24th Vienna International Motor Symposium
May 15 and 16, 2003 |
| Organizer: Prof. Hans Peter Lenz |
| Preface |
Once again, the 24th Vienna International Motor Symposium
was an outstanding event at which leading automotive engineers from
all parts of the world presented the latest results and future trends
in engine development. As in previous years, the Vienna International
Motor Symposium began and ended with joint plenary meetings at which
well-known experts discussed topics of general interest.
After the opening session, two parallel sessions were held, in which
technical papers were presented under the chairmanship of Prof.
Dr. Hans Peter Lenz of Vienna University of Technology, and
Prof. Dr. Rudolf Pischinger, Prof. Dr. Helmut Eichlseder
and Prof. Dr. Günter Jürgens, all of Graz
University of Technology. All lectures and discussions were interpreted
simultaneously into the conference languages German and English.
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1
Introduction
In his welcoming address, Prof. Lenz emphasized the tremendous achievements of the automotive engineering industry and engine manufacturers over the past few years. This industry, he stressed,
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acted as a stabilizing factor in economically difficult times
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was investing ever larger sums in research and development
- has emerged as the innovation leader for the entire industrial sector
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has achieved drastic reductions in exhaust gas emissions combined with better fuel economy, while at the same time improving performance characteristics of both engines and vehicles and heightening driving pleasure.
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Prof. Lenz also pointed out that Austria had played a vital role
in motor car development right from the beginning, and had established
itself as a genuine leader in vehicle design and production over
the past few years, reporting export rates of between 80% and
100%.
Although the conference
was fully booked, 40 students had been sponsored
by the automotive industry and were thus given an opportunity to attend
the symposium and to learn, establish contacts with representatives
of the automotive industry and be inspired by the enthusiasm of vehicle
and engine developers and experts.
It was very gratifying, the speaker went on, to see such a large number
of professors from universities of technology and technical colleges.
Thus, Prof. Lenz concluded, it can be safely assumed that state-of-the-art
expert knowledge will be disseminated in university lecture rooms. |
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An extensive exhibition of new engines, components and vehicles was
an additional attraction above and beyond the lectures, photographs
no. 7, photographs no.8 and photographs
no. 9. |
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| Upon invitation of the Mayor of Vienna, the conference participants spent a pleasant evening at a "Heuriger", a typical Viennese wine tavern. |
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2
Opening Plenary - Future Powertrains

Photo
10: |
The
first plenary lecture was given by Dr.Gerhard Schmidt,
photograph no.10, the Vice-President of Ford
Motor Company, Dearborn, on the topic of "Future
Powertrains - Ford's Global Opportunities and Challenges".
The speaker explained that with the advent of hybrid combustion
systems, the classical boundaries between combustion processes used
in SI engines and diesel engines will become blurred. The fuels
commonly used today will be complemented by new fuels produced from
alternative sources of energy. Thus the range of options will be
widened with the local application of alcohols, the widespread use
of natural gas and, in the long run, hydrogen as "fuels". The diesel
engine, which today has become a more than equal partner of SI engines
in Europe, will certainly also benefit from improved market prospects
in the United States in the immediate future.
Hybrid drives will also compete with conventional drive options.
The degree to which the new technologies will be able to penetrate
markets will be determined by the cost development of hybrid drives
and the exhaust gas after-treatment technologies available for diesel
engines.
Flexibility in US exhaust gas emission legislation will also be
a determining factor. On our road into the future, in which hydrogen
will play a dominant role, hydrogen-driven international combustion
engines will be a credible technology in the transition towards
fuel-cell driven cars.
Fuel cells as drive units of cars represent a fairly young technology
which has proved extremely successful in the recent past and which
presents major challenges for the future.
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The
title of the second report in the plenary was "New
Gearboxes for Powertrain Improvement". It was
presented by Dr.-Ing. E.h. Siegfried Goll, photograph
no. 11, Chairman of the Board of ZF, Friedrichshafen AG,
Friedrichshafen, (co-author Dr.-Ing. M. Ebenhoch):
The lecturer explained that the success of engine developments in
the course of the past few years had clearly demonstrated that the
reciprocating engine was by no means an outdated concept, and that
significant reductions in fuel consumption and emission levels could
still be attained. However, when looking closely at customer operation,
it was obvious that drivers had not yet fully utilised existing potentials,
the speaker pointed out. Therefore, it would be even more important
in the future to harmonise drive-lines with overall systems. The lecturer
stressed that transmission systems of different designs made an essential
contribution to optimising drive lines.
Thanks to their wider stepping and automatic shifting processes, new
transmission systems resulted in better fuel economy with improved
vehicle performance and heightened convenience.
The afore-described features of the currently available systems had
to be further improved and optimised in line with general engine developments,
so that ambitious goals, especially in the area of fuel economy, could
be attained with cost-efficient solutions while maintaining the high
level of efficiency of all vehicle functions, the speaker concluded. |

Photo
11: |

Photo
12: |
The
third lecture in the plenary was entitled "GM's
Global Perspectives on the Future of Internal Combustion Engines"
and was presented by Thomas G. Stephens,
Group Vice President - General Motors Corp., photograph
no. 12.
In order to be able to satisfy the demands of its highly diversified
customer base around the world, General Motors had set up a global
powertrain organisation, the speaker explained. This network of world-wide
partner alliances offered automakers the option of choosing from a
wide variety of different powertrain technologies.
In addition to these alliances, GM was also developing a number of
core technologies which could be applied globally across the entire
range of its powertrain products in order to meet a wide variety of
automotive customer needs. In its engine development efforts, the
speaker stressed, GM pursued three strategic goals: to produce high
value engines for its average customers, high-feature engines for
customers with a particular interest in technology and so-called image
engines for customers with less interest in technological features.
The successful application of GM Powertrain's technology and its product
strategies should ensure the future of internal combustion engines
for many years to come, the lecturer explained. |

3
Session: New Engines
Dr.
Uwe D. Grebe (lecturer), Dr. Peter Gebhard, Torsten Löhnert,
Ivo Opacak, Harald G. Theis; Opel Powertrain GmbH, Russelsheim:
"The New Generation of Fiat-GM Powertrain's
Four-Cylinder Spark-Ignition Engines":
The lecturer underlined that FIAT-GM Powertrain's medium-sized spark
ignition engines, internally designated as "family one", had been
redesigned with a view to reducing fuel consumption and emissions,
improving quality, lessening the need for maintenance and lowering
production costs. Besides optimisation, redesign efforts focused on
the introduction of a modular component system.
The 1.6 litre engine thus created accounted for the largest share
of the Company's production and represented the first version of the
redesigned third generation of this engine family. The engine features
a tappet-valve drive with mechanical lash adjustment and a thermo-management
system. In addition to reaching a power output of 76 kW and a maximum
torque of 147 Nm, the engine development focused on the integration
of a combustion system with port deactivation resulting in significantly
lower fuel consumption, and on attaining a high exhaust gas recovery
rate. The new engine will be used for the first time in the Opel Astra.
With the launching of this vehicle in the market, fuel consumption
in the European MVEG test cycle will be reduced by 7%, from 7 litres
per 100 km to 6.5 litres per 100 km, which will position this car
in the top segment of this category. This segment, the speaker stressed,
was normally occupied by direct-injection engines using much more
complex systems for fuel economy, such as stratified charge gasoline
direct injection. This cost-efficient solution combined optimum customer
benefit due to high fuel economy and excellent driving performance
with optimised manufacturing cost and outstanding long-term reliability.
