DENSO to Establish Engineering Center for Diesel Engine Components in Germany
DENSO Automotive Deutschland GmbH (DNDE), a subsidiary of Japan-based DENSO Corporation, announced today that it will establish Aachen Engineering Center, a new engineering center for diesel engine components. The center, located in Wegberg, Germany, will carry out application design work for diesel engine fuel injection systems. DNDE will invest approximately 13 million euro in the construction of Aachen Engineering Center. This is DENSO's first overseas engineering center for diesel engine components.
“In Europe, the percentage of diesel engines in passenger cars is as high as 50 percent, and a further increase in demand is expected,” explained Hiromi Tokuda, managing officer in charge of DENSO's Powertrain Control System Group. “This facility can help us meet that demand through application designs as well as performance evaluations. In the future, the facility will engineer power train components.”
BMW Group and PSA Peugeot Citroën Present a new innovative engines range
BMW Group and PSA Peugeot Citroën have unveiled the state-of-the-art technologies deployed in their new gasoline engines, the first to be jointly developed and produced by their cooperative venture. Announced in July 2002, the two Companies' cooperation in gasoline engines is now setting new standards for performance, driving comfort and reductions in fuel consumption and CO2 emissions.
Beginning in 2006, the engines will equip small and mid-size cars produced by the Peugeot and Citroën marques as well as future models of the MINI. Production is expected to eventually total roughly one million units a year. At a special technology day at BMW Group's Research and Development Center in Munich, executives from both companies presented the technical features of two types of engines:
- A 1.6-liter atmospheric engine with a variable geometry turbocharger and a power output of 85 kW (115 hp).
- A 1.6-liter direct injection, compressed turbo engine with a power output of 105 kW (143 hp).
The new models are the first in a family that will eventually comprise engines delivering a range of power outputs from 55 kW (75 hp) to 125 kW (170 hp). As a result of both group's expertise, these engines offer a large number of new features including:
- Variable valve timing (from the BMW Group's VALVETRONIC)
- Fully controlled oil pump.
- Single belt drive for all ancillary components.
- Cylinder heads produced by lost foam casting.
In addition, several innovations have been developed, including:
- Direct injection to optimize power.
- Twin-Scroll turbocharger (220 000 rpm, max 0,8 bar) to improve response time and driving comfort.
- Self-disengaging water pump to reduce fuel consumption and emissions.
The co-operation between BMW Group and PSA Peugeot Citroën clearly demonstrates that gasoline engines still offer a great potential of technological progress, thus contributing to the reduction of consumption and CO2 emissions while enhancing the car performances and its related driving pleasure.
Innovative developments for the 2.7 l V6 HDi engine fitting in the Peugeot 607
The new 2.7 l V6 HDi PEF engine constitutes the third phase of cooperation between the Ford
Motor Company and PSA Peugeot Citroën.
The layout of the new DT17 engine necessitated the development of a new sub-frame. Comfort targets led to the development of a new "cruciform" engine mounting with active vertical link rods. Real-time control of the reaction link rods cancels out vibrations transmitted to the body at low engine speeds, thereby significantly improving comfort in terms of acoustics and vibration. This new engine mounting led to the creation of an additional torque reaction crossmember on the sub-frame, in order to secure the front vertical link rod.
Also, the steering crossmember has been strengthened and given a new, improved shape. This crossmember serves to anchor the rear active vertical link rod, and its new " helmet " style shape allows the exhaust to pass under the sub-frame. Lastly, the front crossmember has been modified to allow integration of the new dual fan assembly cooling cassette specific to this engine.
This 60°V6 engine with a capacity of 2721 cm3 develops a power of 150 kW and a torque of 440 Nm. The Peugeot 607 V6 2.7 l HDi PEF is equipped with the new AM6 automatic gearbox developed by AISIN.
- A : Front lower cross member (Radiator support panel)
- B : Front subframe torque reaction cross member
- C : Steering cross member
- D : Rear active lower engine mounting
- E : Front active lower engine mounting
- F : Right-hand engine mounting
- G : Left-hand engine mounting
mens VDO Automotive has unveiled a new direct fuel injection system for spark ignition engines with the capability of reducing fuel consumption by up to 20 percent. The Piezo Direct Injection (PDI) system is based on cutting-edge Piezo-electric actuation technology and enables the first-ever spray-guided combustion procedure.
