FEVs 2-Step VCR: Improve Fuel Consumption

by 5-7% in Existing Engine Families and Improve

Robustness to Fuel Types
Prepared for: Automotive World Webinar
Dean Tomazic, VP Light-Duty Powertrain and Vehicle Engineering
Stephen Bowyer, Manager Light-Duty Engine Design & Thermodynamics
Henning Kleeberg, Manager Gasoline Engine Combustion

May 22nd, 2013

Content
FEV Company Overview

Motivation for VCR Technologies

Design of FEVs 2-Step VCR System
Fuel Economy Improvement Potential
Combination with Future Technologies
Summary and Conclusions

Content
FEV Company Overview

Motivation for VCR Technologies

Design of FEVs 2-Step VCR System
Fuel Economy Improvement Potential
Combination with Future Technologies
Summary and Conclusions

FEV Company Overview

Company Profile
Established 1978
Independent Company
ISO Certified
ISO 9001-2000 & ISO 14001, ITAR

Over 2,600 employees globally (about 450 US)

Diversified Portfolio

Concept to Production Engineering Solutions

Gasoline and Diesel Development
Design
Thermodynamics and Simulation
NVH and CAE
Vehicle Integration
Electronics

Test Systems
4

FEV Company Overview

FEV Worldwide

Content
FEV Company Overview

Motivation for VCR Technologies

Design of FEVs 2-Step VCR System
Fuel Economy Improvement Potential
Combination with Future Technologies
Summary and Conclusions

Introduction to VCR Technologies

2025 Caf Requirement
The Challenge: Mid-Size Passenger Car

2025 Target: ~52.8 MPG

2020 Target: ~42.2 MPG

47%

17%

36.0

40.0

44.7

55.4

62.4

2011 Benchmarks:
Baseline - Honda Accord: 36.0 MPG
Nissan Altima: 35.4 MPG
Kia Optima DI/Turbo: 34.7 MPG
Toyota Camry: 34.2 MPG
Ford Fusion Hybrid: 54.2 MPG

Introduction to VCR Technologies

Influence of Compression Ratio on Fuel Consumption

2000 rpm / WOT

BSFC [%]

high

2000 rpm / BMEP = 2 bar

100

VCR
low

CRbase

14

Compression ratio (CR) [-]

8

Introduction to VCR Technologies

Classification of VCR Systems
Variable piston
TDC position
max
min

Unconventional
Cranktrains

Variable Distance:
Head to Crankshaft

Variable Length
Connecting Rod

Content
FEV Company Overview

Motivation for VCR Technologies

Design of FEVs 2-Step VCR System
Fuel Economy Improvement Potential
Combination with Future Technologies
Summary and Conclusions

10

Design of FEVs 2-Step VCR System

Working Principle: Variable Length Connecting Rod

11

Design of FEVs 2-Step VCR System

Working Principle: Top Mount Mechanical Valve Actuation
View from top
horizontal
movement

valve body

functional surface

Cam disc carrier

12

Design of FEVs 2-Step VCR System

Working Principle: Bottom Mount Mechanical Valve Actuation
System Actuation (Bottom Mount Shuttle System)

Actuator motor

Cam disc unit

13

Design of FEVs 2-Step VCR System

Working Principle: Example Hardware
Prototype Hardware

14

Design of FEVs 2-Step VCR System

Transition Time During Load Step
high

2500

Accelerator Pedal [-]

CR [-]

2000
n = 2000 rpm
Oil temp. = 90C

1500

1000

Manifold pressure [mbar]

Full Load

500
Part Load

ideal CR

actual CR

low
-0.2

0.0

0.2

0.4

0.6

0.8

1.0

Time [s]
15

Design of FEVs 2-Step VCR System

Influence of Oil Temperature
high
n = 2000 rpm
BMEP = 8 bar
Oil temp.:
90C

CR [-]

0C

CR low high

CR high low

low

0.0

0.2

0 .4

0 .6

0.8

1.0

Time [s]
16

Content
FEV Company Overview

Motivation for VCR Technologies

Design of FEVs 2-Step VCR System
Fuel Economy Improvement Potential
Combination with Future Technologies
Summary and Conclusions

17

Fuel Economy Improvement Potential

Simulation Results - USA
FTP75 - Full Size Sedan w/ Premium Fuel

24
Fuel share
in FTP75 [%]

22
Turbocharged DI 2.0L CR=10/14

20
18

BMEP [bar]

