Powertrain - Tech Blog
Fuel-cell push crosses regional borders
Two recent announcements attest to continuing efforts by government and industry to make the hydrogen fuel cell vehicle viable. On Oct. 5, the U.S. Department of Energy said it would make available $1 million for efforts to "identify cost-effective and efficient materials and processes to produce hydrogen from renewable energy sources and natural gas." These projects will also analyze production and delivery technologies to identify key technical challenges and priorities and continue to evaluate technical progress and hydrogen cost status. Applications for the funding can be found on the EERE Funding Opportunity Exchange website. On Oct. 9, Honda announced that it and three other Asia automakers (Toyota, Nissan, Hyundai) have signed a memorandum of understanding with public and private organizations from Nordic countries to support the introduction of fuel-cell vehicles (and supporting infrastructure) in that region (Norway, Sweden, Denmark, and Iceland).
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Honda in September announced that it will launch an all-new fuel-cell vehicle in 2015. Its current fuel-cell offering is the FCX Clarity (shown).
BorgWarner to launch new cam phaser technology in 2015
To support rapidly increasing demand for smaller-displacement engines, BorgWarner is preparing to launch a new variable cam timing technology in global applications in 2015. Engineered specifically for downsized gasoline and diesel I4 engines, the modular design supports a variety of cam phasing technologies, including cam torque actuated (CTA) and torsional assist (TA) phasers with optional mid-position lock technology. Each phaser also features an integrated center bolt and spool valve for smaller package size and easier installation. Using the existing torsional energy in the valvetrain, CTA phasers actuate more quickly, use less engine oil, and operate under a wider range of engine speeds and temperatures than conventional VCT systems do, the company claims. TA phasers, which use torsional energy and standard engine oil pressure for actuation, offer a wide range of authority at 70° or more of crank rotation. The phasers can actuate rapidly, resulting in improved low-end engine performance in downsized, direct-injected boosted engines, according to BorgWarner. The technology is slated for launch on gasoline and diesel engines from a major global OEM, and will be supported by production at a new BorgWarner facility in Eastern Europe.
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For added calibration opportunities, BorgWarner's patented mid-position lock technology allows an increased range of camshaft positioning with a default stop at an intermediate position within the expanded range of travel.
Gentherm to adapt passenger-car thermoelectric generator to heavy vehicles
Gentherm has received a $1.55 million contract modification from the U.S. Department of Energy (DOE) to apply the technology in its thermoelectric generator (TEG) for passenger cars to a similar program for heavy vehicles. The TEG technology, which converts waste heat from gas exhaust into electric energy, has the potential to improve passenger-car fuel efficiency by as much as 5%, the company claims. The grant is an add-on to the $8 million award from the DOE in August 2011 for converting thermoelectric heat to power for passenger cars and extends the technology to heavy military vehicles. With this new project, the U.S. Army Tank Automotive, Research, Development and Engineering Center (TARDEC) becomes a key partner to Gentherm, joining passenger-car partners Ford and BMW. With completion expected by early 2015, the project will scale up the fully functional passenger-car TEG (working prototypes have been delivered to BMW and Ford) and integrate it with a 15-L diesel engine to provide fuel economy improvement and ignition-off auxiliary power for combat vehicles. This add-on leverages the existing program technology for large diesel engines, providing a new solution for military heavy vehicles, Class 8 trucks, marine, and industrial power generating equipment.
Other related articles include: http://www.sae.org/mags/aei/10647 and http://www.sae.org/mags/aei/7916.
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Gentherm's automotive thermoelectric generator (shown), which converts unused waste heat to electricity, is now being scaled up to suit heavy vehicles.
Navistar, JAC one step closer to Chinese engine joint venture
Navistar International Corp. and Chinese truck maker Anhui Jianghuai Automobile Co. Ltd. (JAC) recently received formal approval from China’s National Development and Reform Commission (NDRC) to move forward with their commercial-engine joint venture, first announced in September 2010 when the companies signed an agreement. The JV will provide JAC with access to Navistar’s Euro IV and Euro V compliant technology, and also sets the stage for global export opportunities of JAC’s light-, medium-, and heavy-duty commercial trucks. Navistar has established a central China office in Shanghai, as well as satellite offices in Beijing and Hefei. In Hefei, product development engineers from both companies have been collaborating on engine and vehicle design. Construction also has started on a 93,000-m2 (1 million-ft2) machining and assembly facility, R&D center, and administrative offices in Hefei to support the new venture. Products slated for the JV include Navistar’s MaxxForce 3.2-, 4.8-, and 7.2-L, and JAC’s 2.8-L 4DA1 engines. Now that the JV has received its business license, Navistar and JAC planned to formally submit their commercial truck joint venture application to the Chinese government this fall.
Ford's new global powertrain boss will be based in Europe
For the first time at Ford, the position of Director of Global Powertrain, Research and Advanced Engineering is occupied by an engineer based in Europe. Andreas Schamel recently was named to replace the recently retired Dan Kapp, who was based in Dearborn. In addition to leading Ford’s global powertrain activities, Schamel will retain his position as Joint Managing Director of Ford’s European Research Centre in Aachen, Germany—a role he shares with Pim van der Jagt. Schamel will continue to be based in Aachen. Previously Schamel was Chief Engineer Powertrain, Research and Advanced Engineering, Ford of Europe. He will report to Paul Mascarenas, Ford’s Chief Technical Officer and Vice President of Research and Advanced Engineering.