Favorable direct fuel injection test results created anticipation for increased fuel savings that have yet to be fully realized. This is primarily due to the technology's current air-and wall-guided combustion processes, which relies on the redirection of injected fuel off the cylinder wall and piston base to reach the spark plug. In addition, the fuel-thrifty stratified charge operation approach, in which a very small amount of the combustible mixture is sprayed directly next to the spark plug, can only be employed in select driving situations.
The new Siemens VDO Automotive PDI Piezo-based direct injection system is designed for spray-guided combustion processes. The fuel is injected directly in front of the spark plug during a variety of operations, which greatly expands the range of stratified operation. Since spray-guided combustion processes place extremely high injection pressure, dynamics, jet preparation and feed precision demands on injectors, their realization has been limited by previous injection technology.
A test comparison between a conventional port-injection and a Siemens VDO Automotive Piezo direct injection enabled engine shows that fuel consumption can be reduced up to 20 percent with a power output of more than 60 kW per liter piston displacement. Developed by Siemens VDO Automotive, the core components of the gasoline fuel injection system are the innovative Piezo injector, the newly developed high-pressure fuel pump and a new engine control unit.
As was the case with diesel engines, Piezo technology enabled the breakthrough for the PDI system in gas engines. A Piezo actuator acting directly on the nozzle needle renders the injector highly dynamic. The nozzle needle completes its full stroke in only 0.2 milliseconds. At the same time, the maximum deviation between individual injected quantities of fuel is 2 percent - even with the typically short injection pulses. For engine developers, this combination of injector switching speed and precision is the key to improved control of injection and, therefore, the combustion process. Accordingly, Piezo injectors enable a very late moment of ignition in stratified charge operation without misfiring.
In particular, piezo injectors allow precisely-timed, precisely-dosed multiple injections in the light and medium load range to ensure stable combustion with low cyclical fluctuations. The engine management system can adapt the actual moment of fuel injection to the needs of the combustion process or exhaust aftertreatment. In stratified operation, the quality of the fuel feed is also enhanced by the Piezo element's ability to partially and completely open and close the injector.
For cleaner combustion, it is important to ensure extremely fine atomization of the fuel. At an injection pressure of approximately 200 bar, the average diameter of the fuel droplets is only 15 thousandths of a millimeter. Together with injector nozzles that open into the engine cylinder, making them less susceptible to deposit build-up, an optimally prepared mixture cloud at the edge of the spark plug is yielded under nearly all operating conditions.
Most of cars manufacturers and Diesel injection systems suppliers like Bosch work on the HCCI concept (Homogeneous Charge Compression Ignition).
In all existing diesel injection systems, fuel is sprayed into the combustion chamber only immediately before the ignition., However, this combustion leaves only little time for the fuel to mix with air. Thus the fuel does not burn in an optimal way with the lowest possible emissions. At present, Bosch is looking into alternatives to this combustion process - into so-called homogeneous or partially homogeneous processes - for the lower and medium load and engine speed ranges. In this process, fuel is sprayed into the combustion chamber before the actual initiation of combustion. This gives more time for the fuel to mix with air, and the combustion process in the combustion chamber is at all times more regular and cleaner. The initiation of combustion is decisively controlled by the exhaust-gas recirculation - adding a defined amount of exhaust-gas to the induced fresh air. "First tests indicate a noticeable reduction in particulate and nitrogen oxide emissions. We are currently working on a synchronization of our injection systems to this combustion process", explained Dr. Ulrich Dohle, President of the Bosch Diesel Systems Division.
IFP (Institut Français du Pétrole), involved in many European projects, schedules HCCI for years 2010-2015.
Bosch's engineers in the laboratories and at the test benches are already right now working on further improvements for the Diesel injection technology. By the end of 2006, Bosch will be presenting the 3rd generation of Common Rail with 1,800 bar system pressure instead of the previous 1,600 bar, giving engine designers even greater possibilities to make diesel engines cleaner and more powerful. Further down the road are plans for a 4th generation of Common Rail: "We are at present developing concepts with a ‚Coaxial Vario Nozzle' and pressure booster for the next generation of Common Rail", explained Dr. Ulrich Dohle, President of the Bosch Diesel Systems Division.
