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Zero-dimensional heat release rate models have the advantage of being both easy to handle and computationally efficient. In addition, they are capable of predicting the effects of important engine parameters on the combustion process. In this study, a zero-dimensional combustion model based on physical and chemical sub-models for local processes like injection, spray formation, ignition and combustion is presented. In terms of injection simulation, the presented model accounts for a phenomenological nozzle flow model considering the nozzle passage inlet configuration and an approach for modeling the characteristics of the Diesel spray and consequently the mixing process. A formulation for modeling the effects of intake swirl flow pattern, squish flow and injection characteristics on the in-cylinder turbulent kinetic energy is presented and compared with the CFD simulation results.

Introducing new exhaust-gas aftertreatment concepts at mass production level places exacting demands on the overall development process - from defining process engineering to developing and calibrating appropriate control-unit algorithms. Strategies for operating and controlling exhaust-gas aftertreatment components, such as oxidation and selective catalytic reduction catalysts (DOC and SCR), diesel particulate filters (DPF) and SCR on DPF systems (SCR/DPF), have a major influence on meeting statutory exhaust-emission standards. Therefore it is not only necessary to consider the physical behavior of individual components in the powertrain but also the way in which they interact as the basis for ensuring efficient operation of the overall system.

The valve timing of internal-combustion engines usually represents a compromise with regard to the requirements placed on power output and torque. This paper describes the development of a system for variable valve timing, taking the new Mercedes-Benz 4-valve engines as an example. Gas exchange calculation and tests carried out on a modified 4-cylinder engine have demonstrated that with two intake valve times and one specified exhaust valve time virtually the best possible torque characteristics combined with high power output can be achieved. Intake valve timing is adjusted dependent on load and engine speed by turning the intake chamshaft using a hydraulic-mechanically acting camshaft adjuster, whose functional principles are described in detail.

Load control by means of early intake valve closing (EIVC) permits brake mean effective pressure (BMEP) to be improved by as much as 14 % at full load and pumping losses in part load to be reduced comparable to the unthrottled engine. Concomitant to this, though, the marginal conditions for good mixture formation and part load combustion optimized for efficiency are greatly impaired. With ideal mixture formation, improvements in specific part load consumption (BSFC) of the order of 8 to 12 % are achievable. The mixture formation which occurs at low part load in the combustion chamber itself is not effective as the charge motion induced by the inflow process with EIVC dies away rapidly and at the same time fuel still condenses. The inhomogeneities to which this gives rise impair ignition conditions and the combustion pattern, which greatly limits the actual useful work of the theoretical charge cycle benefit.

A new multicomponent exhaust gas analyzer has been applied to investigate the time-resolved concentrations of the aromatic hydrocarbon exhaust components benzene, toluene, xylene, trimethyl benzene under dynamic engine operation, such as sudden change of speed and load, misfiring and switching off the fuel mixture control. The analyzer consisting of a compact laser mass spectrometer is capable of measuring the concentrations of the individual aromatic hydrocarbon compounds simultaneously with 1 ppm sensitivity at a sampling rate of 50 Hz corresponding to a sampling period of 20 ms. High concentration peaks are observed for these substances at instationary motor operation. However, whereas the real-time concentrations of toluene, xylene, and trimethyl benzene show equal dependence on motor speed and load a different behavior has been observed for benzene even during the emission phase of single combustion cycles.

As the late combustion phase in SI engines is of high importance for a further reduction of fuel consumption and especially emissions, the impacts of unburnt mass, located in a small volume with a relatively large surface near the wall and in the top land volume, is of high relevance throughout the range of operation. To investigate and quantify the respective interactions, a state of the art Mercedes-Benz single cylinder research SI-engine was equipped with extensive measurement technology. To detect the axial and radial temperature distribution, several surface thermocouples were applied in two layers around the top land volume. As an additional reference, multiple surface thermocouples in the cylinder head complement the highly dynamic temperature measurements in the boundary zones of the combustion chamber.

The demand for fuel-efficient, low-displacement engines for future passenger car applications led to investigations with small DI diesel engines in the advanced engineering department at Mercedes-Benz. Single-cylinder tests were carried out to compare a 2-valve concept with 241 cm3 displacement with a 422 cm3 4-valve design, both operated with a common rail injection system. Mean effective pressures at full load were about 10 % lower with the smaller displacement. With such engines a specific power of 40 kW/I and a specific torque of about 140 Nm/I should be possible. In the current stage of optimization, penalties in fuel economy could be reduced down to values below 3 %. The “4-cylinder DI diesel engine with 1 liter displacement” is an interesting alternative to small 3 cylinder concepts with higher displacement per cylinder. An introduction into series production will not only depend on the potential for further improvement in fuel economy of such small cylinder units.

