[Due to the increasing size of the archives, each topic page now contains only the prior 365 days of content. Access to older stories is now solely through the Monthly Archive pages or the site search function.]
New Opel diesels for Mokka and Insignia
January 22, 2015
|1.6 CDTI with 100 kW/136 hp for Opel Mokka. Click to enlarge.|
Opel is introducing two new generation four-cylinder Opel diesels for Mokka and Insignia: the 1.6-liter CDTI (also seen in Astra and Meriva) in the Mokka and a 125 kW/170 hp 2.0-liter CDTI in the Insignia. The engines, which already meet the Euro 6 standards that will be compulsory from September, are another important step in the roll-out of Opel’s new powertrain portfolio.
The all-aluminum 1.6-liter CDTI for the Mokka sub-compact SUV will replace the 1.7 CDTI. The new engine gives more power and torque—up 6 hp and 20 N·m, respectively—from a smaller displacement, as well as significantly lower fuel consumption. The 1.6 CDTI in the 100 kW/136 hp version reaches 85 hp per liter—unrivaled in its displacement class, according to Opel—and delivers torque of 320 N·m.
BMW and Total begin field tests of AdBlue pumps in Germany
January 21, 2015
In Germany, BMW and Total have officially begun the field testing of AdBlue pumps installed at three fueling stations in Munich and Berlin. AdBlue, used in Selective Catalytic Reduction (SCR) NOx aftertreatment systems for modern diesels, is stored in an auxiliary tank in the car. The AdBlue filler neck is found underneath the fuel filler flap or in the engine compartment, depending on the BMW diesel model.
The pump is in lieu of a separate hand-held container of AdBlue, as currently used. Both parties expect to gain new insights into the practice of fueling the auxiliary AdBlue tanks from the field tests—especially from a customer perspective. The experience from the field trial will be used further to develop the AdBlue dispenser technology and to ensure the best user experience, the companies said.
Thomson Reuters analysis finds automotive new propulsion technology patent activities surge 6-fold in 5 years
January 20, 2015
|Automotive patent filings reduced to one document per DWPI family charted by category and the publication year of the earliest family member. Source: Thomson Innovation & Thomson Reuters Derwent World Patents Index. Click to enlarge.|
An analysis of the global automobile industry’s recent patent activity by the Intellectual Property & Science business of Thomson Reuters has found a massive commitment from carmakers and their suppliers to new propulsion technology. Patent data from 2009 through July 2014 show that activity in propulsion technology grew from fewer than 2,000 patents to nearly 12,000: more than any other technology area in the automotive industry. It was also the only area of patents to reflect a year-over-year growth in the five-year span.
For the report, “The State of Innovation in the Automotive Industry”, Thomson Reuters broke patent activity in the automotive industry into five broad categories: Propulsion; Navigation (which included telematics); Handling (which included autonomous driving); Safety & Security (which included driver assistance systems); and Entertainment.
Ford puts the pedal down on performance … but not with electric drive technology right now
January 14, 2015
|The new Ford GT on display in the Ford stand at NAIAS. Click to enlarge.|
In December, Ford President and CEO Mark Fields said Ford would focus on five key areas of innovation, one of them being performance. He said that more than 12 new performance vehicles would be introduced through 2020. (Earlier post.) At the North American International Auto Show (NAIAS) in Detroit this week, Ford delivered first proof of that focus with the reveal of the new Ford GT carbon-fiber supercar, as well as the new F-150 Raptor based on the new aluminum F-150 and the Shelby GT350R Mustang.
The stunning Ford GT—which received the EyesOn Design Award at NAIAS for best production vehicle—serves as a technology showcase for top EcoBoost engine performance, aerodynamics and lightweight carbon fiber construction. Beginning production late next year, the GT will the road in select global markets in honor of the 50th anniversary of Ford GT race cars placing 1-2-3 at the 1966 24 Hours of Le Mans. However, unlike today’s hybrid drive Le Mans racers, or the new Acura NSX hybrid supercar, also revealed at NAIAS (earlier post), the GT—nor any of the other Ford performance vehicles unveiled at NAIAS—makes no use of electric drive technology.
Honda brings FCV Concept to N. America, promises new EV and PHEV models by 2018
January 13, 2015
Honda staged the North American debut of the Honda FCV fuel cell vehicle at the North American International Auto Show (NAIAS); the company also announced US availability for the FCV in 2016. (Earlier post.)
Honda also used the venue to announce that it will offer several next-generation, advanced powertrain vehicles, including a new battery-electric model and plug-in hybrid model by 2018. Additionally, Honda said it plans further application of its two- and three-motor hybrid systems in the years to come. Honda also announced plans to introduce new VTEC Turbo engines to be built in Ohio and debut later in 2015.
Cummins 5.0L V8 Turbo Diesel debuts in new 2016 Nissan Titan XD pickup
January 12, 2015
|2016 Nissan Titan XD Cummins 5.0L V8 Turbo Diesel. Click to enlarge.|
Nissan’s new 2016 Titan XD full-size pickup, which made its debut at the 2015 North American International Auto Show, was also the platform for the debut of the first vehicle installation of the all-new Cummins 5.0L V8 Turbo Diesel engine. Nissan and Cummins have worked together on optimizing a calibration and specific hardware for the Cummins 5.0L V8 Turbo Diesel since the partnership began in 2007. (Earlier post.)
The next-generation Nissan TITAN expands Cummins presence in the North American pickup market from heavy-duty trucks to now extending to serve the light-duty segment. The new TITAN XD engine features more than 70% parts commonality with the commercial variant of the Cummins ISV5.0 engine family, which includes vehicles with 30,000-pound gross vehicle weight ratings. The 5.0L V8 Turbo Diesel stands alone between the smaller and larger diesel offerings in the pickup market.
ARPA-E issues $125M open solicitation for energy R&D; transportation and stationary applications
January 07, 2015
The US Department of Energy (DOE) Advanced Research Projects Agency - Energy (ARPA-E) has issued a $125-million open Funding Opportunity Announcement (FOA). OPEN 2015 (DOE-FOA-0001261) will support the development of potentially disruptive new technologies in all areas of energy research and development, for both transportation and stationary applications.
OPEN 2015 is the third open funding solicitation issued by the agency. Open solicitations ensure that ARPA-E does not miss opportunities to support potentially transformational projects outside the scope of existing ARPA-E programs. The projects selected under OPEN 2015 will pursue novel approaches to energy innovation and support the development of potentially disruptive new technologies across the full spectrum of energy applications.
New GM/Tula DSF cylinder deactivation technology could boost fuel efficiency in engines by up to 15%
January 05, 2015
|Comparison of DSF fuel economy gains and costs with competing technologies, from Tula’s 2013 SAE paper. Wilcutts et al. Click to enlarge.|
GM is working closely with Tula Technology, a Silicon Valley-based supplier of Dynamic Skip Fire (DSF)—a software-enabled powertrain technology that integrates advanced digital signal processing with advanced powertrain controls to create a variable displacement engine. In 2012, GM Ventures made an equity investment in Tula; in 2013, Tula engineers presented a paper on their technology at the 2013 SAE World Congress.
Independent testing commissioned by Tula finds that the application of DSF technology can improve fuel efficiency in a multi-cylinder engine (4/6/8 cylinders) by as much as 15% when compared to a vehicle equipped with an engine that does not have cylinder deactivation.
ORNL study finds multi-mode RCCI can offer 15%+ fuel economy improvements across multiple light-duty driving cycles
|Drive cycle fuel economy for PFI, CDC, and multi-mode RCCI operation. Credit: Curran et al. Click to enlarge.|
A team at Oak Ridge National Laboratory (ORNL) has added to the growing body of work exploring the applications and benefits of reactivity-controlled compression ignition (RCCI) by simulating the fuel economy and emissions for a multi-mode RCCI–enabled vehicle operating over a variety of US drive cycles using experimental engine maps for multi-mode RCCI; conventional diesel combustion; and a 2009 port-fuel injected gasoline engine. Their paper is published in the International Journal of Engine Research.
Among their findings were that multi-mode RCCI has the potential to offer greater than 15% fuel economy improvement over a 2009 gasoline PFI baseline over many light-duty driving cycles, despite the lack of complete drive cycle coverage for RCCI mode. Fuel usage over the drive cycles showed that nearly equal amounts of gasoline and diesel fuel would most likely need to be carried on board for RCCI multi-mode operation, which requires two fuels. During RCCI-only operation, fuel usage was found to be between 57 and 69% gasoline.
Ford Racing offering programming handset to performance enthusiasts for EcoBoost aftermarket tuning
December 31, 2014
|Power and torque curves for stock and performance-tuned Focus ST with 2.0L I-4 EcoBoost. Click to enlarge.|
Ford is now offering EcoBoost engines in all of its high-performance nameplates—from Fiesta ST to Mustang—enabling a new kind of aftermarket tuning. Modifying engine performance can be accomplished with hand-held programmers that adjust several engine parameters; adjusting engine control unit programming can result in performance gains of up to 90 lb-ft (122 N·m) of torque in cars such as the Focus ST.
To allow performance enthusiasts to exploit these capabilities, Ford Racing is offering a programming handset (ProCal, $595, along with required new sparkplugs) for Focus ST’s 2.0-liter EcoBoost engine and Fiesta ST’s 1.6-liter EcoBoost. Plugging the device into the car’s diagnostic link connector port in the driver’s side footwell allows tuners to tap into the many aspects of the car’s performance—anything from throttle response characteristics or idle speed, to turbo wastegate control, to fuel curves and spark timing—while maintaining the Ford-backed limited warranty.
Audi boosting investment over next 5 years by 9% to €24B; 70% to new models and technology
December 27, 2014
From 2015 through 2019, Audi plans to invest €24 billion (US$29 billion)—€2 billion (US$2.4 billion), or 9% more, more than in the previous planning period. 70 percent of the investment will flow into the development of new models and technologies. Audi aims to meet stringent CO2 limits worldwide with a new generation of extremely economical combustion engines and alternative efficiency technologies as well as new features in the areas of connectivity and driver assistance.
Audi also plans to create additional production capacities worldwide in the next five years through large-scale investment. More than half of the planned investment will take place at the German sites in Ingolstadt and Neckarsulm.
Breakthrough in predictions of pressure-dependent combustion chemical reactions
December 24, 2014
Researchers at Sandia and Argonne national laboratories have demonstrated, for the first time, a method to successfully predict pressure-dependent chemical reaction rates. It’s an important breakthrough in combustion and atmospheric chemistry that is expected to benefit auto and engine manufacturers, oil and gas utilities and other industries that employ combustion models.
A paper (Jasper et al.) describing the work, performed by researchers at Sandia’s Combustion Research Facility and Argonne’s Chemical Sciences and Engineering Division is published in the journal Science. As well, a Perspective on the problem and the methodology developed by the Sandia and Argonne team appears in the journal, written by Dr. Michael Pilling at the University of Leeds.