The Coaxial Vario Nozzle differs from the traditional injector through the number, position, diameter and shape of the injection apertures. A piezo-actuator controls two coaxial intermeshing nozzle needles and opens by individual control two superimposed rows of spray holes. The first row of holes with fine orifices for low flow processes small amounts of fuel in the initial combustion process and thus provides a smooth combustion with low combustion noise. Additionally, it sees to a better mixture formation in the partial-load range and markedly reduces emission. Tests have shown that the combustion noise is noticeably reduced and that there is up to 70 percent less emission of particulate and nitrogen oxide. When going into full load, the second row of spray holes with a large orifice diameter is opened as well. "Ideally, it should be possible with the Coaxial Vario Nozzle to do without pre-injection in most speed and load ranges and thus additionally reduce particulate emission", Dohle summed up the previous results.
The system pressure of this type of Common Rail, which should be ready for volume production by 2007, would reach 1,800 bar. The volume production of the other Common Rail concept with pressure booster presently studied by Bosch could start in 2008. In this concept, the high-pressure pump builds up a low pressure of, for example, 1,350 bar in the accumulator - the rail. The fuel is guided to the injectors in pipes, where the injection pressure is hydraulically boosted up to more than 2,200 bar. Due to the high injection pressure, the fuel needed for combustion can be sprayed through smaller injection orifices. This causes a finer fuel spray that mixes more easily with air and burns cleaner and more efficiently.
Acura RL features revolutionary all-wheel-drive system
The Acura RL sedan made its world debut at the New York International Auto Show with a 220 kW (300 horsepower) VTEC V-6 engine and a revolutionary all-wheel-drive system. The Super-Handling All-Wheel-Drive System(TM) (SH-AWD(TM)) is an all-wheel-drive platform that distributes the torque not only between the front and rear wheels but also between the left and right rear wheels.
During straight line cruising and moderate cornering, up to 70 percent of torque is at the front wheels. During full throttle acceleration or spirited driving, up to 70 percent of available torque goes to the rear wheels for increased acceleration and enhanced cornering. In addition to varying the torque front to rear, SH-AWD varies the amount of torque to the left and right rear wheels. When cornering, this ground-breaking technology overdrives the outer rear wheel, sending up to 100 percent of rear torque to that wheel to dramatically enhance the RL's cornering, steering feel, handling and stability.
The RL is mated to a 5-speed Sequential SportShift automatic transmission that enables gears to be shifted using the shift lever on the center console or with the F1(R)-type paddle shifters located on the steering wheel. The SH-AWD will be available this fall in the Acura RL (North America) and the Legend (Japan).
The SH-AWD will be explained in detail in a coming document.
Valeo Fastfill, easily check and refill engine cooling systems
Based on the latest technology, Valeo Fastfill, an enhanced engine cooling tool, will provide automotive professionals with a new way to identify and repair automotive problems.
Fastfill is an innovative quality tool for checking and refilling engine cooling systems based on the use of one integrated tube for simplified refilling procedures. Once the system has been drained, a valve enables the liquid to be easily introduced in the cooling circuit, without any further manipulation.
Fastfill reduces the time previously needed by repairers to complete the full process of refilling and leaks diagnosis by almost 4/5ths - requiring, on average, only 3 minutes vs. 15 minutes. Moreover, it eliminates the "bubble effect": on a previously drained cooling circuit, the "vacuum system" will help to avoid air in the circuit during the refilling process.
Vectra OPC study with 212 horsepower 1.9 CDTI TwinTurbo engine
After BMW and its 535d, Opel's revolutionary new twin-turbo technology represents the next major stage of development for modern passenger car diesel engines.
The Opel Vectra OPC study, which is on display in Switzerland for the first time in Geneva, is powered by a 1.9 liter, 156 kW (212 hp) CDTI twin-turbo engine, which produces maximum torque of 400 Nm from as low as 1400 rpm. With this engine the Vectra OPC needs no more than 6.5 seconds to sprint from zero to 100 km/h. Top speed is limited electronically to 250 km/h, while fuel consumption in the European test cycle is only six liters per 100 kilometers. In addition, the 1.9 CDTI twin-turbo already meets the Euro 4 emissions standard.
The key to this trend-setting twin-turbo diesel technology is its two gas turbo-chargers which, unlike bi-turbo technology, boost the engine serially (two-stage) instead of parallel. A small, fast responding turbo-charger is responsible for lower rpms while a larger high flow rate turbo-charger kicks in at higher rpms. Its efficiency enables the twin-turbo to delivery an extremely high specific performance without the need to accept any fuel consumption or emission behaviour disadvantages.
See our document Turbocharging and turbocompounding.
