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.]

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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Chrysler Introduces Next-Generation V-6 Engine: the Pentastar

April 15, 2009

The new 3.6-liter flex-fuel Pentastar V-6. Click to enlarge.

At the New York International Auto Show, Chrysler LLC introduced the first of an all-new line of V-6 engines intended to improve fuel efficiency across the Chrysler, Jeep and Dodge lineup by 8% on average compared with previous Chrysler V-6 engines.

The 3.6L engine, which is flex-fuel capable, will ultimately replace seven current Chrysler V-6 engines: 2.7L; 3.0L (China); 3.3L; 3.5L; 3.7L; 3.8L; and 4.0L. Chrysler anticipates that the new Pentastar V-6 will contribute a 2 mpg increase to Chrysler’s CAFE by 2015.

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GM’s Expanding Gasoline Direct Injection Engine Portfolio

April 13, 2009

The 2010 Terrain will feature a choice of two new direct injection engines. Click to enlarge.

The newly introduced GMC Terrain (earlier post) became the latest GM North American model that will feature a fuel-efficient gasoline direct injection (DI) engine in 2010. For MY 2009, GM is offering 6 engine variants with direct injection in 10 models in North America, 18 worldwide. For the 2010 MY, GM will have eight direct-injected engines in 38 vehicle models worldwide, with 18 models in North America alone.

The MY 2009 engines include three 2.0-liter Ecotec variants (LNF, LHU and LDK); a 2.2L Ecotec (LCH); and two 3.6-liter variants (LLT and LCS). These are joined in 2010 by the new Ecotec 2.4L (LAF) and 3.0L V-6 (LF1) direct injection engines.

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New Engines for the New Mercedes-Benz E-Class Coupé: More Power, Less CO2

March 25, 2009

The newly developed and modified four-cylinder powerplants have a higher output, despite the reduction in displacement. Click to enlarge.

Mercedes-Benz is offering five newly developed and modified engines—four of them with direct injection—for the new E-Class Coupé, offering more power with lower fuel consumption and CO₂ emissions than their predecessors. Included in the lineup are four-, six- and eight-cylinder diesel and gasoline powerplants with outputs ranging from 150 kW/204 hp to 285 kW/ 388 hp. All of the engines for the new E-Class Coupé are EU5-compliant.

New four-cylinder diesel. A new 2.1-liter, four-cylinder diesel features latest-generation common-rail direct injection, fast piezo injectors, enhanced exhaust gas recirculation, and new twin turbochargers to ensure spontaneous power delivery and excellent performance characteristics. The E 250 CDIBlueEFFICIENCY Coupé, with an output of 150 kW (204 hp) and a torque of 500 Nm (369 lb-ft) is around 36% more powerful and produces 47% more torque than the previous four-cylinder engine in the outgoing model. It consumes around 17% less fuel: 5.1 L/100km (46 mpg US) (provisional NEDC combined figure), equivalent to 135 g CO₂/km.

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Mazda Begins Commercial Leasing of Hybrid Rotary Hydrogen Vehicle

Transparent view of Mazda Premacy Hydrogen RE Hybrid. Battery pack and hydrogen tank are at the rear. Click to enlarge.

Mazda Motor Corporation has begun commenced commercial leasing of the Mazda Premacy Hydrogen RE Hybrid (earlier post), a hydrogen hybrid vehicle that offers substantially improved performance due to the addition of a hybrid system. Mazda is the first automobile manufacturer to begin commercial leasing of a hydrogen hybrid vehicle; the first units will be delivered to local government authorities and energy-related companies during 2009.

The Premacy Hydrogen RE Hybrid features a series-hybrid drivetrain, which combines Mazda’s hydrogen rotary engine with an electric motor. The engine output is converted to electricity, which then powers the motor that drives the wheels.

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FTA Report on Worldwide H2 Bus Demonstrations Finds Better Than Expected Performance and Strong Customer Acceptance; Challenges Remain

March 20, 2009

The US Federal Transit Administration (FTA) has published a report summarizing interviews with participants in the hydrogen-powered buses trials underway in more than 20 cities around the world from 2002 to 2007. These included buses powered by fuel cells or hydrogen-fueled internal combustion engines, as well as a variety of fueling and related technologies.

The report gathers insights from demonstration participants at transit agencies in the United States, Europe, China, Japan and Australia, analyzes lessons learned, identifies key remaining challenges, and suggests potential roles for government in supporting commercialization. Among the findings were that the performance of the fuel cell stacks exceeded expectations, but the batteries and supporting components experienced significant challenges.

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Cummins Unveils Products for EPA 2010 Regulations

March 19, 2009

The Cummins Aftertreatment System used to meet 2010 regulations. Click to enlarge.

Cummins Inc. unveiled its on-highway engine lineup ready to meet the new Environmental Protection Agency (EPA) regulations for the North American market. Cummins’ 2010 products are on display at the Mid-America Trucking Show in Louisville, Kentucky, from 19-21 March.

The new EPA regulations, which take effect on 1 January 2010, are the most stringent in the world, with near-zero NO_x and PM emission levels of 0.2 grams and 0.01 grams per brake-horsepower-hour, respectively. The Cummins solution for 2010 consists of a highly capable base engine with cooled-EGR, along with the Cummins Aftertreatment System, which reduces oxides of nitrogen (NO_x) and Particulate Matter (PM) to achieve the standards.

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Hitachi Restructures, Spinning Off Automotive Systems Business; to Launch Group-Wide Strategies for Li-ion Battery and Renewables Businesses

March 16, 2009

As part of a major restructuring in announced in Tokyo on Monday, Hitachi Ltd. will spin off its Automotive Systems Business into a wholly-owned subsidiary on 1 July. The new automotive business will have a special focus on hybrid and electric drive system components, as well as technologies for enhancing the efficiency of internal combustion engines.

In addition, on 1 April, the company will introduce organizations to plan and propose R&D and business strategies for the whole Hitachi Group regarding lithium-ion battery and renewable energy-related businesses. Hitachi says that it will “take steps to quickly launch businesses in these areas.”