The concept, which is based on modular components, the speaker went
on, constituted the platform for this redesigned engine generation
and was to be applied in different component combinations to all future
versions of the medium four-cylinder gasoline engine series. |
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Dipl.-Ing.
Erhard Voss, Dipl.-Ing. Walter Schnittger, Dipl.-Ing. Achim K”nigstein
(lecturer), Dipl.-Ing. Ingo Scholten, Dipl.-Ing. Manfred P”pperl,
Dipl.-Ing. Stefan Pritze, Dipl.-Ing. Peter Rothenberger, Dr.-Ing.
Matthias Samstag Opel Powertrain GmbH, Russelsheim: "
The 2.2 litre ECOTEC DIRECT - The New All-Aluminium Engine with Gasoline
Direct Injection for the Opel Signum"
After the successful introduction of the 2.2l ECOTEC engine with port
injection in 1999, a new version of this engine family will soon be
launched in the market. The new 2.2l ECOTEC DIRECT all-aluminium engine
represents OPEL'S first gasoline direct-injection engine developed
by FIAT-GM Powertrain.
The threefold development goal for this engine was to attain supreme
driving pleasure, an optimum price/performance ratio and maximum cost-efficiency
with regard to maintenance, the lecturer explained. As a result of
detailed analyses of different gasoline direct-injection concepts,
a gasoline direct-injection engine with a variable inlet geometry
was designed which operates on the basis of a stochiometric air-fuel
mixture. Thanks to its high compression ratio and the high dilution
tolerance achieved through the variable inlet geometry, the fuel economy
of this engine was significantly improved, not only under steady-state
conditions. The advantages of gasoline direct injection, which can
be ascribed to the specific technology used, have resulted in a further
reduction of fuel consumption in transient operation.
In the new European driving cycle, MVEG-B, this engine showed a 6%
improvement in fuel economy, the speaker pointed out. Under full load,
rated power was increased by 6% to 155 HP, but far more significant
was the engine's 6-8% higher torque over the entire speed range as
compared to the base engine with MPFI, the lecturer stressed. |
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Prof.
Dr.-Ing. R. J. Menne, Dr.-Ing. S. Limbach (lecturer), Dr.-Ing. B.
Brinkmann, Dipl.-Ing. C. Hohage, Ford-Werke AG, Cologne; D. Skipp
(BEng), T. Sweet, Ford Motor Company GB, Dunton; "Tuning
and Integration of Gasoline Engines with Direct Injection"
Dr.Ing. S. Limbach reported on the tuning and integration of direct-injection
gasoline engines, using the 1.8 litre Duratec SCi engine as an example.
In addition, the lecturer described the exhaust-gas after-treatment
system and the transmission, the fuel consumption behaviour, and the
emission data of this vehicle. Moreover, he discussed other customer-relevant
characteristics, such as starting behaviour, response and noise characteristics
and illustrated the technological solutions chosen in order to reach
the individual technological goals. The 1.8 litre Mondeo SCi offers
a very attractive overall package of features combining low fuel consumption
as well as excellent driving dynamics and convenience.
Owing to its supreme convenience features and noise/vibration harshness,
the SCi concept distinguishes itself clearly from diesel CR engines,
which will allow this vehicle to occupy a very specific market position. |

4
Session: Simulation and Electronics Development
Ing.
P. Martinelli (lecturer), Ing. N. Cavey, Ing. M. Bollini; Ferrari
Gestione Sportiva, Maranello Dr. P. Schoeggl (lecturer), Dipl.-Ing.
F. Mundorff, Dipl.-Ing. M. Dank, AVL List GmbH, Graz: "Optimization
of Formula One Engine Torque Delivery with New Real-Time Simulation
Methods"
Current formula one engine control systems comprise
complex functions and engine maps for throttle control, injection
and ignition, as well as variable inlet, traction and launch control
mechanisms. Many of these functions not only have a direct influence
on engine behaviour, but also an indirect one on car handling and
the degree of tyre (auáer sie wollen unbedingt US-Englisch!) wear.
Many of these functions had to be calibrated for the individual race
tracks, as the mapping of all of these variables during the weekend
of a race would result in an unacceptable delay, the lecturer pointed
out. Ferrari used new simulation technologies on high-performance,
highly dynamic test benches in order to be able to assist pre-optimization.
The lecturer illustrated the new real-time simulation package VSM
(Vehicle Simulation Model) used for the simulation of the dynamic
behaviour of a formula one racing car on a highly dynamic test bench.
The lecturer stressed that the main objective of VSM was to simulate
the effects of dynamic vehicle load on the engine. The realistic simulation
of the behaviour of the car in any section of the simulated racing
track, including wheel slip and curb jumping,? permitted an optimum
calibration of the engine both during simulation and on the highly
dynamic engine test bench. |
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Dipl.
Ing. Mario Prandstätter, Dipl. Ing. Harald Riener (lecturer),
Dr. Michael Steinbatz, MAGNA Steyr, Engineering Center Steyr GmbH
& KO KG: "Simulation of an Engine Speed-Up Run
with due Regard for Oil Film Properties Integration of EHD, Multi-Body
Simulation and FEH-Service Life"
The lecturer dealt with the numerical assessment of the operational
reliability of crankshafts on the basis of an engine speed-up run
simulation, integrating an elasto-hydrodynamic oil-film model (EHD).
An accurate simulation of deformation or bending characteristics of
a crankshaft at any point in time constitutes the prerequisite for
performing a transient fatigue lifetime prediction for a crankshaft.
Initial tests were carried out using a number of substitute models
(Kelvin-Voigt elements, etc.). These past tests showed that an accurate
description of the dynamic properties of the oil film in the lubrication
gap of the main bearings of the crankshaft constitutes one of the
prerequisites for devising an oil-film model that will yield highly
reliable results.
Based on a modal approach, a new integrated calculation and simulation
method was devised, which combines multi-body simulation with the
finite elements method (FEM) and simultaneously permits an accurate
representation of elasto-hydro-dynamic processes. |
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Dipl.-Ing.
Wilfried Nietschke (lecturer), Dipl.-Ing. Winfried Schultalbers, IAV
GmbH, Gifhorn: "New Results of Electronics Development
for Realizing Future Engine Concepts"
The lecturer stressed that one of the prerequisites for the realisation
of future engine concepts was sufficient information on the cylinder
charge and the combustion processes of and emissions from internal
combustion engines. Possible approaches to obtaining more detailed
information on these processes consisted in using the control algorithms
in order to compensate for errors in the calculation of the exhaust
gas recirculation rate, the calculation of engine torque from the
crankshaft-speed signal and new methods for rapid temperature sensing
both in the intake pipe and in the exhaust system. These data constituted
the basis for control function improvement and better engine management,
the speaker explained. To this end, the management of transient states
and other dynamic processes was becoming ever more important and it
was therefore necessary to adjust the control algorithm to its particular
task.
