Mercedes-Benz Introduces the Mixed-Mode DiesOtto Engine in the F 700 Research Car
11 September 2007
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The F 700 with DiesOtto drive delivers the performance of a S-Class with a 3.5-liter V6 but using a downsized 1.8-liter mixed-mode gasoline engine with hybrid module. Click to enlarge. |
The introduction of the F 700 research car at the Frankfurt Motor Show marks the debut of Mercedes-Benz’ new mixed-mode DiesOtto engine—a 1.8-liter, turbocharged, four-cylinder gasoline direct injection engine that supports a switch to controlled auto ignition (CAI) under certain operating conditions. (Earlier post.)
A hybrid module assists the internal combustion engine mainly in stop-and-go operation. The maximum output is 175 kW (238 hp), the electric motor pitches in another 15 kW (20 hp), and the system’s maximum torque is about 400 Nm (295 lb-ft).
The F 700 achieves the performance level of a current S-Class car with a 3.5-liter naturally aspirated V6 gasoline engine or the 3.0-liter V6 turbodiesel. The F 700 accelerates from 0 to 100 km/h (62 mph) in 7.5 seconds, with a top speed (limited) to 200 km/h (124 mph). Fuel consumption of the F 700 in the standard cycle is about 5.3 l/100km (44 mpg US)—equivalent to CO2 emissions of 127 g/km.
Our strategic objective is to make the gasoline-powered car as economical as the diesel, and the diesel as clean as the gasoline engine.
—Dr. Thomas Weber, Board member of DaimlerChrysler AG responsible for Group Research & Mercedes Car Group Development
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CAI versus spark plug ignition. Click to enlarge. |
The DiesOtto engine. The DiesOtto engine brings the benefits of diesel technology to the gasoline engine: in CAI, mode the air-fuel mixture ignites itself the same as in a diesel engine. The DiesOtto makes no special demands on fuel quality: the engine runs on normal gasoline.
The DiesOtto engine uses spray-guided gasoline direct injection, but applied differently than in the direct injection CLS 350 CGI engine, for example. The CGI engine’s lean-burn operation requires an ignitable mixture cloud around the sparkplug. The DiesOtto engine also operates with a lean mixture, but need direct injection for a homogeneous mixture in the cylinder and for the free control of the injection cycles.
A variable valve control system can adjust valve opening times over a large range, and alter the valve lift as well. To achieve this, the camshaft is provided with two cams, a smaller one and a larger one, for each valve. The large valve lift is needed for full-load operation and high engine speeds, the small valve lift mainly for CAI at partial load.
To meet the different requirements for partial and full-load operation, the DiesOtto engine is fitted with a variable crank mechanism with which the geometric compression can be continuously adjusted.
The fuel consumption advantage results mainly from the relatively lean mixture and high exhaust gas content, and from adaption of the compression ratio depending on operating point. Low emissions of NOx result from homogeneous combustion at a constant, relatively low temperature.
For further emission control a common three-way catalytic converter is adequate for the DiesOtto drive—the F 700 meets Euro 6 specifications.
CAI is suited for the most frequently used driving modes, at low and intermediate speeds as well as for intermediate load requirements. At higher loads, DiesOtto switches to conventional combustion within a single power stroke. In this case it breathes using the large valve lift, fires using sparkplugs and runs as a direct-injection unit in Lambda1 mode.
The DiesOtto drive gets additional power from a two-stage turbocharger system. A larger low-pressure turbocharger and a high-pressure turbocharger of smaller diameter are connected in series and together optimally cover the complete engine speed range. The complex system makes for good responsiveness from low revs, provides high torque and pulling power and delivers high peak output. For driving off, the internal combustion engine additionally gets assistance from the electric motor of the hybrid module.
The F 700 serves as a research platform for several other innovations, including a new PRE-SCAN suspension that uses two laser sensors in the front headlamp units as “eyes”. The sensors deliver a precise image of the condition of the roadway. Based on the image supplied by the laser sensors and the information on the vehicle state, the control unit figures out a specific strategy which the high-pressure hydraulics translate into precisely calculated fluid flows and pressures for each single wheel.
