Sustainable surface transport

Transmission electron microscopy (TEM) and scanning electron microscopy (SEM) (30.000 Euro)

X-ray Photoelectron Spectroscopy known as XPS or ESCA (Electron Spectroscopy for Chemical Analysis) to properly evaluate the optimised oxidation state of Pd atoms and clusters in real conditions especially in the case of Pd-based catalysts (30.000 Euro)

Several other chemical analysis routine that are needed regularly and daily by atomic absorption spectroscopy (AAS), X-ray diffractometry and fluorescence (XRD and XRF) (40.000 Euro)

The use of 都ubcontractinghas been significantly reduced by involving ICSC-PAS (SPB2) for TPR/TPD and TEM/SEM analyses for surface characterisation (required in SPA1 and SPB2).

EON-RUHR: 50.000 Euro within SPB0

H2-permeation test (20.000 Euro) and H2-embrittlement study (30.000 Euro).

VENTREX: 121.500 Euro within SPB1

The work scope of VENTREX Automotive is focused on two devices, the development and manufacturing of the in tank valve and the electronic pressure regulator. The core competence of the company is based on the development and manufacturing of pneumatic actuated valves. Therefore VENTREX will subcontract the design and partly the manufacture of special components for the in tank valve and the electronic pressure regulator in exact accordance to their instructions as far as electronic components are concerned. The subcontract of this development is necessary because VENTREX intend to gain the rights of these developments.

WRUT: 5.000 Euro within SPB1

Set-up of a measuring system based on the optical fiber sensors for strain and temperature field identification in the composite vessels, including: - selection of the sensors (Fiber Bragg Grating, SmartTape, Microbending, etc.) and suitable Signal Processing Units (SPU) as well as software - assembly of the sensors with the vessel surface or embedding into composite structure (gluing technology).

XPERION: 14.000 Euro within SPB1

Mechanical and chemical analysis and tests on simple specimen for prototyping and manufacturing 電ay-by-dayprocess control

BAM: 30.000 Euro within SPB1

BAM will sub-contract to the Ecole des Mines de Paris (FR) some analysis/assessment on ongoing degradations processes by micro-cracks. Ecole des Mines de Paris has in fact developed for years a very interesting approach and testing procedure for the assessment of laminates and composite cylinders.

DELPHI: 4.559 Euro within SPB2

Metal forming and machining processes for special parts, for example components for the heat exchanger or adapters for the burner system.
All the above activities represent a necessary part of the work to be performed and guarantee the most appropriate performance of the tasks. They are being subcontracted as they require a very high and specific professional profile that the Partners could not assure in a reasonable time, with the same quality and costs. All these sub-contracted activities do not constitute core research elements of the project and cover only a limited part of the project's activity.

The subcontractors have been/will be identified by transparent and equal treatment means, in full respect with the provisions of Article II.7 of the Contract and in conformity to the company痴 internal rules applied to procurement contractsselection on the basis of best quality-price criteria.

2.4 Resources to be committed {Cost details / justification}

2.4.1 Sub-Project A1 ｨC cost details

Major Other Direct Costs:

Durable equipment: depreciation of tool equipment calculated according to the Companiesnormal accounting procedure and on the period of utilization within the SP.

New improved laboratory oven for lab. scale driving cycle simulations of advanced catalysts systems for stoichiometric combustion system (ECOCAT).

Other specific project costs:

Use of sub-system test benches (6 months), engine test benches (12 months), roller test benches (2 months), utilisation of shop-floor facilities (6 months), on an hourly base @CRF (26 months @ average total rate 斗abour cost + plus overheadof about 170 euro/h). Starting from 2005, the cost of each laboratory is charged for the part of materials, expenses and depreciation to the general overhead as indirect cost, while the part accounted as 斗abour cost on the facilityis now charged directly on the various cost centers and on the basis on the work performed directly on the various specific projects.

Leasing of Basic engine (Research Engine, Test Bench, Measurement Devices) for 3,75 months (44.450 euro); Leasing of Optical Measurement Device (Excimer-Laser ComPex T150 ,Nd:YAG-Laser Spitlight 600, ICCD Camera Flowmaster 3s, Accessories ) for 2 months (32.000 euro) @ TU-GRAZ

135 days of tests bench and 90 days of 3D modelling/calculation @ IFP

The planned 90.000 euro for subcontracting (CRF) will be re-addressed to build up a second prototype vehicle to demonstrate the innovative packaging of the CNG vessel developed in SPB1 in a most effective way than stand alone. In such a way, it will be possible to assess the claimed vehicle range of 500 km on a real mission.
Consumables:

Cost for base engines, standard engine spare parts and subsystems (injectors, rails, turbocharger). At these costs must be added the 斗abour costsfor Engine validators that will be internally adapted and assembled @ CRF痴 shop-floor (please refer to other direct costs categories: 6 months @ 170 euro/h = about 150.000 euro for 3 engine validators)

Fuels (gasoline, natural gas, natural gas / hydrogen mixtures), lubricants, engine and experimental apparatous spare parts, temperature and pressure transducers, pipes and pipes fittings, carpentry stationary (CNR-IM).

