COMMERCIAL VEHICLES

& INDUSTRIAL ENGINES

2

The foundation of commercial prosperity and economic development includes the availability of a variety of flexible and efficient vehicles for transportation of both people as well as goods. Since the early 1930’s, the diesel engine has represented the preferred option for com-mercial truck propulsion and non-road utility vehicles. This dominance is based on a robust layout and superior economic performance.

Future concepts for commercial vehicles and industrial engines demand contradicting goals for development. Along with minimized fuel consumption, long term reliability and excellent driveability paired with high comfort standards have to be met at competitive costs. In addi-tion, increasingly stringent emission legislation that varies world-wide leads to a broad range of aftertreatment system specification and an increase in system complexity.

Consequently, a major challenge is to reduce the number of variants by using the potential for synergy between on-road and non-road vehicle applications. Reaching the lowest pos-sible emission standards can only be achieved through robust engine design layouts and proper selection of exhaust aftertreatment con-figuration at the earliest concept phase.

FEV, with its global presence and awareness for individual market demands, provides first class expertise in both commercial vehicle and industrial engine development from the initial design and CAE, through vehicle integra-tion and calibration. FEV’s interdisciplinary engineering services also cover functional and durability testing, pilot engine builds and the continuation of supervision for production vehicles which includes fleet testing.

From Concept to SOP

Power Train NVH

Vehicle Testing

2

Turn-Key Program Support:

Design and commercialization Cost engineering Engine and powertrain

durability Vehicle integration Calibration Specialized tools and methods Powertrain electronics and

controls development Vehicle durability Fleet testing Production planning

3

Single Cylinder Engine

Concept Design & Cost Engineering

Functional Development &

Durability Testing

Calibration & Validation

CAE

3

NOx [g/kWh]

Euro V

Stage 3b

Tier 4i

US '07

0.00.00

PM [g

/kW

h]

0.5 1.0 1.5 2.0 2.5 3.0

0.01

0.02

0.03

Euro VIStage 4Tier 4US '10

2

Motivated by both environmental and human health concerns, government enforced emis-sion standards are resulting in a continuous effort to improve both global and local air quality. Significant technical efforts have been made to match the more stringent emission standards while maintaining favorable fuel consumption. Under early emission legislation the initial steps to reduce emissions were real-ized through engine internal measures, such as with four-valve technology, turbocharging and intercooling, increased injection pressure and adapted bowl geometry, tailored charge motion and a precise, electronically controlled, EGR system.

Current exhaust emission standards under the European Union and the US EPA already pose significant challenges for powertrain develop-ers; however, upcoming emission standards, with further reduction in tailpipe emission levels, will increase the efficiency requirement and thus the burden on exhaust aftertreatment. Modern aftertreatment systems must incorpo-rate closed loop controls and detailed diagnostics to maintain high levels of emission control over the lifetime of the vehicle.

The introduction of efficient emission control systems

describes a new chapter in the evolution of heavy-duty diesel

engines. In addition to the demand for achieving the highest possible

efficiency, the durability and reliability of the typical heavy-duty diesel engine must be maintained despite the addition of advanced

exhaust aftertreatment technology.

Emission Compliance at the Highest Efficiency

4

GT-Power Model

Combustion Optimization

eee

r

eee

Tool for Emission Prediction

3

Worldwide Emission StandardsW rld id iWorldwwiiddee iiEEEEEEEmmmmiiiissssssiiiiooonnn SSSSttttaaanndddaarrrdddsssdddnnn

NOx [g/kWh]

Euro V

Stage 3b

Tier 4i

US '07

0.00.00

PM [g

/kW

h]

0.5 1.0 1.5 2.0 2.5 3.0

0.01

0.02

0.03

Euro VIStage 4Tier 4US '10

5

The following are key elements involved in FEV’s process to successfully develop efficient and emis- sion compliant on-road and non-road engines:

CAE-guided concept evaluation with a clear focus on development Early identification of the engine architecture Characterization of all emissions Definition of the entire system concept relative to requirements CFD-assisted combustion system refinement CAE-based exhaust aftertreatment design Strategy development for engine controls Tailored implementation of advanced control logic and global operation strategies DoE-based optimization process

Diesel

Particulate

Filter (DPF)

DoE-Based Optimization

Engine-/DPF-/SCR-Control

2

Technical attributes such as performance, fuel consumption, emissions, reliability and costs are the most important factors for developing a competitive combustion engine. FEV has con-ducted numerous projects focused on evaluating production engines for the potential to reduce manufacturing costs.

FEV conducts these cost reduction projects with a team of experienced designers and special-ists in the areas of production planning and cost analysis.

