Diesel Engine with particulates filter on Mazda Bongo
Mazda Bongo vehicles equipped with the new diesel engine are the first in their class*1 to comply with Japan's New Short-term Diesel Emissions Regulations and the Automobile NOx/PM Control Law*2 making them eligible for sale and registration in the major metropolitan areas of Tokyo, Osaka and Nagoya.
The new 2.0-liter inline four cylinder, common-rail direct injection turbo diesel engine (RF-CDT type) employs technology that greatly reduces the amount of particulate matter (PM) and nitrogen oxides (NOx) in exhaust gas emissions. Based on the MZR-CD engine mounted in the European specification Mazda6, the engine is equipped with an all-new diesel particulate filter (DPF) and an improved engine control unit. As a result, PM emissions have been reduced by more than 75 percent, while NOx emissions have been cut by 25 percent compared to the 2.2-liter diesel engine (R2 type) previously used in the Bongo series.
In order to reduce PM emissions, the engine employs a diesel particulate filter coated with an oxidation catalyst. The ceramic filter traps PM, and when the amount of PM in the filter reaches a designated level, it is automatically removed through the combined effect of the catalyst and combustion temperature controlled by the common-rail injection system. Further, NOx emissions are reduced by optimally controlling the combustion temperature with "Cooled EGR"*3 and by improving combustion efficiency with fuel injected at high pressure from the common-rail. As a result, Mazda Bongo is the first vehicle in its class to comply with Japan's New Short-term Diesel Emissions Regulations and the Automobile NOx/PM Law.
Ford Motor Company's Automatic Transmission New Product Center (ATNPC) in Livonia, Mich., are playing a critical role in the improvement in the quality of Ford's automatic transmissions. At the ATNPC, approximately 800 employees work in three main areas: Prototype Operations, Development Lab and Product Engineering.
Critical system durability testing is among the important functions performed in the Development Lab, which includes 56 dynamometer cells. In recent years, road-load factors have been introduced to "key-life" testing.
"Road-load simulation includes the mechanical inertias that act on a transmission when a vehicle is being driven up or down a hill and when cornering," said Aung Myint, manager, ATNPC Development Lab. "It makes the test more customer focused."
Product design engineers share the same building and get immediate feedback on how their designs go together and perform on test. The ATNPC is part of a complex that includes a test track and one of the most advanced X-ray labs in the country."I don't think any other automaker in the world has the combination of facilities on-site that we do here." said Jean Maki, manager, Prototype Operations.
2.0 TDi and Diesel particulate filter for the Volkswagen Passat
The Volkswagen Passat is now available with a 100 kW/136 hp four-cylinder turbo diesel engine. The 2.0-litre TDI with a six-speed manual gearbox is fitted with a diesel particulate filter as standard.
The additive-assisted diesel particulate filter is located away from the engine in the vehicle underbody. Its housing is made of stainless steel and contains an innovative filter block made of silicon carbide (Si-SiC) with alternate inlet and outlet channels. The inlet channels facing the engine form a "cul-de-sac" for the soot particles. Only the exhaust gasses are able to pass through the porous ceramic wall into the neighbouring outlet channel.
The Passat 2.0 TDI has a maximum torque of 335 Newtonmetres at 1,900 rpm. The saloon and the estate have top speeds of 211 km/h and 205 km/h respectively. The Passat accelerates from zero to 100 km/h in 9.8 seconds. It consumes 6.1 litres of diesel per 100 kilometres (estate version 6.3 litres).
Mass production of Bosch diesel particulate filters to start in 2005
Robert Bosch GmbH has decided to develop particulate filters made of sintered metal for diesel cars and light commercial vehicles and to start series production in 2005. The company will invest around 200 million Euro in development and production equipment. After only three years following start of production Bosch expects annual output to exceed one million particulate filters.
For despite the progress achieved in reducing emissions by "internal" engine measures, the Euro 4 standards for larger cars weighing more than 1800 kg, which will come into force in 2005 in Western Europe, will not automatically be met without diesel particulate filters. In the US market with its especially low emission levels from 2007 on, particulate filters for diesel-powered cars will be essential. Bosch is therefore reckoning on a rapidly increasing demand for this technology for diesel cars - by 2007, the company expects sales of particulate filters to be as high as six million a year.
The diesel particulate filters used so far by automobile manufacturers are made of ceramic materials. The filters being developed by Bosch are based on sintered metals. The filter is designed in such a way that the particulates are deposited very evenly, which makes it much easier to regenerate the filter. The particular geometric form of the Bosch filter means that there is sufficient space for all the deposits likely to accrue during the normal service life of a vehicle, assuming standard rates of deposition. This means that the driver has no extra servicing or aftermarket parts replacements costs.
The development engineers at Bosch are working simultaneously on two different concepts: one for use with fuel additives and the other with catalytic coating. In both cases, the filter is regenerated by the hot exhaust gases which regularly burn off the deposited particulates.
At the end of 2002, Bosch acquired the basic technology for particulate filters from sintered metal, as well as the worldwide rights to further development, manufacturing and sales of such filters for diesel passenger cars and light commercial vehicles, from HJS Fahrzeugtechnik GmbH & Co. in Menden/Germany.
Progress with Bosch engineering: piezo-inline injectors
Since May of this year, Bosch have begun with the large-volume production of our third generation Common Rail system, and at the IAA Motor Show, it has its first appearance in the new Audi six-cylinder diesel engine. Its special feature: it works with fast piezo-inline injectors.
This reduces the pollutant emissions by up to 20 percent in direct comparison to the best previous systems in solenoid and piezo technology. In 2004, Bosch will be producing 300,000 inline injectors, and already 2 million units in 2005.
The Volkswagen Passat is now available with a 100 kW/136 hp four-cylinder turbo diesel engine. The 2.0-litre TDI with a six-speed manual gearbox is fitted with a diesel particulate filter as standard.