Raw materials for catalyst coatings (such as alumina, ceria, zirconia and all the secret additives and promoters/ stabilators); chemicals and liquids for coating processes and their development; - precious metal precursors (Pd, Rh, Pt raw materials); gases for lab simulations and washcoat treatments; fuels for tests and ageings; foils for metallic substrates, various foil grades (ECOCAT).

Standard fuel gases and other operating consumables (i.e. lubrication, coolant additive); Specific validator - engine parts and subsystems; engine spare parts that have to be renewed with every engine-assembly (bolts for main-bearing, conrod-bearing and cylinder head; gaskets) (All others)

Subcontracting: see 2.3.1)

2.4.2 Sub-Project A2 ｨC cost details

Major Other Direct Costs:

Other specific project costs: This item belongs to the costs of test benches and its equipment as well as costs of workshops. The responsible persons for test benches, its equipment and the workshop masters charge the costs to the projects on an hourly base in accordance with the internal policy.

68.600 euro for 400 hours of transparent engine testbed and 384.500 euro for 32 weeks engine test bed (based on 2-shift operation) and 162.200 euro for 12 weeks high dynamic test bed with cycle simulation and additional tail pipe exhaust gas measurement @ AVL

8 weeks chassis dyno and 4 weeks emission dyno @ CONTI

Consumables:

AVL: Consumables and spare parts for cylinder pressure evaluation, ECU incl. wiring loom, transparent engine (glasses, cylinder head, adaptation for CNG operation,｡K); fuel and small parts for engine testing prototype installation etc.: 22.000 euro for fuels (standard bottled CNG); 17.500 euro for Material for test bed setup of Multi-cylinder engines (mounting material, heat exchanger, sensors, shaft｡K); 17.000 euro for Material for test bed setup of transparent engine; 16.400 euro for Special parts for setup of transparent engine (e.g. glas cylinder,｡K); 10.900 for HW for cylinder pressure control tests (Slave ECU + wiring); 3.500 euro for Lubricant, Coolant, Spare parts for Test Bench equipment; 9.000 euro for lubricant, coolant and fuel for the additional vehicle cycle testing; 18.000 euro for special parts to operate the MCE on full transient test bed for vehicle cycle simulation. 4.000 euro for software licences (INCA, Mathlab,｡K); 12.000 euro rent for special measurement equipment; 3200 euro miscellaneous

SIEMENS: 40.000 euro for 10x Injector prototypes Generation I; 20.000 euro for prototype parts for injector valve group; 5.000 euro for Power stages for Piezo injectors; 15.000 euro for 3x Pressure regulator; 40.000 euro for 10x Injector prototypes Generation II; 14.000 euro for Spare parts and optimization parts for injector prototypes Generation II; 17.000 euro costs for parts for unplanned new injector generation with bellow lift transformer.

CONTI: 36.000 euro for test vehicle integration & set-up including sensors, actuators, valves; 9.000 euro for selective wiring harness adapter to ECU + IO boxes including car prolongation; 3.000 euro for Fuel; 35.800 euro for data acquisition unit for in cylinder pressure measuring on vehicle including wiring; 72.000 euro for Emission Measuring System + tool specific material (including Memory emulator for calibration data and driving programs + I/O-Boxes + wiring

Third Parties: Part of the activities of DAI will be performed by its subsidiary MBtech (MBtech Powertrain GmbH, Salierstrasse 38, 70736 Fellbach-Schmiden) because the capacity for this work is not available within DAI. MBtech is a subsidiary (100 %) of DAI (Daimler AG) and it has been already involved as third party within the IP NICE ｨC SPA3 (with similar objectives). Deliverables and performance within InGas will be: materials for engine parts (176.900 Euro); engine assembly, setting-up of engine operation, design support for the above named volume. Here the detailed split of comsumable costs for MBtech (3 engine validator): 25.000 euro for standard production components; 40.000 euro for Cylinderheads; 18.000 euro for Camshaft actuators; 3.000 euro for Pistons; 9.000 euro for Fuel systems; 23.000 euro for Air systems; 20.000 euro for Exhaust systems; 30.000 euro for Oil and water pipes; 8.000 euro for Sensors, actuators; 900 euro for Miscellaneous; Additional deliverables and performance within InGas will be: materials for engine parts (31.500 Euro); retrofit and repair of engines, debugging and design support.