Concept Design & Cost Engineering

6

Robust Crankcase Design in GJL or GJV

Cylinder Head Design for High Peak Firing Pressure

Low EmissionsHigh specific Performance

Low Fuel Consumption

Low Costs/ Weight

Good NVH

Robust and Cost Effective Valvetrain

3

Workshop with Supplier

Detailed Informationof Cost Structure

Line Walks(Machining

and Assembly)

Brainstorming(Interdisciplinary

Project Team Design / Production)

Engine Components and Drawings New Design Layouts

incl. Cost Reduction Potential

7

Typical activities in a cost reduction study include:

Investigating ideas and measures to decrease manufacturing costs Quantifying the cost reduction potential Evaluating the related efforts for realizing the measures Estimating possible effects of the cost reduction measures on function and technical attributes of the engine Evaluating a given design against benchmark designs

Workshop with Client

Work out Approaches

Estimation of Cost Reduction

2

- a Vital Ingredient for the Creation of a Successful Powertrain

Mechanical Development

4

CONCEPT Detail DesignLayout

CAE Refinement Level

FEA

FEV Data Base

MBS

Benchmarking

CAE

Virtual Development

Component Testing

T

8 35

SOPPrototyping Bench Testing Vehicle Testing

SummerMechanical Test CenterFEV Test Catalogue

Winter

On RoadTesting

Physical Development

Troubleshooting Component Rating

Testingroubleshooting

9

2

Hardware-in-the-loop simulators enable the development teams to test new functionalities, I/Os, BUS-communication between different controllers and the diagnostics of controllers in a modular and reproducible environment, independent from the availability of engines or vehicles.

Calibration Methods and Tools

10 3

Integrated Model-Based Software Development and Calibration Process for the Develop-

ment of Control Units by

Requirements

System Design

Control Design

Software Design

Prototype or Production Target

ECU Code

Component

Integration

Acceptance Tests

Feasibility Studies System Simulation

Model-in-the-Loop

Software-in-the-Loop

Coding

Base Calibration

Calibration on the Test Bench Hardware-in-the-Loop (HIL)

Vehicle Calibration

DataAcquisition

STEP 1

Model-Based Data

Evaluation

STEP 2

Offline Calibration

Offline Verification

STEP 3

Final Verification

STEP 4

11

2

FEV continues to conduct full vehicle NVH de-velopment for many programs. Such programs typically are carried out in close cooperation between OEM specialists, suppliers and FEV. FEV’s project managers coordinate activities between the different working groups, ensuring a streamlined development process.

NVH for Production Readiness

Aero Acoustic: Body shape Sealing Windows Side mirrorWiper ...

Body NVH: Global stiffness Stiffness of front-end section Impedances at interface points Vibro-acoustic-transfer functions Subsystem stiffness (steering) ...

Chassis NVH: Stiffness of axles and subframes Bushing insulation Tire noise Brake NVH ...

Interior NVH Quality: Sound insulation Squeak and rattle HVAC noise Electro servo motor noiseAudio and entertainment systems ...

12

The cooperation between OEM, FEV and suppliers includes items such as:

System and components level target setting Experimental and analytical component

refinement NVH development for the OEM using

OEM-specific processes and strategies Full-responsibility for NVH integration NVH robustness for production

Powertrain induced NVH: Engine and transmission driveline Powertrain mount Intake and exhaust systemPass-by noise ...

313

Truck development is mainly driven by costs, fuel consumption, emissions and reliability. In addition to legislative needs for exterior noise, interior NVH/comfort is gaining importance. To achieve an overall well balanced NVH behavior, the entire vehicle has to be taken into account.

It is very important to optimize all relevant NVH systems/components, such as:

Powertrain and driveline Intake and exhaust system Chassis and mounts Cabin including the noise insulation

NVH Powertrain/Drivetrain Development Optimization

NVH Combustion System Development

NVH Vehicle Integration

NVH Component Optimization

w/o NVH Optimization

w/ NVH Optimization

Powertrain Noise [l]

SPL

[dBA

]

5

Pass-By NoiseInterior Noise

NVH Benchmarking: Vehicle/Powertrain/Subsystems

FEV’s key strengths for the optimizations are

Long term experience with on and off-road vehicles

Proven CAE tools and methods Highly-efficient testing tools and methods

FEV’s systematic approach allows for efficient NVH development.

Scatterbands

2

FEV HD Single Cylinder – Setup with Production Cylinder Head

FEV HD Single Cylinder

14

FEV HD Single Cylinder – Design Concept

FEV HD Single Cylinder – Technical Data

Bore: 95 – 150 mmStroke: 110 – 170 mmRated Speed: Max. 3500 rpmPeak Pressure: Up to 300 barCrankcase: Machined steelCylinder head: Production part or customizedValvetrain: OHV, SOHC, DOHC, alternative systemsCrankshaft: Machined steel / 4 main bearingsStarter: Electric starter motor on engineLubrication: Test cell oil conditioning system Cooling: Test cell coolant conditioning system

Component Testing

Friction Test Benches

Catalyst Test Bench

3

Test Facilities

915

> 100 Engine Test Benches (20 Heavy-Duty Capable) 8 Transient test benches 5 Anechoic test benches 8 Motoring test rigs 3 Catalyst aging test benches

Vehicle Test Center 2 Emission chassis dynamometers Anechoic chassis dynamometer Test track Vehicle workshop Climate chambers (- 30 to + 40 °C)

Laboratories Flow lab Injection lab Vibrations lab Audio lab Chemical lab Electromechanical lab

ucc2114FE Height simulation test bench

Thermodynamic Test Benches Steady State/Transient incl. CVS-devices

Semi Anechoic Test Chamber

Com

mer

cial

Veh

icle

s &

Indu

stria

l Eng

ines

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008

CONTACT