Orbital suing Daimler and Bosch for alleged patent infringement on direct injection technology
December 23, 2014
Australia-based specialized engine and vehicle systems company Orbital Corporation has filed court documents in the US District Court for the Eastern District of Virginia alleging the infringement of Orbital patents on direct injection technology by Daimler AG, Mercedes-Benz USA LLC, Mercedes-Benz US International, Inc. (Mercedes), Robert Bosch GMGH and Robert Bosch LLC (Bosch). (3:14-cv-00808-REP Orbital Australia Pty Ltd et al. v. Daimler AG et al.)
Specific patents covered by the complaint are United States Patents Nº 6,923,387 (the “387 patent”) ("injector patent"); Nº 5,655,365 (the “365 patent”); and Nº 5,606,951 (the “951 patent”) (“control patents”),under 35 U.S.C.§271.
Renault & partners show research prototypes: 2-cyl. 2-stroke diesel, 48V mild-hybrid diesel, delivery EV
December 13, 2014
|POWERFUL two-cylinder, two-stroke diesel. Click to enlarge.|
At its recent Innovations@Renault event, the France-based automaker presented three research prototypes developed in tandem with its partners as cooperative projects: a mild-hybrid diesel produced as part of the HYDIVU (Hybrid Diesel for LCVs); a two-cylinder, two-stroke diesel from the POWERFUL (POWERtrain for FUture Light-duty vehicles) project (earlier post); and an electric light commercial van developed as part of the du VELUD (Electric Vehicle for Sustainable Urban Logistics) project.
HYDIVU is a 48V mild-hybrid diesel solution to bring down consumption and emissions in LCVs. The objective of this project is to reduce the consumption of LCVs for business customers who travel long distances. Developed on the base of the Renault Master, this prototype is fitted with a powertrain that integrates an electric motor (mild hybridization), Twin-turbo technology and a downspeeding design. The combination of these three technologies results in a in a fuel consumption saving of up to 10% when used over long distances.
New BMW 218i Coupe to offer new 3-cylinder gasoline engine
December 12, 2014
|New BMW 3-cylinder turbo gasoline engine for the 218i. Click to enlarge.|
With the market launch of the new BMW 218i Coupe, BMW will offer a new a three-cylinder gasoline engine from the BMW Group’s latest engine family (earlier post) for the first time in the compact model. With a displacement of 1.5 liters, the newly developed power unit delivers a maximum output of 100 kW/136 hp and a maximum torque of 220 N·m (162 lb-ft) available at 1,250 rpm.
The car’s BMW TwinPower Turbo technology comprises a supercharger that is integrated into the exhaust manifold; a further developed gasoline direct injection system; the latest version of the variable valve control system VALVETRONIC; and Double VANOS variable camshaft control. The new power unit is conventionally positioned lengthwise in the engine compartment under the hood. Its low weight benefits the well-balanced load distribution of almost 50:50 between the front and rear axle.
Volvo Cars well along with 3-cylinder gasoline engine development program; prototype testing underway
December 11, 2014
|Volvo Car’s 3-cylinder gasoline engine. Click to enlarge.|
Volvo Cars confirmed its production program to develop a lightweight 3-cylinder Drive-E gasoline engine. The engine, wholly developed in Sweden, will join the company’s 4-cylinder Drive-E engines (earlier post). “The development program for the new 3-cylinder engine is very advanced and we have already begun prototype testing of the unit,” said Dr. Peter Mertens, Senior Vice President Research & Development at Volvo Car Group.
Volvo has a long history of developing its own unique 6-, 5- and 4-cylinder engines and in-house expertise. (Volvo has been developing its own powertrain solutions since the company was founded in 1927.) The move to include a 3-cylinder in Volvo’s engine program is a natural next step in its downsizing strategy, the company said.
Achates Power secures fifth OEM contract for opposed-piston 2-stroke CI engines; 3-cylinder configurations under test
December 09, 2014
Achates Power, Inc., the developer of a family of efficient compression-ignition opposed-piston two-stroke (OP2S) engines (earlier post) has secured another contract with a leading global OEM. With this contract, the company has five concurrent customers the contracts for which encompass five different engine applications: passenger vehicle, light commercial vehicle, heavy commercial vehicle, military and marine/stationary power.
Achates Power’s engine allows OEMs to achieve the most stringent current and future fuel efficiency and emissions standards—including EPA 2010, Euro 6 and Tier 3/LEV 3—without additional cost or complexity. During 2014, Achates Power’s annual revenue has increased by more than 300%. The company has customers located in the US, Japan, Europe, China and India and its current engine programs range from 45 hp to more than 5,000 hp.
DOE issues FY 2015 SBIR/STTR Release 2 funding opportunity, including hydrogen fuel cells, electric drive batteries
The US Department of Energy (DOE) has issued its FY 2015 Phase I Release 2 Funding Opportunity Announcement (DE-FOA-0001227) for the Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) Programs. Technical topics for this FOA—which span the range of DOE interests from fossil to nuclear to renewable and low-carbon energies—include two hydrogen- and fuel-cell-related topics: fuel cell-battery electric hybrid trucks and in-line quality control devices for polymer electrolyte membrane (PEM) fuel cells.
Also included are electric drive vehicle batteries, power electronics, on-board reformers, and advanced crank and ignition mechanisms for combustion engines.
Westport Innovations acquires alt fuel systems company Prins Autogassystemen for €12.2M
December 03, 2014
Natural gas engine and vehicle company Westport Innovations Inc. has acquired Netherlands based Prins Autogassystemen Holding B.V. for €12.2 million (US$15.1 million) through a combination of €6.6 million (US$8.2 million) in assumed liabilities and €5.6 million (US$6.9 million) in cash.
Founded in 1986, Prins is a leading developer of high quality alternative fuel systems powered by liquefied petroleum gas (LPG or propane), compressed natural gas (CNG), and liquefied natural gas (LNG) for light-, medium-, and heavy-duty applications. Prins operations in Europe will be combined under the Westport Applied Technologies business unit.
Start-up Eco-Motive developing dual-fuel “H” engine; parallel, independently fueled piston banks
December 01, 2014
|The H-engine—basically two separate engines housed within the same engine block—comprises two switchable parallel piston banks, independently fueled by gasoline and CNG. Click to enlarge.|
Startup Eco-Motive has developed what it calls the first dual-fuel “H” engine; it recently received a patent (#8807098) on the design. The H-shaped engine comprises parallel left-side and right-side vertical inline piston banks, each having a crankshaft and pistons, a cylinder head, and individual fuel feeds, but sharing a common power transmission system. Each piston bank operates independently of the other but is housed within the same engine block and has separate lubrication systems.
The Eco-Motive H-motor—basically two separate engines housed within the same engine block—can be powered by either gasoline or compressed natural gas (CNG), at the driver’s decision. The chosen engine is mechanically or electrically selected via an engine bank selector box using a selector control which selects the fuel type and engages a drive gear on the crankshaft of the selected engine, and transfers power to the transmission. The selector control actuates a transfer system that prevents simultaneous operation of both engines. The vehicle stays in that fuel mode until changed by the driver.
Toyota Motor to consolidate development and production of diesel engines under TICO; manual transmissions under Aisin Seiki; brake systems under Advics
November 29, 2014
Toyota Industries Corporation (TICO) and Toyota Motor Corporation (TMC) will consolidate their joint diesel engine development and production under the control of TICO. The purpose of this decision is to strengthen the competitiveness of both companies by bringing the development and production of diesel engines under one roof and enabling more efficient allocation of resources.
Further, Toyota is consolidating development and Japanese production of manual transmissions under Aisin Seiki subsidiary Aisin AI Co., Ltd. and will accelerate the consolidation of brake system engineering, manufacturing and sales under Advics, which was founded in July 2001 by Aisin Seiki, Denso, Sumitomo Electric, and TMC. (TMC, TICO, Aisin Seiki and Denso are part of the Toyota Group.)
MHI completes development of next-generation LNG carrier; apple-shaped tanks and hybrid propulsion
|Sayaringo STaGE. Click to enlarge.|
Mitsubishi Heavy Industries, Ltd. (MHI) has completed development of the “Sayaringo STaGE,” a next-generation LNG (liquefied natural gas) carrier. The Sayaringo STaGE was developed as a successor to the Sayaendo (earlier post), the company’s LNG carrier evolved from carriers with Moss-type spherical tanks that offer a high level of reliability. (Moss-type LNG carriers use independent spherical cargo tanks supported by a cylindrical skirt integrated with the hull and covered with a hemispherical steel cover attached to the main deck.)
While the Sayaendo (sayaendo = peas in a pod in Japanese) features a peapod-shaped continuous cover for the Moss spherical tanks that is integrated with the ship’s hull, in lieu of a conventional hemispherical cover, the new Sayaringo (ringo being the Japanese word for “apple”) STaGE adopts apple-shaped tanks, resulting in nearly a16% increase in LNG carrying capacity without changing the ship’s width. Further, a hybrid propulsion system has boosted fuel efficiency by more than 20% compared to the Sayaendo (and more than 40% vis-à-vis earlier carriers).
BMW reveals 3 Series Plug-in hybrid prototype with 117.5 mpg; next-gen Power eDrive: 2x current capacity, electric AWD
November 27, 2014
|BMW 3 Series Plug-in hybrid prototype. Click to enlarge.|
BMW has unveiled a 3 Series plug-in hybrid prototype. Combining a four-cylinder TwinPower Turbo gasoline engine from the new Efficient Dynamics engine family with an electric motor, the BMW 3 Series plug-in hybrid prototype offers performance on a par with a conventionally powered BMW 3 Series six-cylinder model, combined with a significant reduction in fuel consumption.
In addition, BMW outlined its work on Power eDrive next-generation electrification platforms—an effort to deliver “highly electrified” plug-in hybrids with higher-powered electric motors and batteries with twice the capacity of present versions. Future plug-in hybrid concepts, said BMW, will use the electric motor—the main source of power for everyday driving—to drive the rear wheels, while a second electric motor driving the front wheels will create an all-electric road-coupled all-wheel-drive system. At the same time, an internal combustion engine will also supply power to the front axle.
New Mercedes-Benz compact CLA Shooting Brake; up to 60 mpg
November 26, 2014
Mercedes-Benz is introducing a Shooting Brake version of its CLA compact coupé. The CLA Shooting Brake (length/width/height: 4630/1777/1435 mm) will initially be available with a choice of two diesel and three gasoline engines—all equipped as standard with the ECO start/stop function and Euro 6-compliant—as well as with 4MATIC all-wheel drive. It goes on sale in January 2015, with the first models going to customers towards the end of March 2015.
Two years ago, with the CLS Shooting Brake, Mercedes-Benz created a sports car with five seats and a large tailgate. (Earlier post.) The CLA Shooting Brake takes the elegant Shooting Brake design into a smaller model. The new CLA Shooting Brake is the latest member of Mercedes’ successful compact range, which now includes five models. A total of 375,000 A-, B-, CLA- and GLA-Class vehicles were sold in the first ten months of 2014.
