Engine Components and Systems. Series Development and Manufacturing of Innovative Systems and Components for the Automotive Industry

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1 Series Development and Manufacturing of Innovative Systems and Components for the Automotive Industry Engine Components and Systems Version: nwv_0507_1

2 The innovative, global development partner an Content Preface The Company 3 Camphasing Systems by Hydraulik-Ring 3 System Description Vane CAM 4 Application 5 Light-weight construction concept aluminium 6 Light-weight Construction Concept Plastic 6 In order to meet the constantly increasing demands for new engine generations as to performance, fuel consumption, emission behaviour engine developers have to resort to variable valve control systems. Hydraulik-Ring develops and manufactures camphasing systems since the late 1980ies. Today this experience and many patented innovations put us in a position to tap and develop further potentials in engine technology. Improved Friction Moment 7 Minimal Leakage 7 Valves for Camphasing Systems 8 Increase of the Adjusting Speed 8 Types of Valves 9 Fast Phaser System 9 Locking in Predefined Intermediate Position 10 Use of Simulation Technology 10 UniValve - Fully Variable Mechanical Valvetrain 11

3 d series supplier for the Automotive Industry The Company Hilite International is an international components supplier for the automotive industry and has locations in the USA, France and Germany. Hilite International has specialised in the development and manufacturing of systems and components for engine and transmission applications as well as of components in emission systems. Hydraulik unloading valves and solenoid valves represent another range of products in which Hydraulik- Ring has many years of experience. The European Headquarters located in Marktheidenfeld near Würzburg is one of three plants in Germany. Here they develop and manufacture mainly hydraulic solenoid valves and system components for emission reduction. The Seckach plant is located in the Odenwald-Neckar-Kreis and specialised in manufacturing pumps and valves. Besides they are specialised in the mechanical production of a variety of individual parts. The plant is equipped with the machinery of the latest state of the art and a clean room. Hydraulik-Ring GmbH offer to their customers an optimal environment and most modern equipment for their developments, starting with a highly motivated team, the latest CAD- and simulation methods and fully equipped test workshops covering all development phases from construction of prototypes to engine testing, Hydraulik-Ring can provide all services. In Nürtingen near Stuttgart Systems for engine and transmission applications are developed and produced in series. Needless to say, that being an experienced manufacturer of industrial series we have the know how to manufacture also your product/s in series. Camphasing Systems by Hydraulik-Ring Design chain adjuster Porsche Variocam F1 The first series engine with camphasing is used in Porsche model 968. It was a twostep chain adjustment system with integrated chain tensioner which by shifting the chain geometry in the short camshaft drive could reposition the inlet camshaft in relation to the crankshaft. Vane CAM Oscillating motor adjusters are the further development of chain adjusters which up to now have been in series in many VW, Porsche and Audi engines. The main advantages of this system are considerably wider adjustable ranges and the possibility to adjust both the inlet and the outlet camshafts. Design vane motor adjuster

4 The innovative, global development partner an System Description Vane CAM Nowadays camphasing systems are not only used in high volume spark ignition engines only; they have also become an essential part of small volume spark ignition engines. The camphasing systems developed and made by Hilite/Hydraulik-Ring are well-known under their product designation Vane CAM These systems work according to the principle of the oscillating motor and use a rotor attached to the camshaft which effects the twist. The rotor blades on either side can be operated hydraulically and are positioned in a way that allows them to twist. Depending on the twist the angular position of the camshaft varies in relation to the position of the crankshaft. State of the art are camphasers which depending on the load and r.p.m. of the engine shift the relative angle of the camshaft variably. Oscillating motor adjuster with the essential parameters Stator 2 Rotor 3 Camshaft 4 Camshaft sensor 5 Integrated Micro filter 6 Integrated return valve 7 Proportional valve 8 Proportional valve in tank supply line 9 Oil filter 10 Motor oil pump 11 Oil temperature sensor 12 Air flow sensor 13 Throttle valve sensor 14 Coolant sensor 15 Crankshaft sensor 16 Motor control unit The oil supply of the camphasers is managed by the oil pump of the engine which should not use too much energy to control the angular position. Depending on the load and r.p.m. the system does not only control the angles of both camshaft and crankshaft, but also the temperature of the engine oil. Camphasers should, whenever possible, also operate during hot idling, i.e. they should work at low oil pressure and at low viscosity. Camphasing system in the AMG V8 6.3l engine