The ICE is dead, long live the ICE!
44mpg (gasoline!) S-class with decent performance to boot! No need for urea after-treatment to scrub NOx.
Between DiesOtto and GM's HCCI on-road demonstrator... these are exciting times indeed!
Posted by: DieselHybrid | 11 September 2007 at 02:16 PM
Very impressive efficiency for such a ride--but that's one complex drive train.
Posted by: Nick | 11 September 2007 at 02:27 PM
Does anyone have a pointer to an explanation of how the variable compression works? I've seen some mention of eccentric crankshaft...
Posted by: Nick | 11 September 2007 at 02:46 PM
I know it is complex, but it is exactly the type of thing I wish I could buy in 5 years. It would be really cool if they could also add in some sort of heat recovery system, like BMW's turbosteamer. I know....I'm being greedy, but I would like to see someone attempt to combine all of the known ICE efficiency improving technologies.
Oh, yeah....maybe throw in E85 compatibility. That shouldn't be much of a problem though - according to GM, HCCI works fine with ethanol.
Posted by: Angelo | 11 September 2007 at 03:36 PM
Car companies must feel threatened by the advance of the plug-in hybrid, and have turned loose their tech-nerds to produce any engine pipedream ever imagined.
The future of vehicle technology is not with any duo-supercharged, variable valve lift multi-cam, variable crankshaft engine. ANY engine used in tandem with a larger electric motor doing most of the driving, need not be that complex. The future car is one that need not be driven. Plan on that, Mercedez Benz.
Posted by: Wells | 11 September 2007 at 04:42 PM
For simplicity, durability, minimum moving parts, clean operations, almost fail proof, could we have a vehicle with an upgradable modular EESU + in-wheel high efficiency electric motors + an optional APU for long distances (if required)?
Posted by: Harvey D | 11 September 2007 at 05:23 PM
@ Wells, Harvey D -
note that Mercedes is also active in the PHEV R&D arean with its Sprinter van. It's not a question of either-or. It's both, and lots of other avenues as well, all being pursued in parallel. Nobody puts all of their eggs in one basket.
That's mainly because auto makers depend on battery vendors to make PHEV/EV concepts fly both technologically and eventually, economically. The DiesOtto is something Mercedes can do with its own resources and existing supply chain, so the development risk is lower.
Posted by: Rafael Seidl | 11 September 2007 at 06:36 PM
I don't think this is intended in any way to suggest this will be the mainstream technology of the future. This is a concept aimed at a potential S-class variant 5 years from now - not a mainstream vehicle by any means.
Yes, no one needs such technology, but many people want it. What, it's ok for my home electronics to evolve into a ridiculously complex instruments, but it's not ok for automobiles? What is so terribly complex about what they are proposing? 15 years ago, we had to live with carburators, static cam lift/timing profiles, and 3-speed automatics. Should we have stopped there? I know I wouldn't be happy driving around a Ford Tempo or Chevy Citation today.
Posted by: Angelo | 11 September 2007 at 06:44 PM
Here's a knock-knock joke for those of you who understand HCCI combustion:
"Knock, knock, knock, knock, knock, knock.......Who's there?.....DiesOtto"
Get it?
Posted by: terry | 11 September 2007 at 07:22 PM
In the past months we've seen three different drive line configuration from GM; the BEV, PHEV and The FCEV. I think these and many of the other car company concepts are nothing more than scrambling to hedge their bets and as pointed out, minimize mistakes.
This business, for the established auto companies, has always been about moving slow. I remember when the only difference between the '53 and '54 Chevy was the chrome pieces; you only had to change the grill and tail light assemblies to move up a year.