As a result of the more stringent demands made upon engine management
and owing to the integration of additional functions into the increasingly
complex vehicle system, the lecturer stressed that a growing number
of algorithms would have to be applied and ever more calibration processes
performed. As a consequence, greater attention should be given to
the question of whether the newly conceived functions would be applied
in practice on the one hand, and on the other hand tools such as Rapid
Calibration(r) would be needed in order to be able to fully exhaust
the available calibration potential. |
5
Session: New Engines 2
Dipl.-Ing.R.Herzog
(lecturer), Dipl.-Ing.B.Heil, Dipl.-Ing.K.Kofahl, Dipl.-Ing. R.Steinbacher,
Dipl.-Ing.H.Brösecke, DaimlerChrysler AG, Stuttgart: "Enhancement
of the SUPREX Concept as an Engine for Sporty "smart" Cars - The New
0.7 Litre Three-Cylinder Turbocharged Gasoline Engine"
Based on the 0.6 litre SUPREX spark-ignition engine with port injection,
which was originally developed for the "smart" compact car brand,
two improved new engine versions and one new version were presented.
In order to achieve volumetric efficiency levels of 37. 45l and 60
kW total displacement was increased to 700 ccm by changing bore and
stroke dimensions. The turbo-charging unit, including waste gate valve
and intercooler, was adapted accordingly.
The 60-kW variant deserved special attention; thanks to its outstanding
117.5 HP per litre displacement, it ranges in top category of small-displacement
engines for large-series vehicles. This high volumetric efficiency
could be attained thanks to the improved combustion chamber - now
featuring a smooth piston head in the exhaust valve area and dual
ignition - as well as the adapted oil supply with separate cooling.
The exhaust manifold and the turbocharger represent a new integration
concept in which the charger is now made of high-temperature-resistant
cast steel. Modified aero-dynamic parameters and optimised gap dimensions
of the Garrett charger ensure higher efficiency of the turbine and
the compressor.
In combination with a completely redesigned concept for the exhaust
system with a bimetal-coated two-brick catalytic converter, emission
values remain clearly below the EURO 4 limits, while at the same time
favourable specific consumption characteristics could be attained.
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Dipl.-Ing.
R. Dorenkamp (lecturer), Dipl.-Ing. H.J. Engler, Dr.-Ing. L. Lohre,
Dipl.-Ing. H. Stehr, Volkswagen AG, Wolfsburg: "The
New 2.0 litre TDI Engine with Four-Valve Technology"
An entirely new 2.0 litre TDI engine with unit injectors was developed
for the fifth generation of the Golf engine platform. The new engine
is equipped with four valves per cylinder, an entirely new approach
for Volkswagen. The 100 kW version (Touran) and the 103 kW version
(Audi A3) meet the EU4 exhaust emission standards. The cross-flow
aluminium cylinder head is characterized by a tangential inlet valve
layout rotated by approximately 45 degrees and valves arranged in
parallel to the cylinders. Tooth-belt driven twin camshafts and roller-finger
followers drive the valves.
Another new component is the Bosch "UI-P2" unit injector system, which
boasts numerous functional improvements such as lower injection noise
and higher pressure-injection. The larger displacement was achieved
by increasing the bore from 79.5 mm to 81.0 mm. With its transition
to four-valve technology and a number of design improvements, Volkswagen
succeeded in producing a unit injector engine that features higher
fuel economy, lower emissions, enhanced road performance and greater
convenience.
The 100 kW and 103 kW engines presented are the first versions of
the new four- valve TDI engine generation, which, after making their
debut in the Touran, the Audi A3 and the Golf V, will later be used
in the Passat successor vehicle as well as in the Audi A4 and A6.
Higher power engine versions will be developed in the future. |
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Dr.-Ing.
F.T. Metzner (lecturer), Dipl.-Ing. U.Kirsch, Dr.techn. W. Demmelbauer-Ebner,
Dipl.-Ing. W. Ebbinghaus , Dr.-Ing. B. Ebel, Volkswagen AG, Wolfsburg:
"Volkswagen's New 3.2 l - V6 - Engine - an Engine
for Most Diverse Applications"
The 2.8 l - V6 - four cylinder engine which has been produced since
1999 was redesigned for a displacement of 3.2 l. The new engine attains
a maximum torque of 320 Nm and a rated output of 184 kW, depending
on the vehicle into which it is integrated. By optimising the intake
and exhaust gas systems to 100 Nm/l it was possible to raise the maximum
specific output and torque to 57.7 kW/l.
This engine covers the entire range of applications, from the sporty
compact Golf R32 hatchback to the base level engine for the Phaeton
and the Touareg, an off-road sports utility vehicle. Other applications
are currently being planned.
This engine is suitable for both transversal and longitudinal installation.
Another option is the conventional layout with longitudinal installation
of the engine on the front axle. |
6
Session: Diesel Exhaust After-Treatment 1
Dr.-Ing.
Michael Krüger (lecturer), Dr.-Ing. Andreas Wiartalla, Dipl.-Ing.
Thomas Lichtenberg, Dipl.-Ing. Thomas Körfer, FEV Motorentechnik,
Aachen: "Emission Concepts for Future Passenger
Car Diesel Engines"
The lecturer analysed combustion processes and exhaust gas after-treatment
systems with regard to efficiency and their impact on fuel consumption.
From today's vantage point it seems difficult to meet the emission
limits which are currently under discussion and have partly been defined
in new legislation that will enter into force in 2005 merely by optimising
the combustion process. In terms of fuel consumption in particular,
a suitable combination of engine design and exhaust gas after-treatment
measures appears more promising. The overall power consumption of
the exhaust gas after-treatment system will be a determining factor
for the success of such a concept. This approach will also have to
consider the thermo-management of the engine and the exhaust gas system.
Furthermore, factors that determine the regeneration capacity of the
discontinuously operated particulate trap and the NOx absorption catalytic
converter will have to be considered as well. Above all, the fuel
additive and the sulphur content of the fuel as well as the sensitivity
to sulphur of the NOx absorption catalytic converter play a significant
role. |
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Dipl.-Ing.
Frida Diefke, Dipl.-Ing. Mats Lundgren, Dipl.-Ing. Per Nilsson, Volvo
Car Corporation; Dipl.-Ing. Rolf BrÜck (lecturer), Dipl.-Ing.
Carsten Kruse, Dipl.-Ing. Simone Schaper, Emitec GmbH: "New
Diesel Catalyst Systems for Compliance with the European Legislation
2003 - Tested on a Volvo S60 Passenger Car"
In order to be able to comply with the limit values stipulated by
the European legislation IV for diesel vehicles, improved catalyst
efficiency will be required for all emission components.
Alongside the optimisation of engines and engine management systems,
oxidation catalysts required for HC and CO conversion must be adapted
to the specific demands of the most recent direct-injection diesel
engines. Because of the trade-off between NOx and particulate emissions,
cars with higher masses will have to be equipped with devices capable
of reducing particulate emissions.
Tests were carried out using a Volvo S60 in order to investigate the
potential of various new and old diesel catalyst systems, such as
hybrid catalysts, PM catalysts and pre-turbo-charged catalysts. |
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Dipl.-Ing.
Seiichi Hosogai, Eng., Honda R&D Co. Ltd., Dipl.-Ing. Kazunari Komatsu,
Eng., Dipl.-Ing. Yasuaki Unno (lecturer), Eng., Emitec Japan: "The
Hybrid Catalyst, a New Concept for Improving Diesel Catalyst Efficiency
by Thermal Management"
With a view to complying with future worldwide legislation on emission
limits for diesel vehicles, the efficiency of the catalyst must
be improved for all emission components. Apart from improving engine
and engine management systems, the oxidation catalyst must also
be adapted to the specific requirements of modern diesel engines.
The efficiency of oxidation catalysts depends mainly on the temperature
of the catalyst and hence the temperature of the exhaust gases.
