Engine Design Division. hofer powertrain GmbH. Output Emission Costs. A company of hofer AG

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1 Output Emission Costs hofer powertrain GmbH A company of hofer AG Gerolzhofen Dr.-Georg-Schäfer-Str. 5

2 Downsizing In general: Downsizing describes the method, by which smaller motors reach the same performance data as motors with larger cubic capacity. hofer-approach: The starting point ist an optimised fuel consumption and associated reduction of the emission by at least equivalent driving performance 2

3 Concept Downsizing Our approach takes into account the following points: Reducing of the cylinders number Reducing of the swept volume Tribologic charecteristics Simulation and virtual testing Charging concepts Valve train concepts Compaction concepts Oil content concepts Cooling system concept New technologies: Hybrid, immediate-start etc. 3

4 Reducing cylinders number and the cubic capacity For maintaining the driving performance there remains the escaping in the charging-air pressure or in the torque VW VR6 Cylinder : 6 in V-Form Capacity : ccm Output: 184 KW Torque: 320 Nm VW Turbo FSI Cylinder: 4 in a row Capacity: ccm Output: 147 KW Torque: 280 Nm Weight : -25% (ca.70 kg) Friction: - 7,5% Honda VTEC Cylinder: 4 in a row Capacity : ccm Output: 177 KW by /min Torque: 208 Nm by /min Graphical material of VW AG / Focus Auto 4

5 Capacity-Reducing MAN D2066 Cylinder: 6 in Reihe Capacity: ccm Output: 235 bis 324 kw Weight: 880 kg (-10%) Friction: - 3% MAN D2866 Cylinder: 6 in Reihe Capacity: ccm Output: 191 bis 338 kw Weight : 980 kg Graphical material of MAN AG 5

6 Cylinder amount- and capacity reducing Perspective: Combustion chambers may not get any smaller by further Downsizing for thermo dynamical reasons Consequence: Outlook: further on decreasing the amount of cylinders 2 cylinder motors with appropriate charging concept can manage to move a middle class car in foreseeable time Bildmaterial: Subaru 6

7 Tribologic charecteristics 1 Polymeric lapping - 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 Kolbenbolzen mit Außenwerkzeug Graphical material of the Fa. FriCSo company 7

8 Tribologic characteristics 2 Laser structuring - Manufacturing of oil deposits - Improving the oil lubrication properties in targeted areas - Improving the friction properties strukturierte cylinderlaufbahn Bildmaterial der Fa. Gehring 8

9 Simulation and virtual testing Valve- and chaindrive simulation to reduce power input Bildmaterial der FH Kaiserslautern 9

10 Simulation and virtual testing Downsizing leeds to new problems and challenges that can be solved by using modern methods: Calculations / vibration analysis Acustic analysis Durability calculations / NVH optimisation Simulation 10

11 Charging concept 1 Approach with compressor and turbo charger Approach with two turbo charger Bildmaterial der Fa. VW AG - Tested method - Loss of power through mechanical drivetrain Bildmaterial der Fa. BMW AG - Tested method - No elektronic control possible 11

12 Charging concept 2 Charging concept electrical charger approach LLK Turbo charger E-Motor with supercharger - New method - Power limiter by means of the air flow - Elektronic control possible Prinzipdarstellung E-Booster von Borg Warner 12

13 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 13

14 Valve train concept 1 CTA-cam phaser with internal check valve (CTA = Cam Torque Assisted) - Function exclusively by use of the cam shaft alternating torque - Very high adjustment speed by low torque on the basis of hydraulic brace support at the internal check valves - Very low oil demand by the means of internal oil flow 14

15 Valve train concept 2 Variable valve lift systems 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 15

16 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. 16

17 Oil Content Concept 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 17

18 Engine Design Division 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 Cooling requirement Mechanical water pump output Graphical material of the Pierburg company Graphical material of the Fendt company 18

19 New technologies: start/stop strategy - by some manufacturers already in series - 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 19

20 New technologies: direct start Advancement of the start/stop strategy - 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 20

21 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 21

22 Methodical concept generation Downsizing is an effective instrument for achieving our goals in the motor design 22

23 output emission costs Hofer ideas for your success hofer powertrain GmbH A company of hofer AG Thanks a lot Gerolzhofen Dr.-Georg-Schäfer-Str. 5

24 Leistung Emissionen Kosten hofer powertrain GmbH A company of hofer AG vielen Dank Gerolzhofen Dr.-Georg-Schäfer-Str. 5