It's taken 100 years for us to get here and what do you know, it's the same place we started only with more sophisticated technology. When Ford built the first T model it was designed to run on ethanol. Then he and the Standard Oil company put gasoline in the ICE, ran the BEV companies out of the business, and so here we are after running in an evolutionary circle, looking at HEVs, PHEVs and BEVs all over again.
Posted by: Lad | 11 September 2007 at 08:00 PM
44mpg : Not bad though if this is a diesel-electric hybrid, it could be better. These cars are supposed to be capable of 60-80 mpg.
Posted by: Gerald Shields | 11 September 2007 at 08:47 PM
I know it is complex
It's not any more complex than any other ICE with a turbo & variable timing.
The only thing complex is the software to control it all.
Despite what you may have heard, engine software doesn't have to be rotated & balanced every 50,00 miles.
Posted by: DS | 11 September 2007 at 09:26 PM
The F 700 achieves the performance level of a current S-Class car with a 3.5-liter naturally aspirated V6 gasoline engine or the 3.0-liter V6 turbodiesel. The F 700 accelerates from 0 to 100 km/h (62 mph) in 7.5 seconds, with a top speed (limited) to 200 km/h (124 mph). Fuel consumption of the F 700 in the standard cycle is about 5.3 l/100km (44 mpg US)—equivalent to CO2 emissions of 127 g/km.
Very impressive. Hope it makes it to market.
Posted by: jack | 11 September 2007 at 09:44 PM
DS:
"It's not any more complex than any other ICE with a turbo & variable timing."
I would assume that variable compression makes for an additional layer of mechanical complexity. This is beyond glorified Honda iVTEC. In addition, it's got a mild hybrid setup with batteries, starter/motor/generator, controller, etc.
I'm not concerned about the complexity of the programming; I'm wondering about the cost, complexity and reliability of all those moving electro and mechanical parts. It may be a tour-de-force, but it looks awfully expensive to me.
Posted by: Nick | 11 September 2007 at 11:57 PM
"It may be a tour-de-force, but it looks awfully expensive to me."
...diesel hybrids aren't going to come in much cheaper.
Posted by: Angelo | 12 September 2007 at 03:52 AM
@ Terry -
zank you, you vill be here al ze week. Try ze veal.
Btw, engine knock is a secondary, *uncontrolled* auto-ignition of a gas pocket near the edge of the combustion chamber, triggered by acoustic supercompression. This is caused by the pressure wave emanating radially from a spark plug in conventional SI and must be avoided because it can very quickly cause the engine to fail.
This is entirely different from *controlled* auto ignition, a combustion concept in which there is no spark, no flame front and therefore no dominant radial pressure wave. Instead, combustion occurs spontaneously at many locations almost simultaneously and is over and done with before any flame front can even form. It's still loud but the pressure signature is much more benign, i.e. there is no risk of damage to the engine.
Posted by: Rafael Seidl | 12 September 2007 at 06:16 AM
The variable compression idea has been done before (by SAAB,prototype only). The Crankshaft actually rides in an eccentric carrier which moves the crank vertically toward/away from the combustion chamber.
The complexity and cost of this approach will never be installed in a car that I can afford.
Posted by: Fred | 12 September 2007 at 09:16 AM
"Knock, knock, knock, knock, knock, knock.......Who's there?.....DiesOtto"
Auto who?
Auto-ignition, you foo! :P
Sorry it takes 24 hrs to post this response.
Posted by: Roger Pham | 12 September 2007 at 09:53 PM
Rafael:
Cold combustion you described is very tricky to maintain, especially at fast varying load and RPM. It is prone to slide to misfire or worth yet – detonation (knock, knock...).
Steady load diesel generator in series hybrid (Chevy Volt) is probably the best candidate for first application of HCCI engines.
Posted by: Andrey | 12 September 2007 at 10:05 PM
Me Likey!!!
Posted by: Schmeltz | 13 September 2007 at 06:40 AM
Steady load diesel generator in series hybrid (Chevy Volt) is probably the best candidate for first application of HCCI engines.