As part of a comprehensive strategic product initiative the most important commercial vehicle manufacturer - Mercedes-Benz AG - is step by step renewing its entire product range. This primarily refers to the heart of the vehicles - the engine. After the OM 457 LA, which was developed together with DDC for the special American market demands and which is produced and sold in the U.S.A. by DDC under the label “Series 55”, has had its premiere in Freightliner's Century Class, the OM 904 LA will now follow in the light commercial vehicle class. This engine has a completely new concept of a direct-injection, highly sophisticated turbocharged four-cylinder in-line engine with air-to-air intercooler, whose main characteristics can be outlined by the terms “multi-valve technology”, high-pressure injection via unit pumps” and “electronic engine control”. This “small” engine has several interesting features, which - up to now - were only known from class 8 engines.

During recent years there has been a continuing increase in the demands for higher braking performance of commercial vehicle engines. Mercedes-Benz had introduced the engine brake with continuously open decompression valve (‘Konstantdrossel’) into series production in 1989 as an option (1). A further increase of braking power was to be achieved while retaining the additional decompression valve in the cylinder head. For this, the decompression valve was no longer kept open during the whole working cycle (continuously open decompression valve), but only for a short period from just before compression TDC to about 90...120° crank angle after compression TDC (pulsed decompression valve). The hydraulic actuating system which opens and closes the decompression valves was developed in cooperation with Mannesmann-Rexroth GmbH, Lohr, Germany. The engine braking performance attainable with this system is shown in comparison to other known engine braking systems.

During the past few years, economy of commercial vehicles has increased considerably due to higher engine outputs a+ lower engine speeds together with enhanced fuel economy. However, the average speed of commercial vehicles is not only determined by the speed attainable on level ground and on uphill gradients, but also to a large extent by the speed attainable on downhill gradients, with the latter depending on the available constant braking power. Since the displacement of commercial vehicle engines has not been increased or has even become smaller, their braking power has increased only slightly ot not at all. In order to enhance the overall economy of commercial vehicles, it was therefore necessary to increase the engine braking performance as well since the wheel brakes cannot be used for constant braking and additional systems for continuous operation are very complex.

After the introduction of four-valve technology for gasoline powered passenger cars, Mercedes-Benz consistently developed this technology also for Diesel engines. Based on the proven success of the prechamber combustion system, this new Diesel engine generation, which includes 4, 5 and 6-cylinder naturally-aspirated engines, will be the first four-valve Diesel engines to be installed in passenger cars. The naturally aspirated 3.0 liter 6-cylinder in-line engine which represents the high end of this generation will be offered for sale in all 50 states of the USA in the Executive Class models starting on January 1, 1994. Four-valve technology allows the prechamber to be located centrally between the intake and exhaust valves which results in a major improvement of the combustion process. In addition, this 6-cylinder engine has a resonance intake system controlled by two butterfly valves to maximize the volumetric efficiency of the engine.

The M119 HL, a twin turbocharged V8-5 I-engine, was developed by Mercedes-Benz AG for Group C World Championship Race events based on the production engine used for the Mercedes-Benz passenger car range. * Due to the fuel consumption limitation for Group C-Cars - 51 litre/ 100 km - a high efficiency race engine was required to achieve the target fuel consumption during race events using a commercially available “pump” fuel. Given these restrictions, the latest version of the M119 HL-engine had a power output of 530 kW and minimum brake specific fuel consumption values of 235 - 260 g/kWh over the engine speed range. This paper discusses the conceptual ideas behind the design of such a high-performance engine with optimized fuel consumption, especially concerning turbocharging and engine management. Furthermore, the development of the engine's mechanical components is shown in comparison to the series production engine design.

Since the introduction of the 4-speed automatic transmissions W4A040 in 1979 and W4A020 in 1981, more than 50% of Mercedes-Benz cars have been equipped with automatic transmissions. These transmissions have undergone continuous development since their introduction. Due to engine/transmission management, the kick-down shift points are electronically influenced, the shift comfort is improved partially by ignition timing manipulation. During the warm-up phase the shift points are raised via output signals from the electronic engine system to improve exhaust gas emissions. In this paper considerations are explained which resulted in supplementing the proven four-speed transmission with a five-speed transmission.