In highly efficient modern diesel engines, the temperature of the
exhaust gases is within the range of the light-off temperature,
especially when driving in urban areas.
An improvement
in efficiency therefore requires better utilisation of the exhaust
gas energy as well as location of the catalyst close to the engine
by combining fast light-off with a heat storage function in one
compact component. The hybrid catalyst assures optimum thermal management. |
7
Session: High Performance Engines
Dipl.-Ing.
Wolfgang Kotauschek, Dipl.-Ing. Hartmut Diel, Dipl.-Ing. Ulrich Baretzky
(lecturer), Dr. Wolfgang Ullrich, Audi AG: "The
Audi V8 FSI® Bi-turbo Engine for the 24 Hour Race in Le Mans"
For the successful 3.6 l V8 bi-turbo engine launched in 2000, the
direct injection technology FSI(r) was developed and applied to the
racing engine.
The most important modifications were made to the cylinder head. In
addition to a complex port design which had to assure the required
charge motion, injectors with specific spray patterns were devised.
With a view to determining the mixture formation parameters, comprehensive
CFD simulations were carried out in parallel to the actual tests.
All of these measures, combined with the increased compression ratio,
resulted in an improvement of torque by up to 9%, with an 8 % to 10%
reduction in fuel consumption. The driveability of this 600 HP engine
was also improved significantly.
Intensive transient-state optimisation efforts were made and endurance
tests were carried out on a highly dynamic AVL engine test bench.
With the 3.6 l V8 FSI(r) bi-turbo engine, Audi won a dual victory
in 2001 and even an historic triple victory in 2002 in Le Mans. The
engine proved its reliability and was equally victorious on many other
ALMS race tracks. |
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Dipl.-Ing.
(FH) S. Knirsch (lecturer), Dipl.-Ing. M. Kerkau, Dipl.-Ing. T.
Wasserbäch, Dr.-Ing. H.J. Neußer, Dr. Ing. h.c. F. Porsche
AG, Weissach: "The New Porsche Cayenne V8
Engines"
With its V8 engines which were entirely redesigned for the Porsche
Cayenne, Porsche succeeded in meeting the most diverse and exacting
demands made upon a state-of-the-art engine concept for a sporty
multi-purpose vehicle.
Typical Porsche characteristics such as high engine power, high
revving ability and lively response, combined with high engine torque
in the low speed range give the Porsche Cayenne superior driving
performance in the segment of sporty multi-purpose cars. At the
same time, specific parameters, such as a power output of 55.4kW/l
of the naturally aspirated V8 engine and of 73.4kW/l of the V8 bi-turbo
engine, an outstanding mean pressure of 11.4 bar at 2000min-1 rpm,
a fuel consumption of 359g/kWh (naturally aspirated engine) and
375g/kWh (bi-turbo engine) and a pme of 2 bar give the new V8 engines
their impressive profile (n = 2.000min-1 and pme = 2 bar).
In addition,
these engines possess excellent off-road capabilities, allowing
the vehicle to overcome uphill and downhill gradients as well as
lateral inclines of up to 45°.
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Dr.-Ing.
Karl-Heinz Neumann, Dipl.-Ing. Andreas Kurowski (lecturer), Bugatti
Engineering GmbH, Wolfsburg: "The High-Power
Engine of the Bugatti Veyron 16.4"
With the Bugatti brand, a famous traditional name in the automotive
industry is coming back to life.
From a technological perspective, the highlight of the vehicle is
its drive: modelled on the 16-cylinder concept which was first implemented
more than 70 years ago, an 8.0 litre 16-cylinder mid-mounted engine
with a power output of 736 kW/1001 PS is used as the efficient, innovative
drive system.
The lecturer described the engine concept, which was selected with
a view to the general design requirements. Despite the limited packaging
space of the vehicle, a supercharged unit with four exhaust gas turbochargers
and efficient charge-air cooling was conceived, which, thanks to the
W-shaped layout, is an extremely compact base design. Besides focusing
on the short-block assembly and the complex crank mechanism, which
is under high load, the lecturer illustrated the special characteristics
of the oil circulation system with its innovative modular-shaft oil
pump.
In order to be able to attain the ambitious goal of instantaneous
power delivery, special attention was given to the turbo-charging
concept. The lecturer illustrated its specific layout and its thermo-dynamic
characteristics in detail. |
8
Session: Diesel Exhaust After-Treatment 2
Dr.-Ing.
Paul C. Spurk (lecturer), Dr. Marcus Pfeifer, Dr. Barry van Setten;
OMG AG & Co KG, Hanau; Prof. Dr.-Ing. Günther Hohenberg, Dipl.-Ing.
Christof Gietzelt; Darmstadt University of Technology: "Examination
of Engine Measures for the Regeneration of Catalytic Coated Particulate
Filters in Commercial Vehicles"
As well as examining catalytic coated particulate traps, the lecturer
also illustrated engine design methods to increase exhaust gas temperatures
in order to initiate regeneration.
The well-known temperature balance test was applied for evaluating
the catalytic coated particulate trap and the soot burning rate in
the trap was determined. Engine design measures destined to increase
exhaust gas temperatures comprised the management of diesel engines
for commercial vehicles and intake air throttling. With a view to
examining the behaviour of the particulate trap under realistic conditions,
a dynamic test cycle was devised which permitted an assessment of
the efficiency of the engine design measures and the behaviour of
the respective particulate trap.
The findings demonstrated that the operating range of a filter system
can be extended through optimised coating of catalysts in combination
with engine design measures. This permits the regeneration of coated
particulate traps, even at low operating temperatures. |
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Dipl.-Ing.
T. Colliou (lecturer), Dr. J. Lavy, Dr. B. Martin, Dr. J.B. Dementhon,
IFP, Lyon ; Dipl.-Ing. G. Pichon, Dipl.-Ing. K. Chandes, Dipl.-Ing.
L. Pierron, RENAULT TRUCKS., St Priest: "Combining
a NOx Absorption Catalyst with a Diesel Particulate Trap to Reduce
Emissions from a Heavy-Duty Six Cylinder Engine"
The study centred on a 6-cylinder RENAULT TRUCKS engine. The initial
investigations involved only one NOx absorption catalyst, in order
to be able to assess adsorption and desorption rates and optimise
both NOx conversion efficiency and fuel economy. The equivalence ratio
level which determines the duration and efficiency of the regeneration
phase, the fuel consumption penalty and the temperature of the NOx
trap emerged as the key parameters. The test findings showed that
regeneration at a high equivalence ratio yielded optimum results.
The need to change over briefly to rich-mode operation led to increased
particulate emissions, which in turn called for the use of a diesel
particulate trap.
In the second phase of the test, various possible arrangements of
exhaust gas after-treatment systems (NOx storage catalyst and catalysted
diesel particulate traps) were investigated and evaluated. The arrangement
of the NOx trap upstream of the CDPT provides the best trade-off between
NOx efficiency and the fuel consumption rate, as this configuration
reduces the release of NOx from the storage catalyst (reaction with
the slipped reductants inside the CDPT) and thus does not interfere
with the enriched impulses.
In order to reach NOx emissions levels below the EURO V limit, more
frequent NOx storage catalyst regeneration phases are necessary; however,
these simultaneously lessen the CRT effect. For this reason, special
diesel particulate trap regeneration strategies are necessary for
these applications. |
|
A.