Andrey, I once thought this as well. But doesn't HCCI mostly improve efficiency at low-load? PHEV engines are sized to avoid low-load operation.
Does anyone else here think DiesOtto is a dumb term?
--ddw
Posted by: doggydogworld | 13 September 2007 at 06:49 AM
@ Andrey -
if flameless combustion were cheap and easy to control, we'd all be driving around with engines that use it in part load. It is hard and expensive, but with modern variable valve trains, GDI, in-cylinder pressure sensors (e.g. by using the spark plug in reverse to measure ion current) and control electronics, it is becoming feasible. On the diesel side, the hard part is precise control of EGR cooling and mass flow. Pressure sensors integrated into the glow plug are available but still expensive.
Btw: smooth mode transitions have been demonstrated in multi-cylinder engines in various prototypes. The hard part is making absolutely sure it is absolutely robust in all weather and operating conditions, with conventional ignition a fallback option if any component of the control system fails or is at least deemed suspect by plausability checks. Also, customer acceptance is not yet a given, both in terms of aural comfort and in terms of cost.
@ doggydoggworld -
agreed, using a gasoline HCCI engine in a genset is pointless. You're better off using a smaller, lighter and running that at high load (open throttle) with a three-way catalyst. Only if you decide to use a diesel *and* you need to meet T2B5 *and* you want to avoid the expense of a LNT or SCR system would flameless combustion make sense in PHEV genset. It would be expensive and the extra weight would reduce the fuel economy benefit, which is anyhow not much at high load.
And yes, DiesOtto is a poorly chosen term. In English, no-one refers to a spark ignition engine as an Otto engine, as the Germans do. Therefore, Joe Average doesn#t even know what the Otto part refers to. Moreover, he's likely to guess that the engine is running on diesel fuel - and all the prejudice that entails - which it is not. Finally, flameless combustion is neither conventional spark nor conventional compression ignition - it is best thought of as distinct from both. Therefore, DiesOtto is not just confusing and misleading, it is also factually wrong, at least wrt the flameless combustion.
I prefer flameless combustion or volume ignition to describe what's going on. It can be achieved for a variety of fuels including gasoline and diesel, but the implementation must be adapted to the intrinsic properties of the target fuel.
Posted by: Rafael Seidl | 13 September 2007 at 11:30 AM
As an engineer I can say that I am happy to see the ICE increase its thermal efficiency but unfortunately, the diesotto engine will be destined to be used in the parallel hybrid configuration. What I really want to see is a "DiesAtkinson" engine that can have an even higher thermal efficiency when working on the HCCI mode. Such an engine will be a breakthrough when used in a series hybrid configuration. Most car companies are dragging their feet by not embracing the series hybrid configuration. Forget hydrogen, the endgame is clear and simple: series hybrid, high power lithium batteries (phosphate or titanate), squirrel cage AC motor, high variable compression HCCI flex-fuel genset.
Posted by: Freddy | 17 September 2007 at 05:31 AM
I agree that HCCI combustion has nothing to do with diesel, it´s very diferent in nature:
HCCI: constant volume
diesel: constant pressure
HCCI:homogeneous (well mixed)
diesel:stratified and heterogeneous(poorly mixed)
HCCI: cold combustion
diesel: very hot combustion
HCCI: fuel must resist some compression (requires octane rated fuels)
diesel:fuel should ignite easily on temperature (cetane rating), which is inapropriate for HCCI.
The HCCI combustion is a clean and efficient one because it´s well mixed, fast and cold, the very opposite to diesel.
Hcci is the way to go and not diesel, as a matter of fact, diesel has delayed what should have always been.
Posted by: Nuno Pereira | 03 October 2007 at 04:15 PM
ya! haha... I think Mercedes wants consumer to think of HCCI as a petrol engine that is as fuel efficient as a diesel. Yet, as powerful as a typical petrol and revvy.
Technically it is all wrong, but thats the way it goes I guess.
Posted by: Chin | 10 October 2007 at 06:20 AM