Significant reduction of the fuel consumption respectively CO: emission is the most relevant driver of the worldwide passenger car power train development. The electrification of the powertrain is a prerequisite to achieve future fuel consumption targets, while the internal combustion engine will remain a key component of all high volume powertrain systems. Key criteria are light weight design, as well as optimization of the mechanical efficiency by friction reduction and auxiliaries on demand. Function integration in combination with modular design is a promising approach to reduce the complexity of the powertrain and minimize the packaging dimensions. Tailored light weight concepts as well as concepts with cost effective casting technologies provide considerable further potential even at the engine main components. At the crankcase function integration and cast iron concepts with extreme low wall thickness are competing with Aluminium designs. At the cylinder head a modular architecture provides potential for increased application of cost optimized pressure die castings. In the definition of new, throughout charged engine families special attention has to be given on the increasing mechanical and thermal loads on the engine .structure, on one hand to reduce the engine weight by a light weight design approach, on the other hand to achieve the complete fuel reduction potential by friction optimisation. At the same time cost reduction at the base engine is a premise, in order to at least partially compensate the increasing technology cost of the additional powertrain components. This leads to high requirements on the engine manufacturing strategy, accompanied with the need to consider a large variety of variants in unpredictable volume splits, as well as regionally differing localisation boundary conditions. A modular family architecture for Gasoline- and Diesel-engines is a promising route. Accurate concept evaluation and optimisation, supported by state of the art CAE-tools, provide further potential for friction reduction at the base engine, in particular in the areas cylinder running surface and crankshaft bearings. An even larger friction reduction potential is to be expected in future by further development of surface treatment and coating technologies, although their current cost level partially still reflects low volume production methods. Further improvements are available by application of additional technologies, such as on-demand controlled pumps and auxiliaries, or thermal management. Conceptual measures with major influence on the architecture have to be considered early in the product definition phase, e.g. block material, crank shaft offset, low friction valve train, minimized main bearing diameter, roller bearings at camshaft and balancers, switchable piston-cooling jets, split cooling. Optimization measures, which can be implemented with moderate adaptions are suitable for introduction in course of an upgrade of existing engines, e.g. reduction of conrod big end bearing diameter, bearing clearance optimization, oil circuit pressure and flow optimization, bore distortion reduction, optimized honing parameters. Add-on measures can be implemented with minor changes to the machining and assembly lines and therefore introduced at existing engine families, e.g. low friction coatings, variable capacity or switchable coolant and oil pumps, electronically controlled thermostat, electric auxilliaries. Whereas friction reduction by concept- and optimisation measures is often achievable with minor impact on the component cost, add-on technologies are cost relevant thoughout, although at a very attractive level in most cases. The combined potential of all optimization measures at the base engine provides 4-5% fuel consumption reduction in the cold NEDC, compared with conventional layout. The optimised base engine therewith represents the basis for further electrification measures, where the cost/benefit ratio needs to be evaluated individually dependent on the specific applications.


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    Title :

    Reibungsreduktion und Leichtbau - Effizienzsteigerung am PKW-Grundmotor


    Additional title:

    Friction Reduction and Lightweight Design - Efficiency Improvement at the Passenger Car Base Engine


    Contributors:


    Publication date :

    2015


    Size :

    28 Seiten, Bilder, Tabellen, 16 Quellen




    Type of media :

    Conference paper


    Type of material :

    Print


    Language :

    German




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