Green Car Congress: Engines

Engines

[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.]

BMW Debuts 6th Generation of 5 Series Sedan; Auto Stop Start on 520d and BluePerformance on 530d for Euro 6 Compliance

November 23, 2009

The new 5 Series. Click to enlarge.

BMW held the world debut of the 6^th generation BMW 5 Series today in Munich. In the course of five model generations, overall sales of the BMW 5 Series have reached more than 5.5 million units.

The new BMW 5 Series Sedan is making its debut with one eight-cylinder and three six-cylinder gasoline engines as well as two six-cylinder diesels. The range is rounded off by a four-cylinder turbodiesel (the 520d) with an aluminium crankcase and common-rail direct injection.

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European Sales of Chevy Spark Begin 1Q 2010 with Two Engines at Launch, LPG Variants

The Chevrolet Spark. Click to enlarge.

GM Europe is launching the Chevrolet Spark (earlier post), providing more detail on the all-new mini car prior to its going on sale in Europe in the first quarter of 2010. The mini-car (A car) segment is the fastest growing area of the new car market globally. In 2009 the A segment represented almost 10% of the total European passenger car market (up from 6.5% in 2008 and less than 5% in 2005.

Two gasoline engines are on offer at launch with displacements of 1.0 and 1.2 liters. They are closely related and use a cast-iron block and alloy head, with a double overhead camshaft and four valves per cylinder. They feature multi-port fuel injection and are both Euro V emissions compliant. Both engines come with a five-speed manual gearbox.

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Study Concludes That Class 8 Truck Fuel Consumption Could Be Reduced By Up to 50% By 2017 Using Existing and Emerging Technologies; Current Payback Requirements Could Forestall Implementation

November 20, 2009

A new study released today by the Northeast States Center for a Clean Air Future (NESCCAF) and the International Council on Clean Transportation (ICCT) found that fuel consumption of Class 8 trucks and the resultant greenhouse gas (GHG) emissions can be reduced up to 50% with the adoption of current and developing technologies and new operational measures by 2017.

However, the study also concluded that given the current short payback period for investment demanded by the trucking industry, a number of the technologies that could enable such savings would not be adopted, absent regulation or a longer payback period.

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Opel Revamping Corsa for 2010; Better Performance, Lower Fuel Consumption and CO2 Emissions

November 19, 2009

The Opel Corsa is receiving a complete re-make for 2010, with major engineering changes, re-vamped powertrain line-up, chassis improvements and steering recalibration to give the Corsa better performance and greater fuel economy as well as comfort, handling and driving dynamics. The Corsa, which accounts for some 30% of Opel/Vauxhall total sales, is available in three-door and five-door variants.

Gasoline engine line-up. The new gasoline engine line-up for the Corsa fully complies with Euro 5 standards. All engines have been re-worked to offer more torque while featuring up to 13% lower fuel consumption and CO₂ emissions. Both the 1.2- and 1.4-liter Twinport variants are each available in two versions with different outputs. Every country selects and offers customers the variants that suit the needs of their region. Some may decide to go for optimal fuel efficiency; other may want to balance it with more performance.

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Hyundai Unveils Its First Production Gasoline Direct Injection Engine

November 17, 2009

The 2.4 Theta II GDI. Click to enlarge.

Hyundai Motor Company unveiled the 2.4 Theta II GDI, its first Gasoline Direct Injection engine before an audience of engineers attending the Ninth Annual Hyundai-Kia International Powertrain Conference in Korea. With a compression ratio of 11.3:1, the 2.4 Theta II GDI delivers 201 ps@6300rpm (198 hp/148 kW) and 25.5 kg·m@4250rpm (184 lb-ft/250 N·m) in its Korean domestic market specification.

Compared to a conventional engine of the same displacement, GDI delivers 7% more torque at low revolutions and 12% more torque at the high-end for better take-off and overtaking performance. A vehicle equipped with a GDI engine will get about 10% better mileage than a vehicle equipped with a conventional multi-point fuel injected engine, according to Hyundai. Precise mileage figures will be announced when retail sales begin.

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Federal-Mogul Introduces New Diesel Piston Design to Support Downsized Engines with Higher Output

November 15, 2009

DuraBowl technology optimizes the grain size around the piston rim to provide much improved resistance to cracking under both mechanical and thermal loads. Microstructure of a typical piston alloy (a), as cast, showing a coarse structure and (b), re-melted, showing a finer structure. The dark grey areas are silicon particles; the light grey areas aluminium. Click to enlarge.

Federal-Mogul Corporation has developed an innovative aluminum piston design that can reliably withstand the mechanical and thermal loads produced by heavily boosted engines, thereby enhancing diesel engine performance and supporting diesel downsizing.

Called DuraBowl, Federal-Mogul’s design strengthens the crown of a piston by locally re-melting the alloy around the bowl, resulting in an enhanced microstrucutre in the alloy which significantly improves the fatigue strength of the aluminum where it is most needed. The result is an extension of engine life to between four to seven times that achieved with a conventional cast piston.

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Accenture Reports Identifies 12 Disruptive Technologies Most Likely to Transform Supply and Demand of Transport Fuels and Cut Emissions Within Next 10 Years

November 10, 2009

Accenture timeline for evolution of electrification technologies, the “game-changing” subset of the disruptive technologies. Source: Accenture. Click to enlarge.

Accenture has identified 12 technologies that it concludes have the potential to disrupt the current views of transport fuels supply, demand and GHG emissions over the next 10 years. In a report comparing advances in combustion engines, biofuels, electrification and other technologies, Accenture warns that the commercial viability of those disruptive technologies will be delayed unless regulators more proactively support the transformation of science into applied technologies.

“Betting on Science – Disruptive Technologies in Transport Fuels” selected 12 innovations in electrification and genetically modified biofuels, as well as existing fuel sources that will have the most immediate impact on emissions and on the gasoline and diesel markets. The study profiled 25 companies that aim to commercialize these technologies in the next five (i.e., by 2014) and also examines different global markets.

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Chrysler Portfolio Segment Mix Shifting to Smaller, More Fuel Efficient Vehicles; 25% Improvement in Portfolio Fuel Economy by 2014

November 04, 2009

Projected shift in volume and segment mix. Click to enlarge.

Chrysler’s worldwide product plan for 2010-2014 envisions a shift in its portfolio segment mix. Micro through mid-size vehicles will increase from 45% to 58% of volume, while large and full-size segments will decline from 55% to 42% of volume, said Joe Veltri, Vice President - Product Planning, Chrysler Group.

Chrysler estimates that diesel engines will represent 14% of its portfolio in 2014, compared to 9% in 2010. Four-cylinder gasoline engines will increase their share to 38% from 19%, Veltri said.

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Cyclone Power Technologies Signs Letter of Intent To Expand Engine Development in China

Cyclone Power Technologies Inc. has signed a Letter of Intent with Great Wall Alternative Power Systems Ltd. to advance the development and production of Cyclone’s heat-regenerative external combustion engine in China. (Earlier post.)

Under the terms of the Letter of Intent, Great Wall Alternative Power Systems (GWAPS) will invest capital, assets and know-how necessary for a development program aimed at making certain of the Cyclone engine systems ready for production, sales and marketing in China within the next 12 to 24 months.

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Chrysler Powertrain Strategy to Rely Heavily on Integrating Fiat Engine Technology; Chrysler to Be Global Center of Competence for Hybrids and EVs for Fiat and Chrysler

Chrysler’s new powertrain strategy relies heavily on the rapid integration of Fiat technologies. Click to enlarge.

Chrysler’s new powertrain strategy is relying on the rapid transfer of Fiat Group technology for Multiair; Gasoline Direct Injection; turbocharging and alternative fuels to support rapid downsizing and improvement of fuel economy, along with the simplification of the company’s engine line-up, according to Paolo E. Ferrero, Senior Vice President, Chrysler Powertrain. Ferrero was speaking during a briefing at Chrysler headquarters today outlining the company’s new five-year business plan.

In addition, Ferrero said, the Chrysler Group will be the global center of engineering competence for hybrids and electric vehicles for Fiat Group and Chrysler Group.

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Navistar Acquires Diesel Engine Components Business From Continental, Forms New Operating Company

November 03, 2009

Navistar, Inc., concluded an agreement to acquire certain assets and the membership interests of Continental Diesel Systems US, LLC, to manufacture key fuel injection components for Navistar MaxxForce diesel engines. The company also will establish a dedicated research and development facility to support Navistar’s diesel power system components.

The company, renamed Pure Power Technologies, LLC, will further vertically integrate research and development, engineering and manufacturing capabilities to produce world-class diesel power systems and advanced emissions control systems.

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Michigan State University Receives $2.5M ARPA-E Award to Build Wave Disc Engine/Generator for Series Hybrid Applications

October 31, 2009

Schematic model of a wave disk engine, showing combustion and shockwaves within the channels. Source: MSU. Click to enlarge.

Researchers from Michigan State University have been awarded $2.5 million from the Department of Energy’s ARPA-E program (earlier post) to complete its prototype development of a new gasoline-fueled wave disc engine and electricity generator that promises to be five times more efficient than traditional auto engines in electricity production, 20% lighter, and 30% cheaper to manufacture.

The wave disc engine, a new implementation of wave rotor technology, was earlier developed by the Michigan State group in collaboration with researchers from the Warsaw Institute of Technology. About the size of a large cooking pot, the novel, hyper-efficient engine could replace current engine/generator technologies for plug-in hybrid electric vehicles.

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Thordon Bearings Retrofitting Ocean-Going Vessels With Seawater-Lubricated Propeller Shaft Bearings To Reduce Stern-Tube Oil Pollution; Annual Leaks Estimated at About 2x Exxon Valdez Spill

October 29, 2009

by Jeff Curtis and Jack Rosebro

Cross-section of COMPAC seawater-lubricated stern tube bearing system for ocean-going vessels. Source: Thordon Bearings Click to enlarge.

At last week’s Ocean Innovation 2009 conference in Victoria, British Columbia, Craig Carter, Director of Marketing and Customer Service at Thordon Bearings detailed the company’s progress in the retrofitting of large ocean-going vessels with seawater-lubricated propeller shaft bearings to reduce waterborne pollution.

At present, most commercial ocean-going ships use a propeller shaft that is supported by oil-lubricated bearings in the ship’s stern tube. Although the stern tube is typically fitted with forward and aft shaft seals, the seals are designed to expel contaminants by leaking aft into the sea or forward into the bilge. Aft seals are also commonly damaged by fishing net or rope that becomes entangled on the propeller shaft.

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Sturman Industries Targeting Diesel-like Efficiency for Natural Gas Using Digital Hydraulic Controls

October 27, 2009

Sturman Industries has begun work on a recently awarded $1-million grant by the California Energy Commission under its Public Interest Energy Research (PIER) program. The grant was awarded in response to a Sturman proposal to convert a diesel truck engine to enabling Sturman Digital Hydraulic air controls to demonstrate its efficient and practical use for natural gas stationary power generation.

