Spectrum 46 E Web

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Technology-Highlights and R&D Activities at FEV

Issue 46, March 2011

www.fev.com

Functional Safety

In the automotive industry, electrical and electroniccomponents are proving to be a key to the balancingact created between, on one hand, cost, emissions andfuel consumption reduction and, on the other hand, animprovement of driving pleasure, performance and sa-fety. The vast majority of modern innovation is relatedto vehicle electronics and the number and complexity ofdistributed functions over many control units continuesto increase.

Functional safety, defined as the absence of unacceptablerisks due to hazards caused by the malfunction behaviorof electric or electronic systems, is quickly becominga key factor in the development of modern vehicles. Itis important to notice that functional safety is a vehicle

property, rather than an application domain. Functionalsafety is applicable to every function implemented viaany electric or electronic component, independent from

Summary

Functional Safety 1Euro 6 for Passenger Car Diesel 4

Acoustics of Electric Vehicles 5

New Challenges

for Commercial Vehicle Engines 6

TOPexpert TraCE 7

Expansion of the FEV

Durability Test Center 8

FEV Shows Transmission

Expertise at the CTI Symposium 8


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FEV SPECTRUM

Fig. 1: Overview about the Fuel Saving Potential of a

Comprehensive Diesel Engine Concept with

Integrated Hybrid Functionalities

Today, the modern passenger car Diesel engine provides avehicle propulsion system that affords the highest efficiency

and lowest CO2 emissions for passenger vehicles and offersan advantageous basis to achieve future stringent legislationrequirements.

The key element in a successful strategy to simultaneouslymeet challenging CO2 targets and increasingly strict emis-sion limits is an intense focus within the relevant operationalarea towards manageable and beneficial operating points.Regarding the combustion process, the essential aspectsfor realizing this parallel strategy are load point shifting (e.g.by downsizing and downspeeding) and the implementationof electric propulsion assistance. Optimized fuel consump-tion and emission performance of the base engine, requirescombined optimization steps in engine mechanics and ther-modynamics, together with targeted integrated thermal ma-nagement to reduce the losses during the warm-up phase.

Additionally, an optimized layout and arrangement of theexhaust aftertreatment components is mandatory to im-prove the actual real-life fuel consumption. This avoids cost-

ly heating measures to improve the conversion efficiency.Regarding the additional hybridization, a prior fine-tuningof the operational strategies, which considers the engineemission characteristics is inevitable. This includes the utili-zation of modern development tools and is based on detailed

knowledge and experience with existing engine concepts andaftertreatment systems (Fig. 2).

Fig. 2: Combined Strategy for Realization

of Challenging CO2-Targets

The potential of such integrated hybrid diesel engine con-cepts has been investigated by FEV for current and potentialfuture drive cycles. FEVs HECS (Highly Efficient Combustion

System) diesel engine concept already accomplishes verycompetitive emission levels for a vehicle in the 1700 kg IWC(Inertia Weight Class), with 95 g/km CO2. This undercutsrepresentative CO2 emissions for vehicles in the 1360 to1590 kg IWC and provides the potential to meet 2020 CO2emission limits with the appropriate technology upgrades

(Fig. 1).

[email protected]

Fuel Consumption Potential for Passenger Car

Diesel Engines beyond EURO 6

ICEOp

tim

izat

ion Electrifi

cation

Diesel-Hybrid Demo

FEV 7H-AMTIntegrated Transmission

C O 2 R e d u c t i o n: u p t o 2 0 %C O 2 R e d u c t i o n: u p t o 2 0 %C O 2 R e d u c t i o n: u p t o 2 5 %C O 2 R e d u c t i o n: u p t o 2 5 %

T o t a l C O 2 R e d u c t i o n: > 4 0 % T o t a l C O 2 R e d u c t i o n: > 4 0 %

B a s e l i n eB a s e l i n e

VehiclesMeasures

(Weight,Resistances,.)

LP-TC HP-TC

IC1

IC3

HP-EGR

DPF

IC4

LP-EGR

IC2

T2

T1

V1

V2

V3LP-TC HP-TC

IC1

IC3

HP-EGR

DPF

IC4

LP-EGR

IC2

T2

T1

V1

V2

V3

100,00

200,00

300,00

NEFZgesARTEMISges

NEFZ _ECE

ARTEMISCity

FTP-75

NEFZ_EUDC

ARTEMISRoad

ARTEMISMotorwayUS Highway

ADAC Eco

Urban Center

City

Automotive MagazineMOT

Automotive MagazineAMS

NSVZ

_

_

Legal or Part of Legal Test Cycle (on Chassis Dyno)

Semi-Official Test Cycle (on Chassis Dyno)

Real World On-Road Cycle

_

_

_

_

FEV Scatterband (for 1360 - 1590 kg) IWC

FEV HECS Gen. 1 Results (IWC 1700kg)

NEDC Target (2020) in 1470 kg IWC


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Future commercial vehicle engine concepts will demandcontradicting development goals. Together with minimalfuel consumption and low emissions, long-term reliabilityand excellent driveability in combination with high comfortmust be obtained at competitive prices.

