BT 3a

Bharat Trem Stage 3A Engine Development
Objective To be ready with the production engines, meeting upcoming emission norms BT3A for the Indian domestic tractor market by choosing appropriate technology.
Target was to achieve the Emission Norm without compromising the Performance
Definition Environmental concerns have led to progressively more stringent emission regulation for diesel engine. Keeping this in view, the government of India regulates the exhaust emission level of engines from time to time New Features / Improvements:-
Engines with Lower Nox, Hydrocarbon , Carbon Mono oxide & particulate matters but with same power , fuel efficiency & cold start ability
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Definition
Current & future emission norms in domestic market

CMVR 2009
(2nd Amendment released dated 22 Feb 09)
Nox+HC / PM / CO - g/kWh
8<=kW<19 (HP<26) 19<kW<37 ( 26 < HP<50) 37<kW<56 ( 50 < HP<76) 56<kW<75 ( 76 < HP<102)
2003 2004
8.5 / 0.8 / 5.5 7.5 / 0.6 / 5.5 15.0 / 1.0 / 9.0 9.5 COMPONENT / 0.8 / 5.5 III BT
BT IIIA
4.7 / 0.4 / 5.0
NOX + Hydrocarbons Carbon Monoxide

2005 2006 2007
9.5 g/kW-hr 5.5 g/kW-hr

2008 2009 2010
7.5 g/kW-hr
4.7 / 0.4 / 5.0
5.5 g/kW-hr
2011 2012 2013 2014 2015 2016
Particulate Matter 0.8 g/kW-hr Bharat (Trem) Bharat (Trem) Stage-III Stage-II
0.6 g/kW-hr
Bharat (Trem) Stage-III A
Key Target : Nox reduction

Below 50 HP : ~ 20 % (9.5 to 7.5 )reduction in Nox Above 50 HP : ~ 50 % ( 9.5 to 4.7 ) reduction in Nox
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Engine Development Flow chart
Concept building
Initial simulation with FIE
Concept design
Design Review/DFMEA
Parts development for combustion
Consistency samples from Bosch

Consistency trials
Combustion development with final FIE configuration
Combustion optimization (Performance & emission)
Assembly of proto engines
Durability trials (Endurance test of first engine 2000 hrs) (Endurance test of second engine 1000 hrs.)
System assessment sign off
Engine pilot batch preparation
Field trials of tractors with BT3A engines
ECA for the engines, ready for Bulk production
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Engine Development Technology selection
For the development of BT3A engines following technology had been tried out 1) Inline FIP with Normal element 2) Inline FIP with KA feature 3) Inline FIP with LLA+LLR combination 4) Inline FIP with LLR feature. 5) All above combination with DSLAP type nozzle and KA factor nozzles. 6) Optimization of the length and dia of high pressure pipe.
With the trials of all above variants following combination had optimized for BT3A Emission Norms. # FIP with LLR feature + DSLAP type nozzle + HPP with optimized length and dia.#
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Bharat Trem Stage 3A Engine Development Concept Design
BT 3A Strategy (Engines < 50 HP)

100% Load Emission Point (Mode-1)
190
New Feature LLR Technology

Retardation at 100% Load Nox improves More deterioration in Bsfc
BSFC (gms/Ps.hr)
10O
12O
Engg Target
180
14O
16O
170
160 4.0 5.0 6.0 7.0 8.0
NOx (g/kW.h)
75% Load Emission Point (Mode-2)

BSFC (gms/Ps.hr)
190 180
14O 16O 10O 12O Engg Target
Retardation at 75% Load (Part Load) Nox improves No / minor deterioration in Bsfc
170 160 4 5
NOx reduction & target bsfc achieved by part load retardation thru LLR technology
NOx (g/kW.h)
8
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Bharat Trem Stage 3A Engine Development Concept Design
LLR Feature in Fuel Injection Pump

Retard
Required amount of retardation at various part loads were achieved with the help of BOSCH inline fuel injection pump with Light Load Retard Feature
Advance
No Load
Full Load
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Bharat Trem Stage 3A Engine Combustion Development

8 Mode Emission Measurement
Procedure for measurement of gaseous emissions for non road vehicles is specified in ISO 8178 part-4 (1996) C1 8 mode cycle 8 modes are selected based on the loading cycle of off road vehicles
100% 75%
MODE : 5 MODE : 6 MODE : 7
MODE : 1 MODE : 2 MODE : 3 MODE : 4
i. ii. iii.
Emissions are Measured at 8 different modes Weighted sum of all 8 modes is the total Emission value Critical is Nox Emissions Engineering Targets for emissions were met for all the engine models
Load
50% 10% No Load MODE : 8 Low Idiling speed
Peak Torque speed
Rated speed
Speed
Weighatage Factor - 15% Weighatage Factor - 10%
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Bharat Trem Stage 3A Validation
Performance & Endurance trials at engine lab level
Fuel Consumption / Smoke Comparison of Bharat Trem III A Vs Bharat Trem III Engines
Brake fuel consumption & smoke were found at par with existing engines Engine performance was found acceptable after endurance test
Intermediate speed 10.0 6.0