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Argonne Devises New Variable Combustion Strategy for Hydrogen-Fueled Engines

March 14, 2009

Researchers at the US Department of Energy’s Argonne National Laboratory’s Center for Transportation Research have devised new variable combustion strategy for hydrogen-fueled engines using the Lab’s Modular Automotive Technology Testbed (MATT).

As they put the engine through its paces, Argonne’s researchers evaluate the fuel economy and emissions generated by different combustion strategies. Argonne engineer Henning Lohse-Busch and his colleagues developed an optimal variable air-fuel ratio combustion strategy that allows a hydrogen internal combustion engine to run efficiently and cleanly in a conventional vehicle.

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High-Pressure Direct-Injection Hydrogen Engine Achieves Efficiency of 42%; On Par with Turbodiesels

H2BVplus hydrogen combustion engine. Click to enlarge.

The BMW Group Forschung und Technik, in cooperation with researchers in Graz and Vienna, Austria, has developed a dedicated (i.e., monovalent) hydrogen combustion engine with diesel-like geometry and progressive H₂ high-pressure direct-injection technology. The result is an efficiency level of up to 42%, on par with that of the best turbodiesel engines.

The “H2BVplus” project is aimed at investigating a hydrogen self-ignition combustion process. Current hydrogen combustion engines are spark-ignited. Sponsored by Austria’s Federal Ministry for Transportation, Innovation and Technology (BMVIT), project partners include BMW, the Institute for Internal Combustion Engines and Thermodynamics at Graz University of Technology, HyCentA Research GmbH in Graz, as well as HOERBIGER ValveTec GmbH in Vienna.

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US EPA Proposes First National Reporting on Greenhouse Gas Emissions, Including Mobile Sources

March 10, 2009

The US Environmental Protection Agency (EPA) proposed the first comprehensive national system for reporting emissions of carbon dioxide and other greenhouse gases produced by major sources in the United States.

The new reporting requirements would apply to suppliers of fossil fuel and industrial chemicals, manufacturers of mobile sources such as motor vehicles and engines, as well as large direct emitters of greenhouse gases with emissions equal to or greater than a threshold of 25,000 metric tons per year. This threshold is roughly equivalent to the annual greenhouse gas emissions from just over 4,500 passenger vehicles.

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Volvo Trucks Introduces New Range of More Fuel Efficient, Lower-Emitting and Higher-Power Engines and Transmission

March 09, 2009

Volvo Trucks D13, D11 and D7 engines. Click to enlarge.

Volvo Trucks is introducing a new range of 13-, 11- and 7-liter engines and a new version of the I-Shift transmission. A number of technical engine improvements with the focus on optimized combustion and a new SCR catalytic converter combine to deliver up to 3% lower fuel consumption, 40% lower emissions of NO_x and higher power outputs.

For trucks with the 13-liter engine in combination with Volvo I-Shift, fuel consumption has been reduced by up to 3% compared with the previous version (Euro 5 incentive). For the 11-liter engine, the corresponding reduction is 1-2% percent. The power range has been broadened and the engine is now available as a fuel-efficient alternative on the entire Volvo FM range.

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Continental Introduces Its First Turbocharger

March 06, 2009

Section drawing: Fully-automated assembly delivers quality and cost advantages, according to Continental. Click to enlarge.

Continental, the international automotive supplier, is expanding its product portfolio with its Powertrain Division’s first turbocharger system for internal combustion engines. The new turbocharger, designed to allow fully-automated assembly, will be installed in a European vehicle platform’s gasoline engines in 2011.

Continental says it has used an innovative production method for its turbocharger. All the main components have been designed for fully-automated assembly along a single axis, whereas conventional turbochargers have to be put together in several stages, partly by hand. Fully-automated assembly delivers quality benefits through lower defect rates; it also produces cost benefits and both are important in view of the fact that these turbochargers are to be installed in high-volume model series.

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Fiat Introduces Multiair Electro-Hydraulic Valve-Timing System

March 04, 2009

Multiair system components. Click to enlarge.

Fiat Group and Fiat Powertrain Technology introduced their new air management technology Multiair at the Geneva Motor Show. 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.

Fiat expects that Multiair, with direct control of the air through the intake engine valves without using the throttle, can help reduce fuel consumption by up to 10% for turbocharged or naturally aspirated gasoline engines. Pollutant emissions are likewise reduced through combustion control. Applied to a turbocharged, downsized engine, MultiAir can contribute to up to a 25% reduction in fuel consumption over conventional naturally aspirated engines with the same performance, according to Fiat.

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Lotus Engineering to Showcase Omnivore Engine Concept in Geneva

February 25, 2009

The Lotus Omnivore engine. Click to enlarge.

Lotus Engineering will display a single-cylinder research engine monoblock demonstrating the architecture of the Omnivore engine concept at the upcoming 79^th International Geneva Motor Show. (Earlier post.)

The Omnivore was designed in collaboration with Queen’s University Belfast and Orbital Corporation Limited Australia for high thermal efficiency when fueled on any alcohol-based fuel or gasoline. It features an innovative variable compression ratio system and uses a two-stroke operating cycle with Orbital FlexDI direct fuel injection. It is ideally suited to flex-fuel operation with a higher degree of optimization than is possible with existing four stroke engines, according to Lotus.

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MCE-5 Development to Show Vehicle Equipped with Prototype Variable Compression Ratio Engine

February 24, 2009

1.5L VCRi engine with two-stage turbocharger. Click to enlarge.

At the upcoming 79^th International Motor Show in Geneva, France-based MCE-5 Development will showcase its first vehicle application (a Peugeot 407) of a prototype 1.5-liter MCE-5 VCRi (variable compression ratio) gasoline engine. The four-cylinder 1.5L VCRi, equipped with a two-stage turbocharger, develops 220 hp (164 kW) of power (comparable to that of a 3.0L V6 engine), and 420 Nm (310 lb-ft) of torque at 1,500 rpm (comparable to a V8 gasoline engine).

Fuel consumption on the NEDC is 6.7 L/100 km (35 mpg US) with 158 g CO₂/km. The technology can be applied to smaller displacements, MCE-5 notes.

