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A SULEV proposal was investigated for a Hyundai Elantra 1.8L Nu Engine, combining advanced catalyst technologies with optimized engine management control. A washcoat system using 20% less PGM loading and an optimized EMS calibration were developed to meet the 50% development target of the LEV III SULEV30 standards. This paper highlights revisions made to the new control and catalyst systems which include, 1) improved light-off time and cold-start emissions, 2) optimized cold lambda control, 3) reduced number of fuel cut events, 4) a new catalyst technology to match exhaust gas characteristics, and 5) a Pd-only front catalyst with reduced PGM.

The future powertrain development is characterized by better fuel economy. To meet this, using turbo system in the engine is becoming more frequent in the vehicle development. But using turbo in the engine is only good for power and fuel economy, and not good for emission. That is because the turbo equipped engine loses lots of heat energy at the cold start due to the turbo mass. And thus for turbo engine, it is required to apply the technologies to shorten the catalyst light-off time to reduce the exhaust emissions. Especially when the turbo equipped vehicle is tested on NEDC cycle which is tested on urban low speed cycle at the start of the cycle, its emission is too much to meet the Euro5 regulation. This paper investigates the successful ways to reduce the catalyst light-off time and exhaust emissions to meet the EU5 emission regulation in turbo gasoline direct injection(Turbo GDI) engine.

The conventional aftertreatment systems to meet the stringent ULEV-II emission regulation are usually composed of warm-up catalytic converter (WCC) and underfloor catalytic converter (UCC). However, those systems bring high cost, high back pressure, the limit of engine room for package design, and other side effects.[4] The new optimized system needs to solve these problems and to meet ULEV-II emission regulation efficiently. There are many technologies and design parameters in exhaust catalytic converter systems; exhaust manifold structure[9], exhaust gas flow distribution, location of catalytic converter, PM coating technologies[1], substrate characteristics, and volume of catalysts. It is a key factor to make a optimized robust system with those parameters and technologies described. The new optimized exhaust and Integrated Close-coupled Catalytic Converter (ICCC) system can meet ULEV-II regulation and can solve those problems of conventional system by a robust design.