Shoji (lecturer), S. Kamoshita, T. Watanabe, T. Tanaka; TOYOTA MOTOR
CORPORATION, Sizuoka Japan M. Yabe; HINO MOTORS LTD, Tokyo, Japan:
"Development towards Serial Production of a
Direct-Injection Diesel Engine for Light-Duty Trucks with Simultaneous
Reduction System for NOx and PM"
TOYOTA has developed the Simultaneous Reduction System of NOx and
PM for installation in light-duty trucks. This system is based on
a turbo-charged direct- injection diesel engine with intercooler.
The system incorporates diesel particulate and NOx reduction (Diesel
Particulate and NOx Reduction/DPNR) systems, a common rail injection
system, an electronically controlled EGR system, a high-efficiency
EGR cooler and an exhaust pipe injector supplying rich gas to the
DPNR catalyst.
The DPNR catalyst, which stores and reduces NOx, undergoes functional
deterioration through mileage accumulation This is a critical issue
in applying DPNR to light-duty trucks. In order to investigate this
problem, an extended durability test was devised. The NOx reduction
ratio of the DPNR was 85% at the beginning, but dropped to 50% in
the course of the durability test. However, even this level of NOx
reduction capability shows a sufficient potential for complying with
future emission standards, such as Japan's new long-term regulations. |
9
Book Presentation
 |
After
the first day's lectures, Robert Bosch GmbH and the Vieweg publishing
house presented not only the second edition of "SI Engine
Management", but also the Automotive Engineering
Manual - Interactive, photograph no. 13.
This novelty is sure of attracting a great deal of attention?
Photo 13: |
10
Session: Diesel Soot: Structure, Evaluation. Health Risk
Dr.
Norbert Metz, BMW Group, München: "Diesel
Particulate Matter - Criteria for the Evaluation of Health Effects"
The mechanisms triggered after exposure to diesel particles are still
not fully understood today. On the basis of such parameters as mass,
size distribution, number, ultra-fine particles, surface characteristics,
chemical composition and morphology, an attempt was made to define
the factors most likely to play a crucial role in presenting hazards
to human health.
Car and commercial vehicle emissions were studied in order to determine
the respective described parameters and potential effects. In addition
to discussing the quantity of such particles remaining within the
lungs, the chemical composition of the organic substances deposited
on the soot and their hydrophobic or hydrophilic character, the lecturer
also commented on the influence of the surface of such particles.
In view of the complex interaction of all of these parameters, the
effect on human health cannot be ascribed to a single factor. It is
therefore necessary to know all parameters in order to understand
the mechanisms at work and initiate suitable measures for improvement.
Once all parameters and all of their interdependencies are known,
gravimetric mass analysis is the most efficient procedure. |
|
Dr. E.
Jacob (lecturer), Dipl.-Chem. D. Rothe MAN Nutzfahrzeuge AG, GB Motoren,
Nürnberg; Prof. Dr. R. Schlögl, Dr. D. S. Su, Dipl.-Phys.
J.-O. Müller Fritz-Haber-Institut der Max-Planck-Gesellschaft,
AC, Berlin; Prof. Dr. R. Nießner, C. Adelhelm, Dipl.-Ing. A.
Messerer M.Sc., Dr. U. Pöschl IWC, Aerosol Research Group, Munich
University of Technology; Prof. Dr. K. Müllen, Dipl.-Chem. C.
Simpson, Dipl.-Chem. Z. Tomovic, Max-Planck-Institut for Polymer Research,
Mainz: "Diesel Soot: Microstructure and Oxidation
Kinetics"
The reduction of mass-related soot emissions results from a lowering
of the number of aggregate particles. In this process, the number
of fine soot particles smaller than 50nm also declines markedly.
With a view to understanding the processes that contribute to a further
reduction of soot emissions by means of engine design modifications,
the microstructures and bonding behaviour of soot particles emitted
by state-of-the-art commercial vehicle engines were examined, using
TEM, HRTEM and EELS methods. These investigations revealed the existence
of primary particles which had hitherto been unknown and which exhibited
a deformed fullerenoid structure (having a size of between 10 and
20nm). Besides these irregularly shaped, fullerenoid soot clusters,
a small number of larger, roundish primary particles with core-shelled
structures were also detected. The smaller, fullerenoid primary particles
show a marked tendency to coagulate, and therefore always constitute
components of larger soot particle aggregates. To a great extent,
the surfaces of these graph-shelled particles, also in black soot,
are bonded to oxygen-active groups and thus exhibit hydrophile properties.
For simulating the behaviour of primary soot particles of the graph
type, a model aerosol can be produced by evaporation. The particle
size determined by means of SMPS measurements masks the range of primary
particles. Components of primary particles in the size category of
2nm can be detected by means of mass spectrometry. The largest particle
found to date is (C96H30)6, which has a mass of 7,098 µ.
Kinetic measurements revealed a correlation between the microstructure
of the soot particles and their chemical relativity to nitrogen dioxide,
NO2. These findings constitute a valuable basis for minimizing diesel
soot emissions from internal combustion engines even further and for
improving the efficiency of exhaust gas after-treatment systems using
filter-free PM-cats? and GD-CAT systems.
The lecturer explained that the formation of fullerene-type soot as
a result of transient high-pressure combustion in diesel engines had
not been expected, as this type of soot had hitherto only been observed
with premixed, steady-state flames under specific conditions. |
|
Prof.
Dr. med. Joachim Bruch1,2 (lecturer); Dr. B. Rehn 2; Frank Seiler
2,3 Institut für Hygiene und Arbeitsmedizin 1, Universitätsklinikum
Essen, IBE 2 Marl i. W., Squarix 3 Marl i. W.: "Cancer
Risk due to Diesel Emissions - New Toxicological Approaches to Assessing
Health Hazards Caused by Diesel Particles"
In the assessment of diesel particles from a hygiene perspective,
different experiences have proved that diesel soot exposure involves
a potential cancer risk as the content of PAH and other organic substances
in diesel soot are cancerogenic. This is corroborated by toxicological
studies and by exposure of individuals to diesel soot (coking plant
workers). In rat experiments it was demonstrated that the character
of the particulates was the prominent causative factor for cancer.
Cohorts exposed to diesel soot have shown a higher incidence of cancer,
which can be interpreted as an indication of, or evidence for, the
cancerogenic effect of diesel soot particles.
A risk assessment initiated by the Federal Environment Agency in Berlin
which sought to analyse the incidence of cancers of the respiratory
tract in the population was based on an extrapolation of the effect
of soot particles on rats. In this study, a linear, stochastic risk
model was used. The fineness of diesel particles (ultra-fine particles)
emitted by modern engines, the lecturer explained, was considered
as a crucial causative factor. From the toxicological perspective,
a distinction must be made between singular ultra-fine particles and
aggregated ones.
A quantitative assessment of the risk for humans must take into account
the low exposure rate of individuals in their normal environments
and the specific effects typical of diesel soot. Toxicological studies
should allow an identification of the mechanisms that give rise to
the potential tumor risk for humans (disease pattern) and quantify
the critical phases in the manifestation of a tumor. This session
demonstrated the extreme complexity of this field.
Although rash conclusions about the harmfulness or harmlessness of
diesel soot in our everyday life should be avoided, it appears that
developments in engine design are pointing in the right direction
and that promising solutions can be expected for the future. |
11
Session: New Engines for Trucks/Injection
Dr.-Ing.
Gian Maria Olivetti (lecturer), Dr.-Ing. Giovanni Bodritti, Dipl.-Ing.
