FEV GmbH demonstrates its diversity at Aachen Colloquium

From traditional powertrain developments to advanced electric and hybrid technologies, calibration and testing, FEV shows its extensive capabilities at annual show

Aachen, Germany, October 8, 2011 - FEV GmbH, (FEV) a leading developer of advanced powertrain and vehicle technologies based in Aachen, Germany, revealed today the technologies that it will exhibit at the annual Aachen Colloquium, held 10 -12 Oct. at the Eurogress Aachen Exhibition Center. The Aachen Colloquium is the largest automotive and engine technology congress in Europe, attracting over 1,800 industry professionals. FEV is a major exhibitor and sponsor of the annual event, also presenting numerous technical papers demonstrating advancesin powertrain technology.

"We are once again proud to participate in the Aachen Colloquium," said Prof. Stefan Pischinger, CEO of FEV GmbH. "Aachen has been our global headquarters since the foundation of FEV, and we view participation in the event not only as a responsibility, but an investment in FEV's future as well as a contribution to the strong economic and technical stimulus for the region around Aachen that the Colloquium represents. The Aachen Colloquium has grown to become one of the most important powertrain events in our industry and is widely recognized throughout Europe and the rest of the world."

These and other technologies will be exhibited at FEV's exhibit stand #3, or as part of the ride and drive program:

Electric Vehicle Range Extender / FEVcom System

The range extender,developed cooperatively by FEV and Kolbenschmidt Pierburg, is a breakthrough in the area of electric vehicle technology, in both alleviating range anxiety and in offering near-electric vehicle noise reduction. The 0.8L 2-cylinder range extender is compact, and able to be integrated easily into existing vehiclesdue to simple vehicle interfaces. The small size offers many options forvehicle designers because it can be mounted beneath the rear of the vehicle, allowing space for overall design creativity. The proprietary FEVcom system is responsible for noise level reductions to near-electric vehicle quietness, reducing vibration by 95 percent at peak load.

SmartWheels project E-charging station and Fleet Control Center

FEV has been directly involved in the publicly funded SmartWheels program, a model for a charging infrastructure in Aachen that would enable expanded use of electric vehicles. FEV, in addition to directing the consortium, developed a fleet of 11 electric-powered FIAT 500 vehicles, one of which will be featured in the Colloquium Ride & Drive event held outside of the Eurogress in Aachen. FEV also developed the Fleet Control Desk that gathers information on a variety of e-mobility considerations, such as battery status and availability of charging stations.

LIION Traction Battery Development

FEV will showcase customized, air- or liquid-cooled battery modules with Liion cells alongside its universal battery management system for rapid control prototyping using FEV software that includes power prediction, and SOC- SOH-calculation. FEV performed cell characterization / testing / selection, thermal modeling, electrical design, module and pack mechanical design and testing, assembly andbattery pack testing.

FEV Spray Guided Turbo E100 Engine

The FEV developed 4-cylinder turbocharged direct injection engine generates 160 kW / 90kW/I andwith a maximum torque of 320 Nm at 1,800 rpm and a peak pressure capability of140 bar on E100 fuel. The fuel injection system consists of an A-nozzle, withmulti-hole injection possible. Major changes that have been accomplished on theengine to support E100 are the spark plug heat range, the material used in thevalve seats, and blow-by system optimization. The engine can be started down to-10°C without an additional cold start device.

Two-stage Variable Compression Ratio (VCR) System

The 2-step VCR System is realized through small variations in the conrod length, that are achieved by using the gas and mass forces for actuation. This novel concept ensures rapid and accurate actuation without the use of an expensive power actuator. FEV previously demonstrated the concept in a diesel engine that achieved compression ratios of 14:1 and 17:1. At this year's Colloquium, FEV will show the 2-stage concept applied to a gasoline engine, achieving compression ratios of 8.8 and 12:1. The gasoline engine variant is applicable to almost all existing engines (with bore diameters as low as 70 mm). While the obvious benefit of the VCR system is increased engine efficiency, it also offers emissions related benefits, depending upon whether applied to gasoline or diesel engines. Other potential benefits include improved cold start ability and the potential to optimize performance while utilizing alternative fuels.

Highly Integrated Combustion ElectricPowertrain System (HiCeps)

The HiCeps system developed by a team of FEV engineers from a clean sheet of paper is a hybrid powertrain with an integrated combustion engine, an automatic transmission, electric motor, actuation system, and control strategy. The parallel hybrid system includes start-stop functionality, pure electric driving mode, and boost and energy recuperation. A key feature of the system is that it will not experience torque interruption when moving from electric to ICE mode, or while in ICE mode. In order to make the concept work, FEV integrated its newly developed planetary gearset transmission. The 7-speed electrically assisted hybrid automatic transmission is uniquely designed for transverse (FWD) applications. The transmission, rated at 200 Nm, is very compact and supports full hybrid functionality.

7H-AMT Transmission

FEV's innovative 7H-AMT is designed specifically for transverse installation, paving the way for wider use of extremely fuel efficient transmissions in smaller vehicles. The transmission also presents new comfort attributes formerly reserved for larger vehicles. The 7-speed hybrid transmission is equipped with an electric motor designed to eliminate torque interruption, a major disadvantage of automated manual transmissions (AMT) that are usually installed in smaller vehicles where shift comfort does not play a key role. Torque interruption can be eliminated due to the transmission's configuration, which provides two independent torque paths, one for the combustion engine (CE) and one for the electric motor (EM). During CE gear shifts, the EM fills the torque gap that would usually occur in a conventional AMT.

FEV Test Systems

FEV has extensive capabilities in the development of turnkey test system operations and test system components. Several systems will be on display atthe Colloquium, including:

FEV Fuel Conditioning / Fuel Rate System

The FEV system for fuel conditioning and fuel rate system is a highly precise fuel measurement system that simultaneously offers short measuring times. The fuel circuit is completely free of non-ferrous metals, making it adaptable to test cells that use new alternative fuel variants. The FEV Fuel Conditioning System is a one-size-fits-all type of device that is suitable for a large range of engine types, ensuring good utilization of the equipment without the need for a variety of devices that are sized for different engines.

FEVIS Combustion Analysis System

The FEV-developed FEVIS combustion analysis system is a real-time processing tool that offers simultaneous measurement of many high speed data channels and provides knock analysis based on user-defined calculations. Using future-proof,state-of-the-art hardware based on PXI, and fully compatible with previous hardware, the system is an 8 - 32 channel high-end system using a 10-24 Venergy supply.

FEVALYS

The FEV developed FEVALYS is a Windows-based test cell automation tool for analysis and visualization of data obtained during engine and vehicle development and testing. The data can be obtained in either steady state or transient state.The system uses an integrated approach for data browsing, calculation and report generation, and is based on the predefined formula catalog from FEV's extensive analysis database.

Ride and Drive Opportunities

FEV-developed technology is featured in several vehicles that will be used in the Ride & Drive event held immediately outside of the Eurogress. Media are encouraged to experience these technologies in a real-world setting.

BMW MINI / Aisin Transmission (Ride & Drive event)

For this vehicle FEV usedits TOP expert proprietary calibration tool to provide calibration for the Aisin transmission.

FIAT 500 LIIONA (Ride & Drive event)

FEV supported the development of this FIAT 500-based battery electric vehicle through system layout, component specification, packaging design and safety engineering. It demonstrates FEV's capabilities in the area of all-electric vehicles. The FIAT500 was developed specifically as part of the SmartWheels e-vehicle infrastructure project.