BMW AG

Wolfgang Mattes BMW Diesel.

DEER 2006
Page 1 12th DEER Conference, August 20-24, 2006, Detroit

BMW Diesel Engines – dynamic, efficient and clean

Wolfgang Mattes
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 2 Contents

• BMW Diesel history

• Engine portfolio and market success

• What do Diesel customers like ?

• Challenges in the US-market

• Emission concept for TIER2 BIN5

• Conclusions
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 3 Dramatic evolution.

Torque:
+ 160 %
Power:
+ 135 %

100 %
Consumption:
- 20 %

Emissions:
- 99 %
Particulates
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 4 Two decades of diesel competence.

1983 1987 1998 2004

- First inline 6 - First Digital - Introduction of DI - Variable
BMW diesel Diesel-Electronic technology by BMW Twin Turbo
(DDE) - BMW 320d wins - Particulate
- 524td, fastest the 24 Hours of filter 2nd
diesel car Nürburgring generation
of its time 1990
- First BMW
diesel with
Oxidation-CAT
1999
- First V8 diesel
with direct injection
within the premium
car segment
BMW 524td
2001
- DI with 2nd generation
Common Rail, 1600 bar
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 5 Production Volumes.
500

450
3rd Generation
until end 2005
400
2.324.000

350

300
Engines 1000/a

250

200

∑ 2nd Generation
150
635.000

∑ 1st Generation
100
262.000

50

0
83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05
Production year
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 6 Diesel Models in Europe.

4-Cylinder Mini 1er 3er 5er 7er X3 X5

318d
118d
One D 320d 520d X3 2.0d
120d
320cd
6-Cylinder
525d
330d
530d
330cd 730d X3 3.0d X5 3.0d
530xd
330xd
535d
8-Cylinder

745d
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 7 Development of 6-Cylinder Diesel-Engines.

200 kW
560 Nm

160 kW
500 Nm *
135 kW
410 Nm
Power [kW]

105 kW 2004
260 Nm
85 kW
210 Nm
2002

1998

1991 * since 03/2005 170 kW / 520 Nm

1983
200 300 400 500
600 Torque [Nm]
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 8 Engine Line up.
8 - Cylinder
4.4 l
250

6 - Cylinder
215
2.5 l / 3.0 l / 3.0 l VVT

175
Power [kW]

4 - Cylinder
2.0 l
150

125

100
1.5 2 2.5 3 3.5 4 4.5
Engine Displacement [ l ]
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 9 BMW Diesel–Mix in Western Europe.

1er 3er 5er

58% 56% 73%

7er X3 X5

70% 88% 89%

Diesel
per August 2005
(2004 54%)
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 10 Australia – development of X5 Diesel-share.

80
Overall Diesel Share PC+ LDV
75
2004 10%
70 2005 11% 1708 units
Diesel share [%]

65
60 1830 units
55
50
1387 units
45
40
35
30
2004 2005 2006
forecast
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 11 Success factors for Diesel engines.

• Fun to drive, outstanding torque characteristic

¾ relaxed cruising
¾ torque on demand
¾ good NVH due to low engine speed
• Low fuel consumption
¾ 20-30 % below comparable Petrol cars
¾ cost saving, sometimes supported by low fuel costs
¾ high cruising range

Æ BMW focus: Sports Diesel

High power output and sporty drivability
combined with low FC under all driving conditions
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 12 Efficient Dynamics.

Dynamics

Weightreduction Fuel-Consumption
and Emissions
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 13 Clean Diesel – Introduction of Particulate Filter.

2004 2005 2006

2007

118d 09/05
120d 06/05

318d 09/05
320d 01/05
330d 09/05

525d, 530d 03/04

535d 09/04
520d 09/05

730d, 745d 03/05

X3 2.0d, X3 3.0d 09/05

X5 3.0d 10/05
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 14 Leading edge engine technology.
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 15 Variable Twin Turbo technology –
a new milestone in diesel history.
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 16 Variable Twin Turbo technology - even more powerful.

630 225

560 200

490 175

420 150

Power [kW]
Torque [Nm]

350 125

280 100

210 75
Variable Twin Turbo 3,0 l :
560 Nm at 2000 min-1
140 200 kW at 4400 min-1 50
Base engine 3,0 l (MJ 05) : 25
70
500 Nm at 2000 min-1
160 kW at 4000 min-1
0 0
0 1000 2000 3000 4000
5000
Engine speed [min-1]
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 17 Variable Twin Turbo technology combines
V8-dynamics with R6 fuel consumption.

