.0Introduction6
2.0FuelEconomyStandardsandTestMethodsaroundtheWorld7
-EuropeanUnion
-Japan
-USA
-Othercountries
-FETestMethods
-ComparisonofFuelEconomyonDifferentTestCycles16
3.0EngineandVehicleTechnologyForFuelEconomy
-VehiclePowerRequirement
-EngineTechnology
-PowerTransmissionTrain
-HybridVehicles
-PotentialFuelEconomyImprovementsofTechnologies(USStudy)
4.0StatusofTechnologyofIndianPassengerVehicles30
-Enginetypes
-Gasolinecars
-DieselCarsandMUVs
-TransmissionTechnology
-SummaryofIndianPassengerVehicleTechnology
-IDIversusHSDIDieselEngineVehicles–ProjectionsonFuelSavings
asaCaseStudy
5.0FuelEconomyNormsforIndianVehicles35
6.0FuelEconomyImprovementTechnologiesforIndianVehicles38
7.0FindingsandConclusions40
8.0References43
Appendix–A
FuelEconomyTechnologiesandPotentialFuelEconomy44
ImprovementsbasedonFindingsofUSNationalAcademyofSciences
Appendix-B
Technology-wiseDistributionofIndianPassengerVehicleModels45
Appendix–C
ProjectionsonAnnualDieselFuelSavingsResultingfrom49
PhasingoutofProductionofIDIPassengerVehicles
Appendix–D
FuelEconomyDataforIndianPassengerVehicles51
Acknowledgements
FinancialsupportwasprovidedbytheGreenpeaceIndiaSocietyforthisstudy.ThanksareduetoMr.R.SoumyabrataofGreenpeaceIndiaandMr.ManojSharmaofIITKanpurforprovidinghelpincollectionoftechnicaldataforIndianvehicles.
0.0SUMMARY
Vehiclefueleconomy(FE)normsarebeingimplementedworldovertoconserveenergyandforreductionincarbondioxideemissions.IntheUSA,fleetaverageFEstandardsweresetbeginningfromtheyear1978,buttheseremainedstagnantaftertheyear1992untiltheyear2005whenthestandardsforlighttruckswereupgraded.Thenewstandardsforthelighttrucksarebasedonvehiclesizedefinedintermsof‘footprint’.ThenewUSstandardsforcarsareexpectedtobefinalizedsoon.TheEuropeanUnionstandardsarebasedonfleetaveragedcarbondioxideemissionswhiletheJapanstandardsarebasedonvehicleweight.TheEUhasalreadysetthestandardsapplicableforthemodelyear2012andJapanfortheyear2015.TheUSandJapanstandardsaremandatory.TheEUstandardsarevoluntaryinnaturesofarbutbecomemandatoryfromtheyear2012.
Majorfueleconomyimprovementtechnologiesbeingpursuedandimplementedonmoderngasolinevehiclesare;
multi-valveengineswithvariablevalvetimingandlift,gasolinedirectinjection(GDI)engineswithstratifiedchargeleanmixtureorstoichiometricmixture,engineundersizingandturbocharging,andcylinderdeactivationfor6-and8-cylinderengines.Inthedieselpassengervehicles,theIDIdieselenginehasbeenphasedoutalmostcompletelyinEurope.Ithasbeenreplacedbythehighspeeddirectinjection(HSDI)enginethathasusually4-valves/cylinder,employscommonraildieselinjection(CRDI)systemandisturbochargedwithintercooling.
Othernewtechnologieslikeidlestop-startsystems,integratedstarter-generatorsarealsobeingimplemented.Newcomponentdesignsforreductionofenginefrictionarebeingdevelopedandlowfrictionlubricantsarebeingused.
Powertransmissionsystemsareusingmorenumbergearsgoingto6-and7-geartransmissionsandcontinuouslyvariabletransmission(CVT)isexpectedtobeusedinlargenumbersonfrontwheeldrivencarmodelsandsinglebodylighttrucks.
Hybrid-electricvehicle(HEV)is30to50%morefuelefficientthantheconventionalpassengervehicles.AllmajorautomotivecompanieslikeGM,Honda,Toyotaetc.,haveintroducedHEVsinmediumtolargesizecarsandSUVmarketsegment.
AstudyoftechnologyusedinthecurrentproductionIndianpassengervehiclesshowsthat;
(a)Ofthetotalpassengervehiclesales,thedieselvehiclesconstituteabout30%.
(b)Nearly70%percentofgasolinecarsuse4-valves/cylinder.However,onlyasmallfractionofcarsi.e.,about11%usesvariablevalvetimings/lift.
(c)Alargepercentageofdieselpassengervehicles(51%)arestillpoweredbytheIDIdieselengines.
(d)Nearly50%ofdieselvehiclesdonotuseturbocharging.
(e)Onlyabout30%ofdieselenginesuse4-valves/cylinder.
(f)Commonrailfuelinjectionsystemisemployedinonly21%ofdieselpassengervehicles.
(g)Mostpassengervehiclesnumberingabout93%employmanualtransmissionwhichprovidesahigherfueleconomycomparedtoautomatictransmission.Also,nearly78%vehiclesuse5-geartransmissionthatgiveshigherFEthanthe4-geartransmission.The6-geartransmissionisyettopenetratetheIndianmarketinsignificantnumbers.