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Saab to Give 9-3X its Debut in Geneva; E85 Plus All-Wheel Drive

February 23, 2009

The 9-3X. Click to enlarge.

Saab will introduce the new 9-3X to the public at the upcoming Geneva motor show in March. The 9-3X sport wagon offers a lighter alternative to heavier and larger crossovers or SUVs. The 210 hp (155 kW), 2.0-liter turbo engine couples Saab’s E85-capable BioPower technology with all-wheel-drive for the first time. A 180 hp (132 kW), two-stage 1.9-liter turbo diesel option is also available with two-wheel drive transmission.

Saab is splitting off from General Motors, which acquired 50% of Saab in 1990 and subsequently acquired the remaining shares. (Earlier post). On 20 February, the Vänersborg District Court in Sweden approved the request for a reorganization and restructuring which Saab’s representative had submitted earlier in the morning.

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Renault Powertrain Strategy: Focus on Electric Motor Development for EV Powertrains, New Technologies for Conventional Engines

February 17, 2009

Renault is currently working on the development of low-emission and zero-CO₂ emissions vehicles in what it calls “a determined bid” to introduce as many effective technologies as possible at an affordable price. Its work on powertrains focuses on two main areas: the development of a range of electric motors for all-electric vehicles, and new technologies for conventional engines, including a new generation of turbocharged internal combustion engines as well as on new automatic transmissions.

Electric motors. Renault is aiming to become the industry leader in the realm of mass-market electric vehicles. The Renault-Nissan Alliance is consequently developing a comprehensive range of all-electric powertrains, with power outputs ranging from 50 to 100 kW (70 to 140 hp).

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Volvo Introduces Two New 5-Cylinder Diesels; More Power, Less Fuel Consumption

The single-turbo 2.4D. Click to enlarge.

Volvo Cars is introducing two entirely new five-cylinder, 2.4-liter turbo diesels: the high-performance, twin-turbo D5 with 205 hp (153 kW) and 420 Nm (310 lb-ft) of torque, and the medium-performance, single-turbo 2.4D with 175 hp (130 kW) and 420 Nm of torque.

The high-performance D5-engine has already been introduced in the Volvo S80. (Earlier post.) Both engines will be available in the Volvo S80, Volvo V70, Volvo XC60 and Volvo XC70 in select markets from the spring of 2009.

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Cyclone Targets Small-Scale Co-Generation Market With External Combustion Waste Heat Engine

February 11, 2009

WHE unit. Click to enlarge.

Cyclone Power Technologies Inc., the developer of the external combustion Waste Heat Engine (WHE) (earlier post), has formed a separate division to market and manufacture WHE systems for applications such as small-scale cogeneration, solar thermal electricity production, biomass combustion, and engines for auxiliary power units for trucks and RVs.

The WHE is derivative of Cyclone’s external combustion Green Revolution Engine. (Earlier post.) Unlike its more powerful counterpart, the WHE operates in a low-pressure, low-temperature range. By contrast, the GRE employs super-critical pressure (3,200 psi, 22 MPa) and super-heated steam (1,200 °F, 649 °C).

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Detroit Diesel Previews its 2010 BlueTec SCR Technology; 5% Improvement in Fuel Economy

February 09, 2009

Detroit Diesel, a Daimler company, previewed its production-intent version of Daimler’s BlueTec technology for emissions control at the Technology and Maintenance Council (TMC) Conference. The DD13, DD15, and soon-to-debut DD16 family of engines were engineered from the ground up to be integrated with BlueTec technology developed to meet the specific needs and conditions of the trucking industry in North America.

Detroit Diesel’s BlueTec Technology incorporates emissions technology already present on today’s vehicles such as the Exhaust Gas Recirculation, Diesel Oxidation Catalyst, and Diesel Particulate Filter. All SCR systems designed to meet EPA 2010 emissions standards will also require the vehicle’s operator to keep the truck filled with DEF and the addition of a few new components. These SCR components include: the DEF tank, DEF doser, SCR catalyst, Aftertreatment Control Module (ACM) and the DEF gauge.

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Ricardo Introducing Ethanol Boost Direct Injection Engine Technology

February 06, 2009

Ricardo, Inc. is introducing Ethanol Boosted Direct Injection (EBDI) technology to optimize flex-fuel engines to a level of performance the company says will exceed gasoline engine efficiency and approach levels previously reached only by diesel engines.

Current flex-fuel engines pay a fuel economy penalty of about 30% compared to gasoline when operated on ethanol blends such as E85. The EBDI technology takes full advantage of ethanol’s higher octane and higher heat of vaporization to “turn the gasoline-ethanol equation upside down”, according to Ricardo President Dean Harlow.

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AVL Concept Turbohybrid Mild Hybrid System Approaches Full Hybrid Fuel Savings at Lower Cost; Improved Driveability

February 04, 2009

Comparison of Fuel Consumption, Fun to Drive and System Cost of the different powertrain concepts. Click to enlarge.

AVL has developed and patented a mild hybrid system and engine operating strategy that combines downsizing with a turbocharged gasoline direction injection engine; downspeeding (the application of a longer gear ratio); and a relatively low power electric machine to deliver a reduction in fuel consumption approaching that of a full hybrid but at lower cost, while improving the driveability of the vehicle.

In testing on a BMW demo 3-Series vehicle, a 1.6-liter AVL Turbohybrid prototype delivered a 24% reduction in fuel consumption on the NEDC compared to the 2.0L naturally aspirated baseline; a 1.6L full hybrid (power-split) system delivered a 36% compared to the baseline. However, the system cost of the Turbohybrid was 150% that of the baseline, while the system cost of the full hybrid was more than 300% that of the baseline. In addition, the Turbohybrid delivered a “fun to drive” rating of 7.81—higher (better) than both the conventional vehicle and the full hybrid.

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ETH Zürich Developing Pneumatic Hybrid Engine; Approaches Hybrid-Electric Performance at Lower Cost

February 01, 2009

Pneumatic hybrid engine on the test bench. Photo: P. Rüegg / ETH Zurich. Click to enlarge.

