EIA: trends in downsized engine design leading to increased demand for higher-octane gasoline

Green Car Congress

One significant trend is engine downsizing coupled with turbocharging. Turbochargers work by using a turbine driven off the exhaust gas to pressurize the intake air. Since 2013, the share of premium gasoline in total motor gasoline sales in the US has steadily increased to 11.3%

2016 83

Achates OPGCI project targeting 50% fuel efficiency gains over downsized GDI engine at reduced cost

Green Car Congress

The engine should yield fuel efficiency gains of more than 50% compared to a downsized, turbo-charged gasoline direct injection engine, while reducing the overall cost of the powertrain system, said Fabien Redon, Vice President, Technology Development at Achates Power.

2015 83

Cummins progressing with lightweight downsized T2B2 diesel for pickup; 40% improvement in fuel economy over gasoline V8

Green Car Congress

Cummins made extensive use of aluminium as well as space-saving design features for new engine weight control. Exhaust system configuration.

2014 148

Viable exhaust-driven on-board ethanol reforming for improvements in fuel economy and emissions

Green Car Congress

Schematic diagram of the successful “shoebox” reformer design and a picture of the core, after insertion of the catalyst. Many papers have described high-temperature steam reforming of ethanol at around 600 °C but.this temperature is too high to be driven by engine exhaust.

2013 102

Hyundai showcasing new downsized turbo engines and 7-speed dual-clutch transmission; i40 48V Hybrid, i30 CNG

Green Car Congress

To keep the engine unit as small as possible, the exhaust manifold is integrated within the cylinder head and can therefore be cooled efficiently using the cylinder head water cooling system. The new 1.4-liter T-GDI engine incorporates a high-pressure single-scroll turbocharger integrated within the exhaust manifold to improve operational efficiency. The new design injects fuel directly inside the cylinder, improving combustion rates for better power and fuel efficiency.

FEV to Display Extremely Downsized Engine at 2010 SAE World Congress

Green Car Congress

FEV’s 698 cm 3 Extremely Downsized Engine. will show its Extremely Downsized Engine (EDE) at next week’s 2010 SAE World Congress in Detroit. FEV engineers also integrated independent, fully-variable intake and exhaust cam phasing using components from Mahle and Hydraulik Ring.

2010 93

Simulation study finds “Millerizing” the Scuderi split-cycle engine could enable 50% engine downsizing with retention of power and torque, along with reduced fuel consumption

Green Car Congress

Simulation study finds Miller version of Scuderi engine can deliver twice the BMEP as naturally aspirated version, theoretically enabling 50% downsizing while maintaining performance. Applying the Miller cycle to the Scuderi engine (right) entails downsizing of the compression cylinder.

2012 112

Controlled Power Technologies Packages Its Switched Reluctance Systems in ‘RegEnBoost’ System for Enhanced Support for Downsizing

Green Car Congress

Power for the battery and VTES electric supercharger is not only supplied by the SpeedStart ISG but also the TIGERS exhaust driven turbo-generator. They have also designed a 100 mpg UK (83 mpg US, 2.8 The three components of the RegEnBoost system. Click to enlarge.

Downsized 5.5L V8 Biturbo in S 63 AMG Delivers 25% Fuel Savings Compared to Predecessor; Stop-Start is Standard

Green Car Congress

An intelligently designed power transfer plays a major part in this: the unique AMG Speedshift MCT 7-speed sports transmission combines dynamism with economy, and includes a new stop-start function in the “Controlled Efficiency” driving mode. AMG 5.5-liter V8 biturbo engine.

VW bringing EA211 1.4L turbo direct-injection engine to Jetta range in US

Green Car Congress

This brings implementation of intelligent downsizing to more than 97% of vehicles sold by Volkswagen in the US, available across all the models on sale. This design generates maximum torque of 184 lb-ft (249 N·m) at 1400 rpm.

2015 99

BorgWarner R2S two-stage turbo boosts performance of new top-end Ford 2.0L diesel

Green Car Congress

One compact KP35 high-pressure turbocharger generates boost pressure at low exhaust gas flow rates for rapid acceleration at low engine speeds without delay or turbo lag. The new high-powered TDCi diesel engine follows the downsizing trend we’ve led with our EcoBoost petrol technology.

