The CPCB-IV+ emission compliance for genset application is applicable with effect from 1st July 2023 as per as per GSR 804(E). The CPCB-II to CPCB-IV+ changeover in very stringent in emission front by almost 90 % emission reduction. It’s a significant advancement in environmentally sustainable powertrain technology. To meet the CPCB-IV+ Emission, combustion development & ATS technology plays an important role.
First is the base engine need to optimize enough with combustion & associated parts.
Second is the after treatment system which will carry the battle further to the engine emission with minimum margin of 10 % engineering target.
This paper present the systematic approach followed to meet CPCB-IV+ emission norms for upgradation of 21 litre TCIC engine for the power range (56 < P ≤ 560). Here the challenge to avoid major changes in the existing CPCB-II FIE recipe & meet the CPCB-IV+ emission with ECU calibration & ATS system calibration with its potential. Here interesting parts unique communication architecture built with genset controller in leading role due to time line constraints. The engine integrates with advanced combustion strategies, improved fuel injections systems, and robust after treatment technology including DOC, DPF & SCR system to significantly reduce NOX, PM, HC & CO Emission.
Phase-I (Base engine Calibration): - Baseline engine optimization with existing CPCB-II recipe & ECU calibration feature. Here we have used the 1600 bar rail pressure potential along with optimized fuel timing. The pilot & post injection strategy plays vital role to meet the targeted base engine emission.
Phase-II (ATS system selection & its calibration): - To meet the CPCB-IV+ emission norms, stringent limits of NOX, PM introduces in India for genset application. For achieving this a highly optimized after treatment system (ATS) comprising DOC, DPF, SCR, and ASC is essential however our strict target is to avoid the DPF.
These strategies collectively help to meet the CPCB-IV+ emission targets with optimum engine performance & fuel economy with potential of ATS architecture and a structured calibration methodology. The DOC enables rapid HC/CO oxidation, while the SCR system, controlled via open-loop urea dosing, achieves >95% NOx conversion. The ASC prevents ammonia slip beyond 10 ppm, ensuring exhaust pipe compliance. This project completed within very low stipulated time month effectively.
Phase-III (OBD): -
The OBD part of CPCB-IV+ contains the following
Check on Torque Reduction & Shutdown Strategy
Components wise diagnostic calibration on first proto
Report on final diagnostic calibration
Phase-IV (Engine Consistency & TA Certification):-