Here the detailed split of consumable costs for MBtech:

8500 Euro for newly designed slide rails; 6000 euro for screws, sealings for engine conversions (piston change) and repair; 8000 Euro for 2 intake and 2 exhaust cam phasers; 2000 Euro for catalyst; 2000 Euro for turbo charger; 5000 Euro for miscellaneous. . Sum of additional budget: 98.400 EUR  

Part of the activities of OPEL will be performed with the use of the facilities and material for the research work made available by its subsidiary GMPT-G that is the owner of the facilities - such as engine dynos - used in the project and supplier of material and consumables and that will stay in the contract linked to Opel as third party. The following costs are scheduled: 45.000 \ bench engine testing (average engine development test bench total cost per hour - excluding direct labor cost): 141 Euro; components and spare parts for validator-engines, components, set-up of validator / testing vehicle, measuring equipment 83.000 \; 5.000 \ x 2 (10.000 \)  transmissions for engine integration on vehicle; 9.000 \ spare parts for engines and test benches;  2.950 \ for fuels.
2.4.3 Sub-Project A3ｨC cost details

Major Other Direct Costs

Durable equipment: depreciation of tool equipment calculated according to the Companiesnormal accounting procedure and on the period of utilization within the SP: up-grading of test equipment for activity test (HT);

Consumables: 97.000 euro for Standard fuel gases (including fuel blends) and other operating consumables (i.e. lubrication, coolant additive); 120.000⁷ euro for specific single cylinder adaptation and set-up (i.e. casting and machining of turbocharger-housings, cylinder head with redesigned port shapes and spark plug application, redesigned camshafts with matched valve timing, pistons); 58.000 euro for engine spare parts that have to be renewed with every engine-assembly (bolts for main-bearing, conrod-bearing and cylinder head; gaskets); 40.000 euro for Boosting System; 30.000 euro for Specific Test Rig Components; 20.000 euro for Specific Multi-cylinder C Components (FEV); vehicle 27.000 euro.

SAPT ( ex GMPT-S): 10.000 euro x 12 Converters + Coating, 30.000 euro for consumables and spare parts (standard gas, sensors and workshop materials).

During the first project year, GMPT-G as beneficiary spent 11.295 euro for components and spare parts for validator diesel engine and 50.173 euro for CNG specific part procurement for development engines based on a 1.6l gasoline engine like pistons, injectors, valve seat rings and valves, mod. ECU and SW to operate 1.6l (gasoline based) InGas dyno engine

HT: noble materials
Other specific project costs: This item belongs to the costs of test benches and its equipment as well as costs of workshops.

FEV: workshop for 58.486 \; CAD station for 52.541 \; 1D/3D CAE station for 91.525 \; Component Rig Testing for 49.567 \; Bench Engine Testing for 278.887 \; Vehicle Testing Bench for 128.512 \. Average hourly rate 120 \/h.

 

SAPT (ex GMPT-S): Component Rig Testing for 20.000 \; Bench Engine Testing for 35.000 \; Vehicle Testing for 40.000 \. Average engine development test bench Sweden total cost per hour: 161 Euro. The total costs per hour include direct Labor Costs per hour, depreciation and burden

Opel : workshop and bench engine testing for 74.105 \ (for 60.000 \);

2.4.4 Sub-Project B0 ｨC cost details

Major Other Direct Costs

Durable equipment: depreciation of tool equipment calculated according to the Companiesnormal accounting procedure and on the period of utilization within the SP: test rig equipment for activity test (EON-RUHR)

Consumables: Consumables and Spare parts for the tests (test rig equipment, engine modification), limit gases supply for other subprojects (EON-RUHR)

Standard fuel gases (NG, pure hydrogen, pure propane, pure methane), exhaust gas analyzer span gases (NO, methane, hydrogen, synthetic air, CO, CO2). Spare parts for testing and in-house provided maintenance of testbeds (sensors, pipes, wiring, amplifiers and signal converters, water pumps; spare parts for 3 test engines; luboil) (CVUT-JBRC)