LiquidPiston unveils 70cc rotary gasoline engine prototype embodying HEHC; power dense, low-vibration
November 19, 2014
|LiquidPiston X1 engine features three separate combustion chambers creating 3 power strokes per revolution for high power density. Source: LPI. Click to enlarge.|
LiquidPiston, Inc. (LPI) the developer of engines based on its High Efficiency Hybrid Cycle (HEHC) (earlier post), has unveiled the alpha prototype of the X Mini—a power-dense, low-vibration, quiet, 70cc spark-ignited, non-Wankel rotary embodiment of the HEHC. Dr. Alexander Shkolnik, President and Co-Founder of LiquidPiston, is presenting the engine in a paper at the SAE International/JSAE 2014 Small Engine Technology￼Conference today in Pisa, Italy.
The compact engine with a 4-lb (1.8 kg) core has only two primary moving parts—a rotor (the primary work-producing component) and an eccentric shaft—and fits in a 6.6" x 6.2" x 5.4" box. In prototype testing, the spark-ignited X Mini engine has shown high power density, producing 3.5 horsepower (indicated at 10,000 RPM). When mature, the engine is expected to weigh 3 pounds, produce more than 5 hp at up to 15,000 RPM, and be more than 30% smaller and lighter than comparable four-stroke piston engines.
Federal-Mogul expands powertrain materials portfolio for more efficient heavy-duty diesel engines
November 16, 2014
Federal-Mogul Holdings Corporation’s Powertrain Division has expanded its range of high performance materials for valve guides, seats and turbocharger bushings that support the commercial vehicle industry’s drive towards more efficient engines. Providing superior wear resistance at elevated temperatures, the new materials use Federal-Mogul’s well-proven powder metal (PM) technology to add other benefits, such as greater corrosion resistance and mechanical strength, depending upon the application.
Downsized, heavily turbocharged engines with high levels of aftertreatment such as particulate filter systems and selective catalytic reduction (SCR) run hotter than their predecessors, explained Frank Zwein, Federal-Mogul’s global application engineering director, Valve Seats and Guides.
Audi offers two new 3-cylinder engines in refreshed A1: 1.0 TFSI and MDB 1.4 TDI diesel for A1 ultra
November 14, 2014
|Audi A1. Click to enlarge.|
Since their introduction on the market in 2010, the Audi A1 and A1 Sportback have sold more than 500,000 units worldwide. Audi is now refreshing its A1 models, including the offer of six engines—gasoline and diesel—that are new or that have been intensively further developed.
For the first time, Audi is offering completely new three-cylinder engines: the 1.0 TFSI gasoline engine and the 1.4 TDI diesel. The 1.4 TDI follows the 2.0L 4-cylinder engine as the second engine in the Volkswagen Group’s modular diesel engine platform (MDB). (Earlier post.) Power output—ranging from from 66 kW (90 hp) to 141 kW (192 hp)—has been increased in most engines, while fuel economy has been reduced by as much as 10% percent. The seven-speed S tronic is available for all engines, either optional or standard (with the 1.8 TFSI).
DSM wins SPE Automotive Innovation Award for bio-based EcoPaXX integrated crankshaft cover for Volkswagen Group diesels
|EcoPaXX crankshaft cover. Click to enlarge.|
A lightweight multi-functional crankshaft cover in Royal DSM’s EcoPaXX high-performance polyamide 410 was top in the Powertrain category at the Society of Plastics Engineers Automotive Division Innovation Awards Competition and Gala in Detroit. The 70% bio-based EcoPaXX is made principally from topical castor beans and is 100% carbon neutral from cradle to gate. Castor oil is obtained from the Ricinus Communis plant, which grows in tropical regions on relatively poor soil, and does not compete with the food-chain.
The EcoPaXX crankshaft cover is produced by DSM’s automotive component specialist partner KACO in Germany for the latest generation of MDB-4 TDI diesel engines developed by the Volkswagen Group. The engines are fitted to various car models made by VW, Audi, Seat and Škoda. Dr. Lutz Wohlfarth from Volkswagen, and Marcio Lima from KACO were both at the Gala in Detroit to collect the SPE award.
Volkswagen outlines a range of near-term technologies for reducing fuel consumption and emissions; stop-start 2.0, 10-speed DSG
November 11, 2014
Volkswagen presented its latest technologies for reducing fuel consumption and CO2 emissions—which includes the first 10-speed dual-clutch gearbox (DSG)—in an Innovation Workshop for the media at the Ehra-Lessien test track facility near Wolfsburg.
Volkswagen AG has set the goal of becoming the world’s most sustainable carmaker by the year 2018. Compared to baseline figures for 2010, the Group wants to reduce energy and water consumption, waste generation and emissions (including CO2 emissions) by 25% in all of its business areas. (I.e., VW’s “Strategy 2018”, earlier post.) To achieve this, the Volkswagen brand—the highest volume brand of the Group—is counting on electric mobility (zero-emission and plug-in hybrid models); on continually more fuel-efficient combustion engines and gearboxes; progressive lightweight design; aerodynamics; and efficiency “in every conceivable area”.
Honda beginning sales of Legend with 3-motor Sport Hybrid SH-AWD system in January; V6 with cylinder deactivation
November 10, 2014
Honda Motor Co., Ltd. will begin sales of the all-new Legend flagship sedan (its cousin is already on sale in the US as the Acura RLX Sport Hybrid SH-AWD) at dealerships across Japan on 22 January 2015. The fifth-generation Legend features the 3-motor Sport Hybrid Super Handling All-Wheel Drive (SH-AWD) system also offered in the RLX Sport Hybrid SH-AWD (earlier post).
Positioned at the front of the vehicle is a newly developed V6 3.5L direct injection i-VTEC engine and a 7-speed dual-clutch transmission (DCT) with an integrated 35 kW electric motor. The rear-mounted TMU (Twin Motor Unit) contains two 27-kilowatt motors that dynamically distribute electric-motor torque to the rear wheels. Both the front and rear motors capture kinetic energy during vehicle deceleration and braking and convert it to electricity to supply the Intelligent Power Unit’s 72-cell, 1.3-kWh lithium-ion battery pack, located behind the rear seatback. Teaming up with a high-output lithium-ion battery, the control unit coordinates the operation of the engine and three motors.
New generation smart fortwo and forfour offer new drive systems, suspension
November 04, 2014
|The new generation smart forfour and fortwo. Click to enlarge.|
The new generation smart fortwo and forfour city cars (earlier post), developed in cooperation with Renault, offer a new range of drive systems: three three-cylinder engines rated at 45 kW/60 hp, 52 kW/71 hp and 66 kW/90 hp, coupled with a five-speed manual transmission or the twinamic dual clutch transmission.
The two most powerful engines will be available for the launch on the market in Europe on 22 November, and the basic gasoline engine will follow a few months after the market introduction. The smart forfour now also features the rear-mounted engine design of the fortwo.
CDTi introduces Spinel technology to replace PGMs and rare earths in catalytic converters
|CDTi says that its Spinel technology uses various base metals to create an effective exhaust catalyst. Click to enlarge.|
Clean Diesel Technologies, Inc. announced new proprietary technology—which it calls Spinel—to replace costly platinum group (PGM) and rare earth metals in catalytic converters. The new technology will power multiple catalytic product lines that CDTi believes will be highly disruptive to the traditional platinum-based or rare-earth based device industry. This is CDTi’s first public announcement regarding its Spinel technology, the development of which has been kept confidential until now.
Spinel is the name initially given to naturally-occurring magnesium aluminate (MgAl2O4) and is now used to describe any composition with the same structure. CDTi’s “Spinel” technology utilizes various base metals which when combined together in a common structure achieve unusual and very effective catalytic conversion activity. The technology is applicable in a wide range of engine and vehicle applications, both gasoline and diesel, as well as other potential vertical markets, CDTi says.
Researchers in POWERFUL develop new two-stroke diesel featuring low consumption and low criteria emissions
|Two-stroke diesel in test car. Click to enlarge.|
A European project led by Renault, in collaboration with the Czech Technical University in Prague, IFP Energies Nouvelles, Delphi, Le Moteur Moderne (LMM) and Universitat Politècnica de València have developed an advanced two-cylinder, two-stroke compression ignition (CI) engine integrating LTHC (low temperature homogeneous combustion) as part of the European project POWERFUL (POWERtrain for FUture Light-duty vehicles).
The €25-million (US$31-million) FP7 project, which ended in June, also supported two other engine projects: an advanced four-stroke two-cylinder SI engine concept characterized by low-cost / low emissions; and an advanced four-stroke, three-cylinder CI engine concept able to run also on new tailored fuels and integrating the LTC (low temperature combustion) mode in the CI combustion system.
Daimler opens new MB R&D center in Beijing, presents G-Code hydrogen-electric plug-in hybrid all-wheel drive concept
Daimler Greater China opened its new 865-million RMB Mercedes-Benz Research & Development Center in China and extended its local R%D network in Beijing. A new Advanced Design Studio is a centerpiece of the R&D facility and represents the company’s new design hub in Asia. At the official opening, Gorden Wagener, Head of Design Daimler AG, presented the Mercedes-Benz G-Code plug-in hybrid crossover show car.
The G-Code is powered by two individually controlled drive cores: a compact, turbocharged hydrogen-fueled combustion engine which solely drives the front wheels, and an electric motor which drives the rear axle and transmits its power selectively to the two wheels via a dual multi-disc clutch. Disclaimer: Mercedes-Benz emphasized that the G-Code, like the previously introduced Ener-G-Force and GT 6 vehicle studies, “makes absolutely no claim to be implemented within foreseeable periods.”
Mercedes-AMG HPP awarded Dewar Trophy for PU106A Hybrid F1 Power Unit
October 30, 2014
|The Dewar Trophy was presented to Andy Cowell, Managing Director of HPP, along with members of his project team from Brixworth. Click to enlarge.|
The UK’s Royal Automobile Club (RAC) has awarded the prestigious Dewar Trophy, presented for outstanding technical achievement in the automotive industry, to Mercedes-AMG High Performance Powertrains (HPP) for the design of the PU106A Hybrid Formula One Power Unit. (Earlier post.)
The team at HPP was recognized for its development of the most advantageous powertrain within the new Formula One regulations. The aim for 2014 was to raise the engine efficiency from around 29% for the previous normally aspirated 2.4-liter V8 to better than 40% with the new 1.6-liter V6 Hybrid turbo. The successful design, research and teamwork resulted in the Mercedes-Benz PU106A Hybrid Power Unit, which has not only been the dominant powertrain in this first season under the new Formula One rules, but is also arguably among the most thermally efficient gasoline powertrains ever produced, with a claimed thermal efficiency of greater than 40%.
Mercedes-Benz wins MATERIALICA awards for diesel passenger car steel pistons and CFRP struts
October 25, 2014
Mercedes-Benz received two MATERIALICA Design and Technology Awards at the MATERIALICA 2014 trade fair for materials applications, surface technology and product engineering in Munich. The first was for the new steel pistons for diesel engines (earlier post), the second for high-strength carbon-fiber reinforced plastic (CFRP) struts.
The MATERIALICA Award 2014 comprised five categories: Material; Surface & Technology; Product; CO2 Efficiency; and Student. The MATERIALICA Design + Technology Award focuses on product and technological developments in all sectors which implement a successful bundling of competencies.
