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A company of hofer AG
•••• 97447 Gerolzhofen •••• Dr.-Georg-Schäfer-Str. 5•••• dragan.popov@hofer.de
•••• www.hofer.de
hofer powertrain GmbH
Engine Design Division
Output Emission Costs
www.hofer.de 2
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Downsizing
In general:Downsizing describes the method, by which „smaller“motors reach the same performance data as motors withlarger cubic capacity.
hofer-approach:The starting point ist an optimised fuel consumption and associated reduction of the emission by at least equivalentdriving performance
www.hofer.de 3
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Concept Downsizing
Reducing of the cylinders´ numberReducing of the swept volumeTribologic charecteristicsSimulation and virtual testingCharging conceptsValve train conceptsCompaction conceptsOil content conceptsCooling system conceptNew technologies: Hybrid, immediate-start etc.
Our approach takes into account the following points:
www.hofer.de 4
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Reducing cylinders´ number and the cubic capacity
VW VR6Cylinder : 6 in V-FormCapacity : 3.189 ccmOutput: 184 KWTorque: 320 Nm
Graphical material of VW AG / Focus Auto
VW Turbo FSICylinder: 4 in a rowCapacity: 1.984 ccmOutput: 147 KWTorque: 280 NmWeight : -25% (ca.70 kg)Friction: - 7,5%
Honda VTECCylinder: 4 in a rowCapacity : 1.997 ccmOutput: 177 KW
by 8.300 1/minTorque: 208 Nm
by 7.500 1/min
For maintaining the driving performance there remains the„escaping“ in the charging-air pressure or in the torque
www.hofer.de 5
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Capacity-Reducing
MAN D2066Cylinder: 6 in ReiheCapacity: 10.520 ccmOutput: 235 bis 324 kwWeight: 880 kg (-10%)Friction: - 3%
MAN D2866Cylinder: 6 in ReiheCapacity: 11.967 ccmOutput: 191 bis 338 kwWeight : 980 kg
Graphical material of MAN AG
www.hofer.de 6
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Cylinder amount- and capacity reducing
Bildmaterial: Subaru
Perspective:
Combustion chambers may not get any smaller by further Downsizing for thermo dynamical reasons
Consequence: further on decreasing the amount of cylinders
Outlook: 2 cylinder motors with appropriate charging concept can manage to move a middle class car in foreseeable time
www.hofer.de 7
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Tribologic charecteristics 1
Graphical material of theFa. FriCSo company
Kolbenbolzen mit Außenwerkzeug
- Creation of very smooth surfaces with high percentage contact area
- Surfaces with rounded spikes and high plateau percentage
- Reducing of the surface roughness up to factor 10
- Improved efficiency through friction- and abrasion reduction
Polymeric lapping
www.hofer.de 8
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Tribologic characteristics 2
strukturierte cylinderlaufbahnBildmaterial der Fa. Gehring
Laser structuring
- Manufacturing of oil deposits- Improving the oil lubrication properties in targeted areas- Improving the friction properties
www.hofer.de 9
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Simulation and virtual testing
Valve- and chaindrive simulation to reduce power input
Bildmaterial der FH Kaiserslautern
www.hofer.de 10
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Downsizing leeds to new problems and challenges that can besolved by using modern methods:
Calculations / vibration analysisAcustic analysis
Durability calculations / NVH optimisation
Simulation
Simulation and virtual testing
www.hofer.de 11
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Charging concept 1
Approach with compressorand turbo charger
Approach with two turbocharger
- Tested method- Loss of power through
mechanical drivetrain
- Tested method- No elektronic control
possible
Bildmaterial der Fa. VW AGBildmaterial der Fa. BMW AG
www.hofer.de 12
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Prinzipdarstellung E-Booster von Borg Warner
Charging concept 2
Charging concept „electrical charger“ approach
E-Motor with supercharger
Turbo charger
LLK
- New method- Power limiter by means
of the air flow- Elektronic control
possible
www.hofer.de 13
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Charging concept 3
Charging concept approach
Exhaust manifold with impulse turbocharging- Analysis of valve timing- Ideal length configuration- Efficiency increase- Improved response characteristics of
turbocharger
www.hofer.de 14
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
CTA-cam phaser with internal check valve(CTA = Cam Torque Assisted)
Valve train concept 1
- Function exclusively by use of thecam shaft – alternating torque
- Very high adjustment speed by lowtorque on the basis of hydraulicbrace support at the internal check valves
- Very low oil demand by the meansof internal oil flow
www.hofer.de 15
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Valve train concept 2
The following function types have to be provided:- low system costs- late opening of the valve- early valve closure- both functions for inlet and outlet valve- all functions individually controllable- high stiffness of the system- low energy consumption
Variable valve lift systems
www.hofer.de 16
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Compaction Concept
Variable motor compression through air flow regulation to the variable „ε“
- Compaction ratio is restricted through the tendency of the fuel to detonate by full-load
- Increasing the compaction ratio by partial load can allow to achieve up to 10% reduction of consumption
- Even more substantial is the consumption saving by turbocharged motors. 15 % could be possible here.
www.hofer.de 17
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Layout, adjustment and redevelopment of the whole oil content respectively through the changed oil demand
- reducing of the engine idle torque- cold start- variable camshaft phasing- cooling requirement of the pistons
- multi-stage regulated oil pump- fully variable oil pump- electrically driven oil pump
Oil Content Concept
www.hofer.de 18
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Cooling system concept
- Layout, Adjustment and redevelopment of the whole cooling module (water cooler, charge air cooler, oil cooler) with pipe work and piping system determined by the changed cooling requirement
- Efficiency loss through pumpage- Application of an electrical water pump
Graphical material of the Fendt companyGraphical material of the Pierburg company
0
1
2
3
4
5
6
7
1 2 3 4 5 6
Mechanical water pump outputCooling requirement
www.hofer.de 19
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
New technologies: start/stop – strategy
- In city traffic this method reduces fuel consumption at up to appr. 8% of and therefore the pollutants as well.
Example
- Bosch Starter for start/stop –strategy
- Valeo starter-generator for start/ stop – strategy
- by some manufacturers already in series
www.hofer.de 20
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
New technologies: direct start
- Through targeted position, injection and ignition is it possible to accelerate the motor in only few revolutions from rest to its idle-running speed, without involving any starter.
- The goal is a substantially faster starting of the motor
Graphical material of the Ford company
Advancement of the start/stop strategy
www.hofer.de 21
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Resume
- Mechanics must be adjusted for downsizing- Loading, temperatures, torque, etc.
- High-capacity and dynamical fuel injection- and charging systems
- Fully variable valve train- Variable compaction ratio- Electrically driven water pumps- Variably and/or electrically driven oil pumps
Additionally for hybrid solutions - Electrical power steering assist- Electrically driven air-conditioning compressor
www.hofer.de 22
Engine Design Division
Dipl.-Ing. Dragan Popovdragan.popov@hofer.de
Methodical concept generation
Downsizing is an effective instrument for achieving our goals inthe motor design
A company of hofer AG
•••• 97447 Gerolzhofen •••• Dr.-Georg-Schäfer-Str. 5•••• dragan.popov@hofer.de
•••• www.hofer.de
hofer powertrain GmbH
Engine Design Division
Thanks a lot
output emission costs
Hofer…ideas for your success…
A company of hofer AG
•••• 97447 Gerolzhofen •••• Dr.-Georg-Schäfer-Str. 5•••• dragan.popov@hofer.de
•••• www.hofer.de
hofer powertrain GmbH
Engine Design Division
vielen Dank
Leistung Emissionen Kosten
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