(h)81%ofpassengercarsalreadyemployFWDwhichresultsinbetterfueleconomy.Nocaryethowever,usesCVT.
(i)Othertechnologieslikeidlestop-start,integratedstarter-generatoretc.arenotyetimplementedonIndianvehicles.
(j)TheGDIenginesandHEVsarestilltomakepresenceintheIndianpassengervehicles.
Asanexample,estimatesonthefuelsavingsthatcouldbeachievedbyphasingoutofIDIdieselvehicleproductionandsubstitutingitbythemodern4-valvespercylinder,turbocharged,HSDIengineswithcommonrailinjectionweremade.Anannualsavingof173.9kgpervehicleisestimatedassumingtheHSDIdieseltobe15%moreefficientthantheIDIdieselvehicles.IfcompleteswitchoverfromIDItoHSDIdieselismadebytheyear2010,thentaking10%annualrateofgrowthindieselpassengervehicleproduction,thismeasurewouldresultinfuelsavingsofabout57,300tonnesduringtheyear2011.Theannualdieselfuelsavingswouldreach358,600tonnesintheyear2015andwouldcontinuetoincreasefurther.
InIndia,mandatoryFEnormswouldservebetterthanthefleetaveragednorms.ThenormsmaybebasedontheweightofvehicleasinJapanrather.EngineandvehicletechnologiestoachievenormssimilartoJapan(year2010forgasolinevehiclesand2005fordieselvehicles)canbeadoptedwithinashortperiodasthesenormsweremetbythemajorityofvehiclesinJapanintheyear2002itself.
TheengineandvehicletechnologiesthatcanbeadoptedonIndianpassengervehiclesinaperiodof2to3yearsinclude,variablevalvetimingandliftongasolineengines,HSDIinplaceofIDIdieselengine,multi-valvedieselengines,turbochargingandCRDIfuelinjection,andidlestop-start.Inthetimeframeof4to5years,GDIengines,integratedstarter-generator,CVT,6-and7-geartransmissiononlargervehiclesandHEVscanbeintroduced.
1.0INTRODUCTION
SaleofpassengercarsinIndiahasgrownatarelativelyfastrateparticularlysincetheyear2000duetoanincreaseineconomicgrowthexperiencedinthecountry.TrendsinthesalesofpassengervehiclesinIndiaareshowninFig.1.Duringtheperiod2000-2007,thecarsaleshaveseenanannualgrowthofnearly16%.Inthefiscalyear2007-08,thedomesticsaleofpassengervehiclesthatincludedpassengercars,utilityvehiclesandmulti-purposevehicles(MPV)stoodat1.548millionunits.Thiscombinedwithahighgrowthinthesalesofmotorcyclesduringthesameperiod,resultedinincreaseofgasoline(petrol)consumptionfrom6.61milliontonnesin2000-01to10.33milliontonnesin2007-08.ThetrendsingasolineanddieselconsumptioninthecountryareshowninFig.2.Itmustbenotedthatonlyabout57%ofthetotaldieselfuelisconsumedinroadtransportsector.Asignificantfractionofdieseldemandisfromrailways,agriculturalsectorandforcaptivepowergeneration.
Figure1-TrendsinannualsalesofpassengervehiclesinIndia(source:
SIAM)
AlthoughcomparedtoEuropeandtheUSA,thenumberofcarsonIndianroadsandconsumptionofpetroleumfuelspercapitaisrathersmall,butintheinterestofconservationofenvironmentandenergyresourcesinlongerterm,itisimperativethatenergyefficiencyofalltheappliancesismaintainedatahighlevel.Weneedtofocusonestablishingamechanismthatensuresefficientutilizationofthetransportationfuels.InEurope,Japanandseveralothercountries,thevehiclefueleconomyorthegreenhousegascarbondioxideemissiontargetsandstandardshavebeennotifiedandmandated[1-3].Inthisreport,thefueleconomystandardsbeingimplementedandproposedintheUSA,Europe,Japanandothercountriesarepresented.Advancementsinpassengercartechnologythathaveemergedinthelasttwodecadesorsoforimprovingvehiclefueleconomyarediscussed.AnoverviewofthecurrentstatusofvehicletechnologyusedonpassengercarsinIndiaispresented.Thefueleconomytargetsorstandardsthatcanbesetupintheneartermandthevehicletechnologiesthatmayberequiredtoattainthesetargetsarediscussed.
Figure2-AnnualconsumptionofgasolineanddieselfuelsinIndia.
2.0FUELECONOMYSTANDARDSANDTESTMETHODSAROUNDTHE
WORLD
Thevehiclefueleconomystandardsalreadyinuseandbeingformulatedforfuturearediscussedinthissection.Inthisreport,thestandardsandtestproceduresfollowedintheUS,EuropeandJapanarediscussedasthestandardsandtestprocedureselsewherearebasedononeofthesestandards.MoredetailscanbefoundintheReferences1to5.
2.1USStandards
TwoseparateCAFE(corporateaveragefueleconomy)standardsforpassengervehi