Ford investing $306M more at Dagenham for new generation of 2.0L diesels; LCVs from 2016 and cars from 2018
October 20, 2014
Ford is investing an additional £190 million (US$306 million) at its Dagenham London site to produce a family of all-new advanced 2.0-liter diesel engines (code-named Panther) in a wide range of outputs due to be applied in commercial vehicles starting in 2016 and in cars starting in 2018. (Earlier post.) This investment includes £8.9 million (US$14.3 million) from the Government’s Regional Growth Fund. Ford is creating 318 new jobs connected with this investment.
The announcement confirms the second phase of investment in the new engine program following the original investment of £287 million (US$462.3 million) for phase one with support from the UK Government’s Regional Growth Fund. The first phase of investment relates to the production of low-carbon 2.0-liter diesel engines for Ford commercial vehicles (CVs) globally. The second phase is for low-carbon, 2.0-liter diesel engines for passenger cars.
California Energy Commission to award up to $2.25M for R&D on advanced ignition systems for Class 3-8 natural gas engines
October 10, 2014
The California Energy Commission has issued a funding notice (PON-14-501) to support the applied research and development of advanced high-energy ignition systems capable of overcoming the challenges of igniting natural gas fuel under high boost pressures with heavy exhaust gas recirculation (EGR) for spark-ignited Class 3-8 engines.
Ignition characteristics of natural gas fuel represent challenges to engine manufacturers working to satisfy tighter emission standards, achieve lower fuel consumption and higher engine performance, and respond to market demand for extended maintenance options. Funded projects must involve the development and demonstration of one or both of the following concepts for new or existing ignition systems:
EPA annual trends report finds new vehicle fuel economy at record 24.1 mpg; new powertrain technologies rapidly gaining share
EPA released the latest edition of its annual report on trends in CO2 emissions, fuel economy and powertrain technology for new personal vehicles in the US. Among the top-level findings was that Model year 2013 vehicles achieved an average of 24.1 mpg (9.76 l/100 km)—a 0.5 mpg increase over the previous year and an increase of nearly 5 mpg since 2004. Fuel economy has now increased in eight of the last nine years; average carbon dioxide emissions are also at a record low of 369 g/mile in model year 2013. The majority of the carbon and oil savings from current vehicles is due to new gasoline vehicle technologies, the report observed.
The report, “Light-Duty Automotive Technology, Carbon Dioxide Emissions, and Fuel Economy Trends: 1975 Through 2014”, also found that the light truck market share increased slightly in MY 2013, after several years of volatility; that the vehicle weight trend is flat and vehicle power trend is increasing more slowly; that many new powertrain technologies are rapidly gaining market share; and that consumers have an increasing number of high fuel economy/low CO2 vehicle choices.
2015 VW Jetta TDI: a more refined, powerful and efficient diesel within a nicely redesigned model line
October 07, 2014
|2015 Jetta TDI. Click to enlarge.|
The Jetta is Volkswagen’s current best selling car in the US; total 2014 Jetta sales through September were 115,055 units, or 42.5% of Volkswagen USA total sales. In addition, its diesel version is the top selling passenger car diesel in the market here, with about 29% share, according to figures compiled by Baum & Associates and hybridcars.com.
For 2015, Volkswagen has refined the entire sixth-generation Jetta lineup, endowing the compact with a crisper exterior design which also improves aerodynamics; an updated interior; a number of newly available driver assistance systems; and, significantly for the diesel model, the new 2.0T TDI Clean Diesel EA288 engine (earlier post) with an EPA-rated highway fuel economy rating of 46 mpg with the manual transmission (45 mpg automatic). Volkswagen’s refreshed 2015 Jetta is now in showrooms in the US.
Volvo Cars reveals triple-boosted 4-cylinder, 450 hp Drive-E powertrain concept
|Drive-E Powertrain Concept. Click to enlarge.|
Volvo has developed a concept 2-liter, 4-cylinder, triple-boost Drive-E concept engine that delivers 450 hp (336 kW). The 450 hp High Performance Drive-E Powertrain Concept is based on a set of technologies not usually found in a four-cylinder engine.
The engine utilizes two parallel turbochargers, which are fed by an electrically powered turbo-compressor. The compressed air from this unit, rather than being fed to the cylinders, is instead used to spool up the two parallel turbochargers. Fuel is fed by a dual fuel pump working at 250 bar pressure. With this kind of power density, this triple boost installation and unique fuel system enables a very dynamic drivability without any turbo lag, compared to a mono-turbo.
Major refresh on 2015 Honda CR-V with new Earth Dreams powertrain provides fuel economy gain of up to 12%
October 04, 2014
|2015 Honda CR-V. Click to enlarge.|
Honda has given its 2015 CR-V compact SUV, which launched in US dealerships on 1 October, the most significant mid-model cycle refresh in the 17-year history of the model. The 2015 CR-V offers a new direct-injected Earth Dreams Technology i-VTEC engine and new continuously variable transmission (CVT); a new suite of “Honda Sensing” safety and driver assistance systems (DAS); significantly enhanced exterior and interior styling; as well a long list of new standard and available features and a new premium Touring trim.
The 2015 CR-V features increased EPA fuel economy ratings of 27/34/29 mpg (8.7/6.9/8.1 l/100 km) (city/highway/combined) for front-wheel-drive models and 26/33/28 mpg (9.0/7.1/8.4 l/100 km) for Real Time AWD models, both increasing +4/+3/+3 mpg over 2014 models—i.e., an increase in the combined rating of 11.5% and 12%, respectively, compared to the 2014 models.
Infiniti Q80 Inspiration concept hybrid delivers 550 hp with 42.8 mpg fuel economy
October 02, 2014
Infiniti unveiled the Q80 Inspiration concept car at the 2014 Paris Motor Show, it what it called a signal of its intent to break into the top tier of the premium sedan category; the concept will lead to a future model. The four-door fastback is powered by a hybrid electric powertrain that is expected to deliver 550 hp (410 kW) with fuel consumption of 5.5 L/100 km (42.8 mpg US) and CO2 emissions of about 129 g/km.
The powertrain incorporates a new aluminum-based downsized twin-turbocharged 3.0-liter V6 that is part of a new engine family which will be introduced within the next two years. (Infiniti plans to double its powertrain range over the next five years.) The 450 hp (336 kW) V6 gasoline engine will be supported by an electric motor powered by a Li-ion battery pack, capable of adding around 75 kW (100 hp) hybrid power boost when required, and a 9-speed automatic gearbox.
Hyundai showcasing new downsized turbo engines and 7-speed dual-clutch transmission; i40 48V Hybrid, i30 CNG
|New engines and transmission. Click to enlarge.|
Hyundai Motor is showcasing two new turbocharged gasoline direct injected (T-GDI) engines at the Paris Motor Show 2014. Both engines—1.0-liter and 1.4-liter units which are part of a new generation of engines from the Kappa family—meet growing demand for small capacity, turbocharged engines to reduce fuel consumption and CO2 emission without compromising performance.
In addition, Hyundai is premiering at the Paris show its first 7-speed dual-clutch transmission, fitted into the i30 CNG natural gas concept car, which contributes to improved fuel efficiency. Hyundai is also displaying the diesel i40 48V hybrid concept, featuring a lead-carbon battery.
Westport updates HPDI 2.0 dual fuel system with new Delphi injectors, upgraded LNG storage and supply
October 01, 2014
|1st-generation Westport HPDI Injector and next-generation injector. (CNW Group/Westport Innovations Inc. Click to enlarge.|
Westport Innovations Inc. is updating its second-generation Westport high pressure direct injection (Westport HPDI 2.0) (earlier post) development program with a new family of high-pressure fuel injectors, co-developed with Delphi Automotive PLC. The new injectors are designed to provide lower cost, smaller size and improved packaging compared to prior generation Westport HPDI injector designs.
The new generation injectors are running in engine tests today and are on display at the Delphi booth at the IAA Commercial Vehicles Show in Hanover, Germany.
Chrysler’s Ram Truck increases EcoDiesel mix to 20% of Ram 1500 production; double expectations
September 30, 2014
Chrysler’s Ram has decided to increase the 3.0-liter V-6 EcoDiesel powertrain mix to 20% of the total Ram 1500 production volume—double the initial expectation. The EcoDiesel delivers 240 hp (179 kW), 420 lb-ft (569 N·m) of torque with up to 9,200 pounds (4,173 lbs) of towing capability and 28 mpg highway (8.4 l/100 km) in the full-size half-ton pickup. (Earlier post.)
When the Ram 1500 EcoDiesel opened for orders earlier this year, Ram Truck received more than 8,000 requests within three days, which quickly filled the initial allocation for the powertrain.
Honeywell Global Turbo Forecast projects 49M turbocharged vehicle sales, $12B revenue per year by 2019
The automotive turbocharging industry will generate $12 billion in revenue by equipping 49 million vehicles with turbochargers annually by 2019, according to Honeywell Turbo Technologies’ 2014 Global Turbo Forecast. The continued growth of turbocharging technologies will be driven by requirements for manufacturers to meet global environmental emissions regulations and bolstered by strong demand in emerging markets.
Automakers are turning to downsized turbocharged engines to satisfy more stringent global fuel economy and emission regulations and customer demand for better-performing vehicles. Turbochargers can help downsized engines improve fuel economy as much as 20 to 40% in gasoline and diesel engines, respectively, when compared with larger naturally aspirated engines and still provide the same or better engine performance. In addition to improving fuel efficiency, downsized turbocharged engines also reduce harmful exhaust emissions.
New Ford Mondeo to offer new high-power diesel, 1L EcoBoost, hybrid model, pedestrian detection technology
September 24, 2014
|Mondeo 5-door. Click to enlarge.|
Ford Motor Company announced that the all-new Ford Mondeo (which is badged as Fusion in the US) in Europe will offer a new high-power diesel engine in addition to a new 1.0L EcoBoost gasoline engine option and a new hybrid option. The new Mondeo goes on sale as a four-door hybrid, five-door or wagon in dealerships across Europe later this year. The high-powered diesel will be available in early 2015.
Additionally, the new Mondeo will be Ford’s first car globally to offer a new pedestrian detection technology that could help reduce the severity of accidents or help drivers avoid them altogether.
Westport unveils proprietary enhanced spark-ignited natural gas system; up to 10% improvement in power and torque over diesel
September 23, 2014
Westport Innovations Inc. unveiled the first generation of its new, proprietary enhanced spark-ignited (ESI) natural gas system. The new approach to natural gas combustion technology is designed to provide vehicle and engine original manufacturers (OEMs) with a “downsized” natural gas solution that is cost competitive while providing similar levels of power, torque, and fuel economy to a larger diesel engine.
Using 100% dedicated natural gas as fuel, Westport’s new technology optimizes the combustion and thermal efficiencies of the engine by taking advantages of the positive properties of natural gas. The Westport ESI combustion system is targeted at sub 9L engines for Class 6 and 7 trucks applications and is also adaptable for sub 2L applications for use in automotive and non-automotive applications.