Walter Knecht (lecturer), IVECO SpA: "A New
High-Speed IVECO Diesel Engine"
Since 1984, IVECO has successfully produced compact, high-speed diesel
engines with direct injection. In the course of redesigning IVECO
diesel engines, a new high speed 2.3 l diesel engine was developed.
This supercharged inter-cooled diesel engine features a common-rail
injection system.
The newly launched four-cylinder engine has been designed for 100
kW and is destined especially for applications in small commercial
vehicles. This engine will be used in vehicles of less than 3,500
kg weight and in the weight category of over 3,500 kg.
The lecturer illustrated the engine's performance characteristics
and also dealt with potential technological solutions that will allow
engine manufacturers to meet future emission limits. |
|
Dipl.-Ing.
Hellmut Freudenberg; Dipl.-Ing. Wendelin Klügl, Dr.-Ing. Willibald
Schürz (lecturer); Dipl.-Ing. Johann Warga, Siemens VDO Automotive
AG "The Third Generation Siemens VDO Piezo Common
Rail System, the Innovative Evolution of the PCR2 System Produced
since 2000."
The second generation Piezo Common Rail System (PCR2) has been successfully
series-produced since September 2000. At present, > 2,000,000 piezo
injectors are manufactured ever year, and it is expected that this
figure will increase significantly in the future.
Development efforts for the PCR3 system focus on increasing the injection
pressure to 1,800 bar (with a potential of 2000 bar), reducing injector
leakage and thus heightening efficiency, attaining steep injection
rate curves in order to take full advantage of multiple injection,
stable and small pilot injection rates, cylinder-selective adjustment
of injection rates in order to be able to comply with emission limits
over the entire service life, and optimized injector and pump design
for minimum packaging space for the engine.
The third generation Piezo Common Rail System (PCR3) offers a large
potential for meeting future demands thanks to the large number of
degrees of freedom and its wide range of development options. |
|
E.Matsumura,
.Tomoda (lecturer), K.Takeda, S.Furuno, TOYOTA MOTOR CO., Japan; Prof.Dr.J.Senda,
Doshisha University, Japan: "Visualization of
Fuel Flow in Slit Nozzles of Direct Injection SI Gasoline Engines"
In direct-injection gasoline engines with spark ignition, injection
takes place in the form of a fan-shaped, finely distributed, deeply
penetrating and widely dispersed jet spray generated by the slit nozzle.
This results in a stratified mixture charge which does not require
a strong induction air flow. With a view to lowering further fuel
consumption in road operation, the stratified charge combustion phase
must be enlarged over the entire torque/speed map by improving the
spray jet characteristics.
As the fuel flow within the injector has a major influence on the
spray pattern, the fuel flow within the injector is illustrated by
means of an optical analysis in which a tenfold enlargement of the
acrylic glass injector is made. This analysis demonstrates that swirl
frequently occurs in the bag-shaped chamber. The intensity of the
swirl determines its influence on spray characteristics.
The combustion of the stratified charge can be improved by reducing
swirl and thus optimizing spray characteristics. |
12
Session: Ignition DI Gasoline Engines
Dipl.-Ing.
Jürgen Gerhardt (lecturer), Dr.-Ing. Uwe Kassner, Dipl.-Ing.
Andr‚ C. Kulzer, Dr.-Ing. Udo Sieber, Robert Bosch GmbH, Stuttgart:
"The Gasoline Engine with Direct Injection and
Direct Start - Potential and Limitations"
The lecturer described an unconventional approach to improving fuel
economy in direct-injection engines, which consisted in starting the
engine without the aid of external energy by merely using injection
and ignition (DI direct start). He explained how a gasoline engine
can be started irrespective of the combustion process chosen, without
using the starter.
Subsequently, he presented the results of a two-year study conducted
by Bosch. In this study, the potential of this new method was explored
with a view to further improving the fuel economy and reducing emissions
of direct-injection gasoline engines.
The lecturer also illustrated possible operating scenarios, such as
start-stop operation, on the basis of the observed limitations of
this method. |
|
Dr. techn.
Walter F. Piock, Dipl.-Ing. Alois Fürhapter, Dr. techn. Eduard
Unger, Dr. techn. Günter K. Fraidl (lecturer); AVL List GmbH,
Graz: "The Practical Application of Auto-ignition
in Gasoline Engines"
The Controlled Auto-ignition System AVL-CSI was devised with a view
to minimum modifications to existing production engines, large-volume
production feasibility and cost efficiency. This goal had been reached
by adopting a design philosophy based on the principle that the additional
components required for auto-ignition fuel economy should also be
available for improving fuel economy with spark ignition. The high
sensitivity to production and operation tolerances typical of auto-ignition
was compensated by a selective cylinder and cycle control of the combustion
process.
While largely maintaining the fuel efficiency of an unthrottled lean-burn
operation, the CSI system permits a sustainable reduction of NOx engine-out
emissions thanks to a partially variable valve-train and a cylinder-pressure-controlled
engine management system. Hence this engine will meet future emission
limits even without DENOx catalytic converters. However, the potential
for reducing fuel consumption alone would hardly justify the required
extra cost and engineering efforts.
Since the components of the CSI system will result in a significantly
better fuel economy also in spark ignition engines, the CSI system
represents an extremely attractive option, with auto-ignition being
only one of its aspects. |
|
Univ.-Prof.
Dr. B. Geringer (lecturer), Dipl.-Ing. J. Graf, Dr. D. Klawatsch,
Univ.-Prof. Dr. H.P. Lenz; Department for Internal Combustion Engines
and Motor Vehicle Engineering, Vienna University of Technology; Dr.
G. Liedl, Univ.-Prof. Dr. D. Schuöcker, Department for Non-Cutting
Manufacturing and High-Performance Laser Technology, Vienna University
of Technology; Dr. W.F. Piock, Dr. M. Jetzinger, Dr. P. Kapus, AVL
List GmbH, Graz: "Laser-Induced Ignition in
Gasoline Direct-Injection Engines"
Owing to more favourable thermodynamic processes, second generation
gasoline direct-injection combustion systems at present show the greatest
potential for improving the fuel economy of gasoline engines. The
trade-off of these combustion methods based on conventional spark
ignition were restrictions with regard to the optimum site of ignition
initialization and problems resulting from spark plug wear.
By combining the technologies for a spray-guided combustion process
and laser-induced ignition, the site of ignition may be freely chosen,
direct ignition in the fuel spray is possible, and thus safe ignition
initialization causing no wear on the spark plugs is assured.
In his lecture, the speaker illustrated the fundamental principles
of laser-induced ignition and its potential as compared to conventional
ignition systems. Furthermore, he presented studies based on investigations
of the minimum laser energy required, and on the contamination and
wear characteristics of combustion chamber optics. |
13
Session: Variable Valve Control
Dipl.-Ing.K.Wunderlich,
Dipl.-Ing.Ch.Enderle (lecturer), Dr.-Ing.U.Keller, Dipl.-Ing.Th.Kaufmann,
DaimlerChrysler AG, Stuttgart: "Electronic
Valve Control (EVC) as a Future Fuel-Saving Technology: Trade-off
between Variability, Complexity and Cost"
Electronic Valve Control (EVC) as a fuel-efficient technology competes
with direct-injection technology, which has established itself in
the market but , as it is based on a stratified charge concept,
will not be able to penetrate all markets because of fuel availability
and maximum permissible emission levels.