Researchers at ETH Zürich are developing a pneumatic hybrid engine—an internal combustion engine connected to a compressed air tank instead of a battery system. A member of the ETH research team, which is led by Lino Guzzella, Professor of Thermotronics, will present a paper on their work at the upcoming SAE World Congress 2009 in Detroit in April—one of a number to be presented on the topic there.

The pneumatic hybrid engine, which follows the downsizing and supercharging paradigm, offers a fuel-saving potential that is almost equal to that of hybrid electric powertrains while inducing much lower additional mass and cost penalties, according to the ETH Zürich researchers.

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Robotic Technology Purchases Beta Biomass Engine System From Cyclone Power Technologies for Use in Series Hybrid Power System

January 29, 2009

Rendering of EATR. Click to enlarge.

Cyclone Power Technologies Inc., the developer of an external combustion engine (earlier post), has received a contract from Robotic Technologies Inc. (RTI), of Potomac, MD, to develop a beta biomass engine system which will be used in a series hybrid subsystem in RTI’s Energetically Autonomous Tactical Robot (EATR), a project sponsored by the Defense Advanced Research Projects Agency (DARPA), Defense Sciences Office.

The EATR is an autonomous robotic platform able to perform long-range, long-endurance military missions without the need for manual or conventional re-fueling. The system is designed to obtain its energy by foraging—engaging in biologically-inspired, organism-like, energy harvesting behavior which is the equivalent of eating.

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New Phenomenological Six-Zone Combustion Model for Direct-Injection Diesel Engines

January 22, 2009

The six zones of the model. Credit: ACS. Click to enlarge.

Researchers at Ecole Centrale de Nantes, France, are developing a new phenomenological multizone combustion model for direct-injection (DI) diesel engines. The model distinguishes six zones and provides local information, such as mean equivalence ratio and temperature in the various zones.

A study on the work published in the ACS journal Energy & Fuels finds that the model is able to calculate the rate of heat release (ROHR) with good accuracy, whereas the variation of calculated local parameters (core spray and flame temperature, lift-off length, and corresponding equivalence ratio) can be used to explain the main tendencies on engine-out NO_x and particulate matter (PM) emissions observed on the engine test bench.

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SwRI Launches HEDGE II Consortium for High-Efficiency Gasoline Engine

January 17, 2009

Cycle simulation comparison of HEDGE and diesel engines in medium-duty applications. Source: SwRI. Click to enlarge.

Southwest Research Institute (SwRI) will launch its second cooperative research program aimed at developing a high-efficiency gasoline engine for both the light-duty automotive and medium-duty engine markets. HEDGE II, a four-year effort, will expand on earlier efforts to improve gasoline engine technology for future emissions and fuel economy requirements.

The first HEDGE (High-Efficiency, Dilute Gasoline Engine) consortium focused on high levels of exhaust gas recirculation (EGR) combined with supporting technologies such as high-energy ignition and advanced boosting systems to develop strategies for high efficiency. (Earlier post.)

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Westport Joint Venture Juniper Introduces LPG Engines; Initial Focus on Industrial Markets with Hyundai Engine Platforms

January 15, 2009

Juniper LPG engines. Click to enlarge.

Juniper Engines Inc., a joint venture between Westport Innovations Inc. and SIT’s subsidiary OMVL SpA (OMVL) of Italy, presented its new 2.0-liter and 2.4-liter alternative fuel engines at the ProMAT Exposition in Chicago, Illinois.

Juniper’s engines, initially targeting the OEM liquefied petroleum gas (LPG) forklift market, will be fully integrated, high-performance, low-emission solutions. The Juniper products are based on the Hyundai Motor Company’s 2.0-liter and 2.4-liter industrial engine platforms, and OMVL’s LPG multipoint injection technology.

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Mercedes Introduces New E-Class With Up To 23% Reduction in Fuel Consumption; BlueZERO Concept in Detroit

January 13, 2009

Mercedes-Benz introduced its new E-Class vehicles in Detroit on the eve of the 2009 North American International Auto Show. The range of engines available for the new E-Class comprises four-, six- and eight-cylinder units with outputs from 100 kW/136 hp to 386 kW/525 hp. The new E-Class models offer reductions in fuel consumption of up to 23% compared to their predecessors

The four-cylinder engines are newly developed direct-injection units, which develop a higher output and torque than the comparable V6-engines of the preceding series despite a smaller displacement. The strategy is to replace to replace large, naturally aspirated engines with turbocharged units.

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Ford’s 3.5L Production EcoBoost Debuts in Lincoln MKS; 1.6L EcoBoost Appears in Lincoln C Concept

January 12, 2009

The 3.5-liter EcoBoost V-6 engine. Click to enlarge.

Ford’s first EcoBoost engine, a 3.5-liter direct-injection, twin-turbocharged V-6, made its debut in the 2010 Lincoln MKS at the North American International Auto Show in Detroit. The 3.5L EcoBoost engine delivers 355 hp (265 kW) and 350 lb-ft (475 Nm) of torque across a broad rpm range, giving the Lincoln MKS the power of a normally aspirated 4.6-liter V-8. The engine will also be applied in the 2010 Ford Flex and Lincoln MKT crossover vehicles.

Ford also used the Detroit show to unveil a Lincoln C (C-size) concept car powered by a 1.6-liter, four-cylinder EcoBoost engine mated to a dual-clutch Powershift Transmission. With that powertrain, the Lincoln C achieves a projected 43 mpg on the highway, while offering up an estimated 180 hp (134 kW) and 180 lb-ft (244 Nm) of torque. That’s a nearly 25% fuel-economy improvement over the C-car sized Ford Focus equipped with a 2.0-liter naturally aspirated engine.

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Volvo Introduces Next-Generation D5 Twin-Turbo Diesel Engine

January 07, 2009

Volvo D5 twin-turbo diesel engine. Click to enlarge.

Volvo Cars is introducing an entirely new 2.4-liter 5-cylinder diesel engine in the Volvo S80. Sharing only the D5 badge and the 5-cylinder configuration with the previous generation, the new D5 is Euro-5 compliant and is more efficient than its predecessor.