Subcontracting: see 2.3.i)

2.4.5 Sub-Project B1 ｨC cost details

Major Other Direct Costs

Durable equipment: depreciation of tool equipment calculated according to the Companiesnormal accounting procedure and on the period of utilization within the SP: prototype manufacturing tool and functional test equipments for in tank valve and electronic pressure regulator (VENTREX);

Tools and machinesparts for vessel prototyping/manufacturing: tool for blow-moulding; tools for the winding machine; tools for the ovens; tools for cycle and bust tester (XPERION)

Consumables: Consumables, raw materials and spare parts for final prototypes of Gas storage systems (30.000 euro, CRF);

For the development and realisation of the additional set of cylinders for the advanced CNG storage system module 50.000 euro of consumables originally allocated to CRF are transferred to Xperion (25.000 euro in consumables + 25.000 euro RTD).

Testing specimen, strain gauge incl. mounting, acoustic emission sensors, temperature sensors, pressure transducer, cylinder adapter, gaskets, fittings and piping; hydraulic testing fluid, hydraulic oil, filters, control valve, high pressure hose, gaskets (BAM)

Working medium for hydraulic tests (oil and glycol); Raw materials for connectors preparation; Sealing; Sensors (AE, pressure transducers, strain sensors, etc.) (WRUT)

Consumables, raw materials and spare parts for sub-systems prototypes for testing and final prototypes (VENTREX)

Carbon-fibres; Glass-fibres; Epoxy-resin; other consumables (gloves, cleaner｡K..) (XPERION)

Computing: CATIA V5 license fees for the time of utilization (VENTREX)

Subcontracting: see 2.3.i)

Other specific project costs: the cost on hourly base for testing and shop floor facilities.

Filament-winding machine (75 days @ 1.000 euro/day); Curing oven (75 days @ 250 euro/day); Cycle test machine (105 days @ 200 euro/day); Burst test machine (15 days @ 250 euro/day); other machines for prototypes manufacturing (around 10%).

2.4.6 Sub-Project B2 ｨC cost details

Major Other Direct Costs

Durable equipment: depreciation of tool equipment calculated according to the Companiesnormal accounting procedure and on the period of utilization within the SP: Gas chromatograph (ICSC-PAS); updating of laboratory test equipment (POLIMI).

Consumables:

DAI: Gases laboratory (testing and analyser calibration) for 8.000 euro; Test rig parts (massflow controllers, valves, fittings,｡K) for 10.000 euro; Analyser calibration/maintenance for 10.000;

AVL: Engine installation material (sensors, heatexchanger, etc.) for 2.700 euro; spare parts for test benches system (sensors, gaskets, etc.) + lubricant, cooling fluid, etc. for 2.400 euro; setup of advanced exhaust system, instrumentation, wiring, gaskets, mounting frame, fuel supply for 3.400 euro; fuels and lubricants for 13.400 euro.

10.000 euro for fuel, lubricants, calibration gases,｡K for testbed operation

9.000 euro for setup material for transient operation

3.700 euro miscellaneous

ECOCAT: Raw materials and gases for washcoat and coating methodology development and samples and fuels for tests.

ICVT: Materials and components for laboratory scale EAT; EAT components; Gases for testing and analysis.

7.900 euro for exhaust generator system for model calibration

POLIMI: gases for testing and analysis; glass laboratory tools; chemical and reagents; spare parts for test equipment;

ICSC-PAS: chemicals, technical gases, spare parts for test equipment.

KATCON: Metal components for canning for 20.000 euro; Welding materials for 5.000 euro; Tools and fixtures for 8.000 euro; Burner system components for 20.000 euro.

Delphi: Heat exchanger components for 37.000 euro; Tools and fixtures for 18.000 euro;
Subcontracting: see 2.3.1)
Other specific project costs: This item belongs to the costs of test benches and its equipment as well as costs of workshops. The responsible persons for test benches, its equipment and the workshop masters charge the costs to the projects on an hourly base.
AVL: 15,5 weeks stationary test-bed (based on 2-shift operation). 13 week fully dynamic test bed for cycle simulation
ICSC-PAS:

According to the initial bugdet, the amount of 35 000 \ had been assigned to the ICSC-PAS (Partner 29) for the gas chromatograph. Due to the fact that the exploitation of the equipment started in 2010, costs of depreciation have been charged to project budget since January 2010. They have estimated that they would use only half of the assigned amount, i.e. ca. 19 000 \ for the depreciation of this chromatograph.