The lecturer emphasized that DaimlerChrysler had adopted specific
strategies in an intensive concept definition phase. Its goal was
to investigate the capacity of electronic valve control for series
production as a technology that could be applied worldwide. As compared
to competitor systems, fundamental modifications had to be made
to the entire system in order to assure the same maintenance, operational
reliability and energy consumption parameters as those of conventional,
cam-controlled systems.
The lecturer described these modifications and explained their impact
on the entire system in detail.
Subsequently
he not only reported on the test results achieved and potentials
that could be exploited, but also evaluated the risks that this
technology currently entails.
|
|
Karsten
Mischker (lecturer), Robert Bosch GmbH, Stuttgart; Dirk Denger, AVL
List GmbH, Graz: "Requirements for a Fully Variable
Valve-Train and Realization with the Electro-Hydraulic Valve-train
System EHVS"
The lecturer emphasized that for complete control of combustion, three
essential prerequisites had to be met: gas exchange, mixture preparation
and ignition had to be adjusted and controlled in a highly flexible
manner for each cylinder and in each cycle.
With the aid of electronic injection and ignition, two of theses prerequisites
had been met for many years now, but gas exchange was still mechanically
controlled by the crankshaft. The lecturer illustrated the concept
development, the practical implementation and first measurements of
a fully variable, electro-hydraulic system for the control of pumping
work in gasoline engines. He pointed out that the goal was to devise
a gas exchange control system that could be applied to all engine
types (gasoline, diesel and heavy-duty diesel engines) and all engine
configurations (including supercharged and direct-injection engines)
and that would permit the use of alternative combustion concepts.
The electro-hydraulic valve-train system (EHVS) consists of a hydraulic
actuator for each engine valve, a hydraulic circuit with a high-pressure
pump integrated into the engine oil circuit and a control unit.
The speaker reported that first measurements had shownthat a four-cylinder
engine featuring an EHVS and designed for EHVS capabilities offered
a high potential for improving fuel efficiency, performance and emission
behaviour, also in comparison to similar state-of-the-art engines. |
|
Mike
Bassett, Richard Pearson (lecturer), Jamie Turner (lecturer), Lotus
Engineering, UK: "Variable Firing Order Enabled
by Fully Variable Valve-Trains"
Electro-hydraulic and electro-mechanical valve-train technologies
for four-stroke engines are emerging which allow much greater flexibility
and control of the valve events than that which can be achieved using
mechanically-based systems. In their presentation, the lecturers reported
on a study carried out using an engine simulation programme to llook
into some of the possible benefits to engine performance that may
be facilitated by the flexibility of fully variable valve-train (FVVT)
systems.
The simulation study indicated that FVVT systems provide sufficient
range in the valve event duration and timing to enable the engine
to produce very high specific outputs whilst achieving a high level
of torque in the low and mid-speed range. It has also shown that an
FVVT system made it possible to modify the basic intake manifold tuning
mechanism by modifying the engine firing order, without recourse to
variable geometry manifold systems. |
14
Session: New and Future Engines:
Dipl.
Ing. Klaus Borgmann (lecturer), Dipl. Ing. Johannes Liebl, Dipl. Ing.
Reinhard Hofmann, Dipl. Ing. Christoph Schausberger; BMW Group, Munich:
"The New BMW 12-Cylinder Engine"
In the course of renewing its entire gasoline engine range, BMW designed
an entirely new 12-cylinder engine for its model 760i car. Following
on from the redesigned 4-cylinder and V8 engines, this new engine
represents a new highlight in BMW's development work. The engine has
a swept volume of 6 litres and is based on the classical, uncompromising
design with a 60ø valve angle. It is the first and only gasoline engine
worldwide that combines fully variable valve timing with direct injection.
The VALVETRONIC system which is incorporated into BMW's 4 and 8- cylinder
engines assures low throttle and has fuel-efficient control under
part load.
Gasoline direct injection for homogeneous operation markedly boosts
engine performance thanks to the advantages of internal mixture formation;
furthermore, it permits the worldwide use of direct injection irrespective
of fuel grades and meets even the most stringent emission standards.
The combination of these innovative technologies makes the new engine
the most powerful and, at the same time, most fuel efficient V12 induction
engine in the luxury-car category. |
|
Dipl.-Ing.
K. Fröhlich (lecturer), Dipl.-Ing. K. Borgmann, Dipl.-Ing. J.
Liebl, BMW Group, Munich: "Potentials of Future
Consumption Technologies"
The current state-of-the-art in engine technology, such as reduced
friction due to roller-rocker arms, lower engine warm-up and catalyst
heating or minimized pumping losses in BMW's engines thanks to the
VALVETRONIC unit, takes full advantage of the potential to reduce
the fuel consumption of gasoline engines designed for stochiometric
mixtures. No significant further improvements in fuel economy have
been achieved through the utilization of fuel parameter modifications
in lean-burn stratified charge combustion using the wall-guided or
air-guided direct-injection processes of production engines.
The lecturer analyzed the limitations of these concepts and illustrated
the solution found for BMW's newly developed spray-guided combustion
process. He then elaborated on the fuel efficiency potential of this
concept and the challenges associated with the implementation of this
technology in real-world vehicles.
With a potential performance of well over 60 kW/litre and improved
fuel economy, at least 20% better than that of conventional gasoline
engines, the speaker stated, this concept had proven its capacity
for application in real-world vehicles. In view of the high system
costs and the need for further technological development of the components,
series production cannot be expected before 2006 at the earliest.
This engine will primarily be used in the premium vehicle category. |

Photo
14: |
Dr.B.Göschel,
photograph no. 14, Member
of the Board, BMW Group, Munich: "Hydrogen
in Internal Combustion Engines"
The BMW Group favours hydrogen as an alternative energy source for
the future, as this fuel does not contain any carbon and can be
produced in virtually unlimited quantities.
Amongst the alternative drive concepts, the BMW Group opted for
a hydrogen combustion engine with external mixture formation, which
is suitable for bi-valent application. The engine features a variable
valve train which can be operated over the entire range at lambda
= 1. Accordingly, NOx emissions in the upper load range can be reduced
most efficiently using the tried-and-tested catalytic converter
technology. A version of the current model 7 car will be produced
with this hydrogen-combustion engine and launched on the market.
The BMW Group's research efforts focusing on hydrogen direct injection
take internal combustion engines to the limits in terms of performance,
efficiency and NOx emission. A single-cylinder research engine which
had been tested since May 2002 showed a highly stable combustion
behaviour, the speaker pointed out. The base engine without supercharger
reached an indicated mean pressure which was significantly above
the full load point in gasoline operation.
On the basis
of BMW's research findings, an ideal combination of gasoline and
diesel engine combustion processes can be achieved by means of the
H2 direct-injection method.
|
15
Session: New Transmission Systems
|
Dipl.-Ing.(FH)
Bernhard Rastinger (lecturer), Dipl.-Ing. Wolfgang Hall, Dipl.-Ing.
Gerhard Walter, Dipl.-Ing.(FH) Edmund Bauchrowitz, Dipl.-Ing.(FH)
Winfried Keller, Dipl.-Ing.(FH) Werner Kröger, BMW AG, Munich:
"The New BMW Six-Speed Manual Gearboxes"
The manual gearboxes installed in BMW cars have always offered optimum
functionality to exacting and sporty customers. These gearboxes, which
were successfully introduced in 1990 and have been mainly applied
in their five-speed versions, represent the benchmark in this car
category in terms of service and control comfort.