Featuring sequential twin turbochargers, ceramic glow-plugs and piezoelectric fuel injectors, the new engine applied in the S80 delivers 205 hp (153 kW) of power and 420 Nm (310 lb-ft) of torque, with fuel consumption of 6.2 liters/100 km (38 mpg US) and CO₂ emissions of 164 g/km.

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GM Presents 2010 Cadillac SRX Crossover; New 3.0L Direct-Injected E85 Engine as Standard

January 05, 2009

The new direct injection 3.0L E85 capable engine in the SRX. Click to enlarge.

GM presented the new 2010 Cadillac SRX Crossover, featuring a new design and more-efficient engine choices. The new SRX, a mid-sized luxury crossover, will debut at the North American International Auto Show in Detroit next week.

A new, 3.0L direct injected and E85 capable V6 engine is standard and a new, 2.8L turbocharged V6 is optional. Direct injection enables a 25% reduction in hydrocarbon emissions. Fuel economy in the mid-20s on the highway is expected, but testing isn’t yet complete.

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Jaguar Introduces New 3.0L Diesel for European Market

December 31, 2008

The new AJ-V6D. Click to enlarge.

Jaguar is introducing a new 3.0-liter diesel engine—the AJ-V6D Gen III—in two power levels in its XF Diesel S sedan for the European market. The new V6 engine, derived from the 2.7-liter diesel, improves fuel economy by 12% and produces 10% less CO₂ (179 g/km) than the 2.7L, while increasing power by 33%. The new 3.0L engines are Euro-5 compliant.

The 275PS (271 hp, 202 kW) version delivers 600 Nm of torque, accelerates the sedan from 0-60 mph in 5.9 seconds, and has combined fuel economy of 35 mpg US (42 mpg UK, 6.7 L/100km)—a 12% improvement in fuel economy over the 2.7-liter V6 diesel. The engine is also available in a 240PS (237 hp, 177 kW) variant, with 16% more power and 15% more torque than the 2.7-liter diesel.

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Stratified Charge Engine With Two-Stage Combustion Mechanism Shows 17% Reduction in Fuel Consumption Without Direct Injection

December 29, 2008

Two-stage combustion mechanism in twin swirl combustion (1, zone containing pure air; 2, spark plug; 3, turbulizer; and 4, zone containing the fuel-rich mixture). Click to enlarge. Credit: ACS

A team of researchers from Istanbul Technical University (ITU) in Turkey has presented a 1.6-liter stratified charge gasoline engine featuring a twin swirl combustion chamber operating with a two-stage combustion mechanism and experimentally shown that it can deliver a 17% reduction in fuel consumption with a 7% increase in power compared to a conventional 1.6-liter port-injected engine.

The proposed combustion mechanism does not require high fuel injection pressures and can be applied on current production engines without significant modification and without direct injection fuel systems, according to the researchers. A paper on the work was published online in the ACS journal Energy & Fuels on 15 December.

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Volvo to Show S60 Concept Featuring New 1.6L GTDi Turbo Direct Injection Engine

December 19, 2008

The S60 concept. Click to enlarge.

When it shows its new S60 Concept car at the North American International Auto Show in Detroit this January, Volvo Cars will be featuring a new 180 hp (134 kW) four-cylinder 1.6-liter gasoline engine using high-efficiency GTDi (Gasoline Turbocharged Direct Injection) technology.

This engine, in combination with a range of other measures such as stratified combustion and stop/start, makes it possible to cut carbon dioxide emissions to 119 g/km (5.0 L/100 km, or 47 mpg US). Volvo Cars’ first production car with the GTDi technology will be introduced during the second half of 2009.

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GM Introduces Two New Direct Injection Engines; Downsizing for the 2010 Equinox

December 18, 2008

The 2010 Ecotec 2.4L I-4 VVT DI (Direct Injection) for Chevrolet Equinox. Click to enlarge.

GM is introducing two new direct injections engines—a 2.4-liter inline four cylinder unit and a 3.0-liter V-6 unit—with initial application on the 2010 Chevrolet Equinox. The more fuel efficient direct injection engines replace the larger 3.4L and 3.6L V-6 engines on the 2009 models.

The 180 hp (134 kW) 2.4L DI engine, which will replace the current entry-level 3.4-liter V-6, delivers an estimated 30 mpg US highway (EPA certification pending). By comparison, the older 3.4L engine produces 185 horsepower (138 kW), but with a rated 24 mpg US highway.

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DME Low-Temperature Combustion Concept Maintains Low NOx with Decreases in CO and HC Emissions

December 14, 2008

Researchers at Shanghai Jiao Tong University are exploring a new combustion concept for dimethyl ether (DME): low-temperature combustion (LTC) of a compound charge combining port aspiration and in-cylinder direct injection (DI). In comparison to a DME homogeneous charge compression (HCCI) combustion mode, DME LTC can extend the engine operating range with little change in NO_x emissions and a considerable reduction in HC and CO emissions. A paper on their work was published online 8 December in the ACS journal Energy & Fuels.

The same research team earlier this published a paper on the development of a DME compound charge compression ignition (CCCI) process. (Earlier post.) The CCCI combustion process consists of HCCI combustion, premixing combustion, and diffusion combustion. The combustion characteristics are mainly decided by the premixed fuel ratio and CO₂ concentration in the air charge.

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Ford, GM Engines Make Ward’s 2009 10 Best Engines List; GM Tops IEEE Spectrum Patent Scorecard

December 12, 2008

2007 Patent Pipeline Power rankings for the automotive sector. Click to enlarge.

Ward’s Automotive Group has named Ford’s redesigned 2.5-liter engine for the Escape and Mariner hybrids and GM’s 3.6L direct injection V-6 VVT engine to AutoWorld magazine’s 2009 “Ten Best Engines” list for North America. Ward’s will present the 10 Best Engine awards at the Detroit Auto Show in January. Separately, the IEEE (Institute of Electrical and Electronics Engineers) named GM first in the automotive sector in its IEEE Spectrum 2007 Patent Scorecard. Ford came in fourth in that ranking, behind Toyota in third and Nippondenso in second place.

