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Liebherr Machines Bulle SA has chosen a technical solution for their 4 cylinder engines on the basis of cooled EGR and a closed DPF system including a fuel dosing unit to achieve Stage IIIB / Tier4i Emission Standards. Main portions of the development, especially the engine and after treatment calibration was performed together with Engineering Center Steyr. The calibration was done under consideration of best fuel consumption, optimized combustion acoustics, satisfying vehicle dynamics as well as fulfillment of legislative regulations, engine and vehicle boundaries. The usage of complex software functionality, a sophisticated calibration process as well as a high end 2000bar injection system was mandatory.

The current legislation for industrial applications and construction equipment including earthmoving machines and crane engines allows different strategies to fulfill the corresponding exhaust emission limits. Liebherr Machines Bulle SA developed their engines to accomplish these limits using SCRonly technology. IAV supported this development, carrying out engine as well as SCR aftertreatment system and vehicle calibration work including the OBD and NOx Control System (NCS) calibration, as well as executing the homologation procedures at the IAV development center. The engines are used in various Liebherr applications certified for EU Stage IIIb, EPA TIER 4i, China GB4 and IMO MARPOL Tier II according to the regulations “97/68/EC”, “40 CFR Part 1039”, “GB17691-2005” and “40 CFR Parts 9, 85, et al.” using the same SCR hardware for all engine power variants of the corresponding I6 and V8 engine families.

The exhaust emissions standards for heavy-duty (HD) truck engines in the U.S. are facing a severe reduction of both PM and NOx emission in the year 2007, making extensive exhaust aftertreatment inevitable. Although the final emission limit values for NOx (0.20 g/bhp-hr) and NMHC (0.14 g/bhp-hr) will see a phase-in between 2007 and 2010, the PM emission limits of 0.01 g/bhp-hr will already take full effect in 2007. Engine-out emissions in the range of EURO 5 / U.S. 2002/04 will be achievable through internal measures as described in this paper. To fulfill U.S. 2007 limits, a diesel particulate filter will be necessary. The final limits taking effect in 2010 will only be fulfilled through application of NOx and particulate aftertreatment. To achieve the low engine-out emission levels, this paper will focus on both internal measures (high-EGR combustion systems and partial homogenization) and external aftertreatment systems.

The introduction of the new emission standards in 2002/04 for heavy-duty diesel engines requires a substantial reduction of the NOx emissions while the particulate emissions remain on a constant level. The application of cooled EGR appears to be the most common approach in order to achieve the required target, although other means such as advanced combustion systems and the application of emission control devices to reduce NOx emissions have to be taken into account as well. The purpose of this study is to investigate the potential of such alternative solutions in comparison with cooled EGR to meet the upcoming emission standards.

Future HD Diesel engine technology is facing a combination of both extremely low exhaust emission standards (US 2002/2004, EURO IV and later US 2007, EURO V) and new engine test procedures such as the European Transient Cycle (ETC) in Europe and the Not-to-Exceed Area (NTE) in the US). Customers furthermore require increased engine performance, improved efficiency, and long-term durability. In order to achieve all targets simultaneously, future HD Diesel engines must have improved fuel injection and combustion systems and utilize suitable technologies such as exhaust gas recirculation (EGR), variable geometry turbine turbocharger systems (VGT) and exhaust gas after-treatment systems. Future systems require precision controlled EGR in combination with a VGT-turbocharger during transient operation. This will require new strategies and calibration for the Electronic Engine Control Unit (ECU).

DEUTZ AG, co-founded in 1864 by Nicolaus August Otto, the inventor of the four-stroke cycle engine, has developed the new 2013 engine for commercial vehicles on the basis of the tried and tested 1012 and 1013 series. With 4 and 6 cylinder models, the engine covers the power range between 100 and 190 kW. At the time of their introduction to the market, the engines will meet the exhaust emission legislation of EURO III and incorporate the potential for EURO IV. Further engineering targets were: Compactness favourable power/cost relation Low weight Low fuel consumption and Low noise level The targeted standards have been reached, for instance, through the application of modern computation and simulation methods. The design configuration of the engines will be described and it will be outlined by examples how the engineering targets have been reached. Particular emphasis will be on measures for noise emission reduction. The 4-valve cylinder head will be described in detail.