More than 2000 bars with the Bosch's Common Rail with piezo injectors
The 3rd generation of Common Rail made by Bosch makes diesel engines more clean, more economic, more powerful and more quiet. The key is the innovative, rapid and compact piezo-inline injectors. Bosch is planning another leap for the Common Rail in 2006. "We are currently analyzing concepts to increase the pressure to more than 2,000 bar at the injector by means of a booster without having to increase the system pressure as such. In a parallel approach, we are studying injectors with variable nozzle geometry", says Dr. Ulrich Dohle, President of the Bosch Diesel Systems Division.
With a forecasted production of seven million high-pressure injector systems of Common Rail and Unit Injector in 2004, Bosch is the world's leading manufacturer. Bosch will make some 250,000 piezo-inline injectors in 2004 and will go up to more than two million units as early as in 2005.
A patented Valeo radiator that can be bent into curved shapes make its debut in the Renault concept car Wind at the Geneva International Motor Show.
The segmented "spinal architecture" of Valeo's new radiator allows it to take on a curved shape, thereby saving space and easily adapting to all types of front-end designs. The innovation has allowed Renault to develop the new front-end theme of the Wind concept car, in which a radiator is located on each side of the car fascia.
Bosch's piezo-electric direct injection for gasoline engine
Bosch continues to work on direct injection for more efficient combustion processes. "DI Motronic with spray-guided combustion lowers fuel consumption by up to 15 percent in comparison to port fuel injection" says Dr. Rolf Leonhard, Vice President Development at Bosch Gasoline Systems. Rapid switching high-pressure injectors with piezo actuators, specifically tuned to the new combustion process, will be ready for large-volume production by 2005.
In parallel, Bosch develops low cost, compact solenoid controlled high-pressure injectors with multi-aperture nozzle, which are universally applicable for all combustion processes with gasoline direct injection.
Two-stage turbocharging Diesel engine in the new BMW 535d
The all-new BMW 535d offers a first for a BMW diesel car engine : a two-stage turbocharging.
The new engine delivers a maximum output of 272 bhp and, more importantly, 560 Nm of torque at 2,000 rpm, with 500 Nm available at just 1,500 rpm. This propels the new BMW 535d from zero to 62 mph in just 6.6 seconds. To put this into perspective, the current 530d, itself no slouch, produces 218 bhp while the E39 M5 offered 500 Nm of torque.
Two-stage turbocharging resolves the conflict of 'turbo lag' when accelerating hard at low engine speed and increases the availability of power at higher engine revs. The first turbocharger provides an almost instant kick of turbo pressure at low engine speeds while the second turbocharger cuts in at higher engine speeds to boost power throughout the higher rev range. The new turbo layout also extends the engine rev range by 500 rpm over the BMW 530d, to a maximum of 4,800 rpm.
See our documentation turbocharging and turbocompounding.
Even with such performance, exhaust emissions are not compromised, since the 535d has a particulate filter and is fully compliant with EU4 regulations. The 535d will be launched this autumn.
In Brazil, two types of alcohol containing fuels are very popular: gasoline with a 22 percent share of alcohol and alcohol with a 7 percent water content. The highly concentrated alcohol is lower in price than the gasoline mix, however, it is not available everywhere in the country.
"The new Bosch ‚Flex Fuel' engine management makes it possible to power vehicles with the one or the other as well as any mixing ratio of both types of fuel", explains Dr. Rolf Leonhard, Vice President Development, Gasoline Systems Division at Bosch.
The lambda sensor measures the oxygen content in the exhaust fumes to determine the alcohol content in the fuel. The engine management adjusts ignition and injection to the respective fuel mix in the tank. The ignition properties of alcohol are inferior to gasoline when the engine is cold. To ensure proper starting even at low temperatures, Flex-Fuel system uses a small separate gasoline tank on board.
In Brazil, probably the world's largest quantity of ethyl alcohol for fuel is produced. In 2001 alone, some 12,000 million liters of ethyl alcohol were made from cane sugar, which corresponds to about 40 percent of the total fuel consumption. On the other hand, diesel engines are outlawed for passenger car powering in Brazil.
The first car with the new Bosch engine management as standard equipment was the VW Fox Total Flex, which was launched in Brazil in 2003.
EPCOS and Bosch sign contract to supply piezo actuators for diesel and gasoline injection systems
EPCOS AG has signed a general agreement with Robert Bosch GmbH to supply piezo actuators for diesel injection systems. By 2008, EPCOS will supply Bosch with piezo actuators worth more than EUR 200 million.