2015 103

Study: splash blended ethanol fuels with higher ethanol percentage enable higher thermal efficiency in SI engine

Green Car Congress

In a paper published in the journal Fuel , the researchers report that at the knock-limited engine loads, splash-blended ethanol fuels with a higher ethanol percentage enabled higher engine thermal efficiency through allowing more advanced combustion phasing and less fuel enrichment for limiting the exhaust gas temperature under the upper limit of 850 °C, which was due to the synergic effects of higher RON and octane sensitivity, as well as better charge cooling.

2017 60

Federal-Mogul Powertrain to showcase hollow-stem valves for higher engine temperatures and increased peak cylinder pressures

Green Car Congress

Among the components produced by the company’s Global Valvetrain business are sodium-cooled valves with exceptionally small stem diameters that deliver both reduced weight and greater resistance to the high temperatures that can be a limiting factor in highly rated downsized engines. Primarily applied to exhaust valves to facilitate temperature reduction, the hollow valves can also be used on the intake side to save weight.

2015 76

Aeristech develops advanced 12V electric supercharger

Green Car Congress

Designed to provide transient boost to support traditional mechanical forced induction systems, the 12V architecture enables the system to be integrated into existing driveline technologies. The car’s downsized 1.2

2016 110

Continental introducing innovative annular catalytic converter for near-complete NOx reduction to meet RDE and SULEV 30 standards

Green Car Congress

Continental will present an innovative close-coupled annular catalytic converter that supports near-complete NO x conversion in downsized turbocharged gasoline engines at the 37 th Vienna Motor Symposium next week. For downsized turbocharged gasoline engines, this presents two challenges.

2016 78

Continental to supply turbochargers for new Ford 1.0L EcoBoost engines

Green Car Congress

Developed for the latest 1-liter downsized gasoline engines. The successful collaboration with Ford resulted in a turbocharger design that meets the particular technical challenges posed by small, downsized engines. Click to enlarge.

2011 102

BorgWarner expands emissions business with new facility in India

Green Car Congress

BorgWarner opened a new 86,000-square-foot (8,000-square-meter) facility in Manesar, India, near New Delhi to produce exhaust gas recirculation (EGR) coolers, tubes, valves and modules. Today’s downsized engines generate higher temperatures in the combustion chamber forming nitrogen oxide (NO x ). BorgWarner’s EGR technologies help automakers reduce NO x to meet stringent emissions regulations by recirculating and cooling exhaust gases to reduce combustion temperatures.

2013 68

Torotrak wins $340K funding for V-Charge project; supercharger integrated with mechanical variable speed drive

Green Car Congress

V-Charge integrates a supercharger with a mechanical variable speed drive to address a key barrier to engine downsizing by providing near instant response at any engine speed.

2014 96

Porsche unveils 2017 version of 919 Hybrid Le Mans prototype

Green Car Congress

The engine combines downsizing turbo technology with efficient direct fuel injection; it delivers just under 500 hp (368 kW) and is the most efficient combustion engine from Porsche to date. The remaining 40% is generated by the exhaust energy recovery system.

2017 93

Scuderi working on turbocharged variant of split-cycle engine; smaller, more powerful, and more fuel efficient

Green Car Congress

The basic Scuderi engine divides the four strokes of a combustion cycle among two paired cylinders—the left cylinder functions as an air compressor, handling intake and compression, while the right cylinder handles combustion and exhaust.

2011 132

New 4-cylinder 2.3L EcoBoost on Lincoln MKC small SUV; future EcoBoost prospects

Green Car Congress

Class-exclusive Active Grille Shutters are designed to help improve MKC fuel efficiency at highway speeds. Two pivotal factors are the three-port integrated exhaust manifold cylinder head and a twin-scroll turbocharger. Lincoln MKC is the first to get the new 2.3L EcoBoost.