The project will show that natural gas can achieve diesel-like efficiency by utilizing state-of-the-art control techniques, said Sturman co-founder Eddie Sturman. Sturman will use its Hydraulic Valve Actuation (HVA) technology to achieve this increased efficiency and decreased emissions.

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ARPA-E Awards $151M to 37 Projects for Transformative Energy Research

October 26, 2009

The Department of Energy (DOE) has selected 37 energy research projects for $151 million in funding through the recently formed Advanced Research Projects Agency-Energy (ARPA-E). This is the first round of projects funded under ARPA-E, which is receiving total of $400 million under the American Recovery and Reinvestment Act.

Among the projects selected are an effort to develop new metal-air batteries using advanced ionic liquids with 6-20 times the energy density of Li-ion batteries at < 1/3 the cost; a project to produce a flow of gasoline directly from sunlight and CO₂ using a symbiotic system of two organisms; and a new type of engine for use as a genset in a plug-in hybrid vehicle that is five times more efficient than traditional auto engines in electricity production, 20% lighter, and 30% cheaper to manufacture.

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UTEP Awarded Nearly $1.3M for 4 DOE Projects On Engine and Turbine Efficiency and CO2 Capture

October 22, 2009

The Department of Energy (DOE) recently awarded The University of Texas at El Paso grants totaling nearly $1.3 million for research to improve the efficiency of engines and creating technologies for detecting, capturing and storing carbon emissions.

Assistant Professor of Mechanical Engineering Chintalapalle V. Ramana, Ph.D., and Associate Professor of Mechanical Engineering Ahsan Choudhuri, Ph.D., will investigate improved materials for thermal barrier coatings, which help protect engine components and improve the efficiency of engines by allowing them to operate at higher temperatures. Ramana will develop nanostructured coatings for hydrogen turbines that have improved resistance to heat and heat-related corrosion.

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Michigan Tech-Led Partnership Investigating Energy Efficient Emissions Control for Heavy-Duty Diesels; $1.7M from DOE

October 21, 2009

A side effect of cleaning up diesel exhaust can be a drop in fuel efficiency and a need to do diagnostics of whether the systems are operating in their design states. A partnership led by researchers at Michigan Technological University is addressing those issues in a three-year, $2.8 million project funded largely by a $1.7 million grant from the US Department of Energy’s National Energy Technology Laboratory.

Additional support and in-kind goods, services and expertise is provided by the partners from the diesel engine companies Cummins, John Deere, and Navistar; sensor manufacturer Watlow; and Johnson Matthey, a producer of diesel catalysts and pollution-control systems. Scientists at Oak Ridge and Pacific Northwest National Laboratories are also collaborating.

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ORNL, Da Vinci Sign Licensing Agreement For Oil-Dilution Diagnostic Technology to Optimize Advanced Combustion Engines

UT-Battelle has licensed an Oak Ridge National Laboratory (ORNL) technology for analyzing automotive engine oil to Da Vinci Emissions Services, Ltd., a Texas firm that specializes in a broad suite of combustion engine lubrication and emissions testing services and equipment. UT-Battelle manages ORNL for the Department of Energy.

The licensed invention, known as “Laser-Induced Fluorescence Fiber Optic Probe Measurement of Oil Dilution by Fuel,” was developed by James E. Parks and William P. Partridge of the Fuels, Engines, and Emissions Research Group in ORNL’s Energy and Transportation Science Division. The oil-dilution diagnostic grew out of a successful and ongoing CRADA, or cooperative research and development agreement, partnership between ORNL and Cummins Inc. The work is sponsored by the Department of Energy’s Office of Vehicle Technologies.

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Use of Reformed Exhaust Gas Recirculation Gas as a Dual Fuel Can Significantly Reduce Both NOx and Smoke in a Diesel Engine at Low Loads

October 17, 2009

Proposed engine-reformer-diesel oxidation catalyst (DOC) system. Credit: ACS, Tsolakis et al. (2009) Click to enlarge.

Using hot reformed exhaust gas recirculation (REGR) gas as a dual fuel in a diesel under low-load operation can result in a “significant” reduction of both NO_x and smoke engine emissions without a penalty in fuel consumption, according to a new study by team of researchers from the UK, Italy and Jordan led by Dr. Athanasios Tsolakis at the University of Birmingham. A paper on their study appeared online 7 October in the ACS journal Energy & Fuels.

In the exhaust gas fuel-reforming method, part of the engine exhaust gas reacts with small amounts of engine fuel in a mini-reactor fitted in the exhaust gas recirculation (EGR) loop to produce gaseous fuel named reformed EGR (REGR), which contains H₂, CO, CH₄, and CO₂. The REGR gas is fed back to the engine inlet.

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BMW to Open Nearly Emission-Free Inorganic Sand Core Foundry in 2010

October 16, 2009

BMW Plant Landshut, light-metal foundry, production of inorganically bonded cores, water jacket cylinder head, 6-cylinder-diesel-engine, quality testing. Click to enlarge.

From 2010, BMW’s Landshut plant will feature the first foundry with nearly emission-free sand core production. The light-alloy foundry at the BMW plant is introducing a new sand core production method for gravity die-casting, in which conventional organic binders will be replaced by inorganic binders, which generate virtually no pollutant emissions—a world first, according to BMW.

This production method will allow the light-alloy foundry to reduce its emissions of combustion residues by 98% The plant will completely decommission its current waste air treatment systems by 2010.

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Study Finds That Late Intake Valve Closing and Increased Intake Pressure Can Reduce NO_x, Soot, HC, and CO Emissions Simultaneously in Diesel PCCI

October 14, 2009

Summaries of the different effects of late IVC on engine emissions and performance from recent studies. (LIVC: late IVC; ←: advance; ↓decrease; ↑increase; – remain constant). Credit: ACS, Peng and Jia (2009). Click to enlarge.

A study by a pair of researchers from the University of Sussex (UK) and Dalian University of Technology, China found that using late intake valve closing (IVC) in diesel PCCI (premixed charge compression ignition) engines, can, with the assistance of increasing intake pressure, reduce NO_x, PM, HC, and CO emissions simultaneously.

A certain EGR (exhaust gas recirculation) rate and optimized SOI (start of injection) timing were always necessary to maintain satisfactory NO_x and soot emissions for diesel PCCI combustion. Their paper was published online 14 October in the ACS journal Energy & Fuels.

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Scuderi Releases Video Footage of Running Split-Cycle 1L Prototype

October 08, 2009

Simplified pressure-volume curve for the Scuderi Engine. Source: Scuderi Group. Click to enlarge.

Scuderi Group, LLC has released the first video footage (with sound) of its split-cycle Scuderi Engine prototype running, on its own, in the laboratory test cell. The two-minute video, the first to show the naturally-aspirated one-liter gasoline prototype engine in operation, provides a view of the engine as it undergoes testing, proving the concept of Firing After Top Dead Center.

In September at the Frankfurt show, the Scuderi Group announced that it had proven the concept of Firing After Top Dead Center and that the naturally aspirated, 1-liter prototype was running. Preliminary test results have matched earlier computer simulation projections. (Earlier post.)

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Delphi Showcases Advanced Powertrain and Vehicle Electrification Technologies at 18th Aachen Colloquium

October 05, 2009

At the 18^th Aachen Colloquium of Automobile and Engine Technology this week (5-7 October), Delphi is highlighting a range of its technologies including advanced gasoline and diesel engine management systems, fuel handling systems, powertrain cooling solutions and hybrid and electric vehicle products.

On Tuesday, Delphi’s Dr. Detlev Schoeppe, technical director for Delphi Diesel Systems, will present a paper detailing Delphi’s developments in fuel injection equipment and control strategies for light-duty diesel engines, including the recent introduction of the Delphi Direct Acting Diesel Common Rail System (earlier post). The paper will demonstrate how the system meets the needs of future diesel powerplants that are being designed for high boost, high power density, low emissions, and low fuel consumption, says Dr. Schoeppe.

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Audi Combines Start-stop Function with Dual-Clutch Transmission on A3

Audi is now offering the its start-stop system in conjunction with an automatic transmission. The A3 1.6 TDI with 77 kW (105 hp) and the 1.4 TFSI with 92 kW (125 hp) combine, for the first time, the start-stop function with the S tronic dual-clutch transmission. In September, Audi introduced new models of the A3 1.6 TDI featuring start-stop with a manual transmission. (Earlier post.)

The diesel 1.6 TDI A3 with automatic transmission consumes 4.2 liters of fuel per 100 kilometers (56 mpg US); the gasoline 1.4 TFSI with automatic consumes 5.3 liters per 100 kilometers (44.38 US mpg) of premium unleaded. The A3 1.6 TDI emits 109 grams of CO₂ per kilometer (175 g/mile); the A3 1.4 TFSI emits 124 g/km (200 g/mile).

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Powertrains for the New Opel Astra

September 30, 2009

The 1.3-liter diesel CDTI for the Astra. Click to enlarge.

Opel introduced the new Astra at the Frankfurt Motor Show (IAA) earlier this month. (Earlier post.) The new Astra is launching with a complete line-up of eight gasoline and diesel engines ranging from 70 kW/95 hp to 132 kW/180 hp. The new Astra has grown slightly to provide a roomier interior and, at the same time, it has benefited from engineering enhancements that allow it to improve fuel efficiency and performance.

The Astra’s line-up of powertrains with manual transmission cuts fuel consumption and CO₂ emissions overall by more than 12% compared with the current generation. The average fuel consumption of the four diesel engines ranging from 70 kW/95 hp to 118 kW/160 hp, which are expected to represent almost half of the new Astra cars sold in Europe at launch, is 4.6 L/100 km (51 mpg US).

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Mazda to Debut Next-Generation Direct Injection Gasoline and Diesel Engines, Transmission and Kiyora Concept at Tokyo Motor Show 2009

September 29, 2009

The Kiyora Concept uses a 1.3-liter version of the new SKY-G gasoline direct injection engine and achieves fuel economy of 75 mpg US on the Japanese 10-15 cycle. Click to enlarge.

Mazda Motor Corporation will showcase the world premiere of its next-generation engine lineup and automatic transmissions at the 41^st Tokyo Motor Show, to be held from Saturday, 24 October through 4 November. Mazda will exhibit the Mazda SKY-G direct injection gasoline engine, the Mazda SKY-D advanced diesel engine and the Mazda SKY Drive high-efficiency automatic transmission.

The Tokyo Motor Show, to be held at Makuhari Messe in Chiba Prefecture, will also mark the Japan debut of the Kiyora concept car as an exhibit of Mazda’s next-generation environmental and safety technologies. Featuring the next-generation Mazda SKY concept powertrain technologies and comprehensive advancements in weight reduction, the Kiyora achieves fuel economy of 32 kilometers per liter under Japan’s 10-15 mode test cycle (3.13 L/100km or 75 mpg US).