BMW decided to develop these new six-speed gearboxes especially in
view of the drastic increase in torque and performance in gasoline
and diesel engines which goes hand in hand with pioneering drive concepts.
In implementing the clearly defined design goals, proven concepts
and components were taken over and new challenges were met by implementing
innovative technology details. |
|
Dipl.-Ing.K.Heber,
Dr.-Ing.R.Eberspächer (lecturer), Dipl.-Ing.M.Kollender, DaimlerChrysler
AG, Stuttgart: "SEQUENTRONIC - Mercedes-Benz'
High-Performance Automated Transmission"
Mercedes-Benz launched its automated transmission, designated "SEQUENTRONIC",
on the market in 2000. The lecturer gave an overview of the further
development of the "SEQUENTRONIC". The new feature in the new concept,
which is based on six-speed transmission, is the "sports mode", with
a sporty service control interface. In the sports mode, drifting times
in particular are shortened without impairing the desired comfort
features.
The target group are drivers who attach great importance to driving
dynamics and a sporty driving style, and who appreciate the direct
coupling of the engine to the drive train via a dry clutch.
The lecturer not only illustrated the system structure and the mode
of operation of "SEQUENTRONIC", but also compared and discussed shifting
processes to the sport mode and the comfort mode on the basis of the
investigated driving situations. |
|
Dr.W.Reik
(lecturer), Dr. Robert Fischer, Dr. Burkhard Pollak, Dipl.-Ing. Georg
Schneider, Dr. Reinhard Berger LuK GmbH & Co., Bühl: "PSG
- The Automatic Transmission of the Future Twin Clutch with Dry Clutches"
The lecturer presented a family of automated transmission systems
(XSG) on the basis of manual transmission systems. The focus was on
the PSG power-shift gearboxes, which are twin-clutch transmission
systems using dry clutches, actuators with motors and the "active
interlock" unit which reduces actuation effort.
This power-shift system results in excellent comfort and minimum fuel
consumption. The fuel consumption data of a PSG were determined on
the basis of theoretical assessments, measurements and simulations.
As compared to conventional automatic transmission systems, the PSG
allows a 15% reduction in fuel consumption. The lecturer demonstrated
the advantages resulting from the use of dry clutches by comparing
the sources of losses typical of different systems. The higher specific
output values of the XSGs not only lead to improved fuel economy,
but at the same time also result in better acceleration characteristics.
At the end of his lecture, the speaker stressed that it was possible
to extend a PSG by adding an electric unit thus creating a mild hybrid.
Start-stop operation and recuperation offer a further potential for
achieving better fuel economy. With the integration of an air-conditioning
compressor, a simple air conditioning system working during immobilization
periods was created. The PSG can also be integrated into all-wheel
drive vehicles with no major alterations. |
16
Final Plenary Session: Future Perspectives

Photo
15: |
T.Tomita,
photograph no. 15, Member of
the Board of Toyota Motor Corporation, Shizuoka: "Formula
One - Encouraging Creativity for Future Engine Technology"
Toyota has been active in car racing since 1957, entering formula
one races for the first time in 2002. The technological challenges
presenting themselves in designing racing cars and in series production
are similar. The formula one project, however, inspires engine developers
to come up with solutions that will later be applied to series-produced
cars.
Even today, the internal combustion engine still has a large potential
for further improvements. Competition and the quest for top performance
in car racing will trigger the next revolution in engine technology.
In the 21st century the most urgent and vital task facing the automotive
industry will be to contribute to lowering CO2 emissions. In the meantime,
with this goal in mind, significant improvements in the efficiency
of internal combustion engines have been achieved.
Significant technologies, such as down-sizing, supercharging and hybridization
still hold out an important potential for improvement. Synergic effects
can be expected from the combination of internal combustion engines
with hybrid systems which will result in marked improvements in engine
efficiency and vehicle performance. |
R.Eckrodt,
President und CEO, K.U.Seidenfuss (lecturer), photograph
no. 16, Senior Executive Officer, Mitsubishi Motors Corporation,
Tokyo: "Opportunities and Challenges Resulting
from the Alliance of Mitsubishi Motors and DaimlerChrysler AG"
Mitsubishi Motors Corporation - lately Japan's fourth-largest automaker
- designs and produces small cars, full-size passenger cars, SUVs
and vans. Its worldwide presence is manifested by the high number
of production plants on all continents. The popularity and broad appeal
of the "Mitsubishi Motors" brand can be exemplified by the U.S. market,
where Mitsubishi Motors Corporation (MMC) actually has the youngest
customer base of all imported brands.
However, Mitsubishi Motors Corporation is still a traditional Japanese
company. Founded in 1870 as a shipping company by Yataro Iwasaki,
Mitsubishi produced Japan's first series-produced passenger car, the
Model A, in the year 1917. In 1970, the automotive division of Mitsubishi
Heavy Industries was spun off to form the Mitsubishi Motors Corporation.
In the year 2000 DaimlerChrysler AG and Mitsubishi Motors Corporation
announced the formation of an alliance that today encompasses several
vehicle segments, consolidated by DaimlerChrysler AG's 37.1% holding
in Mitsubishi Motors Corporation. |

Photo
16: |

Photo
17: |
Dr.M.Winterkorn,
photograph no. 17, Chairman
of the Board of AUDI AG, Ingolstadt: "Future
Perspectives of the Audi Brands Group"
Audi is the leading brand within the sporty brands group of the Volkswagen
Corporation. Sports, technology and design act as the cohesive force
between the three Group members Audi, Seat and Lamborghini. Synergies
were created, in particular, in the areas of technological development
and design, but can be achieved in the production of new models.
The aim of the Brands Group is to address itself to drivers in all
categories, from compact cars to super sports cars. The Brand Group's
internal mission is to heighten the quality, reliability, flexibility,
profitability and customer orientation of its products. The challenges
vary with each brand: Seat is to be positioned upmarket as compared
to its competitors, with primary emphasis on factors such as quality
awareness and the emotional appeal of this brand. With Lamborghini,
the untamed, wild product image must be maintained, while reliability
and superior performance are to be stressed even more strongly. Audi
is to take over the role of technology leader and will be assigned
a place in the even more sporty segment. Clearly sporty concept studies
such as "Pikes Peak quattro" or "Nuvolari quattro", but also production
versions such as the A8, A3, S4 or TT 3.2 quattro, play a major role
in this repositioning exercise.
As regards the drive train, innovative high-efficiency transmission
systems such as the new DSG will establish themselves as important
new technologies. With regard to engines, the turbo SFI concept is
currently being given preference for gasoline high-performance engines
with excellent emission behaviour. |
Conference Report
All lectures are
contained in the VDI research reports, series 12, no. 539,
volumes I and II, and attachments and can be obtained from
the ÖVK (Austrian Association of Automotive Engineering), Elisabethstraße
26, A-1010 Vienna
E mail: info@oevk.at |
Invitation
The 25th
VIENNA INTERNATIONAL MOTOR SYMPOSIUM will be held at the
Imperial Palace in Vienna from April 29 to April 30, 2004.
I should like to take this early opportunity to invite you to participate
in this conference. In view of the large number of participants expected,
we recommend that you apply at your earliest convenience once the
programme has been announced on the internet in December 2003.
Österreichischer Verein für Kraftfahrzeugtechnik
(ÖVK),
Elisabethstraße 26, A-1010 Wien
Tel. +43/1/5852741-0
Fax + 43/1/5852741-99
Email: info@oevk.at
Internet: www.oevk.at
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