2013 121

Opel presents new midsize gasoline engine at Aachen Colloquium; fuel consumption down 13%, torque and power up 33%

Green Car Congress

The structural design considers the engine’s use in a variety of vehicle applications, allowing minimum integration effort and consistent part interchangeability. Two different pistons have been designed for the Eco and Performance Turbo engines. New 1.6L SIDI engine. Click to enlarge.

2012 145

FEV analysis of automotive-scale Pinnacle opposed-piston engine finds potential for significant increases in fuel economy

Green Car Congress

The design merits continued development for automotive application. The fuel economy study, using GT Power, encompassed both a naturally aspirated 1.5-liter, 3-cylinder design of the Pinnacle engine, as well as a downsized, turbocharged 750cc Pinnacle design. FEV added two additional cylinders, piping, exhaust aftertreatment, and an air cleaner to convert the model from a 250cc single cylinder into a 750 cc three cylinder engine. Downsizing with turbocharging.

2013 78

Revised Nissan Juke offers 1.2 DIG-T turbocharged engine

Green Car Congress

1), improved low friction technologies and cooled Exhaust Gas Recirculation. Nissan introduced a significantly revised Nissan Juke compact crossover at the Geneva Motor Show.

2014 110

Porsche presents more efficient Gen 2 919 Hybrid LMP1 racer for 2015

Green Car Congress

Although the basic concept of the Class 1 Le Mans Prototype (LMP1)— a downsized turbocharged direct injection gasoline engine and two different energy recovery systems—was retained in the second generation, virtually every component was refined.

2015 110

Simulation study suggests ORC waste heat recovery system could deliver potential 7% improvement in fuel consumption in a PHEV on highway

Green Car Congress

They then designed a quasi-static thermodynamic model of an Organic Rankine Cycle (ORC) optimized to fit the prototype vehicle. On the other hand, it is well known that in an internal combustion engine up to 35% of the energy developed by the fuel combustion is dissipated in the exhaust gases.

Waste 131

SwRI simulations show turbocharged Scuderi Engine could reduce a standard 2011 Nissan Sentras fuel consumption by up to 35% on FTP cycle

Green Car Congress

The Sentra model was simulated through a standardized Federal Test Procedure-75 (FTP-75) drive cycle for each SSC engine design. Modelled results of fuel consumption in 2011 Nissan Sentra. Source: Scuderi. Click to enlarge.

2011 96

FEV displays Ford 1.0L EcoBoost engine at SAE World Congress; provided early development support

Green Car Congress

FEV provided early development stage support for the engine in the area of design and CAE, combustion development, and engine build for 36 engines. This is a prime example of FEV’s business model, which is designed to integrate its expertise into the development process for customer propulsion systems on an as-needed basis. And these engines are capable of doing that with very low exhaust emissions levels. FEV, Inc., is showing the 1.0L

Volkswagen introduces new 1L, 3-cylinder gasoline Golf; 54.7 mpg

Green Car Congress

Despite its efficiency, the Golf TSI BlueMotion with the 85 kW / 114 hp downsized 999 cc EA211-series engine reaches 100 km/h in 9.7 The Volkswagen EA211 engine series served as the foundation for designing the new 1.0 Exhaust manifold integrated in cylinder head.

2015 117

Silicon Mobility introduces OLEA T222 for hybrid and electric powertrain control

Green Car Congress

Furthermore, OLEA T222 technologies and feature set address other applications; it can also serve as a controller for battery management systems (BMS), exhaust or selective catalytic reduction systems (SCR), or even conventional internal combustion engines.

2016 93

DENSO develops compact EGR cooler for gasoline engines; applied in Prius c

Green Car Congress

The newly developed EGR (exhaust gas recirculation) cooler is 30% smaller than the smallest one currently available on the market, while offering equal performance. DENSO plans to offer this product worldwide as a solution to meet tighter fuel-efficiency and exhaust regulations. To solve these problems, EGR systems recirculate some exhaust gas, instead of using fresh air, into the engine cylinders to reduce piston load while maintaining a small amount of fuel injection.