Ford 2.5L. Ford’s 2.5-liter, dual-overhead cam I-4 hybrid engine (earlier post) was the only engine for hybrid vehicles selected as a winner for this year’s list. This is the fifth year of production for the Escape Hybrid but the first year for the SUV to use Ford’s new 2.5-liter engine. Previous models used a 2.3-liter 4-cylinder engine.

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Fiat Adding Bosch Stop-Start System to Fiat 500; Bosch Projects 50% of Euro New Vehicles to Have Stop-Start by 2012

December 04, 2008

A specially adapted starter and the engine control unit are the central components of the Bosch stop-start system. Click to enlarge.

Beginning in March 2009, Fiat will feature a Bosch start/stop system on the Fiat 500. (Earlier post.) Bosch supplies the specially adapted starter, the engine management system, and the battery sensor. Bosch has been manufacturing this start/stop technology since 2007, and has already delivered more than 500,000 starters to BMW and Mini. (Earlier post.)

In the Fiat 500, the system will initially be available in combination with the Dualogic automated manual transmission and a 1.2-liter engine. Fiat plans to install the system in other variants and models as early as 2009.

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GM Requests $12B in Term Loan and $6B Revolving Line of Credit from Congress; Plan Outlines Increased Production of Fuel-Efficient and Alt Energy Vehicles

December 03, 2008

During the four-year plan window, GM will invest approximately $2.9 billion in alternative fuel and advanced propulsion technologies; more than $2B of that goes to hybrid and EREV platforms; 26% of the total ($758M) goes to EREVs alone). Click to enlarge.

GM is asking Congress for term loans of up to $12 billion to provide adequate liquidity levels through 31 December 2009. In a four-year Restructuring Plan submitted to Congress, GM said it anticipates an initial draw of $4 billion in December 2008, another $4 billion in January 2009, and a third draw of up to $2 billion in the February-March time frame based on recent market developments, for a total draw of $10 billion by the end of the first quarter.

In addition to the bridge loans, the company is requesting a $6 billion line of credit to provide liquidity should a severe market downturn persist. GM’s intent is to begin to repay the loans as soon as 2011. Warrants issued as part of the loans would allow taxpayers to benefit from growth in the company’s share price that might result from successful completion of the plan.

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Ford Asks Congress for $9B Stand-By Line of Credit; Commercial BEV by 2010, BEV Sedan by 2011

December 02, 2008

Overview of Ford’s technology sustainability plan. Click to enlarge.

Ford Motor Company this morning submitted to Congress a business plan detailing a pathway to profitability and requested a “stand-by” line of credit in the amount of up to $9 billion at Government borrowing rates, for a 10-year term, with TARP conditions, in case the current economic crisis worsens or there is a bankruptcy of a major competitor. (TARP is the $700-billion Troubled Assets Relief Program for the financial sector.)

Ford said it will accelerate the transformation of its North American automotive business through aggressive restructuring actions and the introduction of more fuel-efficient vehicles—including a broader range of hybrid-electric vehicles and the introduction of advanced plug-in hybrids and full electric vehicles.

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Delphi Direct Acting Piezo Injector Debuts on the Mercedes C250 CDI

December 01, 2008

Delphi Direct Acting Diesel Common Rail System includes (clockwise from top left): DFI3 Piezo Injectors with Common Rail, Series 9 Modular Fuel Filter, DCM4 Light Duty Controller, and DFP3 High Pressure Pump. Click to enlarge.

Delphi Corporation’s new Direct Acting Piezo injector (earlier post) is making its debut in the new Direct Acting Diesel Common Rail System on the new Mercedes C250 CDI. In the new system, the injector needle is directly activated by a piezo ceramic actuator, removing the hydraulic circuit and its associated lag and energy consumption.

The piezo ceramic actuator directly operates the needle valve of the injector for initial lifts, such as those obtained in pilot injections, and a motion amplifier is used to help complete the lift for large injections. This enables the injector to spray fuel into the combustion chamber faster, with much improved spray momentum and accuracy, at higher pressures (up to 2,000 bar).

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Fiat Extends Bravo Range with New 2.0L Diesel

The Bravo 2.0 Multijet. Click to enlarge.

Fiat has extended its Bravo range with a new 165 bhp (123 kW) 2.0 Multijet with DPF (particulate filter), type-approved to Euro 5 standards. The new diesel is derived from the 1.9 Multijet and offers benefits over its predecessor in performance (+ 18% torque at a lower rpm and +10% power output); emissions; and fuel consumption (-5.4%) over a combined cycle.

The increase in cylinder capacity between the two engine versions was achieved by increasing the bore from 82 mm to 83 mm. The compression ratio was also reduced from 17.5:1 to 16.5:1, enabling a reduction in NO_x levels. Compared to the 1.9 Multijet, the 165 bhp engine uses a new type of low voltage spark plugs that allow starting with minimum preheating times.

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Fisker Automotive to Use GM Ecotec 2.0L VVT DI Turbo, Other Components in EREV Karma

November 22, 2008

The 2009 Ecotec 2.0L VVT DI Turbo. Click to enlarge.

Fisker Automotive, Inc. will use a GM 2.0-liter, direct injection, turbocharged four-cylinder Ecotec engine in the Fisker Karma, its Extended Range Electric Vehicle. (Earlier post.) Fisker will obtain the engines through GM’s on-highway integrator Powertrain Integration LLC. Fisker Automotive says that it is also considering the purchase of several additional GM vehicle components to enhance the Karma.

The 260 hp (194 kW) Ecotec will be used to generate electricity when the series hybrid Karma has exceeded its 50 mile electric-only range.

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Porsche Gets Green Light for Cayenne Diesel; Hybrid Still in the Works

November 20, 2008

Porsche’s Executive Board has approved the production of a Cayenne SUV equipped with a diesel engine. The Board said the decision was in response to changed legal regulations, especially in European markets, resulting in tax incentives for vehicles with diesel engines. Furthermore, it said, Porsche’s stake in the Volkswagen Group, the world’s largest manufacturer of modern diesel engines for passenger cars, has opened up new opportunities to utilize diesel technology.