The lowest emission standards in combination with thehighest desired reliability value for the different markets cantherefore only be reached through robust engine design.This process requires the achievement of high specific powerin the earliest possible (concept) phase as well as properselection of the exhaust gas aftertreatment system.

FEV, with its global presence and awareness of individualmarket demands, provides first class expertise in the deve-lopment of commercial engines from the initial design andCAE, to engine bench testing and vehicle integration andcalibration.

Emissions and Exhaust AftertreatmentCurrent exhaust emission standards under the EuropeanUnion and the US EPA already pose significant challengesfor powertrain developers. However, upcoming emissionstandards, with a further reduction in tailpipe emission le-vels, will increase the efficiency requirements and add tothe burden of exhaust aftertreatment systems. Modern af-tertreatment systems must incorporate closed loop controlsand detailed diagnostics to maintain high levels of emissioncontrol over the lifetime of the vehicle. The introduction ofefficient emission control systems describes a new chapterin 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 dieselengine must be maintained despite the addition of advancedexhaust aftertreatment technology.

Truck development is mainly driven by fuel consumption,emissions, reliability and costs. The initial steps to reduceemissions were realized through internal engine measures,such as with four-valve technology, turbocharging and in-tercooling, increased injection pressure and adapted bowlgeometry, tailored charge motion and a precise, electroni-

cally controlled EGR system. Covering the lifetime of theengines reliability, in terms of functionality, for all these parts

and complex systems often contradicts the aspect of costoptimization.

With regard to these requirements, FEV is able to utilizespecial measurement techniques to minimize risk duringengine development and customer usage. Motivated by thedemands for sound damping, that will also be relevant forfuture trucks, FEV has solid technical knowledge and experi-ence regarding sound and vibration in commercial vehicles,including CAE techniques, test benches and in-truck vehiclemeasurements.

Special Measurement Technique and NVHSpecial measurement techniques can be utilized for near-ly all engine components. If troubleshooting is required, aworkshop at the clients facilities are conducted, using ex-perienced FEV engineers to conduct a root cause analysisand take action. Afterwards, special measurements are takenon components under fired engine conditions. The resultsare then evaluated and critical issues that require designchanges or additional steps are presented. In addition tolegislative needs for exterior noise, interior NVH/comfortis gaining importance. The entire vehicle has to be taken

into account to achieve a well-balanced sound and vibrationbehavior.

[email protected]

New Challenges

for Commercial Vehicle Engines


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FEV SPECTRUM

FEVs calibration tool suite TOPexpert is well known andestablished by calibration engineers worldwide as a meansof efficient calibration support. A major revision of the suitesuccessfully used for over seven years has been performedbased on positive feedback from numerous calibration engi-neers (see Spectrum 45). This has led to an open approachfor supporting easy and flexible integration and adaptation of

calculation routines, simulation models, workflows, scriptsand Matlab-code.

Introducing this open and flexible approach, while keepingthe established calibration knowledge within the tool suite,allows new calibration tools to be provided much faster. Inaddition to the already existing tools for diesel, gasoline andhybrid calibration, a new tool for transmission calibrationcalled TraCE (Transmission Calibration Expert) has beenestablished. A preliminary version of a shift line calibrationtool has become much more flexible, user friendly and hasbeen augmented by online capabilities. Furthermore, a newshift quality assessment module has been introduced that

provides objective metrics. The new flexible architecture ofTOPexpert has also proven to be beneficial, since this toolcould be set up and used in an initial customer project inless than six months.

TraCE consists of two different modules. The first moduleis a model-based tool for the calibration of shift lines thatanalyzes important values like acceleration performance,free wheel torque or shift point hysteresis, according to theactual dataset. Therefore, TraCE uses models for the vehicleand powertrain that can be adapted to the vehicle applicationand can be rapidly calibrated. In different views, all of theinformation generated from the analyzed driving situation isdisplayed online for the calibration engineer to facilitate fastand efficient calibration work.

