2014 Sprinter van for US standard with new 2.1L diesel; new driver assistance features

2014 Sprinter. Click to enlarge.

The new MY2014 Mercedes-Benz Sprinter van for the US now features a 2.1L, 4-cylinder diesel with a t-speed automatic transmission as standard. The familiar V6 diesel is available as an option.

Since 2010, all Sprinters in the US have been powered by BlueTEC diesel engines, marking the first use of BlueTEC technology, with its selective catalytic reduction (SCR) exhaust aftertreatment system, in the commercial van market here. The 2.1-liter four-cylinder diesel engine produces 161 hp (120 kW) and 265 lb-ft (359 N·m) of torque at 1,400-2,400 rpm.

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Volkswagen boosts Beetle Turbo and Jetta GLI with EA888 Gen 3 engine; more power, improved fuel economy

The EA888 for the US. Click to enlarge.

The Volkswagen Beetle Turbo, Beetle Turbo Convertible, and the Jetta GLI receive a number of running changes to 2013 model year cars that go on sale this month. The most notable of these is fitment of a new version of the EA888 Gen 3 2.0-liter turbocharged and direct-injected TSI gasoline engine.

The new engine delivers a manufacturer-estimated improvement in fuel efficiency for the Beetle models of between 4-8% percent on the combined cycle and by up to 9% percent on the city cycle. The new engine produces 210 horsepower (157 kW), an increase of 10 hp over the previous Gen 2 TSI engine.

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Volvo Cars’ tests of flywheel technology confirm fuel savings of up to 25%

Volvo Car’s flywheel KERS system. Click to enlarge.

Results of Volvo Car Group’s testing of kinetic flywheel technology on public roads during 2012 show that the flywheel technology combined with a four-cylinder turbo engine has the potential to reduce fuel consumption by up to 25% compared with a six-cylinder turbo engine at a comparable performance level, according to Derek Crabb, Vice President Powertrain Engineering at Volvo Car Group. (Earlier post.)

If the energy in the flywheel is combined with the combustion engine’s full capacity, it will give the car an extra 80 horsepower. Combined with the swift torque build-up, this translates into rapid acceleration, cutting 0 to 100 km/h figures by seconds. The experimental car, a Volvo S60, accelerates from 0 to 100 km/h in 5.5 seconds.

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FEV’s two-stage VCR system; 5-7% increase in fuel economy using variable length conrods

Working principle of FEV’s two-stage VCR system. Click to enlarge.

Use of a variable compression ratio (VCR) could be one technology approach to reducing fuel consumption in highly boosted (e.g., downsized, turbocharged) gasoline engine, as operating an engine with higher compression ratios at low load can increase fuel economy compared to operating an engine with fixed compression ratio.

At SAE World Congress 2013, engineers at FEV reported on their progress on a two-stage variable compression ratio (VCR) system based on a variable length conrod with eccentric piston pin suspension. The small end of the connecting rod in the FEV systemis equipped with an eccentric sleeve housing the wrist pin. By rotating the eccentric sleeve, the effective connecting rod length, and thus the compression ratio, can be varied. (Diagram at right.)

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Johnson Controls to supply AGM batteries to Chery Jaguar Land Rover in China; introducing 48V micro hybrid system

Johnson Controls will provide its Absorbent Glass Mat (AGM) advanced lead-acid battery technology to power the Chery Jaguar Land Rover Start-Stop and other vehicles made in China to serve the China market. Start-Stop systems help reduce fuel consumption as the engine shuts off when the vehicle comes to a stop in traffic or at a red light. The battery restarts the engine when the driver’s foot releases the brake pedal or engages the clutch.

Separately, the company will debut to the China market its 48-volt Micro Hybrid battery demonstration module (earlier post) at the 15^th Shanghai International Automobile Industry Exhibition (Auto Shanghai 2013). Leveraging a dual voltage architecture, the Micro Hybrid battery system involves a low voltage lead-acid battery and a 48 volt Lithium-ion battery that enable optimization of energy generation and consumption, thus saving fuel.

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EDAG study finds aluminum BIW can deliver mass savings of 35-40% over steel; fuel economy boost

Material selection for the Venza aluminum BIW. Click to enlarge.

A new study by EDAG Group, commissioned by the Aluminum in Transportation Group of the US Aluminum Association, finds that an all-aluminum body in white (BIW) can deliver potential mass savings in the 35 – 40% range over a base steel BIW. This, when combined with secondary mass savings and other design changes, could boost fuel economy by around 18%.