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Auto Industry Backs Additional Funding for Research into Impacts of Mid-Level Ethanol Blends

September 25, 2009

Status of research into the effects of mid-level blends. Programs with red borders are unfunded; red bars are gaps in research. Source: Joint IEPR/TC workshop. Click to enlarge.

The Alliance of Automobile Manufacturers (AAM) and the Association of International Automobile Manufacturers (AIAM) sent a letter to US House and Senate Energy and Water Appropriators in support of additional funding to complete research into the impacts of mid-level blends of ethanol.

The US Environmental Protection Agency (EPA) is current considering a request to allow more than the current limit of 10% ethanol in gasoline to increase overall ethanol consumption in the US fuel pool. (Earlier post.) The auto industry in principle is not opposed to the introduction of such mid-level blends (i.e., above 10% but below 85%; but it wants the completion of current durability testing plans. (Earlier post.)

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Concept: Garric Rotary Variable Compression Ratio Engine

Basic components of the Garric engine. Click to enlarge.

A pair of Florida entrepreneurs, Rick Ivas and Gary Kelley, are developing the concept of the Garric engine: a rotary, variable compression ratio engine promising a combination of high power and torque and low fuel consumption.

With a 3.8-inch piston bore (comparable to a contemporary midsize V6) and a 10-inch toroidal radius, the Garric engine is calculated to deliver more than 225 hp (168 kW) of power and 733 lb-ft (994 Nm) of torque while running at 1050 rpm. Fuel consumption is estimated to be approximately one-third to one-quarter of current production V-6 engines.

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Delphi Highlighting New Components and Systems for Improving Fuel Consumption in Spark Ignition Engines

September 24, 2009

Spray stratified GDi. Click to enlarge.

Delphi is highlighting new developments in the area of fuel injection systems, ignition, valve train and ancillary systems for improving fuel consumption and lowering CO₂ emissions from spark ignition engines without what it calls the cost and risk of different technologies. The new systems are part of Delphi’s broad portfolio of powertrain technologies for gasoline, diesel, hybrid and alternative fuel vehicles.

Delphi’s portfolio of technologies for gasoline engines includes port fuel injection, homogeneous and stratified gasoline direct injection (GDi) and compressed natural gas (CNG), new Multi-Charge Ignition, and the new electrically driven cam phaser (e-Phaser).

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CPT VTES Electric Supercharger Selected for Two Projects

September 22, 2009

The VTES unit (inset) and installed in the AVL VW Passat demonstrator. in Click to enlarge.

Controlled Power Technologies’ VTES (Variable Torque Enhancement System) electric supercharger (earlier post) is being incorporated in a project by engine developer AVL (earlier post) and will also feature in the Ricardo-led £3 million (US$5-million) HyBoost program announced by the Technology Strategy Board on 9 September (earlier post). Both projects are seeking to maximize powertrain efficiency at the lowest possible cost.

VTES is an air-cooled Switched Reluctance machine, coupled to power electronics and an optimized radial compressor, that delivers high airflow, pressure and efficiency. The electric supercharger operates independently of engine speed, making it suitable to maintaining vehicle transient performance and driveability. The product is designed for integration into both Otto and Diesel engines to deliver enhanced torque, emissions control and CO₂ reduction. VTES is optimized to use the standard 12V vehicle architecture.

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US House Passes $2.85B Bill for Advanced Technology Vehicle R&D from 2010-2014

September 17, 2009

The US House yesterday passed by a vote of 312-114 a bill that would authorize additional appropriations totalling $2.85 billion over the 2010-2014 period for the US Department of Energy (DOE) to support a broad range of research activities for advanced technology vehicles.

H.R. 3246, the “Advanced Vehicle Technology Act of 2009” covers research on light-, medium- and heavy-duty vehicles, as well as infrastructure and pilot programs. Ultimately targeting the development of technologies and practices that improve the fuel efficiency and reduce emissions of vehicles produced in the US, the bill also aims to “ensure a proper balance and diversity of Federal investment in vehicle technologies”, while strengthening “partnerships between Federal and State governmental agencies and the private and academic sectors.”

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Audi’s Downsized 1.2L TFSI for the A3 and A3 Sportback

Audi has introduced a new low-displacement turbocharged gasoline engine in the A3 model line. (Earlier post.) The 1.2L TFSI engine generates 77 kW (105 hp), with fuel consumption of 5.5 L/100km (42.8 mpg US); CO₂ emissions are 127 g/km (204 g/mile).

Downsizing entails the replacement of engine displacement with turbocharging. The wholly redesigned 1.2 TFSI—which produces a specific power output of 87.7 hp per liter from 1,197 cc (73.05 cu. in.) of displacement—uses the same technologies as its siblings with 1.8 and 2.0 liters displacement.

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Ford Debuts Four-Cylinder EcoBoost Engine Family at Frankfurt; 1.6L and 2.0L I-4s to Start, Smaller Displacement Engine to Follow

September 16, 2009

1.6L I-4 EcoBoost. Click to enlarge.

Ford revealed further details of the upcoming four-cylinder versions of its turbocharged, gasoline direct-injected EcoBoost engine family (earlier post) at the Frankfurt Motor Show, prior to their first European production applications in 2010.

The all-new EcoBoost 1.6-liter and 2.0-liter (earlier post) I-4 engines combine turbocharging and direct-injection technology to deliver fuel consumption and CO₂ emissions reduced by up to 20% versus conventional, larger-displacement gasoline engines with similar power output. At the same time, EcoBoost engines will deliver the off-the-line power and performance comparable to diesels.

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Volkswagen Unveils New One-Liter Concept Car; Smallest Production-Intent Diesel Yet from Volkswagen Applied in A Full Hybrid Design

September 15, 2009

Dr. Ulrich Hackenberg, Member of the Board of Volkswagen Brand Technical Development, in front of the Volkswagen Concept Car L1 in Frankfurt. Click to enlarge.

Volkswagen unveiled the L1, its second-generation one-liter class concept car, at the Frankfurt Motor Show. The diesel-electric full-hybrid vehicle, weighing just 380 kilograms (838 lbs), offers an initial glimpse at how a future production version might appear.

The “one-liter” designation refers to the design target of fuel consumption of 1 liter per 100 kilometers (235 mpg US). Volkswagen first revealed a one-liter concept at the annual meeting in 2002, then cancelled the project in 2005. (Earlier post.) In 2007, Volkswagen CEO Martin Winterkorn confirmed that VW was resurrecting the 1-liter car project and would place it in production. (Earlier post.)

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Audi Adds A4 and A4 Avant 2.0 TFSI Flex Fuel Models; Optimized for E85

Audi has added new flexible-fuel versions to its A4 model series: The A4 and A4 Avant 2.0 TFSI flexible fuel can operate on up to E85 ethanol blends. The 2.0 TFSI flexible fuel engine is based on the 2.0 TFSI with Audi valvelift and start-stop system. Like that engine, it produces 320 N·m (236 lb-ft) of torque between 1,500 and 4,200 rpm and puts out 132 kW (180 hp).

The four-cylinder engine is optimized for operation on E85. E85 is currently available at nearly 300 gas stations in Germany, with Norway and Sweden having the densest network of E85 filling stations in Europe.

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Mercedes-Benz Adds Two Four-Cylinder BlueEFFICIENCY Diesels to GLK SUV Lineup; Potential to Meet EU6 and US BIN5 Limits

September 11, 2009

Mercedes-Benz GLK 250 CDI 4MATIC BlueEFFICIENCY, AMG sports package exterior. Click to enlarge.

Mercedes-Benz has added two new four-cylinder diesels to its GLK family of SUVs: the rear-wheel drive GLK 220 CDI BlueEFFICIENCY and the all-wheel drive GLK 250 CDI 4MATIC BlueEFFICIENCY. The latter features the most powerful four-cylinder diesel currently applied in an SUV. Both vehicles meet the EU5 emissions standard and have the potential to fulfill the future EU6 limits as well as the existing BIN 5 requirements in the USA.

GLK 250 CDI 4MATIC BlueEFFICIENCY. The new 2143 cc diesel engine with direct fuel injection produces 150 kW/204 hp and 500 N·m (369 lb-ft) of torque. With its high torque already present at 1600 rpm, the GLK 250 CDI 4MATIC requires 7.0 seconds to accelerate from 80 to 120 km/h (50 to 75 mph) for overtaking. Fuel consumption is 6.7 L/100 km (35 mpg US), with CO₂ emissions of 176 g/km.

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Volkswagen and LichtBlick Partner on Home Combined Heat and Power Systems; LichtBlick Plans a “SchwarmStrom” for 2,000 MW of Decentralized Power

September 09, 2009

An EcoBlue CHP unit. Click to enlarge.

Volkswagen and German energy supplier LichtBlick have formed an exclusive world-wide energy partnership. Volkswagen will produce the high-efficiency EcoBlue CHP (combined heat and power) plant, which is to be driven by natural gas engines from Volkswagen. LichtBlick will market the plants as “ZuhauseKraftwerke” (home power plants) and will use them in a new, decentralized intelligent power supply scheme: “SchwarmStrom” (current swarm).

LichtBlick plans eventually to network some 100,000 of the distributed home power plants to form a 2,000 MW virtual decentralized power plant to handle fluctuations in future electricity generation as renewables grow to represent a larger component of the power mix, according to Dr. Christian Friege, CEO of LicbtBlick.

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Grail Engine Adopts Enerpulse Pulse Plugs for Forced Semi-Homogeneous Charged Compression Ignition in Concept Two-Stroke Engine

September 08, 2009

Rendering of the Grail Engine. Click to enlarge.

Grail Engine Technologies, the designer of a two-stroke engine using forced semi-homogeneous charged compression ignition (FS-HCCI) combustion, has adopted the Pulstar pulse plugs from Enerpulse (earlier post). The Pulstar product offers very high power spark discharge, on the order of 1MW, to accelerate combustion pressures enabling forced semi-homogeneous combustion for all conditions.

HCCI is a combustion regime in which well-mixed fuel, exhaust gas and air are compressed to the point of auto-ignition. Unlike a spark ignition gas engine or diesel engine, HCCI produces a low-temperature, flameless release of energy throughout the entire combustion chamber. All of the fuel in the chamber is burned simultaneously. HCCI combustion can deliver a very efficient engine, potentially providing a 20% to 30% boost in gasoline engine efficiency without the NO_x or PM emissions of a diesel.

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Lotus to Introduce Range Extender Engine

September 07, 2009

The Lotus 1.2-liter, 3-cylinder Range Extender engine with integrated electrical generator. Click to enlarge.

Lotus Engineering will unveil its Range Extender engine at the 63^rd Frankfurt International Motor Show next week. In a series hybrid vehicle, the Range Extender engine is attached to an electricity generator and provides an efficient source of energy to power the electric motor directly or charge the vehicles battery. The battery can also power the electric motor which enables the design of a drivetrain that has low emissions, optimized performance and acceptable range.

The Lotus three-cylinder 1.2 liter Range Extender engine is optimized between two power generation points, giving 15 kW of electrical power at 1,500 rpm and 35 kW at 3,500 rpm via the integrated electrical generator.