Porsche will equip the Cayenne with a 3.0-liter V6 turbo diesel engine with 240 hp (176 kW) of power and 550 Nm (406 lb-ft) of torque supplied by Audi AG, a subsidiary of the VW Group. The average consumption of the Cayenne Diesel is 9.3 liters per 100 kilometers (25 mpg US), with CO₂ at 244 grams per kilometer. The new Cayenne diesel will initially be offered in Europe. Preparations for market introduction in other countries are underway.

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Production Version of the Renault-Nissan 3.0L V6 dCi Diesel; Targeted for the Maxima in the US

November 19, 2008

The 3.0-liter V6 dCi 235. Click to enlarge.

The Renault-Nissan Alliance unveiled the production version of its new 3.0-liter V6 dCi Diesel engine on the Laguna Coupé at the Paris motorshow in October 2008. In 2007, the Alliance had shown a concept version of the engine. (Earlier post.)

This is the first diesel V6 developed and produced by the Alliance, and will equip upper-range vehicles to meet the demand for engines that are powerful and yet fuel- and CO₂-efficient. The engine will be used in the upcoming US Tier 2 Bin 5 compliant Nissan Maxima in 2010.

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Toyota Auris to Offer New 1.33L Dual VVT-i with Stop&Start

Toyota Optimal Drive 1.33-liter Dual VVT-i gasoline engine with Stop&Start. Click to enlarge.

Toyota is applying its new 1.33-liter, Dual VVT-i gasoline engine with Stop&Start in the Auris. The engine is also to be applied in the iQ. (Earlier post.) The new 1.33L engine in the Auris delivers a 19% improvement in fuel consumption and a 17% decrease in CO₂ emissions compared to the previous 1.4L VVT-i unit.

The new Auris 1.33 Dual VVT-i Stop&Start is being branded as an “Optimal Drive” vehicle. (Earlier post.) Toyota Optimal Drive covers a range of different technologies that can be applied to achieve real-world results in decreasing fuel consumption and emissions without compromising driving pleasure. This approach, Toyota says, is in contrast to “some car manufacturers which have elected to launch special eco-themed models with design, engineering and equipment tweaks to achieve lower emissions and better fuel consumption, often at the cost of comfort and driving pleasure.”

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Waste Heat Recovery System Receives Powertrain Innovation of the Year Award

November 18, 2008

Cutaway diagram of the heat2power system mounted on an engine. Click to enlarge.

The Paris, France-based developer of a waste heat recovery (WHR) system, heat2power, won the Powertrain Innovation of the Year Award at the Professional Motorsport World Expo in Cologne (11-13 November) with its Thermal Energy Recovery System (TERS). heat2power says that its WHR system can provide fuel savings of 15-35% under all driving conditions at a cost of approximately 30% more than a comparable turbocharged gasoline engine.

The heat2power system uses one or more cylinders for the regeneration of waste heat. These cylinders can be in replacement of the combustion cylinders inside an existing engine or as an add-on module that is connected to the engine by means of a gear set or a belt drive. It is also possible to have no mechanical linkage between the combustion engine and the WHR unit in case the power from the regeneration unit is taken off electrically.

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Ricardo Introduces New Real-Time Simulation Technology for Next-Generation Engine Design

Ricardo has introduced WAVE-RT, the first version of Ricardo’s engine simulation product specifically designed to enable highly accurate real-time simulation to become an embedded part of the engine management system development process.

With wave propagation effects fully captured, the transient response of the model is much closer to that of the real engine than would be the case with mean-value engine models typically used to date for this application. WAVE-RT thus enables validation of strategies to perform close control of engine performance during transients, and the accuracy of its airflow simulation allows development of concepts such as variable valve timing and lift control including more unusual examples such as negative overlap for controlled auto-ignition or for camless engine control. The system can thus serve as a significant enabler for the more rapid development of next-generation low fuel consumption, low emission engines.

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GM Opel to Introduce Turbocharged CNG Van

November 13, 2008

The Zafira CNG Turbo. Click to enlarge.

GM Opel will introduce its first turbocharged Compressed Natural Gas compact van at the Bologna motor show (5-14 December 2008). The Zafira CNG Turbo 1.6-liter engine is designed to run on either natural gas, biomethane or any mixture of the two.

The new 1.6 CNG Turbo delivers 150 hp (112 kW) of power, with maximum torque of 210 Nm (155 lb-ft) at 2,300 rpm. Fuel consumption is 5.3 kg of natural gas per 100 km in the MVEG cycle, with 144 g/km of CO₂. Top speed is 200 kph (120 mph). the 1.6 CNG Turbo delivers 60% more horsepower than the naturally aspirated CNG model for a difference of 6 grams in emissions.

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EPA to Award Up to $1.35M to Projects to Advance Hydraulic Hybrid, Engine and Fuel Technology

November 06, 2008

The US Environmental Protection Agency (EPA) is soliciting applications from eligible entities to collaborate with EPA in a set of hybrid technology pilot projects that can span the optimization of Hydraulic Hybrid Vehicle (HHV) technology (including plug-in electric-hydraulic hybrids); unique clean and efficient engines for full-series hybrid vehicles; and clean lower greenhouse gas transportation fuels.

The EPA expects to select 5 programs. Estimated total program funding is $1,350,000, with an award ceiling of $450,000. The EPA’s Office of Transportation and Air Quality (OTAQ) has identified the following as high priority specific technology projects:

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Hyundai Shows New R-Engine Diesel

November 04, 2008

The R-Engine. Click to enlarge.

Hyundai Motor Co. revealed some details of the R-Engine, its newest passenger diesel, during the 8^th Advanced Diesel Engine Technology Symposium held at the company’s Namyang R&D Center. The R-Engine will enter production next year and will see its first application on the 2010 Tuscon and Sonata models which are due to be launched in the coming year.

Available in 2.0- and 2.2-liter displacements, the four-cylinder engines deliver 135 kW (181 hp) and 147 kW (197 hp) of power respectively. Torque is 392 Nm (289 lb-ft) and 436 Nm (322 lb-ft) respectively. Hyundai positions the R-Engine as outperforming its German and French competitors.

