engine design division - hofer powertrain · engine design division output emission costs. 2...

A company of hofer AG

•••• 97447 Gerolzhofen •••• Dr.-Georg-Schäfer-Str. 5•••• [email protected]

•••• www.hofer.de

hofer powertrain GmbH

Engine Design Division

Output Emission Costs

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Dipl.-Ing. Dragan [email protected]

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

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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:

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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

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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

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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

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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

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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

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Simulation and virtual testing

Valve- and chaindrive simulation to reduce power input

Bildmaterial der FH Kaiserslautern

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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

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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

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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

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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

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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

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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

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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.

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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

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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

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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

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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

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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

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Methodical concept generation

Downsizing is an effective instrument for achieving our goals inthe motor design






Thanks a lot

output emission costs

Hofer…ideas for your success…






vielen Dank

Leistung Emissionen Kosten

engine design division - hofer powertrain · engine design division output emission costs. 2...

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