With a view to future emission and driving dynamics requirements, the aim is to further reduce vehicle mass and increase powertrain efficiency. Modern all-aluminum combustion engines have already reached a very high level in this respect. Major leaps in development can probably only be accomplished with alternative manufacturing processes. FEV has now highlighted its potential in the LeiMot research project.

The focus was on the cylinder heads and crankcase of a state-of-the-art, mass-produced, two-liter diesel engine. Both parts were manufactured using a selective laser powder bed fusion (LPBF) process instead of die-cast aluminum as in the past.

“This allows components to be fabricated through additive manufacturing. That is, one layer at a time based on material in powder form. In this specific instance, it was aluminum alloy AlSi10Mg, but we also considered fiber-reinforced plastics. The components produced using this method weigh around 21 percent less. At the same time, the new, installation-compatible engine parts – cylinder head and crankcase – increase the powertrain’s efficiency.”

says Ralf Bey, LeiMot project manager at FEV.

Cylinder Head Loses Mass but Retains Durability

The newly designed cylinder head alone saves 2.3 kilograms, or 22 percent of the weight compared to the original component. To accomplish that, engineers needed to reinforce certain areas, especially those subjected to high mechanical stress, because the combustion process primarily exerts bending loads, while the engine as a whole is subjected to torsional loads. The best ratio of weight reduction to rigidity is a combination of an I-beam (IPB) and an integrated, closed drawer.

“Thanks to additive manufacturing, we were able to produce the exhaust port with heat insulation, built-in using a 3-D printer. That not only heats up the exhaust after-treatment systems faster, but it also boosts the turbine inlet temperature, making the turbocharger more efficient.”

states Bey.

Crankcase reinvented

When considering the aspects of weight and rigidity of the crankcase, the decision was made to go with what is called a short-skirt design with a bedplate of aluminum. Replacing the steel bearing caps with the bedplate was made possible by the reduced friction main bearing diameters of the diesel base engine. With the redesigned crankcase, including the bedplate, the weight was lowered by 5.1 kilograms compared to the original components.

The bulkheads of the crankcase were given open, horizontal load structures reinforced by a cross-rib network inappropriate places. Additional strength is provided by two low-weight connecting tubes in the area of the balance shafts. Based on topology analyses, low-stress zones were optimized with lattice structures and hollow spaces.

The crankcase side covers now consist of fiberglass-reinforced phenolic resin, making them roughly 15 percent lighter.

Less Water Allows More Cooling

The new cross-current cooling system enables the cylinders’ temperatures to be lowered, while at the same time reducing the amount of water needed. One main difference in design is the individual cooling channels in the cylinder head, which replace the large-volume cooling jacket. They decrease the temperatures in the combustion chamber plate by as much as 40 percent. Despite using 40 percent less coolant, the temperatures of the walls were reduced significantly compared to the reference engine. As a result, both the warm-up phase after a cold start was shortened and the power needed to run the water pump was lowered.

Advancements in Oil Circulation Reduce Pressure Loss

Advancements in oil circulation lead to additional advantages during cold starts and in normal operation. The measures aimed at optimization also include a new approach to route the related hoses, with gentle curves instead of sharp redirection, and changes in diameters. Altogether, the approach reduced the amount of pressure loss in the cylinder head and crankcase by 22 percent. A reversed siphon prevents oil from running off when standing still. This keeps the appropriate oil pressure for operating the valves available more quickly once the engine is started. Hollowed bulkheads provide for return oil circulation.

“Additive” Teamwork

Germany’s Federal Ministry for Economy and Energy is funding the LeiMot research project. FEV is leading the dedicated consortium consisting of a renowned automobile manufacturer, research institutions, universities of applied sciences, development service providers, equipment manufacturers, and automotive suppliers. Their common goal is to enable even conventional production methods to benefit increasingly from the opportunities afforded by additive manufacturing – far beyond the example of the engine described.

Source: FEV

The post FEV Lightweight Engine Boosts Efficiency and Helps Reducing CO2 Emissions appeared first on North America FarmQuip Magazine.

• The development center (eDLP), which is located in the triangle between Halle, Dessau and Leipzig, includes state-of-the-art test technologies designed for all standardized and client-specific test requirements for high-voltage battery systems.
• In addition to enabling all developmental tests to be conducted in one place, the 350 kN shaker with climate hood provides another globally unique feature of the testing facility. The shaker enables combined mechanical and electrical tests in ambient conditions ranging from -40 to 100°C.
• With this investment, FEV affirms its commitment to Germany as a business location and sets its sights on the future of mobility..

In the third quarter of 2020, FEV will finalize the commissioning of a state-of-the-art development and test center (eDLP) for high-voltage batteries for passenger and commercial vehicles at the Sandersdorf-Brehna location. The 12,000 square meter complex contains facilities for the electrical testing of both modules and complete high-voltage batteries. This includes a test chamber volume of approximately 600 m³, distributed over 54 climatic chambers with an electrical output of 30,000 kW. The new development center will thus have the largest operational, independent battery testing facility in the world. Systems for validating all (international) environmental and mechanical tests, as well as four bunkers will be installed. A fire hall for abuse tests, along with an associated disassembly and diagnosis workshop complete the spectrum. Together, these facilities cover every evaluation necessary for series production. The state of Saxony-Anhalt funded the project with over EUR 6 million.

“This strategic investment will enable us to offer our customers a globally unique development service for passenger and commercial vehicles at one location. All common test methods for batteries are covered – in life expectancy, environmental and transport tests, as well as crash safety for cells, modules and packs”

said Professor Stefan Pischinger, President & CEO of the FEV Group.

The energy required to test components is provided almost entirely by power generated from renewable resources. Essential for this is a roof area of 12,000 m², fully covered by photovoltaic panels with an output capacity of over 900 kWp. “The facility therefore operates in a climate-friendly manner using a zero CO2 emissions approach,” added Pischinger.

With the opening of the eDLP, FEV is expanding its development expertise for future mobility at the Sandersdorf-Brehna location. The seven pure-electric and more than ten hybrid powertrain test rigs in the nearby continuous testing center (DLP), only 9 km away, complement FEV’s full service in electromobility development. With this investment, the Central German Metropolitan Region will also benefit from FEV’s global growth, as the Managing Directors of the eDLP, Dr. Christoph Szasz and Hans-Dieter Sonntag, emphasized:

“The opening of this battery development center created almost 100 new jobs, strengthening FEV’s position as an important employer in Saxony-Anhalt with a total of around 350 employees.”

Source: Fev

The post Fev begins operations at the world’s largest development and test center for high voltage batteries appeared first on North America FarmQuip Magazine.