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Argonne and Three Area Universities Form Illinois Center for Advanced Tribology

October 31, 2008

The US Department of Energy’s (DOE) Argonne National Laboratory has teamed with the University of Illinois at Urbana-Champaign (UIUC), the University of Illinois at Chicago (UIC) and Northwestern University to form the Illinois Center for Advanced Tribology (ICAT), which will develop solutions to technical issues related to transportation, health and systems that operate in extreme environments.

Tribology is the science and technology of friction, lubrication and interactive surfaces in relative motion that are evident in virtually everything that moves, including human beings.

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2010 Ford Fusion and Mercury Milan Feature New Engines, 6-Speed Transmission, New Hybrid System

October 30, 2008

The 2010 model year Fusion and Milan, which will arrive in showrooms next spring, will offer Ford’s all-new Duratec 2.5-liter I-4, producing 175 hp (130 kW); an enhanced 240 hp (179 kW) flex-fuel capable 3.0-liter V-6 with 19 more horsepower than its predecessor; and a high end 3.5-liter V-6 that delivers 263 hp (196 kW) on the Fusion Sport model. Fusion models equipped with the 2.5-liter I-4 engine are expected to deliver at least 3 mpg better on the highway than the Honda Accord and 2 mpg better than the Toyota Camry.

All are paired with six-speed transmissions for up to a 10% fuel economy improvement and other new technologies aimed at improving performance while gaining fuel economy. The new lineup will also include Ford’s first sedan-based hybrid models. (Earlier post.) The more efficient hybrid system that debuts with the Fusion and Milan models delivers a more seamless driving experience and is expected to beat the Toyota Camry hybrid by at least 5 mpg in the city cycle, according to Ford.

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Simultaneous Reduction of Biodiesel NO_x and PM Emissions with Low Temperature Combustion

October 29, 2008

Time integration of spatially integrated flame luminosity (SIFL) and NO_x emissions of the 12 cases with different injection strategies and fuel blends. Click to enlarge. Credit: ACS

Simultaneous reduction of NO_x and soot in a biodiesel-fueled engine is possible through the use of low-temperature HCCI combustion modes, according to a study by a team of researchers from the US and Taiwan. Their paper was published online 28 October in the ACS journal Environmental Science and Technology.

A number of studies are exploring mechanisms for enabling the use of biodiesel in light- and heavy-duty diesel engines for lower PM, CO, SO_x, and HC emissions without incurring a NO_x penalty. (Earlier post.) Low-temperature combustion (LTC) is one promising technique to meet these requirements. LTC includes homogeneous-charge compression ignition (HCCI) and several other newer combustion concepts.

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DLR Outlines Approaches for 40% Reduction in Global Light-Duty Vehicle GHG Emissions by 2050

October 27, 2008

Well-to-wheel CO₂ emissions of light duty vehicles in the reference and energy [r]evolution scenarios from 2000 to 2050. Click to enlarge.

A combination of higher efficiency vehicle technologies, a major switch to grid-connected electric vehicles and incentives for travellers to save CO₂ could result in a reduction of well-to-wheel greenhouse gas (GHG) emissions in the global light-duty vehicle sector in 2050 by roughly 25% compared to 1990 and 40% compared to 2005, according to a new report produced by the European Renewable Energy Council (EREC) and Greenpeace International.

Total LDV sector energy consumption in total is reduced by 23% in 2050 compared to 2005, in spite of tremendous increases in some world regions. Even with the aggressive focus on new technologies and demand reduction, 74% of the final energy used in cars will still come from fossil fuel sources, 70% from gasoline and diesel, according to the findings. Renewable electricity covers 19% of total car energy demand, biofuels cover 5% and hydrogen 2%.

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HOTFIRE Project Wins Engineering Award; Homogeneous Direct Injection with Fully Variable Valve Train

October 21, 2008

The HOTFIRE head on the 3-cylinder demonstrator engine. Click to enlarge. Source: Lotus Engineering

Project HOTFIRE has taken the top award in the automotive sector in ‘The Engineer Technology + Innovation Awards 2008’ in the UK. The project team, comprising engine designers from Lotus Engineering, fuel injection specialists from Continental Powertrain and thermodynamics and mechanics experts from University College London and Loughborough University, developed a gasoline direct injection (GDI) engine concept that reduces fuel consumption by 15%. The project was funded by EPSRC (Engineering and Physical Sciences Research Council).

The end application of this project is a direct injection spark ignition engine architecture that does not require stratified lean burn combustion to achieve the approximate 15% fuel savings. This ensures that the system can be used over all speed/load ranges and eliminates the need for an expensive lean NO_x trap which is usually required when lean combustion is employed.

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Freescale Introduces New High-Performance MCU Targeted at Fuel-Efficient, Low-Emission Engines

October 20, 2008

The MPC5674F is targeted at fuel-efficient, lower-emission applications in high-volume automobiles.

Freescale Semiconductor has introduced a new high-performance microcontroller (MCU) that it says is the industry’s most powerful for engine control in mainstream, high-volume automobiles. The new MPC5674F is the latest addition to the company’s growing portfolio of 32-bit automotive MCUs built on its Power Architecture technology.

The MPC5674F addresses the automotive industry’s need for precise control of engine events, enabling developers to optimize combustion and tune engines for improved fuel efficiency and cleaner emissions, without sacrificing performance.

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Port Injection of Secondary Fuel Can Simultaneously Lower NOx and PM in a Direct Injection Biodiesel Engine

October 08, 2008

Effect of premixed fuels on the engine emissions at different equivalency ratios. Click to enlarge. Credit: ACS

Researchers at Shanghai Jiao Tong University found that port fuel injection of a secondary fuel with a lower boiling point in a biodiesel-fueled, direct injection engine can simultaneously reduce both NO_x and PM emissions. A paper on their work appeared online 4 October in the journal Energy & Fuels.

A number of studies have shown that the use of biodiesel in light- and heavy-duty diesel engines can lower PM, CO, SO_x, and HC emissions compared to standard diesel fuel combustion with comparable or even slightly better engine efficiency. However, NO_x levels can increase—a problem when confronting more stringent regulatory limits on NO_x emissions.

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