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Citroën Launches the New C3; 99 g CO2/km Model Available From Launch

September 04, 2009

The new C3 with Zenith windshield. Click to enlarge.

Citroën is launching the new version of the C3 supermini (earlier post)—a best-seller that has sold more than two million units since its introduction. (The C3 was also Citroën’s first production vehicle fitted with a stop-start system, beginning in 2004. Earlier post .)

Controlled weight and aerodynamics (C_d 0.30) contribute to management of fuel consumption and CO₂ emissions; a 99 g/km HDi DPFS 90 diesel version is available from launch. This will be the first full production Citroën to emit less than 100 g CO₂/km.

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Hyundai to Debut ix-Metro Hybrid Concept and i10 Electric Vehicles at Frankfurt Show

The ix-Metro is a hybrid-electric CUV for the European sub-B segment which promises CO₂ emissions of 80g/km. Click to enlarge.

Hyundai will stage the world debut of the ix-Metro—a new hybrid-electric CUV concept for the European sub-B segment which promises CO₂ emissions of 80 g/km—at the upcoming Frankfurt Auto Show. The other world debut Hyundai will be making at Frankfurt is the i10 Electric, an electric urban commuter vehicle which will see limited series production beginning in 2010 with the Korean market.

The fifth in a series of concept cars to be created by the Global Design Team in Namyang Korea, the ix-Metro is powered by an inline three-cylinder, 1.0-liter gasoline engine. Direct injection, dual CVVT, turbocharging are all combined with a six-speed dual clutch transmission.

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Mercedes-Benz Provides Update on BlueZERO E-CELL PLUS Extended Range Electric Vehicle Concept

September 03, 2009

The BlueZERO E-CELL PLUS. Click to enlarge.

At the North American International Autoshow in January, Mercedes-Benz presented the Concept BlueZERO for electric vehicles. Based on a single vehicle architecture, this modular concept supports three models with different drive configurations: the BlueZERO E-CELL with battery-electric drive; the BlueZERO F-CELL (fuel cell); and the BlueZERO E-CELL PLUS with electric drive and internal combustion engine as range extender. (Earlier post.)

Mercedes has now provided some additional details on the extended range electric vehicle, BlueZERO E-CELL PLUS.

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Collins Bus Corporation Enters Agreement With CleanFUEL USA to Develop LPI Type A School Bus

The GM Cutaway G4500 will be the basis for the Collins LPI Type A buses. Click to enlarge.

Collins Bus Corporation has entered an exclusive agreement with CleanFUEL USA to develop the first Type A small school bus to operate on autogas with a Liquid Propane Injection (LPI) system. Type A school buses can typically transport between 14 and 30 passengers.

CleanFUEL USA is a leader in the development of Liquid Propane Injection and the only company that will currently offer an EPA- and CARB-certified system on the GM 6.0L gasoline engine cutaway chassis. Collins, as the largest builder of Type A school buses will offer this system as an option for several of its GM dual rear wheel models (e.g., the Collins Super Bantam).

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Ford Unveils New 6.7-L Power Stroke V-8 Turbocharged Diesel

August 31, 2009

6.7-liter Power Stroke V-8 turbocharged diesel engine. Click to enlarge.

Ford has provided initial details on the new Ford-engineered, -tested and-manufactured 6.7-liter Power Stroke V-8 turbo diesel engine. Debuting in the next-generation F-Series Super Duty truck, the new diesel engine will deliver improvements in torque, horsepower and fuel economy while adding more fueling flexibility—the engine is sanctioned for up to B20 biodiesel blends—and meeting 2010 emissions requirements.

The diesel engine team made improvements and changes throughout the engine architecture—including the use of an “inboard exhaust” design, a first for a modern production diesel engine—to deliver on aggressive horsepower, torque, emissions and fuel economy targets.

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Fiat Punto Evo To Debut at the Frankfurt Motor Show; Start&Stop Standard, Dual Fuel Versions

The Punto Evo. Click to enlarge.

The Fiat Punto Evo, the evolution of the Grande Punto, will make its debut at the Frankfurt Motor Show next month. The Punto Evo will offer a range of Euro 5 engines, including a 1.3 second-generation Multijet diesel and a 1.4-liter gasoline engine with the MultiAir electro-hydraulic valve-timing system developed by Fiat Powertrain Technologies and eventually to be incorporated in all Fiat Group engines. (Earlier post.)

The new Punto Evo also offers Start&Stop, the system that switches off and restarts the engine in stop-and-go traffic. Start&Stop is being introduced as standard on all Euro5 gasoline and diesel engines. Fiat is also offering methane and LPG units with the Punto Evo.

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Audi Introducing Three New Models at Frankfurt Show; New 1.2L A3, 3.0L TDI A4, and S5 Sportback

August 28, 2009

Audi will unveil three new vehicles at Frankfurt’s International Motor Show (IAA): the efficient A3 1.2 TFSI, the low-emission A4 3.0 TDI clean diesel quattro, and the S5 Sportback.

Audi A3 and A3 Sportback 1.2 TFSI. Downsizing is a key element of Audi’s efficiency strategy. Designed from scratch, the new turbocharged, gasoline direct injection 1.2 TFSI generates 77 kW (105 hp) from a displacement of 1,197 cm³ (73.05 in³). Due to an aluminum crankcase, this four-cylinder engine weighs just 89.5 kilograms (197.31 pounds).

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Saab to Introduce New 9-5 at Frankfurt

August 27, 2009

The new Saab 9-5 will debut in Frankfurt. Click to enlarge.

Saab provided initial information on its new 9-5 sedan, which will have its world debut at the upcoming Frankfurt Motor Show in September. The new sedan is slated to go on sale in 2010.

The all-turbo powertrain line-up is the broadest ever offered by Saab, carrying forward Saab’s rightsizing engine strategy through the development of efficient four-cylinder turbo engines. There is a choice of three fuels: gasoline, diesel and E85 bioethanol. A four-cylinder, 2.0-liter turbo diesel with six-speed manual transmission diesel offers CO₂ emissions as low as 139 g/km and fuel consumption of 5.3 L/100km (44.4 mpg US).

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Freescale Offers New Electronic Control Solution for Small Combustion Engines

Small engine system controls. Click to enlarge.

Faced with worldwide emissions regulations and rising gas prices, the small engine market is migrating from mechanical carbureted systems to cleaner, more efficient electronic control and electronic fuel injection (EFI). To meet these requirements, Freescale has combined a highly integrated analog device with a 16-bit microcontroller (MCU) to provide a cost-effective platform solution for small engine control.

Target applications for Freescale’s small engine control platform include small-displacement two- and four-stroke engines used in motorcycles, mopeds, scooters and three-wheeled taxis. The platform is also ideal for small engine designs in a wide range of outdoor power equipment, such as lawnmowers, garden tractors, trimmers, edgers, chainsaws, snow and leaf blowers, tillers, electrical generators and outboard motors.

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Using Hydrogen Injection to Improve Idle Combustion and Emissions Performance at Lean Conditions of Gasoline Engines

August 19, 2009

Gasoline and hydrogen rails and injectors installed on the intake manifolds. Credit: ACS. Click to enlarge.

Spark-ignited engines suffer high specific fuel consumption, emissions, and cyclic variation at idle and lean conditions. Increasing levels of hydrogen enrichment of a gasoline fuel charge in a spark-ignited (SI) engine can increase engine-indicated thermal efficiency and emissions at idle and extend the lean-burn limit, according to a study by researchers from the Beijing University of Technology. A paper on their work was published online 18 August in the ACS journal Energy & Fuels.

Changwei Ji and Shuofeng Wang modified a 4-cylinder (SI) engine to permit hydrogen and gasoline to be injected into the intake ports simultaneously to realize a hybrid hydrogen-gasoline engine (HHGE). The hydrogen and gasoline flow rates were governed by a hybrid electronic control unit (HECU).

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GM Developing New Concept for Emission Control for Lean-burn SIDI Engines: Passive Ammonia SCR

August 14, 2009

Engineers at GM’s R&D Center are developing a new low-cost concept for NO_x control from lean-burn spark ignition direct injection (SIDI) engines: passive ammonia SCR.

Lean-burn (i.e., a high air-to-fuel ratio) SIDI (e.g., gasoline) engines, with a higher charge mass and higher temperature spread, can deliver improved thermal efficiency and better fuel economy. However, SIDI engines also have the potential for increased pollutant formation, and require either careful control of combustion for reduced engine-out emissions, or an exhaust after-treatment systems similar to those under development for diesel vehicles.

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Advanced Turbocharged, Direct Injected Gasoline Engines Poised to Take on Diesels in US and in Europe for Reduced Fuel Consumption and Emissions

August 10, 2009

A confluence of technology developments, future emissions regulations and economic conditions will not only allow advanced light-duty spark-ignited gasoline engines to keep diesels at bay in the US market, but may also allow the gasoline units to push into the diesel-dominated medium-duty commercial truck and off-highway segments in the US, according to several presentations at the US Department of Energy’s 2009 Directions in Engine-Efficiency and Emissions Research (DEER) conference last week.

Additionally, suggested one of the speakers, advanced SIDI (spark-ignited, direct-injection) engines can take light-duty market share back from diesels in Europe based on the same trends.

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Detroit Diesel Developing a Model-Based Controller for Real-Time Fuel Efficiency Optimization in a Heavy-Duty Diesel

August 05, 2009

A team of researchers from Detroit Diesel and Chris Atkinson, of Atkinson LLC, are developing, demonstrating and validating a next-generation, model-based diesel engine controller that can optimize fuel efficiency in real time in low-emissions heavy-duty diesel engines under fully transient engine operating conditions.

To meet increasingly stringent emission control standards, heavy-duty diesels have become increasingly complex. While a diesel engine in 1998 would typically have one actuator, noted Marc Allain in his presentation of the project at the DEER 2009 conference in Dearborn, engines for 2010 and beyond will have 7-8 actuators.

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Use of Supercritical Diesel Fuel for Improved Efficiency and Reduced Emissions

August 04, 2009

An experimental P-T diagram mapping the liquid, liquid-vapor, and SC regions for diesel fuel-CO₂ mixtures with different compositions and densities (numbers in red and black, respectively). The fuel may coke for temperatures higher than 750 K (at the right of the red line). Anitescu et. al., Energy & Fuels 2009. Click to enlarge.

Researchers at Syracuse University (New York) have developed a method to prepare, inject and combust supercritical (SC) diesel fuel. The central part of the method is a new fuel system including high-temperature fuel injectors and a common rail to deliver SC fuel-diluent mixtures for combustion over ranges of conditions which will significantly improve engine efficiency, reduce PM and NO_x and mitigate the environmental thermal impact. Heat required to bring the fuel to SC states is recovered from the exhaust gas of the engine. George Anitescu from Syracuse presented the work in a poster at the DEER 2009 conference in Dearbon, Michigan.