ORNL team using neutron imaging to study cavitation inside GDI fuel injector
September 22, 2014
Researchers from the Fuels, Engines and Emissions Research Center (FEERC) at the Department of Energy’s Oak Ridge National Laboratory and collaborators from ORNL’s High Flux Isotope Reactor (HFIR) (earlier post) are using neutron imaging to study the formation of damage-causing bubbles in fuel injectors. When gas bubbles form in injectors, they disrupt the spray pattern and ultimately deteriorate the injector material properties.
Under a Laboratory Directed Research and Development (LDRD) project, the team, led by Eric Nafziger, Derek Splitter and Todd Toops from FEERC/ORNL, is attempting to make the first neutron images of cavitation—the physical event that leads to bubble/gas formation—inside the body of a spray-guided gasoline direct-injection (SGDI) unmodified 6-hole injector.
Study finds US refining sector could produce higher octane E20 and E30 at modest additional cost; enabling more efficient engines
September 18, 2014
|A new study concludes that using ethanol can be a cost-effective approach to increasing the octane rating of the US gasoline pool. Source: ACS, Hirshfeld et al. Click to enlarge.|
A number of studies recently have pointed out that increasing the octane rating of the US gasoline pool (currently ∼93 Research Octane Number (RON)) would enable higher engine efficiency for light-duty vehicles through reducing engine knock constraints, thereby enabling the design of new spark-ignition engines with higher compression ratios and boost levels. (Earlier post.) Such a move would also have significant implications for refineries in the US refining sector, whether the higher octane was achieved via more severe refining operations, increased use of ethanol, or both.
A linear programming analysis of US refining sector by a team from MathPro Inc., Ford, GM and Chrysler has found that, by increasing the volume of ethanol, the refining sector could produce hydrocarbon blendstocks for oxygenate blending (BOBs) yielding finished E20 and E30 gasolines with higher octane ratings at modest additional refining cost (ARC): e.g., ∼1¢/gal for 95-RON E20 or 97-RON E30; 3–5¢/gal for 95-RON E10, 98-RON E20, or 100-RON E30; and 96-RON E10, 99-RON E20, or 101-RON E30 gasoline pools at approximately 10¢/gal.
MAHLE NanoNapier Steel piston ring helps reduce weight and improve quality
MAHLE has developed a piston ring with new technology that offers engine manufacturers improvements in weight, quality and overall value. MAHLE’s new “second” piston ring uses chrome-silicon steel to replace cast iron traditionally used for the second of three rings found on gasoline-powered spark-ignition engines. MAHLE’s thinner, lighter-weight steel-wire design for the second ring is based on the company’s own NanoNapier Steel (NNS) technology for which a patent is pending.
Conventionally, there are two types of piston rings: compression and oil control. A piston assembly includes one or more compression rings that generate a seal between the outer surface of the piston and the wall of the cylinder to prevent high-pressure combustion gases and air from escaping the combustion chamber. Today’s engines have three piston rings: two compression rings: top (or first) and second and the oil control ring. The second ring is known as a Napier ring.
Two new generation TwinPower Turbo diesels in BMW 518d and 520d; up to 57.4 mpg
September 17, 2014
|New BMW 518d sedan. Click to enlarge.|
BMW has introduced two variants of its new generation of 2.0-liter four-cylinder diesel engines in the 5 Series which boost the output of the new BMW 518d and new BMW 520d by another 5 kW apiece. Average fuel consumption drops to as little as 4.1 l/100 km (57.4 mpg US) (European cycle) and CO2 emissions to 109 g/km; this marks a reduction in consumption and CO2 emissions in the EU test cycle by as much as 0.4 liters per 100 kilometers / 10 grams per kilometer.
For example, the new BMW 520d Sedan—which now produces 140 kW/190 hp—burns 4.7–4.3 liters of fuel per 100 kilometers (50 - 54.7 mpg US) with CO2 emissions of 114–124 g/km. If the optional eight-speed Steptronic transmission is specified, these figures improve further to 4.5–4.1 l/100 km (52.3 – 57.4 mpg US) with CO2 emissions of 109–119 g/km, depending on the tire format fitted.
Ford introduces new C-MAX and Grand C-MAX with standard Start-Stop on new EcoBoost and diesel engines
|New Ford C-MAX. Click to enlarge.|
Ford of Europe has unveiled the new C-MAX and Grand C-MAX prior to the Paris Motor Show. The models offer significantly improved CO2 figures and for the first time feature as standard Ford’s Auto-Start-Stop technology on EcoBoost gasoline and 2.0-liter TDCi diesel engines. The most improved model is expected to offer a 20% reduction in CO2 emissions.
The new C-MAX family powertrain line-up is being extended to include Ford’s fuel-efficient new 1.5-liter EcoBoost gasoline engine with 150 PS (110 kW) and 182 PS (134 kW), and also will be offered with Ford’s new 1.5-liter TDCi diesel engine, delivering 95 PS (70 kW) or 120 PS (88 kW), and a new ECOnetic version that is expected to deliver 99 g/km CO2 in the five-seat C-MAX. The C-MAX family will continue to be offered with 100 PS (74 kW) and 125 PS (92 kW) versions of the multi-award winning 1.0-liter EcoBoost gasoline engine.
Ford reveals all-new S-MAX; Adaptive Steering Technology
Ford of Europe revealed the all-new S‑MAX seven-seat sports activity vehicle. The new S-MAX will debut Ford Adaptive Steering technology in Europe for optimized response to driver input when it goes on sale in 2015. It will also offer Intelligent All-Wheel Drive and a range of powertrains—including a new 1.5-liter EcoBoost gasoline engine.
S-MAX will also be the first Ford globally to feature Ford Dynamic LED Headlamps with Glare-Free Highbeam that maintain maximum illumination without distracting other road users. Ford’s advanced Pre-Collision Assist technology will assist in mitigating accidents even at motorway speeds.
New gen 2.0L diesel for BMW 220d Coupe, Active Tourer; coming 3-cylinder diesel
September 16, 2014
|BMW 2 Series Coupe. Click to enlarge.|
BMW is introducing a new generation (earlier post) four-cylinder 2.0-liter diesel for its 220d Coupe and 220d Active Tourer. Coupled with the optional 8-speed Steptronic transmission, the BMW 220d Coupe now only hits the 100 km/h mark in a 7 seconds, but also attains a CO2 emission level of less than 100 grams/km. In the Active Tourer, the engine delivers combined fuel consumption of 4.5 - 4.4 l/100 km (52.3 - 53.5 mpg US) with CO2 emissions of 119 – 115 g/km).
The 2-liter diesel power unit is a member of the new BMW Group engine family. It features the latest version of BMW TwinPower Turbo technology, achieves a maximum power output of 140 kW/190 hp, while delivering a maximum torque of 400 N·m (295 lb-ft). With the standard 6-speed manual gearbox, the two-door car accomplishes an average fuel consumption of 4.4 to 4.1 liters/100 km (53.5 to 57.4 mpg US) and a CO2 level of 115 to 107 grams per km.
SwRI launching consortium to develop new dynamic engine bearing test rig
Southwest Research Institute (SwRI) has announced the formation of a consortium for joint research into new technologies to evaluate engine bearings for internal combustion engines. The objective of the Dynamic Bearing Rig Consortium is to design, to demonstrate and to validate a dynamically loaded bearing test rig that can replicate the variable loads critical to how bearings perform in an operating engine under transient and steady-state conditions.
Various rig tests are used in the bearing industry for comparative material evaluation. While these tests are effective in comparing new materials and coatings against existing designs, they do not successfully replicate the engine operating environment. As such, SwRI notes, they are not useful in correlating fatigue or scuff performance to what is seen in the field.
Peugeot introducing new Euro-6 versions of 3-cylinder gasoline and 4-cylinder diesel engines
September 15, 2014
Peugeot is introducing new Euro 6-compliant versions of its three-cylinder PureTech gasoline and four-cylinder BlueHDI diesel engines. All are equipped with Stop & Start (S&S) technology. Each engine is also coupled with Peugeot’s third-generation Efficient Automatic Transmission 6 (EAT6) transmission.
The introduction of the new engines has reduced the average weighted CO2 emissions of Peugeot’s European range to 111.2 g/km, as measured at the end of May 2014. That compares with 115.1 g/km at the same point in 2013, putting PSA Peugeot Citroën at the top of the CAFE (Corporate Average Fuel Economy) ranking.
Facelifted Mercedes-Benz B-Class with diesel, gasoline, natural gas and electric drives debuting at Paris show
September 12, 2014
Mercedes-Benz has given its B-Class range—more than 350,000 of which have been sold worldwide since market launch in late 2011—a major facelift including exterior and interior enhancements along with redefined design and equipment lines. Sales of the new B-Class commenced on 12 September, with the world première taking place during the Paris Motor Show (4 to 19 October). The revamped models will be making their way to dealerships from 29 November 2014.
Buyers have a wide choice of powertrains: five diesel models with fuel ranging from 3.6 to 5.0 l/100 km (65.3 to 47 mpg US); four gasoline engines at between 5.4 and 6.6 l/100 km (43.6 and 35.6 mpg US); alternative drive systems (B 200 Natural Gas Drive and B-Class Electric Drive); as well as optional 4MATIC all-wheel drive. The sports tourer also features a Cd value of less than 0.25. Prices in Europe will start from €27,102.25 (around US$35,000) for the B 180.
UK EPSRC awards almost $10M to two low-carbon vehicle technology projects; energy storage, engines and fuels
September 11, 2014
Two new low-carbon vehicle technology research projects will receive £6 million (US$9.7 million) funding from the Engineering and Physical Sciences Research Council (EPSRC), as part of the Research Councils UK (RCUK) Energy Programme. The two discrete projects—ELEVATE (ELEctrochemical Vehicle Advanced Technology) and Ultra Efficient Engines and Fuels—will involve academics from eight UK universities.
The announcement was made by UK Minister for Universities, Science and Cities, Greg Clark to coincide with the annual Low Carbon Vehicle Event - LCV Cenex 2014 at the Millbrook Proving Ground near Bedford.
Opel’s new generation 2.0L turbo diesel to debut in Paris
September 10, 2014
|Opel’s new generation, 125 kW/170 hp 2.0 CDTI for Insignia and Zafira Tourer. Click to enlarge.|
Opel’s new-generation, 2.0-liter turbo diesel will make its debut in the Insignia and Zafira Tourer at “Mondial de l’Automobile 2014” in Paris (4-19 October. Delivering 125 kW/170 hp and torque of 400 N·m (295 lb-ft), it will replace the current 120 kW/163 hp 2.0 CDTI engine at the top of Opel’s diesel range.
The Euro 6 compliant engine delivers almost 5% more horsepower and 14% more torque while reducing fuel consumption and CO2 emissions. The engine is also quiet and smooth as a result of Opel’s focus on sound engineering measures to minimize NVH (noise, vibration, harshness).
Jaguar Land Rover investing $1.6M in two new Centers of Excellence for Engine Combustion Research at Oxford and University College London; gasoline and diesel
Jaguar Land Rover announced the creation of two new Centers of Excellence for Engine Combustion Research at two leading UK universities. The £1-million (US$1.6 million) investment will be shared equally between University College London (UCL) and the University of Oxford to support the development of new research facilities and fund two 5-year study programs.