In the second module, FEVs shift quality calibration processis supported by generating objective values that represent the

quality of a shift event based on measured online or offlinedata. These values can be adapted to the customers needsand are very flexible in terms of being automatically sortedon a shift quality rating sheet and compared to target values.Unacceptable and acceptable shifts are marked for the engi-neer immediately, using different colors and further analysesabout the different phases of the shift are displayed. In com-

parison with the normal methods for shift quality calibration,the calibration engineer now has clear targets for work, whichsignificantly accelerates the whole project.

[email protected]@fev.com

TOPexpert TraCE:

Transmission Calibration Expert

A Sample Analysis of the Up- and Down Shiftmaps in the Shiftline Calibration Module of TraCE


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FEV SPECTRUM

NEU

and

areregisteredTradeMarksofFEVMotorentechnikGmbHintheStatesoftheEuropeanCommunityandtheUnitedStatesofAmerica.

1/2011

FEV--allrightsreserved

Editor:A.

Witts

tamm

Layout:FEV

Has your address changed? Do you know a colleague who would also like to receive futureissues of the SPECTRUM? Send the name of your company, persons name, and completemailing address via E-Mail to: [email protected]

Reader Service

FEV, Inc.4554 Glenmeade LaneAuburn Hills, MI 48326-1766 USATelephone +1 248 373-6000Fax +1 248 373-8084E-Mail [email protected]

FEV Motorentechnik GmbHNeuenhofstrae 18152078 Aachen GermanyTelephone +49 241 5689-0Fax +49 241 5689-119E-Mail [email protected]

FEV China Co., Ltd.No. 35 Xinda Street QixianlingHigh Tech Zone 116023 Dalian ChinaTelephone +86 411 8482-1688Fax +86 411 8482-1600E-Mail [email protected]

FEV India Pvt, Ldt.Technical Center IndiaA-21, Talegaon MIDCTal Maval District Pune-410 507 IndiaTelephone +91 2114 666 - 000E-Mail [email protected]

Contacts

FEV has been operating 31 engine and powertraindurability test benches for more than two years atthe Brehna test center near Leipzig. During this time,several hundred test programs of different types havebeen run, and several powertrain types have beenreleased for production.

The fully continuous operating mode allows for ef-ficient planning of the testing programs, yields quickdevelopment results and offers short project dura-tions. During this period, the testing technology, theorganizational prerequisites and the processes (for ex-

ample, a sophisticated monitoring to protection of thetest objects) were continuously developed and adapt-ed to new and sometimes contradictory requirements.

Globally different legal considerations, country-spe-

cific fuels, new fuel saving technologies, cost reduc-tion programs and the resulting powertrain variantsrequire new tests and more refined test methods.Specifically, new tests and refined test methods will

be needed for the examination of different start/stopsystems.

FEV will expand the durability testing center basedon this comprehensive experience by adding an-other four engine test benches. The commissioning

of these new test benches is planned for the fourthquarter 2011.

[email protected]

FEV Durability Test Center, Brehna

FEV Exhibition Booth at the CTI Symposium, Berlin 2010

Experts discussed the latest developments concern-ing transmissions and drive systems at the 9th In-ternational CTI Symposium Innovative AutomotiveTransmissions, which took place in Berlin from 29thNovember to 2nd December 2010. Presentations andreports of recent innovations in the field of conven-

tional and electrified drives were the main topics ofdiscussion. For the first time, FEVs participation inthe event included an exhibition stand, which generat-

ed extraordinary interest from attendees at the event.

FEV presented two of its own developments for hy-brid vehicle transmission concepts. The automatedmanual transmission, 7H-AMT is based on efficient,cost-effective technology and allows gear shiftingwithout interrupting torque. The HICEPS hybrid pow-ertrain provides this feature as well and utilizes a newtype of interconnected planetary gear sets and anintegrated electric motor.

Additional exhibits addressed FEVs competence inthe field of transmission development. A BMW Miniwas displayed, which featured an automatic trans-mission that highlights FEVs experience in regularproduction calibration projects. In this project, morethan 20 different vehicle variants were successfullycalibrated.

[email protected]

8

Expansion of the FEV

Durability Test Center

VisitourExhibitionBoothat

SAE2011WorldCongress

Detroit,

April12nd-14th,

2011

VisitourExhibitionBoothat

32ndIn

ternationalViennaMotore

nsymposium

Vienna,M

ay5th/6th,

2011

FEV Shows Transmission

Expertise at the

CTI Symposium

Spectrum 46 E Web

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