The study built upon research EDAG performed last year for the US Environmental Protection Agency (EPA) examining mass reduction, safety and cost variables in a mid-size crossover Toyota Venza. The EPA study aimed to reduce vehicle mass by 20% while meeting all NHTSA and IIHS safety standards, and maintaining or improving performance, handling and braking.

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Ford launches the 1.5L EcoBoost engine; first in Mondeo, Fusion following; computer-controlled clutch on water pump

Ford’s 1.5L EcoBoost engine. Click to enlarge.

Ford Motor Company officially launched the new 1.5-liter EcoBoost engine into its lineup. The new engine will be first introduced in China in the all-new Ford Mondeo, making its public debut later this month at Auto Shanghai 2013 (earlier post), with applications following in the Fusion sedan in North America this year, and later the new Mondeo in Europe.

The 1.5-liter EcoBoost is the first engine from Ford to incorporate a computer-controlled clutch on the belt-drive water pump, which further improves efficiencies by reducing warm-up time. A water-cooled charge air cooler is added to offer a more efficient feed of air into the engine.

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Zhongding Power to invest more than $200M to build EcoMotors opoc plant in China

p> Zhongding Power and EcoMotors have entered an agreement for the production of the opoc (opposed-piston, opposed cylinder) engine (earlier post). One of the largest automotive component conglomerates in China, Zhongding will finance and construct the first opoc plant in the Anhui Province.

The plant represents an investment by Zhongding of more than US $200 million and will have a capacity of about 150,000 engines per year—or more than US $1 billion in revenue potential. High-volume production is expected to begin in 2014.

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GM investing $332M in 4 sites to produce new Ecotec small gasoline engine, 8-speed, V6

General Motors Co. will invest nearly $332 million in four manufacturing sites to produce more fuel-efficient engines and transmissions. The investments at GM plants in Flint and Bay City, Mich.; Toledo, Ohio; and Bedford, Ind. will support production of a new Ecotec small gasoline engine, a new V6 engine, 8-speed transmission, and tooling for an existing 6-speed transmission.

The new small Ecotec gasoline engine is part of a new global engine family that could top 2 million engines a year by the end of the decade, based on production in Flint and other locations around the world. The new family comprises a range of three- and four-cylinder engines in displacements from 1.0L to 1.5L and is the result of an engineering partnership between GM and the Shanghai Automotive Industry Corp. (SAIC), Shanghai General Motors (SGM) and the Pan Asia Technical Automotive Center (PATAC). (Earlier post.)

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Down to the wire for final round of public voting in DOE Apps for Vehicles challenge

The public voting period for the final round of the US Department of Energy’s (DOE’s) $50,000 Apps for Vehicles Challenge began on 18 March, and runs through 25 March. (Earlier post.)

Nearly 40 teams initially submitted ideas for the $50,000 Apps for Vehicles Challenge that seeks to improve safety and fuel efficiency through data innovation. Eight finalists were selected to move on to this second and final phase of the competition based on the business plans and product prototypes they submitted during the first phase.

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Tsinghua study compares two diesel-gasoline combustion modes; both deliver high efficiencies and low emissions

The effects of gasoline ratio on indicated thermal efficiency of HCII and GDBF modes. Yu et al. Click to enlarge.

Researchers at Tsinghua University have compared the combustion and emissions characteristics of two dual-fuel (diesel-gasoline) modes intended to integrate the advantages of both fuels to achieve high thermal efficiency and low emission targets. A paper on their results is published in the journal Fuel.

Gasoline Homogeneous Charge Induced Ignition (HCII) by diesel combines the port fuel injection of gasoline to form a homogeneous charge with the direct injection of diesel fuel as an ignition source. (E.g., RCCI, earlier post.) Gasoline/Diesel Blend Fuels (GDBFs) use a premixed blend of diesel and gasoline which is directly injected into the cylinder for combustion. (E.g., dieseline, earlier post.)

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Peugeot 2008 crossover delivers CO2 emissions as low as 99g/km for gasoline, 98 g/km for diesel

The 2008 on display in Geneva. Click to enlarge.