% BSFC
% Smoke
10.0 6.0 2.0 -2.0 -6.0 -10.0
Intermediate speed
2.0
-2.0 -6.0
-10.0 25 50 75 90 95 100
25
50
75
90
95
100
Load, %
Load, %
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COLD CHAMBER TRIALS
Instrumented Engine Inside Cold Chamber
Cold Chamber Trials
1. 2. 3.
Engine soaked in cold chamber for 5 6 Hours at 0 Deg After Starting engine taken to flyup rpm immediately, Starting time , white puff & fluttering phenomenon is recorded
Engine started immediately , No white puff & fluttering was observed
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Comparison of Bharat Trem III A Vs Bharat Trem III Emissions for the Field trials on tractor
Tractor Field Trials
Field Trials - Gear "H1" 4
Field Trials - Gear "L4"
2
% Change
% Change
The entire field trails fuel consumption & average out put are within 3 % as compared to BT 3 Emission norms
-2
-2
-4 Avg. Fuel Consumption (L/Hr) Avg. Fuel Consumption (L/ac) Avg. output ac/hr
-4 Avg. Fuel Consumption (L/Hr) Avg. Fuel Consumption (L/ac) Avg. output ac/hr
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Comparison of Bharat Trem III A Vs Bharat Trem III Emissions for the haulage trials on the tractor
Tractor Haulage Trials

2
Haulage Trials
% Change
-1
-2 Avg. Travel speed (KMPH) Avg. Fuel Consumption (L/Hr) Avg. Distance Avg. cc/km/tonne travelled per litre of fuel (KM/Lt)
The entire field trails fuel consumption & average out put are within 1.5 % as compared to BT 3 Emission norms
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11
Conclusion
Bharat Trem 3A emission are achieved by Escorts with minimum modification in engine and FIE systems and minimum cost effect. Finalized strategies exhibit durable and high emission reduction as well as minimum sacrificing fuel economy Following models has been covered under switch over activity from BT3 to BT3A for <50 hp applications. 1) FT30 7) PT445 2) FT35 8) PT434 3) FT60 9) PT439 4) FT45 10) FT60 Xtra Torque 5) FT50 EPI 11) MPT Plus 6) E335 Josh 12) MPT Jawan
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Bharat Trem Stage 3A Engine Development

Bharat Trem Stage 3A Engine Development

Current & future emission norms in domestic market

NOX + Hydrocarbons Carbon Monoxide

9.5 g/kW-hr 5.5 g/kW-hr

Key Target : Nox reduction

Bharat Trem Stage 3A Engine Development

Initial simulation with FIE

Parts development for combustion

Consistency samples from Bosch

Combustion development with final FIE configuration

Combustion optimization (Performance & emission)

Assembly of proto engines

System assessment sign off

Engine pilot batch preparation

Field trials of tractors with BT3A engines

ECA for the engines, ready for Bulk production

Bharat Trem Stage 3A Engine Development

Bharat Trem Stage 3A Engine Development Concept Design

BT 3A Strategy (Engines < 50 HP)

New Feature LLR Technology

160 4.0 5.0 6.0 7.0 8.0

75% Load Emission Point (Mode-2)

Bharat Trem Stage 3A Engine Development Concept Design

LLR Feature in Fuel Injection Pump

Bharat Trem Stage 3A Engine Combustion Development

MODE : 5 MODE : 6 MODE : 7

MODE : 1 MODE : 2 MODE : 3 MODE : 4

50% 10% No Load MODE : 8 Low Idiling speed

Peak Torque speed

Bharat Trem Stage 3A Validation

Performance & Endurance trials at engine lab level

Intermediate speed 10.0 6.0

10.0 6.0 2.0 -2.0 -6.0 -10.0

Bharat Trem Stage 3A Validation

Instrumented Engine Inside Cold Chamber

Cold Chamber Trials

Engine started immediately , No white puff & fluttering was observed

Bharat Trem Stage 3A Validation

Tractor Field Trials

Field Trials - Gear "H1" 4

Field Trials - Gear "L4"

Bharat Trem Stage 3A Validation

Tractor Haulage Trials

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