Each center will focus on specific combustion technologies, both targeting higher engine efficiency. The work at UCL’s Department of Mechanical Engineering will be dedicated to spark ignition in gasoline engines, led by Dr. Pavlos Aleiferis. At the University of Oxford’s Department of Engineering Science, Dr. Martin Davy will lead the project on compression ignition in diesel engines.
New Ford Focus in Europe delivers fuel economy improvements up to 19% with new 1.5L TDCi; 1.5L EcoBoost, Enhanced Transitional Stability
September 09, 2014
|New Ford Focus. Click to enlarge.|
The new Ford Focus for Europe (earlier post) delivers the car’s most fuel-efficient powertrain line-up yet with improvements of up to 19%, and a significant CO2 emission reduction across the entire line-up.
The new Focus will be the first vehicle in Europe to offer Ford’s new 1.5-liter EcoBoost gasoline engine and new Focus also will be available for the first time with Ford’s 1.5-liter TDCi diesel engine. Ford engineers have further optimized power, torque and fuel efficiency from the 2.0-liter TDCi engine; and Focus will continue to be offered with the award-winning 1.0-liter EcoBoost gasoline engine, including a 99 g/km CO2 1.0-liter EcoBoost model.
Chevy’s Cruze Diesel: a compact diesel contender in the US
September 08, 2014
|The Cruze Diesel is identified by a discreet badge on the trunk. Click to enlarge.|
US buyers hunting for a non-premium diesel passenger car (i.e., not a truck or SUV, and not a vehicle from BMW, Audi, Porsche or Mercedes-Benz) have until recently only had Volkswagen-brand cars as an option: Beetle, Golf, Jetta, Passat. Accordingly, Volkswagen of America (VoA) diesel sales to date in 2014 represent slightly north of 23% of all Volkswagen of America sales. In August, Jetta posted 3,988 diesels sales (26% of Jetta sales, while Passat TDI sales were 2,767 units, representing 30.1% of sales of the vehicle.
However, Chevrolet is trying to challenge that passenger car diesel hegemony with the compact Cruze Diesel, introduced for MY 2014, and now with a facelift for MY 2015. (Earlier post.) Chevrolet is positioning the Cruze, which features a US-modified 2.0L diesel from GM’s European lineup (the engine is manufactured in Kaiserslautern, Germany) to challenge Jetta on the basis of highway fuel economy and power, as well as content. Based on a week with the car (MY2014), the claimed fuel economy superiority may be tough to realize in real-world driving (especially in the face of the new, more fuel-efficient diesel in the 2015 Jetta, earlier post) but overall, the Cruze Diesel is a worthy challenger, and a very good and thrifty drive, especially on the highway.
Camry in Europe features new 2.0L engine with VVT-iW for both Atkinson and Otto cycles; 13% lower fuel consumption
September 05, 2014
The 2014 Camry in Europe is benefitting from a new, Euro V-compliant, 4-cylinder, 1,998 cc, 16v, DOHC petrol engine mated to a 6-speed Multi-mode automatic transmission which replaces the existing 2.0-liter unit and its 4-speed automatic transmission.
With a high 12.8:1 compression ratio, the new engine generates maximum power of 150 DIN hp/110 kW at 5,600 - 6,500 rpm, and maximum torque of 199 N·m (147 lb-ft) at 4,600 rpm. This accelerates the Camry from 0-100 km/h in 10.4 seconds, and on to a top speed of 210 km/h (130 mph). At 7.2 l/100 km (32.7 mpg US), fuel consumption is a substantial 13% less than that of the outgoing engine.
Researchers propose new class of high-temperature alloy; eutectic high-entropy alloys with both high ductility and high strength
August 29, 2014
High-entropy alloys (HEAs), which represent an emerging effort in materials science and engineering, are multi-principal-element (at least four) alloys that are promising for high-temperature applications due to their high resistance to softening at elevated temperatures and sluggish diffusion kinetics.
However, HEAs so far have either high strength or high ductility; achieving both has been a challenge. Further, the inferior castability and compositional segregation of HEAs have been obstacles for commercialization. Now, researchers in China are proposing a new strategy for designing high-entropy alloys using the eutectic alloy concept to accomplish both attributes. As reported in a paper in Nature’s open access journal Scientific Reports, an eutectic high-entropy alloy (EHEA) showed an “unprecedented” combination of high tensile ductility and high fracture strength at room temperature. The excellent mechanical properties could be kept up to 700 °C.
Volvo reveals new XC90; limited diesel, gasoline First Edition on sale only online
August 27, 2014
|The new XC90, with “Thor’s hammer” DRL lights. Click to enlarge.|
Volvo Cars revealed the XC90, its new 7-seat SUV, at an event in Sweden. Three years in the making and part of an $11-billion investment program, the new XC90 leverages the new Scalable Product Architecture (SPA) technology, and will offer a range of two-liter, four-cylinder Drive-E powertrains. The two launch engines are the D5 twin turbo diesel and the T6 supercharged and turbocharged gasoline unit. Top of the model range will be the XC90 Twin Engine—a plug-in hybrid delivering around 400 hp (298 kW) with carbon dioxide (CO2) emissions of around 60 g/km (NEDC driving cycle). (Earlier post.)
Volvo Cars also announced the release of a limited First Edition of its new flagship; the 1,927 individually numbered cars celebrate the year Volvo was founded and will only be available for sale online at www.volvocars.com, beginning 3 Sep.
Shanghai GM introduces new Chevrolet Cruze; up to 24% more fuel efficient than current generation
August 22, 2014
|The new Chevrolet Cruze. Click to enlarge.|
Shanghai GM officially launched the new generation Chevrolet Cruze midsize performance sedan in Shenzhen. Priced between RMB 109,900 and RMB 169,900 (US$17,870 and US$27,626), the new Cruze is offered in China in seven variants with a choice of segment-first 1.4L mid-mounted direct injection turbocharged or 1.5L mid-mounted naturally aspirated gasoline engines. Among its features are an energy-efficient automatic climate control which filters out 90% of PM2.5 in the interior.
The mid-mounted direct injection engine technology and wide range of fuel-saving features such as start/stop technology and ultra-low rolling resistance tires make the new Cruze up to 24% more fuel efficient than the current-generation Cruze. The engines offer peak fuel economy of only 5.9 liters per 100 km. In addition, they are up to 50% quieter than engines in competitive models.
DOE awards $17M for vehicle technologies; batteries, PEEM, engines, materials, fuel
August 21, 2014
The US Department of Energy (DOE) is awarding $17.6 million in 14 cooperative agreements with small businesses and institutions of higher education to develop and to deploy efficient and environmentally friendly highway transportation technologies that will help reduce petroleum use in the United States. The awards made under an Incubator Funding Opportunity Announcement (DE-FOA-0000988) issued in January. (Earlier post.)
The newly selected projects are in five areas: energy storage; power electronics and electric motors (PEEM); advanced combustion engines; materials technologies, and fuels and lubricant technologies. Awardees are:
Volvo Trucks introduces new monofuel natural gas version of FE
August 20, 2014
|Volvo FE CNG. Click to enlarge.|
Volvo Trucks is expanding its model range in Europe with a new version of the Volvo FE running entirely on natural gas. The Volvo FE CNG (Compressed Natural Gas) has been primarily developed for operations involving short driving cycles with repeated starts and stops such as refuse collection and local distribution.
The Volvo FE CNG is powered by an all-new 9-liter Euro 6 engine featuring spark plug technology that produces 320 hp (239 kW) and 1356 N·m (1000 lb-ft) of torque. Spark plug technology is particularly suitable for driving cycles where the truck covers short distances with a lot of start-stop traffic, said Christina Eriksson, Business Manager Alternative Drivelines at Volvo Trucks.
DOE to award more than $55M to 31 projects for plug-in and efficient vehicle technologies; Delphi receives $10M to further GDCI
August 14, 2014
The US Department of Energy (DOE) is awarding more than $55 million to 31 new projects to accelerate research and development of vehicle technologies that will improve fuel efficiency and reduce costs under a program-wide funding opportunity announced in January. (DE-FOA-0000991, earlier post.) These new projects are aimed at meeting the goals and objectives of the President’s EV Everywhere Grand Challenge (19 projects), as well as improvements in other vehicle technologies such as powertrains, fuel, tires and auxiliary systems (12 projects).
The largest single award ($10 million) goes to Delphi Automotive Systems to further the development of its Gasoline Direct-Injection Compression Ignition (GDCI) low-temperature combustion technology (earlier post) that provides high thermal efficiency with low NOx and PM emissions. The largest number of awards (9) in a single area of interest goes to developing beyond Li-ion battery technologies.
Emissions study suggests E10 + renewable hydrocarbons a high bioenergy alternative for conventional cars
Researchers from VTT Technical Research Center of Finland and Neste Oil analyzed the exhaust emissions from three different spark ignition engine technologies—multipoint fuel injection (MPFI); direct-injection spark-ignition (DISI); and flex-fuel (FFV)—using different biofuels—low- and high-concentration ethanol blends; isobutanol; and biohydrocarbons. They report their findings in a paper in the ACS journal Environmental Science & Technology.
Among their conclusions was that the combination of ethanol or isobutanol with renewable hydrocarbon components (i.e., drop-in biohydrocarbons) could offer an option to achieve a high-bioenergy-content gasoline that is compatible with conventional gasoline-fueled cars (i.e., those limited to a 10% ethanol blend) without a significant change in emissions.
Jaguar Land Rover Special Operations reveals new lightweight E-type
August 12, 2014
|Jaguar Land Rover Special Operations’ new Lightweight E-type. Click to enlarge.|
Jaguar Land Rover Special Operations unveiled its new Lightweight E-type—the first recreation to come from Jaguar Heritage, which operates within the Jaguar Land Rover Special Operations division. Only 6 will be built. Car Zero has been completed and, on 14 August, will be revealed at the opening reception to the Pebble Beach Automotive weekend. Jaguar announced in May 2014 that it would recreate six new Lightweights, each built by Jaguar Heritage, part of Jaguar Land Rover’s new Special Operations division.
In recreating the Lightweight, Jaguar Heritage has drawn on Jaguar’s engineering and design resources, including the company’s aluminum body technology. The specification includes an aluminum bodyshell with doors, trunklid, hardtop and hood also in aluminum. The six-cylinder XK engine mirrors the original power units, with an aluminum block, wide-angle aluminum cylinder head and dry sump lubrication.
Mercedes-Benz to use new steel pistons in V6 diesel of E 350 BlueTEC
August 11, 2014
Mercedes-Benz will replace conventional aluminum pistons with a new generation of steel pistons in the V6 diesel engine of the E 350 BlueTEC in September. Combined with the innovative NANOSLIDE (earlier post) cylinder bore coating technology and the aluminum housing, the advantages of the shift include lower fuel consumption and CO2 emissions.
Mercedes-Benz has already announced the coming use of steel pistons in the OM 626 four-cylinder diesel produced by Renault and applied in the C-Class Estate. (Earlier post.)