Peugeot’s new 2008 B-Segment urban crossover, introduced at the Geneva Motor Show, leverages its light-weight design, aerodynamic silhouette and a wide range of gasoline and diesel engines equipped with Stop&Start—including a new generation of 3-cylinder gasoline engines—to offer fuel consumption and CO₂ emissions as low as 3.8 l/100km (62 mpg US) and 98g/km for diesel, and 99g/km for gasoline.

New generation of 3-cylinder gasoline engines. The PSA Peugeot Citroën Group designed the new generation of 3-cylinder gasoline engines, which, while maintaining comparable output to 4-cylinder engines, are more compact and lightweight (a 21 kg reduction of the 1.2-liter VTi over a 4-cylinder counterpart). (Earlier post.)

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Study finds that increased vehicle travel and decreased occupancy have undercut the impact of improving fuel economy over last 40 years

A new study by Dr. Michael Sivak, Director, Sustainable Worldwide Transportation, University of Michigan Transportation Research Institute (UMTRI), has found that from 1970-2010, an increase in vehicle distance travelled in the US, coupled with a decrease in the number of occupants in the vehicles, combined to undercut the impact of advances in vehicle fuel economy during that period.

From 1970 to 2010, vehicle distance travelled in the US increased by 155% (from 1.674 trillion km to 4.260 trillion km); however, because vehicle load (i.e., occupants carried) decreased by 27% (from 1.9 to 1.38 persons), the occupant distance travelled increased by 84% (from 3.182 to 5.867 trillion km). Sivak found that while the vehicle fuel economy of the entire light-duty fleet improved by 40% (from 13 mpg US to 21.6 mpg US, or from 18.1 l/100km to 10.9 l/100km), because of the decrease in vehicle load, the occupant fuel economy only improved by 17% (from 24.8 mpg US to 29.8 mpg US, or 9.5 to 7.9 l/100km).

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Volkswagen to produce XL1 diesel plug-in hybrid at Osnabrück; 261 mpg US

The XL1. Click to enlarge.

Volkswagen has confirmed that its XL1 Super Efficient Vehicle, featuring fuel consumption of 0.9 l/100 km (approx. 261 mpg US), will go into limited production at the company’s Osnabrück factory in Germany. The plug-in diesel-electric hybrid, which Volkswagen will showcase at the Geneva show, can cover a distance of up to 50 km (31 miles) in all-electric mode.

The XL1 is low weight (795 kg), aerodynamic (Cd 0.189) and with a low center of gravity (1,153 mm high). This gives it the ability to cruise on the road at a constant speed of 100 km/h (61 mph) using just 6.2 kW / 8.3 hp, Volkswagen says. In all-electric mode, the XL1 requires less than 0.1 kWh to cover a driving distance of more than one kilometer.

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Consumer Reports testing finds many small turbo engines underperforming; fuel economy, acceleration no better than in larger conventional powertrains

Consumer Reports’ own fuel economy tests of vehicles equipped with small turbocharged engines has found in many cases that the turbocharged cars tested by CR have slower acceleration and no better fuel economy than the models with larger conventional engines, the organization said.

Consumer Reports tests many cars with small, turbocharged engines, and many competitors with traditional, naturally aspirated engines, large and small. Based on the EPA fuel-economy estimates, many of the charged engines look better. However, CR testers found those results don’t always map to real world driving and Consumer Reports’ own fuel economy tests.

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Achates Power opposed-piston diesel for TARDEC will demonstrate multi-cylinder configuration

Achates Power says that its 2-stroke OP engine offers higher best point brake thermal efficiency than diesel or gasoline engines. Source: Achates Power. Click to enlarge.

In December 2012, the US Army Tank Automotive Research, Development and Engineering Center (TARDEC) awarded Achates Power, Inc., developer of a two-stroke, compression-ignition (CI) opposed-piston (OP) engine, and AVL Powertrain Engineering, Inc. a $4.9-million contract for design and construction of the Next-Generation Combat Engine. (Earlier post.)

TARDEC, commented David Johnson, Achates President & CEO, in general has used COTS (Commercial Off-The-Shelf) engines, but is now looking for better fuel efficiency and is funding its own development activity; the solicitation won by Achates and AVL is a big departure for them, Johnson said. “We won on our data. The proposal we submitted with AVL had a substantial set of data [for the engine].” Achates Power has accumulated more than 3,600 hours of dynamometer testing and achieved 47.5% brake thermal efficiency with its OP engine. (The Achates/AVL project was the sole award from the solicitation.)