5 d series supplier for the Automotive Industry Application Camphasing systems made by Hydraulik-Ring can be used in any type of engine construction, irrespective of the number of cylinders. Any drive concept, be it chain, belt or gearwheel, can be realised. Vane CAM for V5 und V6 Engines Vane CAM for W12 und W16 Features of Vane CAM Camphasing Increase of power and torque Reduction of fuel consumption and emissions Improved idling performance Possibility to return exhaust fumes internally in the overlapping range Vane CAM for V6 with belt drive Cost-efficient Simple to adapt Adjustors on the inlet and the outlet side can be operated independently. Vane CAM for V8 with gearwheel drive

6 The innovative, global development partner an Light-weight construction concept aluminium The use of aluminium allows to reduce the total weight of camphasing systems and particularly of the mass in motion. Particularly for small volume engines these are decisive criteria in favour of using such a system. A camphasing system with two steel adjustors and two hydraulic proportional valves weighs about 2.2 kg. Whereas by using aluminium for the rotor housing, the rotor and the lids of the housing the weight can be reduced by approx. 900 g. housing which can thus be realised, this construction just like the comparable steel camphaser solution - results in the lowest system friction and subsequently in a spontaneous and quick adjusting of the camphasers. In the six-cylinder-engines of BMW, e.g. we use aluminium camphasers where the stator housing, the chainwheel and the one-piece rotor are made of sintered aluminium. Aluminium camphaser with aluminium chain wheel. In order to meet the high demands as to wear, to which especially the chainwheel gearing is exposed, we have developed a sintered aluminium material with a high silica content. The camphasing system goes without additional sealings between the rotor and the stator housing. Due to the contact-free sealing and the narrower gap between the rotor and the Light-weight Construction Concept Plastic Additional reductions in the weight of individual parts can be achieved by concepts using plastic material. As you can see from the pictures stator, belt pulley and lid can be combined in one part. First tests made with combustion engines showed a positive long term running behaviour. The weight advantage and at the same time the economic manufacturing of the components will be of great importance for future engine generations.

7 d series supplier for the Automotive Industry Improved Friction Moment The friction moment rests against the adjuster which is subject to pressure and has to be overcome during the adjustment. The diagram shows the friction moment of the adjuster solution offered by Hydraulik-Ring with a one-piece rotor construction, a narrow sealing gap and without any additional sealing elements.. Starting from zero and after overcoming the initial breakaway torque the friction moments of the rotor when twisted in its housing will remain constant. Due to this extremely low friction moment the solution offered by Hydraulik-Ring guarantees top functionality, even when the oil is hot and the supply pressure is low; this applies also for the r.p.m. range close to idle running. Minimal Leakage Leakage flow at T Oil =20 C Low losses resulting from leakage imply also lower requirements in oil at the oil pump. Hydraulik-Ring camphasers possess due to their one-piece construction and their optimised sealing gap very low leakage values. The diagram shows the leakage flow in l/min at an oil temperature of 20 C and at the respective oil pressure at the rotor.

8 The innovative, global development partner an Valves for Camphasing Systems Another important compontent in the camphasing system is the proportional valve. It controls the pressurisation of the rotor with pressure oil. In order to clamp the rotor pressurised from both sides immovably in an intermediate position, the system uses return valves. As in the cylinder head ther is not always sufficient space for a return valve seat, Hydraulik-Ring has developed a valve into which this function has been integrated. Apart from that they also use valves with fine filters with integrated ring channels. Spool sealing Electric connection Min. spool diameter = 25 mm 3 fine filters Integrated return valve Increase of the Adjusting Speed Apart from the above the check valve and the proportional valve are positioned close to the adjustor. This leads to a higher adjusting speed at low r.p.m. The diagram shows the advantage of a check valve integrated in the hydraulic control valve. In the low speed range adjusting speed can be increased considerably. In the range near idling run where the functioning of the camphaser also has to be ensured this advantage brought about by the integration is essential. At running speeds between n = 1,000 up to 1,250 1/min the adjusting speed can be doubled.