Mercedes-Benz showcasing new 7.7L Euro VI natural gas engine for medium-duty commercial vehicles at IAA; replaces two earlier models
August 08, 2014
|Relative (percent) CO2 emissions benefit of the new natural gas variant as compared to the 220 kW diesel engine. Benz et al.. Click to enlarge.|
Among its trucks on display at the upcoming IAA in Hanover, Mercedes-Benz will showcase an Econic equipped with its new Euro VI medium-duty natural gas engine (M 936NGT), which is derived from the 7.7-liter Euro VI M 936 inline six-cylinder diesel. This engine will replace the current natural gas engines based on 900 and 400 model series engines, with 6.9 and 12 liters of displacement respectively. These are lean-burn engines and fulfill Euro V EEV emissions specification.
As a mono-fuel engine, the new engine runs on compressed natural gas (CNG) and has an output of 221 kW (301 hp) while delivering maximum torque of 1200 N·m (885 lb-ft)—the same performance as the single-stage turbocharged diesel model. CO2 emissions are up to 22% below those of diesel (during high-load conditions), even with the lower efficiency of an Otto-cycle SI combustion engine relative to diesel. Using biogas further improves the carbon footprint.
32.5M hours of supercomputer time to aid GM, Ford engine projects with Oak Ridge Lab
August 06, 2014
|Simulation of injector. Graphic from GM, Edwards AMR 2014 presentation. Click to enlarge.|
As part of its 2014 ASCR Leadership Computing Challenge (ALCC) awards of processor time (totaling more than 3 billion processor hours), the US Department of Energy’s (DOE) Office of Science has awarded 15 million hours on Oak Ridge National Laboratory’s (ORNL) Titan supercomputer to a project led by General Motors, and 17.5 million hours on Titan to a project led by ORNL with Ford and Convergent Science as co-investigators. Titan is current Nº2 on the Top 500 Supercomputer list, and offers 27.1 petaflop (PF) peak processing capacity, with about 300,000 compute cores.
The two projects are part of a larger multi-year DOE-funded project to develop and to apply innovative simulation strategies and tools to maximize benefits of predictive information from high performance computing (HPC) for internal combustion engines. The Principal Investigator on that DOE project is Dean Edwards of ORNL.
Continental Motors introduces new diesel V-6 aviation engine
August 02, 2014
|The new CD-300 engine made its debut in Oshkosh. Click to enlarge.|
Continental Motors introduced the CD-300, its new V-6 diesel engine, at EAA AirVenture in Oshkosh this week. The CD-300 was flown for the first time in July at Continental’s German development center in Altenburg onboard an Cirrus airframe. The company said that the flying test-bed exhibited rates of climb and cruise performance that exceeded engineer’s expectations.
The CD-300 features common rail technology, direct injection, turbo charging, liquid cooling, and an advanced reduction gear system. Like the smaller CD-100 engine, the CD-300 is based on a Mercedes-Benz automotive core adapted for aviation use. In interviews at AirVenture, Continental Motors president Rhett Ross suggested that the company would begin to deviate from focusing on an exclusive automotive-derived approach.
Space station droplet combustion experiments reveal cool-burning flames; potential to lead to better engines
July 30, 2014
Isolated droplet combustion experiments performed on the International Space Station (ISS) by a team of international researchers have revealed a new type of cool-burning flames. The long durations of microgravity provided in the ISS enable the measurement of droplet and flame histories over an unprecedented range of conditions, enabling the discovery. The researchers detailed their findings in an open access paper in the journal Microgravity Science and Technology
A better understanding of the cool flames’ chemistry might help improve internal combustion engines in cars, for example by developing homogenous-charge compression ignition, which could potentially lead to engines that burn fuel at cooler temperatures, emitting fewer pollutants such as soot and nitric oxide and NOx, while still being efficient.
Jaguar: aluminum-intensive XE will feature fuel consumption lower than 4L/100km; structure is 75% aluminum
July 29, 2014
|The aluminum body of the XE. Click to enlarge.|
In the second of four technology previews leading up to the introduction of the new Jaguar XE on 8 September, Jaguar outlined its extensive use of aluminum in the new model. Designed around Jaguar’s modular vehicle architecture, the XE is the only car in the class to use an aluminum-intensive monocoque, with lightweight aluminum accounting for 75% of the structure.
The new aluminum-intensive SE will be paired with engines from the new Ingenium family of efficient diesel and gasoline engines (earlier post)—powertrains specifically designed and calibrated to complement reduced-weight vehicles. Jaguar projects that the resulting XE will achieve fuel consumption of less that 4.0 l/100 km (59 mpg US) on the NEDC combined cycle (subject to certification) and CO2 emissions of less than 100 g/km.
Delphi to debut new Tech Truck at IAA CV show; new high-pressure fuel injection system and new HPDI injector for natural gas
July 27, 2014
Delphi Automotive PLC will unveil the second generation of its Technology Truck concept highlighting future technologies at the upcoming IAA Commercial Vehicles show being held 25 Sept - 2 Oct in Hannover, Germany.
Among the technologies Delphi will unveil is the next-generation fuel injection system for commercial vehicles applications. The system, which builds on the performance of its 2700 bar F2 common rail technologies, includes a patented fuel injector and will help vehicle manufacturers meet future legislated emissions and fuel efficiency levels. Also at IAA, Delphi will showcase the new second-generation High Pressure Direct Injection (HPDI) natural gas injector for heavy-duty engine applications. Delphi co-developed the new HPDI injector with Westport.
IHS: continued legislative focus on pollutants to drive sensor market for internal combustion engines
July 24, 2014
The global market for sensors used in internal combustion engines (ICE) is on the road of steady growth for the next few years, propelled by increasing utilization in engine management and exhaust aftertreatment, according to a new report from IHS Technology. IHS projects that sensor shipments for ICEs will top 1.34 billion units in 2019, up from about 1.08 billion in 2013. Overall, IHS expects a six-year compound annual growth rate (CAGR) from 2013 to 2019 of 3.6%.
The report—“Powertrain Sensor Market Tracker – H1 2014”—is part of the Semiconductors & Components service of IHS Technology. The report examines more than 20 sensors attached to the engine, fuel and exhaust systems of passenger vehicles. The list includes pressure sensors, devices to monitor flow and temperature, ceramic sensors for the gases nitrogen oxide (NOx) and oxygen, in addition to knock sensing, position and speed.
97% of US buyers opted for 2.5L stop/start base engine on 2014, 2015 Malibu
July 23, 2014
|2014 ECOTEC 2.5L I-4 iVLC DI (LKW) with stop/start. Click to enlarge.|
Ninety-seven percent of customers in the US who purchased a 2014 or 2015 Malibu—accounting for about 83,000 vehicles—opted for the 2.5-liter, 4-cylinder base engine (LKW) equipped with standard stop/start technology, according to GM. (Earlier post.) This marks the the most aggressive rollout of stop/start technology in the US by an American automaker.
The 2014 Malibu was the first in its segment with a standard engine featuring fuel-saving stop/start technology. Stop/start is featured along other technologies in the Malibu’s new 2.5L intake valve lift control (iVLC), powertrain along with direct injection, variable valve lift control and a new six-speed automatic transmission. All contribute to EPA-estimated fuel economy ratings of 25 mpg (9.4 l/100 km) in city driving and 36 mpg (6.5 l/100 km) on the highway—14% and 6% improvements, respectively, over earlier models.
Ford provides some performance specs for its new 2.7L twin-turbo EcoBoost for the MY2015 F-150
July 22, 2014
The MY 2015 Ford F-150 will offer a new high-output, twin-turbo 2.7-liter EcoBoost V6 producing 325 hp (242 kW) and 375 lb-ft (508 N·m) of torque. Due to the extensive lightweighting in the new F-150 (earlier post), this will improve the power-to-weight ratio of the 2015 truck by 15% over the 2014 5.0-liter V8-equipped F-150 with similar torque output.
Boosting 2.7-liter EcoBoost fuel efficiency is the debut of standard Auto Start-Stop technology for F-150. The technology is off when towing or in four-wheel-drive mode. The 2.7-liter EcoBoost 4x2 has a maximum payload rating of 2,250 lbs (1,021 kg) and maximum tow rating of 8,500 pounds (3,856 kg), suited for meeting mid-range capability needs.
Argonne VERIFI researchers applying GSA to investigate combustion engine parameters; seeking cleaner and more efficient engines
July 18, 2014
Researchers at Argonne National Laboratory, as part of the new Virtual Engine Research Institute and Fuels Initiative (VERIFI) (earlier post), are using global sensitivity analysis (GSA)—a specific form of uncertainty analysis which breaks down the uncertainty into constitute parts—to investigate a number of parameters in the internal combustion process. By gaining a better understanding of how these parameter uncertainties affect outcomes, the VERIFI researchers, along with colleagues at the University of Connecticut, are seeking to create cleaner and more efficient engines.
The parameters being investigated include the relationships between the diameter of the nozzle in the fuel injector; the dynamics of the fuel spray; the proportion of fuel to air in the combustion chamber; and the exhaust products. In an SAE paper presented at the World Congress this year, the researchers described the results of the first demonstration of GSA for engine simulations.
Two new Wärtsilä JVs with CSSC: 2-stroke engine business and medium-speed diesel and dual-fuel engines
Wärtsilä and China State Shipbuilding Corporation (CSSC)—one of the largest shipbuilders in the world—will form two new joint ventures. The first will take over Wärtsilä’s 2-stroke engine business. Through the agreement, CSSC will own 70% of the business through its affiliate CSSC Investment and Development Co. Ltd, while Wärtsilä will hold a 30% ownership position.
Wärtsilä and China State Shipbuilding Corporation (CSSC) also signed an agreement to establish a joint venture for manufacturing medium- and large-bore medium speed diesel and dual-fuel engines. The company will in particular target the growing offshore and LNG markets, as well as the market for very large container vessels. The Wärtsilä share of the joint venture is 49% and the size of Wärtsilä’s equity investment is approximately €12 million (US$16 million).
First high-heat plastic air intake manifold with integrated charge air cooler in production on hybrid sports car
|Plastic air intake manifold with integrated CAC for 3-cylinder 1.5-liter engine.|
The world’s first high-heat plastic air intake manifold (AIM) with integrated charge air cooler (CAC) in Stanyl Diablo, Royal DSM’s high-temperature-resistant polyamide 46, recently went into production on a recently introduced hybrid sports car—by its description (although not by confirmation from DSM) the BMW i8 (earlier post). Royal DSM noted that the use marks another major step forward in the use of thermoplastics in automotive high-heat zones.
The injection-molded AIM/CAC manifold operates at 220 °C and withstands pulses of high internal pressure. DSM worked closely together with a leading system supplier to develop the AIM/CAC combination, with DSM providing extensive development and processing support. The part is made in Stanyl Diablo OCD2100, which contains 40% glass fiber reinforcement as well as a specially developed and patented heat stabilizer. This grade has a continuous-use temperature of 220 °C and is able to withstand peak temperatures up to 250 °C.
Two Audi TDI technology studies with electric biturbo, 48V electrical systems; both technologies to go into series production
July 17, 2014
|V6 TDI bi-turbo with electric compressor. Click to enlarge.|
Audi has built two technology studies with the “electric biturbo” technology it is developing (earlier post): the Audi A6 TDI concept is equipped with a new 3.0 TDI monoturbo (i.e., a single turbo with supplementary electric compressor), while the Audi RS 5 TDI concept with a 3.0 TDI biturbo (two in-series turbochargers with supplementary electric compressor).