A supercritical fluid is any substance at a temperature and pressure above its thermodynamic critical point. The injection and combustion of supercritical fuels is also the core of Khosla-backed startup Transonic Combustion’s technology. (Earlier post.)

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University of Wisconsin Researchers Investigating Dual-Fuel (Gasoline and Diesel) Partially Premixed Combustion for High-Efficiency, Ultra-Low Emission Combustion; 53% Thermal Efficiency

August 03, 2009

The dual-fuel PCCI strategy showed thermal efficiency of 53%. Source: Rolf Reitz. Click to enlarge.

Researchers at the University of Wisconsin, led by Dr. Rolf Reitz, are investigating a blended dual-fuel (gasoline and diesel) concept to extend the operating range of partially premixed charge compression ignition combustion by using the varying fuel reactivity of the charge blend, which is determined in real time.

In an invited talk given at the DEER 2009 conference in Dearborn, Michigan, Reitz described experimental results showing the dual-fuel partially premixed combustion (PPC) approach at 9-11 bar IMEP operating point (about 60% load) easily meeting US 2010 emissions standards in-cylinder while achieving thermal efficiency of 53%, compared to 45% for conventional low temperature diesel combustion (LTC).

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Ford Australia Invests A$230M in Fuel-Efficient Engines; First Global RWD Application of New 2.0L EcoBoost, LPG and Diesel

July 24, 2009

The Ford Falcon (XT model shown) will be the first global RWD application of the new 2.0L EcoBoost engine. Click to enlarge.

Ford Australia is investing A$230 million (US$188 million) to improve the fuel efficiency and environmental impact of its Australian-made models, including the first global rear-wheel drive application of Ford’s turbocharged, gasoline direct-injection 2.0L 4-cylinder EcoBoost engine (earlier post) in a rear-wheel drive vehicle, the Ford Falcon, starting in 2011. (Ford Australia has produced Falcons since 1960, originally based on the North American Falcon, a compact car Ford produced from 1960-1970.)

Ford Australia is taking two other steps in addition to the EcoBoost deployment to offer consumers more choices for vehicles with better fuel economy and lower CO₂ emissions. First, in 2010, Ford will introduce an advanced liquid-injection LPG system for the Ford Falcon, making the Falcon more attractive to private, taxi and fleet markets.

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Ford Announces 2.0L EcoBoost Engine; First Production EcoBoost with TI-VCT

July 22, 2009

The 2.0-liter EcoBoost I-4 Ti-VCT. Click to enlarge.

Ford has officially announced the second member of its turbocharged, gasoline direct-injection EcoBoost family, a 2.0-liter, four-cylinder version that will go on sale next year. The first engine in the EcoBoost line, a 3.5L, V6 engine (earlier post), is being applied in the 2010 Ford Taurus SHO and Flex and Lincoln MKS and MKT.

At the debut of the 3.5L EcoBoost engine at the North American International Auto Show in Detroit in January, Ford had also shown a Lincoln C (C-size) concept car powered by a 1.6-liter, four-cylinder EcoBoost engine mated to a dual-clutch Powershift Transmission. (Earlier post.) The 1.6L engine in the concept featured twin independent variable camshaft timing (TI-VCT)—a powertrain system also being used in the production 2.0L engine, the first EcoBoost production engine to include the system.

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DfT Publishes Ricardo Report on Technology Options for Reducing CO2 Emissions from Heavy Goods Vehicles; Focus on Vehicles, Powertrains and Fuels

July 18, 2009

Representation of cost vs. benefit of low-carbon HGV technologies. Source: Ricardo/DfT. Click to enlarge.

The UK Department for Transport has published a report prepared by Ricardo on the potential of various technologies for reducing CO₂ emissions that are applicable to the heavy goods vehicle (HGV) sector. HGVs (goods transport vehicles with >3.5t GVW) represent 24% and vans 12% of total UK road transport greenhouse gas emissions.

The report presents an analysis of a number of HGV technologies with carbon saving potential and evaluates these technologies in terms of CO₂ benefits, technology costs, environmental costs arising from production of the technology, safety and other limitations, and the maturity of the technology within the market. The report then summarizes which technologies are the most promising in terms of CO₂ benefits when all these other factors are taken into consideration.

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Nissan Introduces New Dual Injector System for Improved Fuel Efficiency in Small-Displacement PFI Engines

July 14, 2009

Nissan’s Dual Injector. Click to enlarge.

Nissan Motor Co., Ltd. has developed a Dual Injector system designed to improve fuel efficiency in small-displacement gasoline engines using port fuel injection (PFI).

While most current port fuel injected gasoline engines utilize one injector per cylinder (furnishing fuel to two intake ports), the new Nissan Dual Injector system uses an injector for each intake port—i.e., doubling the number of injectors per cylinder.

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New Delphi Powertrain Mounts Use Magneto Rheological Fluids to Improve Performance, Safety and Refinement; Improved Handling of Transient Torque Events

July 09, 2009

Delphi’s new MR Mount is the first technology that allows precise real-time management of all the relevant frequencies created by an automotive powertrain. Click to enlarge.

Delphi Corporation has developed a new powertrain mount that uses magneto rheological (MR) fluid to change its dynamic rate in real time. MR fluid is a suspension of magnetically soft particles in a synthetic hydrocarbon fluid.

The new MR Mount prevents the build-up of resonance in a system by maintaining control of the mounted mass across all appropriate frequencies. As well as significantly reducing powertrain noise and vibration, the new mount can improve vehicle performance and stability and help isolate the occupants from torque step events such as those generated by start-stop operation.

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RadMax Axial Vane Rotary Diesel Engine Drawings Released for Bid

July 07, 2009

Rad Max assembly. Source: REGI US. Click to enlarge.

REGI US, Inc. and Reg Technologies Inc. have completed a final set of manufacturing drawings for the RadMax Diesel Engine, and have released them competitive bid.

The companies are developing an improved axial vane type rotary engine known as the RadMax. The RadMax design was mainly developed by Radian Milparts and assigned to REGI US, Inc. in December 2005. (Earlier post.) The RadMax engine has only two unique moving parts, the vanes (up to 12) and the rotor; the design makes it possible to produce up to 24 continuous power impulses per one rotation that is vibration-free and extremely quiet.

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Bosch: Electrification is Coming, But Combustion Engines to Dominate for Another 20 Years

July 01, 2009

In the long run, the large variety of drivetrain concepts will give way to electric drive. Source: Bosch. Click to enlarge.

While full electric powertrains (battery and fuel cell) will at some point become pervasive in light-duty vehicles, the dominance of the internal-combustion engine will remain unchallenged over the next twenty years, according to Robert Bosch GmbH executives at their annual International Automotive Press Briefing in Boxberg, Germany. This is due in part to important technological challenges to powertrain electrification that must first be overcome and in part to ongoing efficiency improvements in combustion engine technology.

As a supplier, Bosch is active in both areas, said Dr. Bernd Bohr, chairman of the Bosch Automotive Group. Bosch is working hard to get the electric drive of the future readied for large-scale series production, while also doing its utmost to further improve the internal-combustion engine for decades to come, Bohr said. The company is investing €3 billion (US$ 4.25 billion) in R&D in the automotive technology sector in 2009.

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BMW Technology Day 2009: Focus on Aerodynamics, Two New Engines and 8-Speed Transmission

June 25, 2009

The new 3.0-liter gaosline engine combines turbocharging, direct fuel injection and VALVETRONIC for the first time. Click to enlarge.

For its Technology Day 2009 in Germany, BMW focused on describing its work with aerodyanmics, engines and transmissions in the context of its EfficientDyanmics development strategy.

The company presented the capabilities of its Aerodynamic Test Center and Aerolab; a new 3.0-liter gasoline unit combining turbocharging, direct fuel injection and VALVETRONIC fully-variable valve management; a new 3.0-liter twin turbo diesel with 2,000-bar injection pressure; and an 8-speed automatic transmission that can also be used in a hybrid application.

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Citroën Introduces New 3.0L Diesel

June 19, 2009

Torque curve for the HDi 240. Click to enlarge.

Citroën has introduced the new 3.0-liter diesel V6 DPFS HDi 240 engine for the C5 and C6. Improvements in the engine offer a reduction in fuel consumption and CO₂ emissions by between 12% (in the C5) and 15% (in the C6) compared to the outgoing 2.7L version it replaces. The engine features a new third-generation direct common-rail injection system; new generation combustion chamber; dual variable geometry turbochargers; exhaust gas recirculation; and an alternator which recovers energy during deceleration and braking.

Power output is now 177 kW (237 hp)—an increase of 18%—with a maximum torque of 450 Nm (332 lb-ft) at 1,600 rpm. Fitted with an 6-speed automatic gearbox, the fuel consumption on combined cycle of the two cars is 7.4 L/100 km (32 mpg US) with CO₂ emissions of 195 g/km. The engine complies with the future Euro V emission standards.

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Integral Powertrain Developing New Variable Ratio Drive B-ISG System for Stop-Start Applications

June 18, 2009

A variable ratio pulley allows improvements in cost and functionality. Click to enlarge.

UK-based engineering consultancy Integral Powertrain has developed a new generation of belt-integrated starter generator (B-ISG systems) for stop-start applications using a new multi-mode, variable ratio drive pulley. The company anticipates that the total CO₂ reduction achieved by the system will be greater than that possible with current B-ISG systems.

The core of the new system is the Variable Ratio Pulley, which packages a two-ratio epicyclic gearbox into the belt drive pulley hub. To start the engine, the high ratio (3.1:1 in the development system) is engaged to substantially reduce the torque requirement, allowing a medium-sized diesel engine to be cranked without the need for a high belt tension and the associated friction and wear.

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“Clean Sky” Joint Technology Initiative Launches Initial €25M Call for Research Proposals on Cleaner Air Transport

June 17, 2009

The Clean Sky JTI effort is arranged around six technology demonstrators. Click to enlarge.

The European Clean Sky Joint Technology Initiative (JTI) launched a call for proposals for aeronautical R&D with a total value of more than €25 million (US$35 million), focused on the development of a new generation of quieter, more fuel-efficient and lower emitting aircraft.

The Clean Sky JTI is a major public/private partnership to develop technology that can reduce aviation CO₂ emissions by 40%; NO_x emissions by 60%; and noise by 50%. (Earlier post.) This call is the first in what will be one of Europe’s biggest ever research projects, with €1.6 billion (US$2.2 billion) to be invested up to 2014. The Clean Sky initiative will run until 31 December 2017.

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Volvo to Introduce Proprietary Medium-Duty Engine in 2010

The Volvo Group is developing its own medium-duty (MD) engine for trucks and buses. The first of these new medium-duty engines will be launched in 2010, according to Volvo CEO Leif Johansson in his presentation at Volvo’s Capital Market Day in Eskilstuna, Sweden.

Johansson also said that the Volvo Group’s investments in research and technology will remain at high levels in the next few years since new emissions legislation will be introduced for trucks, buses and construction equipment.