2012 80

ICCT: decline in diesel sales will have negligible impact on attainment of European CO2 emission standards

Green Car Congress

But gasoline engines are gaining ground against diesel engines thanks to a suite of efficiency technologies, such as direct injection, turbocharging and downsizing, cooled EGR, and variable valve timing. Additional advances in gasoline-vehicle design, such as variable compression-ratio engines, will further erode the efficiency advantages of diesel.

2018 68

Porsche secures third straight FIA WEC Manufacturers’ World Championship title with the 919 Hybrid

Green Car Congress

Especially in regard to battery technology, downsizing, efficiency improvements with the turbocharged petrol engine and, in particular, for energy recovery systems. For 2016, many details of the 919 got a makeover, but not a totally new design.

2017 78

Bosch leading Direct4Gas consortium to develop direct injection for monovalent natural gas engines

Green Car Congress

Today’s CNG vehicles are generally bivalent, running on gasoline and CNG with engines designed for gasoline direct injection. The very high octane rating and resulting high resistance to knock is promising for small, supercharged, downsized SI engines.

2015 114

Rotrak testing prototype variable drive supercharger in vehicle on dyno

Green Car Congress

Initial design layout of the Rotrak system with the corresponding block diagram. Both solutions involve part load losses which compromise some of the fuel consumption savings made by downsizing. It gives the next generation of downsized powertrains ‘big-engine’ response.

2012 115

Honeywell Global Turbo Forecast projects 49M turbocharged vehicle sales, $12B revenue per year by 2019

Green Car Congress

Automakers are turning to downsized turbocharged engines to satisfy more stringent global fuel economy and emission regulations and customer demand for better-performing vehicles. In addition to improving fuel efficiency, downsized turbocharged engines also reduce harmful exhaust emissions.

2014 114

Hard parts supplier Rheinmetall Automotive expects electrification to account for more than half of sales in 2020

Green Car Congress

The Liteks design, which is repeatedly being fine-tuned, has been developed specifically for lightweight, low-friction yet rugged gasoline pistons for car engines. Another part of this year’s show presentation was devoted to exhaust-gas recirculation on gasoline engines.

2017 104

Team from GM, Ford, FCA reviews how to calculate engine efficiency benefits of high octane fuels

Green Car Congress

Knock and fuel octane rating are becoming increasingly important due to many powertrain design trends including downsizing, downspeeding, cylinder deactivation, and hybridization. …

2015 94

ACCESS project targeting 30% improvement in fuel economy and SULEV emissions in light-duty gasoline engine; multi-mode SI/HCCI combustion

Green Car Congress

Elements of the multi-mode combustion system include: Spark-ignited (SI) combustion with high compression ratio and high boost assisted by cooled external exhaust gas recirculation (EGR). Two-stage boost—a small supercharger for HCCI, and a regular turbocharger for downsizing.

2011 99

ICCT: 2025 target average of 70 g/km CO2 for new cars in EU feasible and economical; more so with electric drive

Green Car Congress

A 2025 CO 2 target of an average 70 g/km for new cars in the EU could be met with very little electrification and with an average payback period of less than 4 years, according to a new study by the International Council on Clean Transportation (ICCT).

2016 121

Achates Power opposed-piston diesel for TARDEC will demonstrate multi-cylinder configuration

Green Car Congress

a $4.9-million contract for design and construction of the Next-Generation Combat Engine. Since the pistons cyclically expose or occlude the exhaust and intake ports, there is no valve train. Scavenging continues until a 230° crank angle, at which time the exhaust ports close.

2013 119

GMZ-led project tracking to deliver vehicular thermoelectric generators for Bradley Fighting Vehicle, Honda Accord

Green Car Congress

GMZ Energy and its partners are on track to deliver a 1 kW thermoelectric generator (TEG) for the Bradley Fighting Vehicle as well as to design and to integrate a light-duty vehicle TEG into a Honda Accord as part of a DOE-funded project. down-speeding, downsized engine, etc.),

2014 104

CPT VTES Electric Supercharger Selected for Two Projects

Green Car Congress

The product is designed for integration into both Otto and Diesel engines to deliver enhanced torque, emissions control and CO 2 reduction. Our electric supercharger is an ideal enabling technology for the extreme engine downsizing being advocated by European carmakers.

2009 104