The electric biturbo system comprises a classic exhaust turbocharger (mono- or bi-turbo) working together with a supplemental, electric-powered compressor arranged in series and powered by a separate 48-volt electrical system. Instead of a turbine wheel, it contains a small electric motor that applies a maximum drive power of 7 kW to accelerate the compressor wheel to maximum speed within 250 milliseconds.
UK study finds low carbon policy has bolstered UK automotive sector, but trucks neglected and biofuels stalled
|Value of low carbon investments by year and cumulative. Click to enlarge.|
A major new report published at the Low Carbon Vehicle Partnership’s Annual Conference shows the UK automotive sector has been revitalized by consistently applied policy centered on cutting carbon.
Carried out for LowCVP by E4tech and the Centre for Automotive Industry Research at Cardiff Business School, the study was conducted between March and June 2014. The broad industry survey, supplemented by in-depth interviews with senior executives showed that a consistent and sustained policy approach can produce both green results and growth. The link between consistently applied policy and a win-win in terms of investment and emissions performance was validated by the survey involving more than 120 senior industry and stakeholder respondents.
World premiere of new smart fortwo and forfour
July 16, 2014
|The new smart fortwo: Body panels in white, tridion safety cell in lava orange (metallic). The new smart forfour: Body in white, tridion safety cell in black. Click to enlarge.|
In a world premiere staged in Berlin, Daimler brand smart unveiled the new versions of its iconic smart fortwo and forfour city cars. The new smart fortwo, developed in partnership with Renault (sharing the third-generation Twingo platform) has undergone improvements in virtually all areas and is markedly more comfortable, while the smart rear engine concept is now being offered for the first time in the four-seater smart forfour as well.
Drive power is supplied by three-cylinder engines rated at 45 kW/60 hp, 52 kW/71 hp and 66 kW/90 hp, while power transmission is performed by a five-speed manual transmission or the twinamic automatic dual clutch transmission. A new version of the smart fortwo electric drive (earlier post), based on the new model, will follow.
Refreshed 2014 Toyota Yaris features revamped 1.0L engine with switching between Atkinson and Otto cycles; new hybrid
|2014 Yaris Hybrid. Click to enlarge.|
Toyota’s refreshed 2014 Yaris for Europe offers a choice of four powertrains, including a thoroughly reworked 3-cylinder 1.0 gasoline unit that is the first member of a new family of 14 highly efficient engines to be launched by 2015. With a thermal efficiency of 37%, the engine delivers a combined-cycle fuel consumption of 4.1 l/100 (57.4 mpg US), and CO2 emissions reduced to 95 g/km in conjunction with a stop/start system. (Mass-produced gasoline engines on average have a thermal efficiency of between 30 and 35%, Toyota said.)
The hybrid powertrain has also been revamped, with its CO2 emissions reduced still further to 75 g/km and corresponding combined-cycle consumption lowered to 3.3 l/100 (71.3 mpg US). A 4-cylinder, 1.33-liter gasoline engine and 1.4-liter diesel complete the range.
Continental supplying first turbocharger with aluminum housing
July 15, 2014
|The water-cooled aluminum turbine housing. Click to enlarge.|
Continental’s powertrain developers have launched series production of the first car turbocharger with an aluminum turbine housing. Integration of the unit in the three-cylinder, 1.5L 100 kW gasoline engine for the MINI Hatch (earlier post) has been ongoing since spring 2014.
Water-cooling enables the use of the lightweight material and thus enables a significant weight reduction by nearly 30% while simultaneously providing cost and system benefits.
New Mercedes C-Class Estate offers new 1.6L diesel, diesel hybrid options; gasoline plug-in hybrid model coming
Mercedes-Benz is adding a new Estate (wagon) model to its C-Class family starting in September 2014. The powertrain range for the Estate, which includes diesel, gasoline and hybrid options, features a new 1.6-liter 4-cylinder diesel (OM 626) produced by Renault. Compared with the predecessor Estate, certain members of the line-up consume in excess of 20% less fuel.
Depending on its configuration, the single-stage turbocharged engine generates 85 or 100 kW (116 or 136 hp) of power from a displacement of 1598 cc and delivers 280 or 300 N·m (207 or 221 lb-ft) of rated torque. Fuel consumption for both variants is rated at 4.3 l/100 km (54.7 mpg US) NEDC.
Cummins ETHOS 2.8L optimized E-85 engine demonstrates 50-80% reduction in CO2 emissions in medium-duty truck
July 14, 2014
|The ETHOS 2.8L demo truck. Click to enlarge.|
Cummins has developed an E-85-specific engine and powertrain that reduce carbon dioxide emissions by as much as 80% compared with a baseline gasoline-powered medium-duty truck. The work was jointly funded by Cummins and partners ($3,790,027) in partnership with the California Energy Commission (CEC) ($2,712,140).
The Cummins ETHOS 2.8L is designed specifically to use E-85 (85% ethanol and 15% gasoline). To take full advantage of the favorable combustion attributes and potential of E-85, the engine operates at diesel-like cylinder pressures and incorporates advanced spark-ignition technology. It delivers the power (up to 250 hp / 186 kW) and peak torque (up to 450 lb-ft / 610 N·m) of gasoline and diesel engines nearly twice its 2.8-liter displacement.
Volkswagen to produce new CrossBlue-based midsize SUV in Chattanooga; $900M investment
|The new mid-size SUV is based on the CrossBlue concept. Click to enlarge.|
The Board of Directors of Volkswagen Group of America has decided to award the production of its new midsize SUV to the Chattanooga plant in Tennessee. The Group will be investing a total of approximately US$900 million (€643 million) in the production of the newly developed, seven-passenger SUV, creating 2,000 additional jobs in the US. About US$600 million (€432 million) will be invested in Tennessee.
The midsize SUV, which is based on the MQB-based CrossBlue plug-in hybrid concept vehicle, was developed especially for the North American market. The CrossBlue made its global debut at the 2013 North American International Auto Show in Detroit. (Earlier post.)
Alcoa unveils first aluminum alloy fan blade forging for jet engines; $1.1B supply agreement w/ Pratt & Whitney
Click to enlarge.
Under a new 10-year, $1.1-billion agreement, Alcoa will supply key parts for Pratt & Whitney’s jet engines, including the forging for the first aluminum fan blade for jet engines. The forging was developed for Pratt & Whitney’s PurePower engines using an advanced aluminum alloy and a proprietary manufacturing process. Also for the PurePower engines, Alcoa is developing a fan blade forging using its most advanced aluminum-lithium alloy.
Under the $1.1 billion deal, Alcoa will supply components for Pratt & Whitney’s PurePower PW1000G, V2500, GP7000 and several other regional jet and military engines. The unique Geared Turbofan architecture of the PurePower engine allows for aluminum alloys to be used in the Pratt & Whitney designed fan blades, making the engine lighter, as well as more fuel and cost efficient.
Review: Chevrolet Silverado 2500HD with bi-fuel CNG option
|View of the CNG tank in the bed of a Silverado 2500HD with bi-fuel option. Click to enlarge.|
GM’s 2015 Chevy Silverado 2500HD with the bi-fuel (natural gas) option (earlier post) offers buyers—primarily commercial and fleet buyers—a strong natural-gas option in the ¾-ton pickup market that combines the excellent qualities of the base Silverado 2500HD with the economic (lower cost) and environmental (lower emissions of GHGs and criteria pollutants) benefits of natural gas fuel and packages the two together seamlessly.
As with any vehicle choice, there are trade-offs that need to be balanced against target use. In the case of the 2500HD bi-fuel, the two main trade-offs are a reduction in power and torque in CNG mode compared to gasoline mode, and the loss of a portion of the bed of the truck to the 3,600 psi CNG tank and its box-like enclosure. (It looks like a hefty black tool box mounted across the front of the bed.) Of those two trade-offs, only the second is permanent. The driver can easily switch from CNG to gasoline with the flick of a switch, essentially reverting the 2500HD to its conventional gasoline cousin, with the accompanying boost in power and torque for occasions that might call for it.
Researchers develop efficient technique to develop new materials with desired coefficient of friction
July 11, 2014
Researchers at Japan’s National Institute for Materials Science (NIMS) have developed a highly efficient method for developing friction materials with a desired frictional property. Using the new method, it would be possible to find the appropriate crystal preferred orientation for coatings with the desired value of the coefficient of friction.
The method, described in a paper in the journal Tribology Letters, could thus significantly accelerate the development of materials that have a friction coefficient suited to the purpose of use, such as low-friction materials for reducing energy loss and high-friction materials required for high-performance brakes.
Jaguar shares details about new Ingenium family of efficient gasoline and diesel engines
July 10, 2014
|Ingenium engine. Click to enlarge.|
Jaguar Land Rover has revealed some details about its new Ingenium family of efficient diesel and gasoline engines. The powerplants—designed, engineered and manufactured by Jaguar Land Rover—deliver class-leading levels of torque, horsepower and refinement while reducing emissions and fuel consumption.
Design goals for the new engine family included: configurable and flexible to enable seamless installation in a range of new Jaguar and Land Rover vehicles; scalable up and down to create smaller or larger displacement variants in the future; able to accommodate a range of powertrain layouts including rear-, all- and four-wheel drive; engineered to support manual and automatic transmissions as well as electrified hybrid drive systems; and easily accepting of new advances in engine technologies as they become available.
Mercedes-Benz outlines synergies between F1 motorsport and production car engineering
Mercedes-Benz has outlined areas of actual synergies between its F1 motorsport activities with Mercedes AMG Petronas and Mercedes-Benz Cars. While there is definitely a technology transfer between race and road car engineering, said Paddy Lowe, Executive Director (Technical) at Mercedes AMG Petronas, “it’s a more subtle process than bolting bits from one car onto another.”
There are examples of direct transfer—such as the Nanoslide technology used to coat cylinder bore surfaces (earlier post)—and then there are examples of indirect transfer, such as F1 serving as a research laboratory for developing new solutions and showing the world what is possible, he noted.
Opel reveals 5th generation Corsa; new 1.0L, 3-cylinder turbo
July 09, 2014
|5th generation Corsa Click to enlarge.|
Opel revealed the new, fifth-generation of the Corsa, which will make its world premiere in October at the Paris Motor Show. The gen 5 Corsa will offer new, refined and efficient 1.0-liter three-cylinder turbo engines, smooth-shifting transmissions, a new suspension and optimized steering. The new Corsa will be in production in Zaragoza and Eisenach before the end of the year.
The highlight under the hood of the new so-called “Corsa E” of the fifth generation is the installation of Opel’s newly-developed three-cylinder, 1.0 ECOTEC Direct Injection Turbo, part of the brand’s major powertrain offensive. This is the only 1.0-liter three-cylinder production engine with a balance shaft, which enables it set a new class benchmark for exceptionally low noise, vibration and harshness (NVH) characteristics, as well as high driving comfort.