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GE Aviation Unveils GEnx Engine at Paris Air Show; Up to 15% More Fuel Efficient

June 16, 2009

The GEnx-1B turbofan engine. Click to enlarge.

GE Aviation unveiled its new GEnx engine in a special ceremony at the 2009 Paris Air Show at Le Bourget. The GEnx engine offers up to 15% improved fuel efficiency compared with GE’s CF6 engine that it will replace. This fuel efficiency translates to approximately 15% less CO₂. The GEnx will also be the quietest engine that GE has produced, based on the ratio of decibels to pounds of thrust.

The new engine is designed to stay on wing 30% longer, while using 30% fewer parts, greatly reducing maintenance. The GEnx’s emissions will be as much as 95% below current regulatory limits, ensuring future compliance. Based on the GE90”s proven architecture and often called its “little brother,” the GEnx combines a number of breakthrough technologies:

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Fiat Launches MultiAir Combined with Start/Stop on the MiTo

June 15, 2009

The MiTo Multiair. Click to enlarge.

Fiat is launching a 1.4-liter turbocharged gasoline engine equipped with the new MultiAir air handling system (earlier post) on the Alfa Romeo MiTo (earlier post) in September. The MultiAir models will also feature the Start&Stop system (from Bosch, earlier post)—the first application in the MiTo. This also marks the first production engine using the MultiAir system, introduced at the Geneva Motor Show earlier this year.

MultiAir is an electro-hydraulic valve-timing system that provides dynamic and direct control of air and combustion, cylinder by cylinder and stroke by stroke. With direct control of the air through the intake engine valves without using the throttle, MultiAir helps reduce fuel consumption and pollutant emissions.

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BorgWarner Electric Butterfly EGR Valve to Debut with Diesel Engine OEM in 2010

BorgWarner’s new electric butterfly EGR valve technology will debut with a leading commercial engine manufacturer in 2010. Click to enlarge.

BorgWarner is introducing an electric butterfly EGR (exhaust gas recirculation) valve for diesel applications. The EGR valve was developed to deliver precise, responsive flow control combined with high flow capability, excellent sealing, corrosion resistance and reliable operation in the most severe operating environments. The technology will debut with a leading commercial engine manufacturer in 2010.

Recirculating exhaust gas and combining it with an air and fuel mixture reduces the combustion temperatures that produce NO_x emissions. New engine concepts for commercial diesel vehicles require greater use of state-of-the-art EGR systems to meet ever stricter emissions standards, according to Roger Wood, BorgWarner Engine Group President.

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DOE to Fund Up to $240M for Class 8 Supertruck and Advanced Technology Light-Duty Powertrains

June 10, 2009

The US Department of Energy will provide up to $240 million in funding for research projects in two specific areas of interest: (1) developing systems for and demonstrating a 50% total increase in vehicle freight efficiency measured in ton-miles per gallon in Class 8 trucks (Supertruck); and (2) accelerating the development of cost-competitive engine and powertrain systems for light-duty vehicles capable of attaining at least a 25% fuel economy improvement for gasoline-fueled vehicles and at least 40% fuel economy improvement for diesel-fueled vehicles while meeting future emissions standards (ATP-LD). Measured fuel economy improvements cannot factor in a hybrid system.

Projects under this funding opportunity (DE-FOA-0000079) will be financed, in whole or in part, with funds appropriated by the American Recovery and Reinvestment Act of 2009. Applications are due by 9 September 2009.

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UK LowCVP Launches ‘Technology Challenge’ to Accelerate Low Carbon Vehicle Innovation; Libralato Engines First Registrant

June 08, 2009

The first registrant in the Challenge is Libralato Engines, developer of a novel rotary engine (cutaway shown) promising a 5.5% gain in combustion efficiency and 50% reduction in NO_x emissions. Click to enlarge.

The UK Low Carbon Vehicle Partnership is launching a Technology Challenge to provide a platform for promising innovations to be showcased to senior managers and directors of the component and vehicle manufacturers. The LowCVP is calling on UK innovators to submit creative concepts with the potential to cut emissions from road vehicles without the need for radical new infrastructure. The target of the Challenge is mainstream passenger cars producing less than 80 g CO₂/km.

The LowCVP Technology Challenge is supported by the Institution of Mechanical Engineers (IMechE) and with an associated media partner, Cleantech Investor.

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Australian Cam-Drive Gasoline Engine Reaches 39.5% Efficiency in Independent Testing; Potential for Production Engine in China

June 06, 2009

The 2.4-liter X4V2 prototype was originally designed for an aviation application. Click to enlarge.

Australia-based Revetec is designing what it calls the Controlled Combustion Engine (CCE)—a cam-drive gasoline spark-ignited internal combustion engine that is smaller, lighter, cleaner, less expensive to manufacture and that produces higher torque due to higher mechanical transfer than equivalent conventional engines.

Revetec has prototyped 6 different versions of Revetec engine designs over the last 10 years. The latest version, the X4V2, was designed as a development engine for the aviation industry, and in early 2008 it was independently tested by Orbital Australia.

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ORNL Research Project Seeks to Boost Combustion Engine Efficiency To 50-60% By Reducing Combustion Irreversibility; RAPTR

June 04, 2009

The RAPTR experimental device. RAPTR is being designed to investigate Regenerative Air Preheating and Thermochemical Recuperation concepts for reducing losses from combustion irreversibility. Click to enlarge.

Researchers at Oak Ridge National Laboratory (ORNL) are investigating mechanisms for extending the efficiency of combustion engines closer to their theoretical potential. The work, which started in FY 2005, involves a complex optimization of materials, controls and ultimately, the thermodynamics, said C. Stuart Daw in a presentation at the recent DOE merit review meetings in Washington, DC.

Today’s engines can deliver a fuel efficiency of 40-42%, with corresponding loss of initially available fuel energy of 58-60%. The ORNL project is seeking essentially to flip that, to enable efficiencies of 50-60%, with losses of 40-50%. “This is long-term, high-risk [research], but obviously the payback is increasingly important,” Daw said.

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Oil Drum Licenses On-Board Hydrogen Generator for Baltic States

June 03, 2009

University of Kent (UK) spin-off Oil Drum Ltd, has signed a licensing deal with UAB Hydro2 that will enable its on-board hydrogen generator technology to be manufactured, sold and installed in the Baltic States. The deal will allow UAB Hydro2 to manufacture, sell and install the Save-Fuel On Demand Hydrogen Technology for the truck, bus and coach industries in Lithuania, Latvia and Estonia.

The retrofit device reduces fuel consumption by adding hydrogen, produced by electrolysis, into the engine via the air intake of the vehicle before the combustion process. As a result the engine burns fuel more efficiently and produces less particulate emissions and reduces the vehicle’s environmental impact.

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BorgWarner Acquires ECCOS Radio Frequency Electrostatic Ignition Technology for Leaner Burning Engines

June 02, 2009

Comparing standard and ECCOS combustion. Source: Etatech. Click to enlarge.

BorgWarner Inc. has purchased the ECCOS (Electrically Controlled Combustion Optimization System) radio frequency electrostatic ignition technology targeted at lean-burn engines from Florida-based Etatech, Inc. Terms were not disclosed.

High-performance, lean-burn engines can significantly improve fuel economy and reduce emissions compared with conventional combustion technologies. Independent lab tests have shown peak energy efficiency improved up to 40%, NO_x emissions decreased 80% and CO₂ emissions fell 50%. However, current spark plug technology is unable to optimize the lean burning engines.

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Ford Team Given 2009 National Inventor of the Year Award for Plasma Transferred Wire Arc Engine Coating Technology

May 29, 2009

Application of PTWA Coating to Ford ZETEC 1.4 Liter VCT Engine. Click to enlarge.

The Intellectual Property Owners Education Foundation is awarding the inventors of the Ford-patented Plasma Transferred Wire Arc (PTWA) technology used to apply coatings on engine cylinder bores the 2009 National Inventor of the Year Award. Ford presented a paper on PTWA at the SAE 2008 World Congress. (Earlier post.)

Ford’s PTWA thermal spray coating process for aluminum engine blocks replaces heavy cast iron liners, thereby improving fuel efficiency by reducing engine weight and internal piston friction losses. Ford has 95 issued and pending patents related to the new PTWA coating technology and will introduce it on its North American powertrain lineup within the next year.

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GM’s HCCI Demonstrator Combines a Set of Enabling Technologies and Strategies for Extending Operating Range

May 28, 2009

GM approaches to extending the operating range of classic HCCI. Adapted from Yun et al. (SAE 2009-01-0499) Click to enlarge.

General Motors last week again highlighted the progress it is making with advanced HCCI (homogeneous charge compression ignition) gasoline engines by showcasing a demonstrator unit. GM has also begun to publish SAE papers describing the techniques and strategies it is using to extend the fuel-efficient, low-emissions HCCI operating range down to lower load regions.

To extend HCCI to idle (shown last year, earlier post), GM is using a Multiple Injection and Multiple Ignition (MIMI) strategy, combined with the use of in-cylinder fuel reforming during recompression as a bridge technique up to the classic HCCI operating range, said Paul Najt, Lab Group Manager, GM Powertrain Systems Research. (Najt, then at the University of Wisconsin, and David Foster published the first study of a gasoline-fueled four-stroke HCCI engine in 1983.)

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Fiat Launches New 1.8L Gasoline Direct-Injection Turbo in Lancia Delta

May 25, 2009

The 200 HP 1.8 Di TurboJet. Click to enlarge.

Fiat has launched a new 1.8-liter, four-cylinder turbocharged gasoline direct-injection engine—the 1.8 Di TurboJet—in the Lancia Delta. Produced by Fiat Powertrain Technologies (FPT) and coupled with a six-speed automatic transmission, the 1.8 Di delivers maximum power of 200 hp (147 kw) at 5,000 rpm and a maximum torque of 320 N·m (236 lb-ft) at 1,400 rpm.

A new scavenging strategy combined with the engine control system contributes to a specific drive torque (185 Nm/L) that is one of the highest currently available. The 200 HP 1.8 Di Turbo Jet E5 drive torque is comparable to the one of an aspirated V6 engine which is almost twice its displacement, according to Fiat, but with significant efficiency gains through the downsizing.

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Concept: Downsized and Supercharged Hybrid Pneumatic Engine for 30%+ Reduction in Fuel Consumption

May 23, 2009

Schematic of downsized and supercharged four-stroke hybrid pneumatic spark injection engine. Source: ETH Zürich. Click to enlarge.

Researchers at ETH Zürich, with partners Robert Bosch GmbH, Wenko Swissauto and the Swiss Federal Office of Energy are developing a downsized and supercharged hybrid pneumatic engine that they say can deliver a fuel consumption reduction of more than 30% compared to a standard engine with the same rated power. (Earlier post.)

The reduction in fuel consumption is obtained mainly through enabling the effective use of a heavily downsized engine, rather than from regenerative efficiency. The injection of the additional air during transients can overcome the poor driveability usually associated with heavily downsized and supercharged engines, the team notes.