16

CR = 10

14
12

CR = 14

10
3

8
6

4
1

2
0

1000

2000

3000
4000
Engine Speed [rpm]

5000

6000

18

Fuel Economy Improvement Potential

Simulation Results - USA
US06 - Full Size Sedan w/ Premium Fuel

24

Fuel share
in US06 [%]

22

BMEP [bar]

20

Turbocharged DI 2.0L CR=10/14

18

16

CR = 10

14

12

CR = 14

10
2

0.8

0.5

0.3

1000

2000

3000
4000
Engine Speed [rpm]

5000

6000

19

Fuel Economy Improvement Potential

Thermodynamic Potential of 2-Step VCR: FTP Cycle
FTP-75 Full Size Sedan / Turbocharged Engine
194
192

CO2 Emissions [g/km]

190

188

-4.5%

-4.8%

-5.3%

186

-6.0%

184

-5.6%

-6.5%

182
180
178
176
174
172
Baseline
CR = 10

CR = 9/12 CR = 9/13 CR = 9/14 CR = 10/12 CR = 10/13 CR = 10/14

20

Fuel Economy Improvement Potential

Thermodynamic Potential of 2-Step VCR: European Cycles
1 60
NEDC

WLTP

CO2 Emission [g/km]

1 50

1 40

Base
fixed CR

-5.6%

-5.9%

-5.1%

1 30

-5.2%

-5.7%

-4.5%

-5.8%

-5.0%

-5.5%

-4.3%

1 20
1 10
1 00
CR = 9.6

CR = 8/12 CR = 8/13

CR = 8/14

CR = 9/14

CR = 10/14

21

Content
FEV Company Overview

Motivation for VCR Technologies

Design of FEVs 2-Step VCR System
Fuel Economy Improvement Potential
Combination with Future Technologies
Summary and Conclusions

22

Combination with Future Technologies

Synergistic with Several Advanced Concepts
Alternative fuels

Extreme
downsizing

Gasoline controlled
auto ignition (GCAI)

23

Combination with Future Technologies

Two-stage VCR Combined with Extreme Downsizing
1 60

CO2 Emission [g/km]

1 50

1 40

Inertia weight class: 1372 kg

6-speed MT, gear ratios adapted
Pmax = 180 kW (const.)
Base fixed CR

-5.9%

NEDC

Extreme Downsizing
Fixed CR
-5.2%

1 30

WLTP

-7.1%
-6.5%

1 20
1 10
1 00
2.0l, CR = 9.6

2.0l, CR = 8/13

1.5l, CR = 8.2

1.5l, CR = 8/12

24

Combination with Future Technologies

Two-stage VCR Combined with GCAI
Base vehicle: 1372 kg, 1.8L

Load too high for GCAI

-4% CO2 in NEDC

Fixed CR

Load too low for GCAI

GCAI operation area

Two-stage VCR

-12% CO2 in NEDC

25

Combination with Future Technologies

Two-stage VCR Combined with Alternative Fuels
2.0l, TC, Two-Stage VCR 8/12 (optimized for RON 95)
25
Exx

BMEP [bar]

20

RON 98
15
RON 95
10
RON 91
5
0

1000

2000
3000
4000
Engine Speed [rpm]

5000
26

Content
FEV Company Overview

Motivation for VCR Technologies

Design of FEVs 2-Step VCR System
Fuel Economy Improvement Potential
Combination with Future Technologies
Summary and Conclusions

27

FEVs 2-Step VCR Systems

Summary and Conclusions
VCR can help to resolve the conflict between part load and full load CR
layout especially for boosted downsized gasoline engines
The presented two-stage VCR system is based on a variable length conrod
with eccentric piston pin suspension and can be adapted to existing engines
with moderate effort
The transition time can be adjusted according to the thermodynamic
requirements
CO2 reduction potential for moderate downsized GDI engines 5 6%
Increased benefit for extreme downsized GDI engines of up to 7% in NEDC
Operating area of GCAI technology can be significantly enlarged resulting in
up to 12% CO2 reduction in combination with two-stage VCR in NEDC

The higher knock resistance of alternative (flex) fuels can be used via
adaptation of the VCR shift line in the map
28

FEV Variable Compression Ratio Programs

Thank you for your attention!

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