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GM debuts 2014 Stingray; direct injection, cylinder deactivation, CVVT contribute to more power and reduced fuel consumption

2014 Corvette Stingray. Click to enlarge.

GM staged the debut of the all-new, 7^th generation Chevrolet Corvette Stingray on the eve of the Detroit Auto Show. The 2014 Corvette Stingray is the most powerful standard model ever, with a new LT1 6.2L Small Block V8 delivering an estimated 450 hp (335 kW) and 450 lb-ft of torque (610 Nm). The new LT1 combines advanced technologies, including direct injection, Active Fuel Management (cylinder deactivation), continuously variable valve timing and an advanced combustion system that delivers more power while using less fuel.

The Stingray accelerates from 0-60 in less than four seconds and achieve more than 1g in cornering grip; it is also expected to be the most fuel-efficient Corvette, exceeding the EPA-estimated 26 mpg (9.05 l/100km) of the current model.

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Mercedes-Benz adds two more fuel-efficient models to new A-Class range; 5% improvement in both diesel and gasoline models

A 180 CDI BlueEFFICIENCY. Click to enlarge.

Just a few months after the launch of the new A-Class, Mercedes-Benz is now adding two BlueEFFICIENCY Edition models to the range. The new A 180 CDI BlueEFFICIENCY Edition features a fuel consumption figure of 3.6 l/100 km (65 mpg US) according to the MVEG cycle and CO₂ emissions of 92 g/km—making the new A 180 the most fuel-efficient combustion-engined Mercedes-Benz yet, according to the company.

The A 180 BlueEFFICIENCY Edition gasoline model, with consumption of 5.2 l/100 km (45 mpg US) and 120 g of CO₂/km is likewise one of the most efficient vehicles in its class. The models will go on sale on 1 February 2013, while the first vehicles will reach customers in March 2013.

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Volvo Car Group making multi-billion dollar investment in Scalable Product Architecture and Volvo Engine Architecture

Volvo Car Group, owned by Zhejiang Geely Holding Group Co., Ltd. in China, is making a multi-billion dollar investment in its SPA (Scalable Product Architecture) and VEA (Volvo Engine Architecture, earlier called Volvo Environmental Architecture). (Earlier post.) The main part of the two projects will be carried out in Sweden, constituting one of Sweden’s largest ever industrial investments.

SPA (Scalable Product Architecture) is a flexible, scalable product architecture that covers most of Volvo’s future car models. It is a product range consisting of shared modules and scalable systems and components, all manufactured in a flexible production system. The first car model based on the new architecture is the next-generation Volvo XC90, which will be launched at the end of 2014.

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New Lacks eVOLVE hybrid wheel technology shows 1.1 mpg highway gain in fuel efficiency on Ford Focus

Design of the eVOLVE wheel. Click to enlarge.

Lacks Wheel Trim Systems LLC, a business unit of Lacks Enterprises, Inc., a global supplier of trim systems to the automotive industry, introduced its new patented eVOLVE hybrid composite wheel technology, based on Lacks’ Chromtec wheel technology, at the Los Angeles Auto Show.

Hybrid-composite eVOLVE wheels developed for the Ford Focus as an initial proof of design showed a fuel economy improvement of 1.1 miles per gallon highway by balancing weight reduction and optimizing aerodynamics. As a comparison, the Focus production wheel BM5J-1007-DB (17x7x50) weighs 23.7 lbs (10.75 kg); the eVOLVE wheel (17x7x50) weighs 19.2 lbs (8.7 kg). Use of the eVOLVE wheels showed a 0.4 mpg improvement on the city cycle.

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Toyota introduces 4th gen RAV4; discontinues V6 option as segment moves towards more fuel efficiency

2013 RAV4 Click to enlarge.

The all-new fourth-generation 2013 RAV4 crossover SUV made its world debut at the 2012 Los Angeles International Auto Show. In redoing the RAV4, Toyota discontinued the optional V6 engine of the previous-generation; the new RAV4 only features Toyota’s 2.5-liter four-cylinder engine, which will produce 176 hp (131 kW) at 6,000 rpm and 172 lb-ft (23 N·m ) of torque at 4,100 rpm.

Replacing the previous four-speed automatic will be a six-speed transmission with Sequential Shift. First and second gear ratios will be optimized for around-town performance. To keep engine revs lower at highway speeds and enhance fuel mileage, fifth and sixth gears will be overdrives.

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