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Envera LLC Nearing Completion of New Actuator Mechanism Project for Variable Compression Ratio Engine

May 22, 2009

The Envera VCR mechanism. The rack and pinion can be located vertically (shown) or horizontally. Source: Envera. Click to enlarge.

Envera LLC is nearing completion of a project to develop a new hydraulic actuator mechanism for its variable compression ratio (VCR) engine. Charles Mendler, the principal of Envera and the inventor of this particular approach to a VCR engine, provided the update on the project at the Department of Energy (DOE) Merit Review this week in Washington, DC.

A number of studies have concluded that fuel economy could be improved by about 30% with a combination of VCR, boosting and engine down-sizing. Analysis conducted by Envera in 2004 indicates VCR can provide fuel economy gains larger than 30% through optimized conventional combustion and/or homogeneous charge compression ignition (HCCI).

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Cummins Progressing In Development of More Efficient Light-Duty Diesel Engines; Targeting 10.5% Fuel Economy Improvement Over 2007 Baseline With Tier 2 Bin 5 Emissions

May 21, 2009

Cummins’ Light Duty Efficient Combustion technology is designed to scale down across smaller light-duty engines. Source: Cummins. Click to enlarge.

Cummins is progressing in the development of Light Duty Efficient Clean Combustion (LDECC) technology for light-duty diesel engines. The objective of the DOE co-funded R&D program, which began in October 2007 and runs through November 2010, is to develop and design an advanced diesel combustion system that meets Tier 2 Bin 5 standards while delivering improvements in fuel efficiency. Project partners include Chrysler and BP.

Cummins is developing LDECC on a V8, and is targeted at improving the fuel efficiency of a 5,000 lb test weight LDV over the FTP city drive cycle by 10.5%. Cummins is designing LDECC with the intention of scaling it down across its family of smaller I-4 light duty engines, with displacements down to 2.8L.

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EngineLab Developing New Approach to Engine Control (updated)

May 20, 2009

by Bill Cooke

EngineLab GUI. Source: EngineLab. Click to enlarge.

EngineLab, a new technology company focused on automotive electronics embedded system design, is planning to revolutionize the engine control business by applying advanced technologies developed for consumer electronics to a vehicle’s Electronic Control Unit (ECU).

The company is especially excited about how this development has the potential to unleash the creativity of innovators with princely visions but pauper budgets by allowing them to monitor and control an engine’s inputs and outputs in real time using a graphical user interface. The company is evaluating producing ECUs for aftermarket tuners (performance and green) as well as licensing their technology to Tier 1s and OEMs.

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AVL Introduces New Modular Range Extender Technologies and Engineering Services

May 17, 2009

A Range Extender Module based on a rotary engine. Click to enlarge.

AVL has introduced new range extender system technology and engineering services targeted at OEMS for short-term market introduction of range-extended electric vehicles.

The Range Extender is an autonomous auxiliary power unit added to pure electric drive vehicles to extend the operational range beyond that obtainable in the pure electric mode. AVL took a modular approach; depending on the specific customer production background and product needs, the internal combustion engine (ICE) component can be designed as a 2- or 4-stroke piston engine, or for lowest NVH and best compactness, as a rotary engine.

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Optimized Series Hybrid-Electric System Delivers Best Fuel Consumption Results Yet for Double Deck Vehicle

May 14, 2009

The Gemini 2 HEV. Click to enlarge.

In a recent independent test cycle at the Millbrook Proving Ground in the UK, a Wrightbus Gemini 2 HEV achieved the best results for fuel consumption and CO₂ emissions ever recorded from a double deck vehicle: 10 mpg UK (8.3 mpg US, 28 L/100km).

The test was part of the Wrightbus Product Development team’s collaboration with Queens University Belfast and key component suppliers including Siemens, Valence Technology and Ford. The series hybrid-electric drive system also uses an optimized engine management program developed by Revolve Technologies. Revolve Technologies was formerly the UK-based Roush Technologies Limited. An investor group acquired Roush Technologies from its US parent late in 2007, and changed the name to Revolve in December 2008.

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Volvo Upgrades Power, Lowers Fuel Consumption of 2.5L Flex-fuel Engine

Volvo Cars has boosted the power of its five-cylinder, 2.5-liter Flexifuel engine by 30 hp and delivered an additional 40 N·m of torque. (Earlier post.) The 2.5FT now produces 231 hp (170 kW) and 340 N·m (251 lb-ft) of torque. At the same time, Volvo engineers have cut fuel consumption by between five and six percent depending on transmission.

Fuel consumption (EU, mixed driving cycle on gasoline) for the upgraded 2.5FT is 8.8 L/100 km (26.7 mpg US) (V70) and 8.6 L/100 km (27.4 mpg US) (S80) with manual transmission, and 9.7 L/100 km (24.2 mpg US) (V70) and 9.6 L/100 km (24.5 mpg US) (S80) with automatic transmission. This is an improvement of about 5% for the manual versions and almost 6% for cars with automatic transmission.

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Volkswagen Emphasizes Downsizing at 30th Vienna Engine Symposium; Highlights 1.2 TSI and 1.6 TDI

The new 1.6-liter TDI. Click to enlarge.

Continuing to emphasize a downsizing approach, Volkswagen presented two new engines at the at the 30^th Vienna Engine Symposium (7-8 May): the 1.2-liter TSI gasoline engine and the 1.6-liter TDI diesel. Both engines will be available to order for the new Polo and the Golf this year. (Earlier post.)

Due to its modular structure, the 1.6-liter TDI engine will serve as a basis for all future four-cylinder diesel engines of Volkswagen.

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European Automotive Industry Outlines R&D Priorities for EU Green Car Initiative

May 07, 2009

European automotive suppliers and vehicle manufacturers have united to submit a series of R&D priorities to the European Commission to shape the European Green Car Initiative (EGCI), announced by the EU. CLEPA (the European umbrella membership organization representing the interests of the global automotive supply industry) and EUCAR (the European Council for Automotive R&D from the major European passenger car and commercial vehicle manufacturers) jointly prepared the document.

The Green Car Initiative, a part of the European economic recovery plan, aims to allocate €5 billion (US$6.7 billion) through a Public Private Partnership to bolster innovation in the automotive sector and sustain its focus on environmental progress. The initiative complements the European Clean Transport Facility which, through the European Investment Bank, serves to provide more immediate financial relief to the sector.

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GM And University of Michigan Form GM/U-M Institute Of Automotive Research And Education; Focus On Fuel-Efficiency And Reinvention Of The Automobile

General Motors and the University of Michigan have formed the GM/U-M Institute of Automotive Research and Education, with a strategic focus on reinventing the automobile and developing the next generation of high-efficiency vehicles powered by diverse energy sources.

The Institute, which builds on more than 50 years of collaboration between the organizations, supplements GM’s ongoing research and development in key areas: advanced batteries, engine systems, smart materials and vehicle manufacturing.

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Transonic Combustion Completes New Round of Venture Funding

May 06, 2009

Start-up Transonic Combustion, Inc., has raised a C-round of equity funding. Existing investors Venrock, Khosla Ventures, Rustic Canyon Partners and Saints Capital all increased their support of Transonic in the round.

Transonic Combustion is developing an advanced lean combustion process and associated gasoline fuel injection system which it projects will enable practical 100 mpg cars. The patented combustion process remains stable well above a 200:1 air/fuel ratio and can support vehicle cruise power at a 100:1 air/fuel ratio.

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Controlled Power Technologies and AVL Collaborate on Advanced Direct Injection Gasoline Engine Demonstrator

May 05, 2009

CPT electric VTES installed in AVL demonstrator. Click to enlarge.

Controlled Power Technologies (CPT) and AVL List GmbH (AVL) have developed a gasoline engine that retains all the traditional cost, weight, NVH refinement and emission benefits as well as the fun-to-drive factor, while reducing CO₂ levels to that of an equivalent diesel powertrain.

The AVL demonstrator vehicle incorporates an advanced 2-liter 4-cylinder engine with gasoline direct injection (GDI), double cam phasing and single-scroll, waste-gated turbocharger to deliver high power and torque outputs of 200 PS (197 hp, 147 kW) and 400 N·m (295 lb-ft) respectively.

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Polystyrene-Biodiesel Blends for Energy Recovery from Waste Plastics

May 04, 2009

Comparisons of NO_x, CO, soot, and engine brake power using different PS blends with the factory-set injection timings. Credit: ACS. Click to enlarge.

Researchers at Iowa State University are proposing dissolving waste polystyrene (PS) in biodiesel for use as a diesel engine fuel as a mechanism for energy recovery from the waste plastic. Use of polystyrene-biodiesel blends can result in an increase an engine power with polystyrene concentrations of up to 5%, according to a new study by a team of researchers from Iowa State University. At concentrations higher than 5%, engine power decreased.

However, emissions of NO_x, soot, CO and hydrocarbons increased with polystyrene concentrations if the injection timing was free to advance due to the increased bulk modulus and fuel viscosity. Varying engine operating parameters, including the fuel injection timing and exhaust gas recirculation resulted in lower NO_x emissions but still resulted in higher soot, CO, and HC emissions.

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DOE Announces Up to $13M in Funding for Six Advanced Combustion and Emissions Controls R&D Projects

The US Department of Energy (DOE) selected six cost-shared University Advanced Combustion and Emissions Controls research and development projects totaling up to $13 million in DOE funding, subject to annual appropriations.

The research projects will contribute to the development of high efficiency internal combustion engines with the goals of improving fuel economies by 20-40% in light-duty vehicles and attaining 55% brake thermal efficiency in heavy-duty engine systems.

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Ford Conducts Design of Experiment Investigating Thermoelectric Energy Regeneration

by Jack Rosebro

Conceptual schematic of direct thermoelectric generator mounted in a vehicle’s exhaust stream. Indirect configurations are also possible. Adapted from Hussain et al. Click to enlarge.

At SAE 2009 World Congress in Detroit last month, Ford Motor Company presented a research paper that detailed the results of an initial investigation, termed a Design of Experiment, into thermoelectric exhaust heat energy recovery in conjunction with a hybrid powertrain.

The investigation, conducted by Ford engineers Quazi Hussain, Clay Maranville, and David Brigham, used computer modeling to predict the performance of TE devices of various physical configurations, using average highway-speed exhaust gas flows and temperatures of a 2.5L engine with an Atkinson-cycle engine, as used in Ford’s Escape hybrid SUV.

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Study Finds Strong Synergy Between Spark Ignition Engine Downsizing and Low-to-Moderate Alcohol Blend Fuels

May 01, 2009

A study by engineers from Mahle Powertrain Ltd and BP found strong synergy between spark ignition (SI) engine downsizing and fuel containing low-to-moderate amounts of alcohol, including ethanol and butanol. The team presented a paper on their work at the recent SAE 2009 World Congress in Detroit.