9 d series supplier for the Automotive Industry Types of Valves Cartridge valve to be screwed in with ring channels Cartridge valve with ring channels O-Ring sealings, flange mounting and lead connection Cartridge valve with position-oriented borings, aluminium, flange mounting and lead connection, angular connector Cartridge valve with flange mounting, ring channels and straight connector Fast Phaser System Another new adjusting system of Hydraulik-Ring is the Fast Phasing which allows a faster adjusting, particularly in the range of low engine speeds and with hot oil. Another advantage of Fast Phasing is the reduced requirement of oil which allows to design and use a smaller oil pump. This system also uses in a patented solution for intelligent oil management the torque of the camshaft from the resulting shares of the valve spring power. Camphasing system with integrated Fast Phasing option Comparison of adjusting speed measured on an electrically operated towing test stand by engine speed with and without fast phasing at predefined, constant oil pressure

10 The innovative, global development partner an Locking in Predefined Intermediate Position The locking system of Hydraulik-Ring allows to lock the camphasers for the starting operation of the engine on the inlet and/or the outlet side in a predefined angular position. Preferably these positions can be the late endposition on the inlet side and the early final angular position on the outlet side. Thus the valve overlap is negative and the starting of the engine becomes easier. For some combustion engines, however, it is desirable to have a locked start of the engine in a predefined intermediate position of the rotor. Independent of the angular position obtained when shutting off the engine the adjuster is switched to the defined locked position, before ignition. This leads to exactly defined start conditions. The diagram shows an extract from a misuse test during start of the engine. Before the start the adjuster is in the early position (red line) which it can take at the shut off of the engine. Already in the ramping up phase and before the first ignition the adjuster can be securely locked in an intermediate position as desired and defined by the OEM Use of Simulation Technology The significance of simulation technology for camphaser design has increased. Apart from standard durability tests for the design of adjusting components by means of the finite element method modern CFD-applications also allow to map the oil stream within the system three-dimensionally. To shape the basic design of the adjusting geometry consisting of volumes, flow sections and affected areas the entire oil circuit of the camphasing system as well as the hydraulic on/off valve can be dimensioned by using a simulation of the hydraulic circuit. This helps to shorten the development time considerably. Prototypes close to series and test results can be realised quicker. Section from a substitue diagram to depict the oil circuit of camphaser and hydraulic on/off valve in the adjuster. 10

11 d series supplier for the Automotive Industry UniValve - Fully Variable Mechanical Valvetrain In the UniValve System the fully variable valve train is achieved by two intermediate rocker levers mounted on a shaft with a roller running on needleroller bearings. The roller runs in a gate connected with the cylinder head. A shaft links the two intermediate levers so that they form a fork. Methods of varying valve lifts Draft for UniValve patent application They are actuated by the camshaft. The intermediate lever performs a tilting movement around the eccentric shaft. The height of the valve lift is determined by rotating the eccentric shaft in order to displace the tilting point of the intermediate lever. 4 Cylinder test cylinder head with UniValve system and camphasing system System Features: Combining camphasing system and UniValve means: Load control for spark ignition engines and Swirl control for diesel engines Control of NOx exhaust gas emissions Improvement of fuel consumption Modular valve control concept Increase of driving dynamics. Test setup 4-cylinder engine Increase of torque at test engine Continuously adjustable camphaser Potential for savings in consumption 11

12 Engine Applications Transmission Applications Components for Emission Systems Valves info@hydraulik-ring.de Europazentrale Plant Marktheidenfeld: Am Schlossfeld Marktheidenfeld Tel.: +49 (0) Fax: +49 (0) Plant Nürtingen: Weberstr Nürtingen Tel.: +49 (0) Fax: +49 (0) Plant Seckach: In der Au Seckach Tel.: +49 (0) Fax: +49 (0) Sales Office in USA: 2701 Cambridge Court Suite 218 Auburn Hills, Mi Tel.: Fax: