Fuel Economy.docx

Fuel Economy.docx

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FuelEconomy

FuelEconomyofIndianPassengerVehicles-StatusofTechnologyandPotentialFEImprovements

Prepared

by

Dr.B.P.Pundir

Professor,MechanicalEngineering

IndianInstituteofTechnologyKanpur

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