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INGAS
Grant agreement N
218447
Project acronym
Project title
INGAS
Integrated GAS powertrain Low
emissions, CO2 optimised and efficient
CNG engines for passengers cars (PC) and
light duty vehicles (LDV)
Instrument
Theme
Integrated Project
SST 2007 RTD 1
Sustainable Surface Transport
01.10.2008
36 Months
IP Co-ordinator
IP Project manager
Subproject
Sub-project Co-ordinator
SPB1
David Storer, CRF
Deliverable
Prototype of electronic
pressure regulator
D.B1.7
31/03/2011
30/09/2011
Bernhard Kiener
VENTREX
Report status
Consortium confidential
Revision version
3.0
Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Contract N.:218447
Revisions table
Version
Date
1.0
2.0
3.0
Reason
Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Contract N.:218447
Table of contents
Executive summary ................................................................................................................. 4
1 Research activities .......................................................................................................... 4
1.1
Development and validation....................................................................................... 4
1.1.1
Functions in Detail ............................................................................................. 5
2 Conclusions .................................................................................................................... 11
Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Contract N.:218447
Executive summary
This Deliverable Report documents the activities and results of Task B1.3.1
Development and validation of an electronic, proportionally controlled pressure
regulator which forms part of Work Package WPB1.3 Advanced storage system
components.
The aim was to develop a new generation of an electronic pressure regulator which
is able to vary the rail pressure in front of the injectors continuously.
On the basis of the already existing pressure regulator improvements concerning
size, weight and functionality have been made. An appropriate integrated control
strategy was defined and developed in cooperation with SP A1.
1 Research activities
According to the DOW the R&D focus of task WPB1.3.1 was the development and
validation of an electronic, proportionally controlled pressure regulator including
safety tests. The new pressure regulator is able to react on different pressure
requirements in the CNG rail.
Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Contract N.:218447
Solenoid valve
Regulator body
High pressure connector
Customer specific
Fig. 1
1.1.1
Functions in Detail
1.1.1.1 Filtration
The inlet gas is filtered with a wire grating at the inlet of the pressure regulator. The wire
grating filters particles which have dimensions higher than 50 m. It is designed to prevent
the pressure regulator from failure due to particles.
Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Contract N.:218447
The electronic regulation mainly consists of a proportional valve. A pressure sensor in the
injection rail provides information of the current pressure to the ECU. The software applied to
the ECU calculates the optimum rail pressure for the current driving condition and sends
signals to the proportional valve accordingly. Depending on the peripheral equipment (i.e.
injection valves, turbo charger, compressor, and geometry of the inlet manifold) the
proportional valve regulates pressure between 4 to 10 bar. In theory the range of output
pressure is between 0 and 20 bar.
To fully open the proportional valve the coil needs a minimum current of 1.2 ampere.
Different outside temperatures have effect on the resistance and the voltage of the battery.
The following graph (Fig. 2) shows the relation between current and temperature at given
voltages. The pink line at 1.2 ampere marks the minimum current necessary to open the
proportional valve 100 percent.
2,20
9V
10V
2,00
11V
1,80
12V
13V
1,60
14V
15V
current [A]
1,40
1,20
1,00
0,80
0,60
0,40
0,20
0,00
-40
-20
20
40
60
80
100
120
temperature [C]
Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Contract N.:218447
idle
Full throttle
Push
Change gear
Figure 3 shows the pressure regulation in the rail in a time range of 40 seconds. The red line
shows the set pressure calculated by the ECU. The green line shows the measured pressure
in the rail. The tank pressure (yellow line) remains nearly constant in this short regulation
sample.
The following picture (Fig. 2) shows the regulation quality during field trial. The displayed
values were measured at the set point.
Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Full throttle
Contract N.:218447
Set point
Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Contract N.:218447
CH4
40
38
36
34
32
20 bar
100 bar
200 bar
30
4
10
The proportional valve which is a solenoid valve is controlled by a PWM signal (12V, 0,52
kHz). Without PWM signal the proportional valve is in closed position and works as a shut-off
valve. The reaction time for opening and closing of the valve over all pressure ranges is
always less than 100 ms. The PWM signal is triggered to a duty cycle from 0 to 100 percent.
0 percent means a closed valve, 100 percent means the proportional valve is fully open.
30
25
20
15
10
5
0
0
10
20
30
40
50
60
70
80
90
100
Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Contract N.:218447
Figure 6 shows the mass flow depending on inlet pressure and duty cycle. The duty cycle is
increased up to 100 percent (red line) and then decreased to 0 percent (blue line). The
hysteresis between the two lines is important for the application in the car.
With this pressure regulator plenty of different tests were performed. The main focus
was on the improvement of the control quality. Fig. 8 shows the pressure regulator in
a test car and Fig. 9 shows the test rig where durability tests and component tests
were done.
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Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Fig. 8
Fig. 9
Contract N.:218447
Additional to the internal tests SPA1 received pressure regulators and a control unit
from VENTREX to perform some hardware testing on the engine test bench. These
tests were performed successful. After the testing the pressure regulator was
integrated into the test vehicle of SPA1 a FIAT Bravo.
According to the DoW VENTREX presented a prototype of the electronic pressure
regulator after 24 months (DB1.7). This deliverable was successfully presented.
2 Conclusions
During the Subproject 1.3.1 VENTREX developed a new generation of an electronic
pressure regulator. The focus was on the functional optimisation and the reduction of
size.
Parallel to the design work plenty of tests on the test bench and test vehicle have be
performed. After the design freeze and the definition of the final project status
hardware was presented to other project partners and other Subprojects. Especially
INGAS Integrated Project
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Deliverable Report
INGAS_DR_VENTREX_D B1 7_final version_rev 2_sept 2011
Contract N.:218447
with SPA1 we had a close communication and exchange of Know how and
hardware. Finally a test vehicle, FIAT Bravo, was built up with the pressure regulator
and the control unit of VENTREX.
Summarized VENTREX was able to reach the project targets and is satisfied with the
results.
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