EPCOS and Bosch are also working on piezo actuators for gasoline injection systems.
Advantages of piezo technology :
Bosch uses EPCOS's piezo technology in its third-generation common-rail systems. As piezo components can switch more than twice as fast as conventional solenoid valves, the injection process be divided into as many as five injection events. The considerably finer fuel dosing obtained offers motorists several benefits. The third generation of common-rail injection systems from Bosch reduces diesel engine emissions by up to 20% or alternatively increases attainable engine output by 5 to 7%, reduces fuel consumption by 3% or perceptibly reduces engine noise by 3 dB(A), depending on application.
Piezo effect :
If a voltage is applied to a piezoelectric crystal, its dimensions change momentarily because the atoms are mutually displaced. But this effect cannot be exploited and no significant change in length obtained until several hundred layers of extremely thin piezoelectric material are superimposed. The piezo actuators made by EPCOS today contain more than 350 layers in a stack. In a 30 mm stack, the piezoelectric effect produces an increase in length of 40 thousandths of a millimeter or more than 0.1%. This difference can be used to open the injection valve.
Valeo's G5 clutch facings meet new European environmental regulations
Valeo's new range of G5 clutch facings for car and commercial vehicle applications, is now being supplied to OEMs worldwide.
All clutch facings in the G5 range are manufactured using new water-based, solvent free, production processes. These processes represent a significant innovation that have enabled Valeo to totally eliminate chlorinated solvents and so achieve compliance with European regulations well in advance of their introduction. End-of-life recycling of the clutch facings is made possible because of their lead-free construction.
The new production processes employ state-of-the-art technology to manufacture a wide variety of G5 clutch designs to meet individual customer specifications. These customers include BMW, Nissan, PSA Peugeot Citroen, Renault, Toyota and Volkswagen Group.
Haldex Traction Systems, a division in the Haldex group, has been chosen by Land Rover and Volvo Car Corporation to supply AWD systems. Deliveries are estimated to start in a few years time.
Land Rover, which is one of Europe's largest and most prominent manufacturer of 4x4 vehicles with true off-road capabilities, hereby becomes a new Haldex customer. This product is known on the Volkswagen Golf 4-Motion equipment up to now. Land Rover represents a partly new segment with cars that put high demands on off-road characteristics. Haldex will, therefore, at the same time further develop the second generation's AWD system to meet these special demands.
Air Liquide will provide Bosch with gases required for the production of injection equipment
This turnkey installation will provide Bosch with all the gases required for the production of high-pressure diesel injection equipment involved in the "Common Rail Technology".
With its new ALNATTM HP solution, Air Liquide enables Bosch to use high pressure nitrogen quenching for fast cooling metal parts after heat-treatment aiming at enhancing their resistance. This gas quenching technology is an environment friendly alternative to oil quenching which requires component cleaning and oil recycling… The ALNATTM HP system enables the customer to have instant high-pressure nitrogen. It causes no emission.
BMW Group and PSA Peugeot Citroën have unveiled the state-of-the-art technologies deployed in their new gasoline engines, the first to be jointly developed and produced by their cooperative venture. Announced in July 2002, the two Companies' cooperation in gasoline engines is now setting new standards for performance, driving comfort and reductions in fuel consumption and CO2 emissions.
- Variable valve timing (from the BMW Group's VALVETRONIC)
The Acura RL sedan made its world debut at the New York International Auto Show with a 220 kW (300 horsepower) VTEC V-6 engine and a revolutionary all-wheel-drive system. The Super-Handling All-Wheel-Drive System(TM) (SH-AWD(TM)) is an all-wheel-drive platform that distributes the torque not only between the front and rear wheels but also between the left and right rear wheels.
Based on the latest technology, Valeo Fastfill, an enhanced engine cooling tool, will provide automotive professionals with a new way to identify and repair automotive problems.
After BMW and its 535d, Opel's revolutionary new twin-turbo technology represents the next major stage of development for modern passenger car diesel engines.
A patented Valeo radiator that can be bent into curved shapes make its debut in the Renault concept car Wind at the Geneva International Motor Show.
The all-new BMW 535d offers a first for a BMW diesel car engine : a two-stage turbocharging.
EPCOS AG has signed a general agreement with Robert Bosch GmbH to supply piezo actuators for diesel injection systems. By 2008, EPCOS will supply Bosch with piezo actuators worth more than EUR 200 million.
EPCOS and Bosch are also working on piezo actuators for gasoline injection systems.