10,8

10,4

10,0
Fuel consumption [l/100 km]

9,6
Alternative
8-cylinder concept
9,2

8,8

8,4

8,0
535dA 530dA MJ 05
7,6

7,4
6,0 6,4 6,8 7,2 7,6
8,0
Acceleration 0-60 mph [sec]
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 18
Technology proofed in Rally Sport.

Engine : BMW inline 6 cylinder diesel

with Variable Twin Turbo
Power : about 270 HP
Torque : over 600 Nm

Æ Winner of the Diesel category in the 2003 and 2004 Paris-Dakar Rally.
Æ First Diesel to win a special stage
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 19 The package for EU4 emission regulations.

Engine internal measures

Emission aftertreatment
including particle filter
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 20 The package for EU 4 emission regulations.

Intake manifold Throttle

with controlled flap

Coated soot
filter (CSF)
EU 4 injector

Lambda
probe

Optimized Electrically EU4

catalyst controlled TC EGR-cooler
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 21 Combustion Chamber Configuration.

6-Cylinder 8-Cylinder
central injector position
4 valves
symetrical combustion chamber
variable air control
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 22 BMW Diesel Particulate Filter.

Particles are filtered

and burnt off in the
ceramic filter with its
catalytic coating.

no power loss
no significant increase in FC
reduced HC/CO-emissions
no maintenance necessary
reduced system effort
 Market Study Diesel Image Germany and UK 2005
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 23 What do Diesel customers like .
General Attitude towards Driving & Cars

Petrol drivers (n=598) Petrol drivers (n=676)

When I buy a new car, the fuel consumption Diesel drivers (n=420) Diesel drivers (n=329)
is very important for me, even if it means
spending 74 66
more money for this lower fuel consumption 85 83
I couldn‘t imagine life without a car 75 83
82 89
A car has to be at the cutting 60 62
edge of technology 72 57
A car‘s eco-friendliness is 65 29
of the greatest impotence for me 66 32
For me a car is simply a functional object 64 64
66 64
For me a car is of particular interest if it is a 56 36
very innovative and advanced model 40
60 38
Cars are a major problem for the environment 46
When I buy a car, the price is the 60 65
absolutely decisive criterion 64

I can get really enthusiastic about cars 51 76

54 73
Data in %

Diesel Systems Source : BOSCH

Internal | DS/MKT3 5920753e | 1/10/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights.
We reserve all rights of disposal such as copying and passing on to third parties.
 Market Study Diesel Image Germany and UK 2005
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 24 What do Diesel customers like .
Timing of Engine Choice

Petrol drivers Diesel drivers Petrol drivers Diesel drivers

(n=598) (n=420) (n=676) (n=329)

Decided right at the beginning 37 55 37 52

Before going to the dealership 14 16 18 22

I listen to the dealer‘s advice

and then decide between 21 13 16 8
petrol and diesel

After going to the dealership 17 8 11 11

Don‘t know / No answer 11 8 12 4

Data in %

Diesel Systems Source : BOSCH

Internal | DS/MKT3 5920753e | 1/10/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights.
We reserve all rights of disposal such as copying and passing on to third parties.
 Market Study Diesel Image Germany and UK 2005
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 25 What do Diesel customers like .
Spontaneous Associations with Diesel

Petrol drivers Diesel drivers Petrol drivers Diesel drivers

(n=598) (n=420) (n=676) (n=329)

Positive aspects 46 67 36 72

Negative aspects 40 22 36 11

Makes/models 10 9 18 13

Others 3 4 16 11

No specific image 8 3 3 3

No answer 7 6 16 9

Data in %

Diesel Systems Source : BOSCH

Internal | DS/MKT3 5920753e | 1/10/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights.
We reserve all rights of disposal such as copying and passing on to third parties.
 Market Study Diesel Image Germany and UK 2005
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 26 What do Diesel customers like .
Spontaneous Associations with Diesel

Petrol drivers Diesel drivers Petrol drivers Diesel drivers

(n=598) (n=420) (n=676) (n=329)
Positive aspects

Consumption level 24 42 15 42

Performance (hp, 18 22
acceleration, torque) 36 8

Eco-friendly technology 6 10 3 7
Strongly improved
diesel technology 7 6 6 13

Smooth engine 4 9 5 12
For longer distances /
high mileage 3 3 3 1

Diesel engine 1 3 2 3
lasts longer
Reliability 1 3 3 18

Data in %

Diesel Systems Source : BOSCH

Internal | DS/MKT3 5920753e | 1/10/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights.
We reserve all rights of disposal such as copying and passing on to third parties.
 Market Study "Diesel Image in Germany/UK 2005"
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 27 What do Diesel customers like .
Willingness to change – Germany 2002/2004/2005
100

9 7
17
24
36 40 27
24
29
35 Convertible
(=wechselbereit
41 )
41 37 45
34 Shallow
(= schwankend)

33 Average
(= verbunden)
18 20 26
20 21
8 Entrenched
0
5 3 (= verwurzelt)
Benzin
2002 Benzin
2004 Benzin
2005 Diesel 2002 Diesel
2002 20042004 Diesel
20052005
2002 2004 2005
petrol drivers diesel drivers
Source : BOSCH
Internal | DS/MKT3 5920827e | 03/01/2006 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights.
We reserve all rights of disposal such as copying and passing on to third parties.
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 28 Challenges in the US market.

• Stringent emission legislation (orientation on gasoline engine)

• High requirements to OBD

• Various fuel quality with large dispersions

• Intensified climatic edge conditions

Æ Robust, sustainable solutions are required

Æ New technologies are needed

BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 29 NOx challenge BIN 5.

N0x
g/mi X5 3.0d with EU4
technology incl. DPF
0,98

Tier 1 LDT3
0,6

Tier 2 Bin 10 (till MJ 08) - 94%

0,14
0,10 0,05 0,10 0,32
PM 0,08 0,075 0,23
NMHC
g/mi
g/mi

Tier 2 Bin 8 (MJ 09) 3,4 Tier 2 Bin 5

(MJ 09)

6,4
CO
g/mi
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 30 TIER2 BIN 5 concept.

• Modified combustion
• Advanced EGR- system
• Adapted fuel injection system
• Electrical control devices
• Additional sensors
• OBD functions
• Diesel Particulate Filter (DPF)
• SCR-System (Selective Catalytic Reduction)
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 31 Fuel Consumption – Diesel efficiency.

LDT PC

> +25%
> +30%
FE [mpg]

BMW Fleet X5 Diesel BMW Fleet 3-series Diesel

X-Vehicles P/C
MY 06 MY 06
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 32 DPF + SCR-system layout.

Closed Mixer with hydrolysis

coupled DPF function

UREA Mixing
injection section SCR-catalyst

Additional requirements:
- heated tank with fluid-level indicator (OBD)
- heated Urea pipes from tank to dosing unit
BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 33 SCR system – chemical reactions

NO + NO2 + 2 NH3 Æ 2 N2 + 3 H2O

4 NO + O2 + 4 NH3 Æ 4 N2 + 6 H2O
NO + ½ O2 Æ NO2 6 NO2 + 8 NH3 Æ 7 N2 + 12 H2O

(NH2)2CO Æ NH3 + HNCO

HNCO + H2O Æ NH3 + CO2

BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 34 Characteristics of SCR system.

Advantages
- High NOx-efficiency up to high engine loads
- Long term emission stability
-No increase in fuel consumption

Challenging requirements
- UREA infrastructure Æ common efforts necessary necessary
- OBD

SCR systems are available for trucks in Europe and Japan

Æ BMW judgement: long term solution for diesel engines

BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 35 Conclusion.

• Portion of BMW Diesel passenger cars in Europe has

significantly increased within the last decade

• BMW Diesel philosophy is “efficient dynamics”

• BMW at leading edge of diesel technology

• BMW target for US is to fulfil 50 state legislations

• Technology concept for BIN 5 defined, but still challenging

• Compromisses to Diesel necessary (i.e. phase-in`s)

Æ BMW Diesels: dynamic, efficient and clean

BMW AG
Wolfgang Mattes BMW Diesel.
DEER 2006
Page 36 Ready for the future.

Thank you very much

for your attention!