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While based in the U.S., Schamel was a key figure in the introduction of Ford's EcoBoost gasoline engine technology.
Tier 4 small diesels coming from MHI
Mitsubishi Heavy Industries, Ltd. (MHI) has announced the production schedule for its new Tier 4 small diesel engines in the output range of 19 to 74 kW (25 to 99 hp). The Tier 4 compliant D03CJ and D04CJ will begin production in 2013; the Tier 4 interim D04EG is currently available, and the Tier 4 final version will be available in 2015. These engines will be suitable for a variety of construction, agricultural, and industrial equipment, such as compressors, generators, welders, off-highway equipment, material handling, etc.
Compared to the previous Tier 3 compliant models being replaced, the D03CJ (1.655 L) and D04CJ (2.207 L) offer a smaller displacement, while output has been increased. The three-cylinder D03CJ produces up to 41 kW (55 hp) and 165 N·m (122 lb·ft) at 1800 rpm. The four-cylinder D04CJ produces a maximum of 55 kW (74 hp) and 230 N·m (170 lb·ft) at 1800 rpm. Fuel efficiency is reportedly 16% better than the previous engines.
The new Tier 4 interim, four-cylinder D04EG (3.331 L) delivers up to 74 kW (99 hp) and 375 N·m at 1600 rpm, with a power density of 0.22 kW/L. Compared with the Tier 3 engine it replaces, the D04EG offers 12% improved fuel economy. To achieve Tier 4 final compliance in the 57- to 74-kW (76- to 99-hp) range, MHI currently plans to incorporate a selective catalytic reduction (SCR) system.
All three new engine models are equipped with high-performance turbochargers, manufactured at the same plant that the engines are produced. Combined with a new optimized common-rail system, the engines achieve an enhanced power density that increases output up to 50% compared with the previous Tier 3 compliant engines, MHI claims.
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The D03CJ (pictured) and D04CJ both feature an optimized common-rail system with a diesel particulate filter (DPF) and diesel oxidation catalyst (DOC) for Tier 4 compliance.
Daimler-Renault partnership adds MY2016 powertrain projects
Daimler and Renault-Nissan announced Sept. 28 one new engine and one new transmission project added to previously agreed projects, as part of a partnership the two OEMs formed in 2010. The new engine project is a jointly developed four-cylinder gasoline engine family co-led by Renault and Daimler. The direct-injection, turbocharged engine will feature state-of-the-art technology in a compact package, according to the companies. They expect to jointly manufacture the new engines, which will debut in Daimler, Renault, and Nissan vehicles in 2016. In the new transmission project, Daimler grants Nissan a license to manufacture automatic transmissions using Daimler´s latest technology for Nissan and Infiniti vehicles starting in 2016. Nissan subsidiary Jatco is planning to manufacture the gearboxes in Mexico. The new transmission will feature stop-start and by-wire control of park and gearchange functions.
Michigan engineering-services companies partner
With the goal of offering total-vehicle services, Powertrain Integration LLC and Triad Services Group have entered into a partnership. The two companies, both of Madison Heights, MI, say they will now have the combined resources to design, engineer, develop, validate, and certify complete vehicle products, while leveraging OEM componentry without requiring OEM involvement. Both PI and Triad have a long-standing relationship with General Motors. As one of GM Powertrain’s On-Highway integration partners, PI has access to GM engines, transmissions, controls systems, math data, and components released in the GM parts bin and supports their integration into vehicles. PI employs 25 engineers, and Triad currently has 72 designers, engineers, and highly skilled technicians.
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Powertrain Integration has a full-service engine dynamometer facility with abundant data acquisition and the ability to test multiple fuels.
Batteries in a buggy
Why permanently weigh down an electric car with an outsized, excessively heavy battery when EV drivers can hitch up a small trailer full of batteries for the needed driving distance and then unhitch the unit when no longer needed? Indeed, says Stuttgart company ebuggy GmhH, which has developed a prototype battery trailer and is working to develop a network of pickup/dropoff stations to allow unlimited range for various EVs. The beauty of the vision, says ebuggy, is that EV makers can design their cars with smaller, less expensive battery packs and thus charge customers less. In a Sept. 19 press release announcing ebuggy, the company noted that the prototype trailer was constructed with the support of the Germany Ministry of Economics and Technology and several project partners including the Fraunhofer Institut IPA and Stuttgart University. Ebuggy video and animation can be viewed at http://www.youtube.com/user/ebuggy01/videos.
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ebuggy envisions a network of stations for pickup and dropoff of the battery-filled trailers.
ZF's 2015 growth plan puts squeeze on suppliers
Companies are constantly looking to lower their purchasing costs and otherwise lean on suppliers to help their bottom line. ZF is doing so in a very public way, having announced on Sept. 13 sweeping changes to its purchasing practices and to its own supply chain. The German Tier 1 plans to significantly reduce the size of its supply base, and to further centralize purchasing. The changes are part of a plan to increase global sales from €15.5 billion today to €20 billion by 2015, a strategy supported by a substantial investment in new production facilities. ZF's suppliers are being asked to contribute cost reductions to help the company realize €500 million in purchasing savings, according to a press release. ZF CEO Dr. Stefan Sommer, who is also in charge of corporate materials management, noted that "sales growth itself is not a value" and that increased profits is the end game.
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ZF headquarters is placing greater emphasis on suppliers' global capabilities.
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