The oil supply of combustion engines today is typically realized by oil pumps with constant displacement. To secure the operational safety in hot idling these pumps are oversized, what causes low efficiency in most of operating speeds. IAV developed a vane-type oil pump, which allows to infinitely regulate the delivery rate. Because of no oil release over a pressure limiting valve the pump achieves a higher efficiency in a wide range of operation. The design of the theoretical delivery characteristic allows the calculated and particular increase of oil pressure to avoid critical operating conditions and to support hydraulically operated functions as variable camshaft timing.

State-of-the-art powertrain concepts with automatic transmission must comply with increasingly stringent legislation on emissions and fuel consumption while fulfilling or surpassing customers' expectations as to driveability. In this respect, automated manual transmissions (AMT) and automated shift transmissions (AST) must compete with conventional automatic transmissions (AT) and continuously variable transmissions (CVT). In order to exploit the theoretical advantages of ASTs and put them into practice, complex ECU functions are needed to coordinate engine and transmission. Adaptive control, sophisticated clutch management and an intelligent shifting strategy allow shifting quality and shifting points to be simultaneously optimized to the effect that performance and comfort are increased while fuel consumption is reduced.

The shifting comfort of automatic transmissions of diesel engines at low temperatures can be substantially improved by using springs with temperature dependent rates in the control valves. These springs utilize the shape memory effect of Ni-Ti alloys. They provide a simple and economic way to control both shifting pressure and shifting time. The Mercedes- Benz automatic transmission uses two different springs with thermovariable rate (TVR) in the shifting pressure system to adapt the pressure in the switching elements to the lower torque of cold diesel engines. One spring is used in the shifting pressure control valve and one in the accumulator system.

Secondary air injection after cold start gives two effects for reduced exhaust emissions: An exothermic reaction at the hot exhaust valves occurs, which increases the temperature of the exhaust gas. It gives sufficient air to the catalyst during the cold start fuel enrichment that is necessary to prevent driveability problems. Handicaps for the wide use of air injection include space constraints, weight and price. An electrical air blower was choosen to best satisfy all these requirements. The development steps are described. The result is a three stage radialblower with extremly high revolutions of about 18000 rpm. The system configuration and the outcome are demonstrated on the new C-Class of Mercedes-Benz. The results show emission reductions higher than 50 %, while also satisfying the development goals of noise, volume, weight and cost requirements.

Under the persistent pressure to further reduce fuel consumption worldwide, it is necessary to advance the processes that influence the efficiency of gasoline engines. In doing so, harnessing the entire potential of fully variable mechanical valve trains will involve targeting efforts on optimizing all design parameters. A new type of valve timing system is used to portray thermodynamic and mechanical as well as electronic aspects of developing fully variable mechanical valve timing and lift systems

Modern commercial vehicle engines are equipped with turbocharging and intercooling. This results in low emissions and fuel consumption. In the lower speed and load range and under transient conditions, these engines have disadvantages, as the fuel injection rate has to be limited to avoid excessive smoke emission. Also, the engine braking performance of highly charged, small displacement engines is also lower than that of large displacement engines. Mercedes-Benz decided to develop a combination of turbocharger and mechanical supercharger. In the lower speed range higher torque levels are possible and maximum torque is available without any lag especially in the transient mode with low smoke emission and fuel consumption. Vehicle performance during acceleration can be improved by up to 30%. During engine braking operation, the mechanical supercharger is activated throughout the whole engine speed range which results in a distinctive increase in braking power.

A physico-chemical model of a Cu-zeolite SCR/DPF-system involving NH₃ storage and SCR reactions as well as soot oxidation reactions with NO₂ has been developed and validated based on fundamental experimental investigations on synthetic gas test bench. The goal of the work was the quantitative modeling of NOx and NH₃ tailpipe emissions in transient test cycles in order to use the model for concept design analysis and the development of control strategies. Another focus was put on the impact of soot on SCR/DPF systems. In temperature-programmed desorption experiments, soot-loaded SCR/DPF filters showed a higher NH₃ storage capacity compared to soot-free samples. The measured effect was small, but could affect the NH₃ slip in vehicle applications. A bimodal desorption characteristic was measured for different adsorption temperatures and heating rates.