The researchers found that the combination of technologies allowed improvements in fuel economy over the engine drive cycle. Furthermore, a reasonable improvement in dilution tolerance could be achieved at higher engine loads, which could eliminate over-fueling requirements under such conditions.

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Orbital Corporation and Changan to Develop Concept Engine

The ChangAn CA18 FlexDI Concept Engine shown at Auto China 2008. Click to enlarge.

Orbital Corporation Limited and Chongqing Changan Automobile Co., Ltd, China’s fourth largest automotive manufacturer, have entered into a joint development contract for a concept engine. The development will be carried out on Changan’s current gasoline engine platform with an objective to achieve a significant fuel economy benefit utilizing Orbital’s FlexDI technology. (Earlier post.)

The program is focused on fuel economy improvement while achieving Euro IV emissions level. Orbital was selected as the technology with the best potential to meet the aggressive targets required for the program.

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Developing Ford’s EcoBoost Combustion System

April 29, 2009

Configuration of the 3.5L V6 EcoBoost Combustion System. A 6-hole fuel injector is mounted between intake ports. The spark plug is at the center of the chamber. The piston has a shallow bowl designed to ensure stable combustion during engine cold-start operations. Source: Ford. Click to enlarge.

Ford’s turbocharged, gasoline direct injection EcoBoost engines are targeted to play a significant near-term role in Ford’s efforts to reduce fuel consumption by enabling downsizing. The first application of this technology bundle in a 3.5L V6 engine (the Duratec D35 EcoBoost) delivers up to 12% better fuel economy and 15% lower emissions with comparable torque and power as a 5.4L port fuel injected (PFI) V8 engine. (Earlier post.)

At the recent SAE 2009 World Congress, Ford engineers presented six papers detailing aspects of the EcoBoost technology, including a discussion of the development and optimization of the EcoBoost Combustion System—a key to the performance of the engine.

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Ford E85 Direct Injection Boosting Study: A Less Expensive Alternative to Diesel

April 26, 2009

Using a separate E85 direct injection boosting system combined with gasoline port fuel injection (PFI) makes the engine more efficient in its use of gasoline, and can be viewed as a more cost-effective alternative to a modern diesel, according to a Ford study presented by Robert Stein, currently of AVL, formerly of Ford, at the SAE 2009 World Congress.

Proposed by John Heywood and colleagues at MIT in 2005, the basic premise of E85 boosting is that ethanol (or other lower alcohols) suppresses knock due to the large evaporative cooling effect it has on the air-fuel mixture when injected directly into the cylinder, supplemented by ethanol’s inherent high octane number. Using the E85 boosting concept requires two fuel tanks and vehicle owner acceptance of dual fueling.

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Israeli Microturbine-Based Range-Extended Electric Vehicle Startup Lands $12M Series A Round

April 25, 2009

Drawing of the proposed advanced microturbine. Source: ETVM Click to enlarge.

ETV Motors Ltd. (ETVM), an Israeli start-up developing a range-extended electric vehicle (REEV) technology combining a novel dual-power micro-turbine and a new high-voltage lithium-ion battery chemistry, has closed a US$12-million Series A investment round. The round was led by The Quercus Trust of Newport Beach, California. New York-based 21Ventures LLC co-invested.

The investment enables ETVM to move ahead with a multi-year research and development program in which it is partnering with universities and development organizations.

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Concept: Honda R&D Developing Variable Compression Ratio Engine with Dual Piston Mechanism

April 22, 2009

Engineers from Honda R&D Co., Ltd. presented a pair of papers at the SAE 2009 World Congress describing the development of a variable compression ratio (VCR) engine enabled by a dual piston mechanism. The compact VCR uses the inertia force of the piston and external hydraulic pressure to raise and to lower an outer piston to switch the compression ratio between low and high stages.

In testing in an otherwise conventional production 2.0-liter, 4-cylinder engine, the dual piston mechanism was able to adjust the engine from a CR of 9.6 to 14.2 and back again. Combining the high compression ratio with the Atkinson cycle, the engineering team demonstrated a 7.4% improvement in fuel economy in operation over the Japanese 10-15 cycle. As part of the study, the team also demonstrated switching durability of the dual piston mechanism of more than one million cycles.

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Toyota Brings New Gasoline and Diesel Engines With Optimal Drive Technology to the Auris

April 17, 2009

Toyota Auris. Click to enlarge.

Following on its introduction late last year of the Toyota Optimal Drive 1.33-liter Dual VVT-i engine with Stop & Start (earlier post), the Toyota Auris is now gaining the new 1.6-liter Valvematic gasoline engine and revised versions of the 1.4 and 2.0 D-4D and 2.2 D-CAT 180 diesel units.

Toyota launched the Auris—a strategic compact passenger vehicle for both Japan and Europe—in Japan in 2006 and Europe in 2007. (Earlier post.) Since its debut, it has become one of Toyota’s top models. Cumulative sales in Europe reached 318,236 units by the end of 2008.

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Engines

BMW Debuts 6th Generation of 5 Series Sedan; Auto Stop Start on 520d and BluePerformance on 530d for Euro 6 Compliance

November 23, 2009

European Sales of Chevy Spark Begin 1Q 2010 with Two Engines at Launch, LPG Variants

Study Concludes That Class 8 Truck Fuel Consumption Could Be Reduced By Up to 50% By 2017 Using Existing and Emerging Technologies; Current Payback Requirements Could Forestall Implementation

November 20, 2009

Opel Revamping Corsa for 2010; Better Performance, Lower Fuel Consumption and CO2 Emissions

November 19, 2009

Hyundai Unveils Its First Production Gasoline Direct Injection Engine

November 17, 2009

Federal-Mogul Introduces New Diesel Piston Design to Support Downsized Engines with Higher Output

November 15, 2009

Accenture Reports Identifies 12 Disruptive Technologies Most Likely to Transform Supply and Demand of Transport Fuels and Cut Emissions Within Next 10 Years

November 10, 2009

Chrysler Portfolio Segment Mix Shifting to Smaller, More Fuel Efficient Vehicles; 25% Improvement in Portfolio Fuel Economy by 2014

November 04, 2009

Cyclone Power Technologies Signs Letter of Intent To Expand Engine Development in China

Chrysler Powertrain Strategy to Rely Heavily on Integrating Fiat Engine Technology; Chrysler to Be Global Center of Competence for Hybrids and EVs for Fiat and Chrysler

Navistar Acquires Diesel Engine Components Business From Continental, Forms New Operating Company

November 03, 2009

Michigan State University Receives $2.5M ARPA-E Award to Build Wave Disc Engine/Generator for Series Hybrid Applications

October 31, 2009

Thordon Bearings Retrofitting Ocean-Going Vessels With Seawater-Lubricated Propeller Shaft Bearings To Reduce Stern-Tube Oil Pollution; Annual Leaks Estimated at About 2x Exxon Valdez Spill

October 29, 2009

Sturman Industries Targeting Diesel-like Efficiency for Natural Gas Using Digital Hydraulic Controls

October 27, 2009

ARPA-E Awards $151M to 37 Projects for Transformative Energy Research

October 26, 2009

UTEP Awarded Nearly $1.3M for 4 DOE Projects On Engine and Turbine Efficiency and CO2 Capture

October 22, 2009

Michigan Tech-Led Partnership Investigating Energy Efficient Emissions Control for Heavy-Duty Diesels; $1.7M from DOE

October 21, 2009

ORNL, Da Vinci Sign Licensing Agreement For Oil-Dilution Diagnostic Technology to Optimize Advanced Combustion Engines

Use of Reformed Exhaust Gas Recirculation Gas as a Dual Fuel Can Significantly Reduce Both NOx and Smoke in a Diesel Engine at Low Loads

October 17, 2009

BMW to Open Nearly Emission-Free Inorganic Sand Core Foundry in 2010

October 16, 2009

Study Finds That Late Intake Valve Closing and Increased Intake Pressure Can Reduce NOx, Soot, HC, and CO Emissions Simultaneously in Diesel PCCI

October 14, 2009

Scuderi Releases Video Footage of Running Split-Cycle 1L Prototype

October 08, 2009

Delphi Showcases Advanced Powertrain and Vehicle Electrification Technologies at 18th Aachen Colloquium

October 05, 2009

Audi Combines Start-stop Function with Dual-Clutch Transmission on A3

Powertrains for the New Opel Astra

September 30, 2009

Mazda to Debut Next-Generation Direct Injection Gasoline and Diesel Engines, Transmission and Kiyora Concept at Tokyo Motor Show 2009

September 29, 2009

Auto Industry Backs Additional Funding for Research into Impacts of Mid-Level Ethanol Blends

September 25, 2009

Concept: Garric Rotary Variable Compression Ratio Engine

Delphi Highlighting New Components and Systems for Improving Fuel Consumption in Spark Ignition Engines

September 24, 2009

CPT VTES Electric Supercharger Selected for Two Projects

September 22, 2009

US House Passes $2.85B Bill for Advanced Technology Vehicle R&D from 2010-2014

September 17, 2009

Audi’s Downsized 1.2L TFSI for the A3 and A3 Sportback

Ford Debuts Four-Cylinder EcoBoost Engine Family at Frankfurt; 1.6L and 2.0L I-4s to Start, Smaller Displacement Engine to Follow

September 16, 2009

Volkswagen Unveils New One-Liter Concept Car; Smallest Production-Intent Diesel Yet from Volkswagen Applied in A Full Hybrid Design

September 15, 2009

Audi Adds A4 and A4 Avant 2.0 TFSI Flex Fuel Models; Optimized for E85

Mercedes-Benz Adds Two Four-Cylinder BlueEFFICIENCY Diesels to GLK SUV Lineup; Potential to Meet EU6 and US BIN5 Limits

September 11, 2009

Volkswagen and LichtBlick Partner on Home Combined Heat and Power Systems; LichtBlick Plans a “SchwarmStrom” for 2,000 MW of Decentralized Power

September 09, 2009

Grail Engine Adopts Enerpulse Pulse Plugs for Forced Semi-Homogeneous Charged Compression Ignition in Concept Two-Stroke Engine

September 08, 2009

Lotus to Introduce Range Extender Engine

September 07, 2009

Citroën Launches the New C3; 99 g CO2/km Model Available From Launch

September 04, 2009

Hyundai to Debut ix-Metro Hybrid Concept and i10 Electric Vehicles at Frankfurt Show

Mercedes-Benz Provides Update on BlueZERO E-CELL PLUS Extended Range Electric Vehicle Concept

September 03, 2009

Collins Bus Corporation Enters Agreement With CleanFUEL USA to Develop LPI Type A School Bus

Ford Unveils New 6.7-L Power Stroke V-8 Turbocharged Diesel

August 31, 2009

Fiat Punto Evo To Debut at the Frankfurt Motor Show; Start&Stop Standard, Dual Fuel Versions

Study Finds That Late Intake Valve Closing and Increased Intake Pressure Can Reduce NO_x, Soot, HC, and CO Emissions Simultaneously in Diesel PCCI