In the course of the project implementation, however, it turned out that some additional equipment was necessary, and, after seeking and obtaining the approval of project coordinator, ICSC-PAS charged part of the depreciation for the items listed below to INGAS:

Hydraulic press: 780 \

PW3081/60 Programmable Divergence Slit - XRD phase analysis: ca. \2250

Ball Mill: ca. \ 1260

Magnetic Field Cancelling System : ca. \ 11 100.
2.4.6 Sub-Project C0 ｨC cost details

Management costs cover the project coordination activities performed by the Co-ordinator and the Core Group members / SP leaders.

3. Impact
鼎ars are an important part of the everyday lives of a large number of Europeans, and the automotive industry is a significant source of employment and growth in many regions of the EU. However, car usage has significant impacts on climate change, with about 12% of the overall EU emissions of carbon dioxide (CO2), the main greenhouse gas, coming from the fuel consumed by passenger cars. Even though there have been significant improvements in vehicle technology ｨC in particular in fuel efficiency which also means lower CO2 emissions ｨC this has not been enough to neutralise the effect of increased traffic and car size. While the EU as a whole has reduced its emissions of greenhouse gases (GHG) by just under 5% over the 1990-2004 period, the CO2 emissions from road transport have increased by 26%.”⁸
The CO2 reduction can be achieved not only by increasing the fuel conversion efficiency of the powertrain but also by an increased use of those gaseous fuels which:

have a higher hydrogen to carbon ratio in the molecule, like methane that is the major constituent of natural gas;

are biofuels, such as biogas;

contain hydrogen such as the mixtures of natural gas and hydrogen.

These actions, i.e. the increase of fuel conversion efficiency and the development of light-duty vehicles running on the above gaseous fuels, require a high degree of innovation in vehicle motor technology within the constraints of future emission limits. Such an innovative technology will impact on the following topics:
Contribution to CO2 reduction emissions from surface transport operations aligned with Kyoto targets with a global warming index (GWI) 10% and 15% lower than that of a 2006 diesel engine when running on pure natural gas and a mixture of natural gas and biogas respectively (see Table 1.3); mixtures of natural gas and hydrogen will be also considered.

Being the natural gas intrinsically a clean fuel as described in Paragraph 1.1.1, a reduction of exhaust and local emissions higher than future Euro 6 and US Tier II emissions limits (see Table 1.3) will be achieved thus allowing national and local authorities to meet their air quality engagements consisting in reduced particulate matter (PM) and ozone (O3) concentrations. About these last two pollutants, the PM level of a vehicle running on compressed natural gas is negligible (just lube oil can contribute to PM but it will be minimized by a proper engine design) while its ozone potential is extremely low (see Paragraph 1.1.1).

Increased share of bio-fuels and alternative hydrocarbon fuels in surface transport applications as pointed out by the Green Paper published by EC DG TREN to reduce the European dependence from crude oil. Their introduction is planned in several steps up to 2020: the aim for natural gas is to arrive at 2%, 5% and 10% by 2010, 2015 and 2020 respectively, while for hydrogen is 2% in 2015 and 5% in 2020. Biogas is also considered (see Table 1.3).
The steps required to bring about the above impacts are based on the development of an innovative technology joining all together the different aspects of fuel, on-board gas storage, combustion system and aftertreatment considered in the sub-projects B0, B1, A and B2 respectively. High incremental steps characterize the impact of the InGas technology with respect to the previous projects, in particular to the Sub-project A3 擢uture gas Internal Combustion engines with Diesel equivalent fuel consumptionof NICE (哲ew integrated combustion system for future passenger car engines, i.e. the most recent project on the matter. Targets of InGas (Table 1.3) are a better fuel conversion efficiency than that of a Diesel engine not only at max load but also at part load operations; and the emission limits to be complied with by IngGas are the Euro 6, instead of Euro 4 as it was for NICE, with a sensible impact on the EU air quality⁹. Furthermore the proposal joins all together those aspects which were dealt with by separate projects such as METHACAR (溺ethane fueled ultralow emitting cars for engine/vehicle, LEVINGS (鏑ow emission vehicle with integrated natural gas storage system for natural gas on-board storage, NG COMPONENTS & FUELS (填se of NG Passenger Cars Components for Bi-fuel Vehicles and Concepts to Handle Varying Gas Compositions for fuel quality and NICE for engine combustion. This means a substantial contribution to the diffusion of natural gas as an automotive fuel given by the project according to the objective of 10% in 2020, as demanded by the European Union: this appears as a real and sensible justification of the cost of the InGas project.