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Hyundai showcasing new downsized turbo engines and 7-speed dual-clutch transmission; i40 48V Hybrid, i30 CNG

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New engines and transmission. Click to enlarge.

Hyundai Motor is showcasing two new turbocharged gasoline direct injected (T-GDI) engines at the Paris Motor Show 2014. Both engines—1.0-liter and 1.4-liter units which are part of a new generation of engines from the Kappa family—meet growing demand for small capacity, turbocharged engines to reduce fuel consumption and CO2 emission without compromising performance.

In addition, Hyundai is premiering at the Paris show its first 7-speed dual-clutch transmission, fitted into the i30 CNG natural gas concept car, which contributes to improved fuel efficiency. Hyundai is also displaying the diesel i40 48V hybrid concept, featuring a lead-carbon battery.

Kappa 1.0-liter T-GDI. The new Kappa 1.0-liter T-GDI is the first of a new generation of small turbocharged gasoline engines, offering enhanced performance, driving pleasure and efficiency. The 998 cc three-cylinder unit is based on the established Kappa 1.0 liter MPI engine, carrying various enhancements and new technologies, including direct gasoline injection and a small, single-scroll turbocharger.

The 1.0 liter T-GDI engine, which was developed at Hyundai’s European Technical Centre in Rüsselsheim, Germany, is able to produce up to 120 PS (118 hp, 88 kW) and 172 N·m (127 lb-ft) of torque and will enhance the New Generation i20 engine line-up in 2015.

The new engine comes with an electronically-controlled waste-gate to optimize flow and improve low-end torque and throttle response. The unit features a six-hole GDI injector, pressured to a higher-than-average 200 bar, securing a clean combustion and improving fuel economy and emissions to fulfill Euro 6c emission standards, three years ahead of their introduction in 2017.

It uses a new split-cooling concept to manage different temperatures in the cylinder head and block area. The cylinder block is heated quickly for lower friction and more efficient run, while the cylinder head is operating at lower temperatures to optimize injection and combustion.

To keep the engine unit as small as possible, the exhaust manifold is integrated within the cylinder head and can therefore be cooled efficiently using the cylinder head water cooling system. These efforts result in faster warm-up of the catalyst and ultimately in reduced real-world fuel consumption and emissions.

Kappa 1.4-liter T-GDI engine. The second engine to be showcased at the Paris Motor Show 2014 is the Kappa 1.4-liter T-GDI unit. This newly developed 1352 cc four-cylinder turbocharged gasoline engine is significantly lighter than its predecessor, the Gamma 1.4-liter engine. At only 87 kg (192 lbs), the engine’s base weight has been reduced by 14 kg (31 lbs) compared to the Gamma 1.4-liter unit. As well as being lighter and smaller, it features greater efficiency and power.

The new 1.4-liter T-GDI engine incorporates a high-pressure single-scroll turbocharger integrated within the exhaust manifold to improve operational efficiency. The relocated and re-engineered turbo means throttle response time and low-end torque have improved. The new design injects fuel directly inside the cylinder, improving combustion rates for better power and fuel efficiency.

Showcased in the i30 CNG concept car displayed on Hyundai’s Paris Motor Show booth, the Kappa 1.4-liter T-GDI engine provides 117 PS (115 hp, 86 kW) in CNG mode, delivering 206 Nm of torque. The CO2 emissions of the i30 CNG concept car are just 87 g/km, which already meet strict Euro 6c emission standards.

Seven-speed dual-clutch transmission. Another premiere at the Paris Motor Show 2014 is the seven-speed dual-clutch transmission (7DCT), also showcased in the i30 CNG concept car. It is the first time that Hyundai has presented a dual-clutch transmission with seven gears, combining the benefits of both automatic and manual transmissions. The 7DCT provides an improvement in fuel consumption and CO2 emission compared to a conventional six-gear automatic transmission, while acceleration performance also improves.

The 7DCT consists of two dry clutches and an actuator for each clutch, with engine power transferred independently into the odd and even gear train, ensuring it is ready to shift into the next gear without any torque interruption. For optimized responsiveness the electric motor-driven actuator is applied, while the external damper improve the noise vibration harshness during driving.

48-volt hybrid version of the i40. The i40 48V Hybrid reduces CO2 emissions and fuel consumption significantly compared to the standard production model, yet only costs a quarter of a full hybrid solution to build. Based on a 1.7-liter diesel powertrain, the show car is fitted with a 48-volt lead-carbon battery, boosting power by 15% and reducing CO2 output by up to 20%.

With a belt-driven starter generator (BSG) replacing the conventional alternator, the engine is able to restart with almost no noise or vibration. The i40 48V Hybrid can operate in electric-only mode at low speeds and when cruising. The lead-carbon battery pack recharges itself during deceleration and through regenerative braking, with the BSG working as a generator. While accelerating, the BSG supports the engine with its additional 10 kW to reduce fuel consumption and CO2-emissions.

In combination with a larger turbocharger, the system’s performance increases to 155 PS (153 hp, 114 kW) and a maximum torque of 360 N·m (266 lb-ft).

The lead-carbon battery was chosen due to its excellent power-to-cost ratio, rapid charging capability and high levels of durability. It requires no active cooling system and can therefore be stored within the spare-wheel well, ensuring luggage space is not compromised. In addition, the lead-carbon battery is almost completely recyclable at the end of its lifecycle.

As the 48V Hybrid technologies are cost effective, have compact dimensions, apply a minimal weight penalty (just 46 kg), and can be easily introduced alongside existing powertrains, they could have far-reaching potential application in future production cars, Hyundai suggested.

New Generation i30 CNG. The New Generation i30 CNG features a debut of the company’s new 1.4-liter T-GDI engine, mated to the new seven-speed dual-clutch transmission, as well as the latest application of its CNG research and development program.

When equipped with the new 7-speed dual-clutch transmission, the engine emits CO2 emissions as low as 87 g/km, a significant reduction compared to the equivalent gasoline-fueled model, and meets the strict Euro6c emission standards three years ahead of introduction in 2017. Running on CNG, the engine develops 117 ps and maximum torque of 206 N·m (152 lb-ft) from 1,500 rpm to 3,500 rpm.

The CNG is stored in an innovative rectangular tank within the floor pan, ensuring interior space remains the same as its ICE counterpart. Lined with a gas-impermeable polyamide matrix (inside) and protected by high-performance glass-fibre reinforced plastic (outside), the new system provides a high-strength, low-cost solution to gas storage, and weighs 50% less than the equivalent steel tank.

Up to 15 kg of gas can be stored in the tank at 200 bar pressure. A new electrical pressure regulator lowers gas pressure to an operable state in two steps, first to 20 bar and then to 4 to 11 bar, which is fed into the engine. The bi-fuel power plant uses both gasoline and compressed natural gas as fuel, with the flexibility to automatically switch to gasoline once the supply of CNG has been used.

ix35 Fuel Cell and Intrado fuel cell vehicles. Alongside the new powertrains, Hyundai is showcasing the latest vehicles from its fuel cell programme, including the first mass-produced hydrogen-powered vehicle, the ix35 Fuel Cell and the Hyundai concept car, Intrado.

In 2013, Hyundai Motor Europe achieved registrations of 422,930 units, taking a new-car market share of 3.4%.

Comments

HarveyD

Hyundai is progressing fast in many new technologies.

It may be the first manufacturer to come out with mass produced lower cost 48-Volts mild hybrids and FCEVs.

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