FEV exhibit at 2016 SAE World Congress explores the future of propulsion and connected vehicle systems technology
With exhibits ranging from advanced engine and transmission technology and power systems, to active safety features and connected car cyber security, FEV offers a glimpse of the industry’s future.
Auburn Hills, Mich., April 8, 2016 – The future of the automobile is changing at cyber speed. Just yesterday, the buzz was the electric vehicle, and now connected and autonomous vehicles have been added to the mix. Automakers are scrambling to keep abreast of the challenges inherent in this changing landscape in order to make the right choices for future products. FEV North America, Inc. will provide a look into some of those future technologies with innovative solutions displayed at the 2016 SAE World Congress, April 12 – 14 at Cobo Center in Detroit, Michigan.
The Connected Car
Being connected also means accepting exposure to cyber-attacks. This is particularly evident in the automotive industry, which is embracing connectivity as an integral part of the new vehicle eco-system being demanded by consumers. Developing this eco-system and its numerous components and interfaces is one aspect that FEV’s Automotive Cyber Security Services have focused on in the development of safety and security technologies that consider the entire product lifecycle from concept to in-field support. FEV’s services provide management, testing, hardware and software design solutions and address, together with its partners, IT specific security threats and solutions to the problems FEV’s customers may face.
Functional safety is one of the key requirements for a connected vehicle ecosystem. The development and implementation of FEV’s Autonomous Driving (AD) technology leverages the company’s in-depth understanding of vehicle powertrain, chassis, body, infotainment and connectivity sub-systems. FEV assists customers in the design and integration of advanced ADAS active safety features and functions.
3-Cylinder Technology Demonstrator
FEV looks at traditional propulsion on a broad scale that combines features such as downsizing and down-speeding that are sought by manufacturers as they prepare products that are compliant with demanding CO2 emissions and efficiency targets with emerging technologies that create a more efficient, functionally enhanced engine. The 3-cylinder mock-up exhibit demonstrates the potential combination of several advanced technologies developed by FEV into a smaller, yet more powerful package of technologies that can help meet these emerging needs. Featuring innovations such as a hybrid roller bearing crank train, 2-stage variable compression ratio (VCR), active engine mounts, and advanced combustion diagnostic tools, the 3-cylinder mock up demonstrates how technologies can be synergistically and innovatively used in anticipation of future customer needs.
A-segment vehicles are generally not known for comfort or high-end technologies. Globally, they typically incorporate conventional powertrains and a basic 5-speed manual transmission. While Automated Manual Transmissions (AMT) have found their way into A-segment vehicles, the AMT is plagued by characteristically rough gear shifts caused by the torque interruptions.
While Dual Clutch Transmission (DCT) architectures feature softer powershifts, they are typically more expensive. The DCT’s cost disadvantage can be compensated by the re-use of high-volume production components – and this is the approach that FEV has followed in developing the 5-DCT130 dual-clutch transmission, which relies almost exclusively on off-the-shelf parts. FEV’s 5-DCT Transmission demonstrates how an automatic transmission can be particularly useful in an A-segment city car by enhancing comfort during numerous gear changes and start-stop events. Given the predicted growth of two percent on top of its 2014 level of 5.2 million vehicles, a DCT transmission could be a viable option to increase both capability and customer satisfaction.
2.0L 4-Cylinder Diesel Engine
A demonstration of how FEV can support design and development of customer engines, the Jaguar Land Rover Ingenium engine is configurable, flexible and modular. FEV supported Jaguar Land Rover in the development of a new family of advanced technology, low-friction, high-performance gasoline and diesel engines to meet growing customer demand for lower fuel consumption and cost of ownership, without compromising performance and the driver experience. FEV provided base engine CAD and CAE support, single-cylinder engine testing for combustion optimization, friction analysis and optimization, and base engine dyno calibration. The finished product will be on display.
Electronics / Electrical
To achieve fleet consumption thresholds in nearly all vehicle segments, electrification of the powertrain is necessary. Plug-in hybrid powertrains typically demand massive intervention into the design of the transmission, which generates additional cost for relatively small production volumes.
FEV engineers are working on a mild hybrid approach that has promise, in this regard. FEV has developed a 48-Volt e-charger that it has incorporated into a technology demonstration vehicle as a way of showcasing its capabilities to support this upcoming technology. The e-charger integrated into a 48-Volt system enables new vehicle features with high power demand like active damping, electric power steering, and off-engine climatization. In combination with a 48-Volt battery and 12-Volt DC/DC converter, mild hybridization is also be possible. The e-charger combined with high power vehicle electrical system supports downsized engines with high specific power by improving transient response and low-end torque. FEV engineers performed the mechanical integration of e-Booster hardware and modified the charging system, integrated the 48V electric system, and performed all the Rapid Control Prototyping (RCP) functional development and calibration for the e-Booster operating strategy.
FEV Development Tools
FEV Virtual Engine
FEV Virtual Engine is an industry-specific vertical market software product that features a template-based architecture, coupled with a unique communicator technology for coupling an arbitrary number of subsystems to an assembly. FEV Virtual Engine is built on the foundation of Adams® MBS solver from MSC Software. It provides all the building blocks needed to create dynamic models of combustion engines including the complete powertrain. FEV Virtual Engine provides realistic internal 3D parametric geometry modeling based on the Parasolid kernel, the world’s leading 3D solid modeler. Alternatively, native CAD models can be imported. With FEV’s Virtual Engine software, engineers can model any mechanical system – if you can build it, you can simulate the dynamics. The software allows flexibility to combine a variety of powertrain components and subsystems, supporting the development process from concept definition to series development with simulation results.
FEVFLEX / FEVALYS
FEVFLEX supports the complete information process in the development of new products from planning and job creation through documentation of all activities, data management, and through analysis and reporting. FEVFLEX supports test field management by comprehensively and efficiently providing access to large amounts of data that are generated in today’s test facilities. Designed with years of test field operation experience and best practices in mind, FEVFLEX offers advanced functionality to test field operators in one easy to use tool. It is an easily integrated software tool that supports test data management, visualization, log-book, scheduling and tracking, resource management, analysis, maintenance, reporting and more, using a one-click approach. This unique tool is coupled together with FEVALYS, a flexible analytical software tool that provides efficient and effective analysis of a wide variety of information; including trends, operational measurements, cycles, and benchmark data. FEVALYS allows users to generate high quality reports for a complete analysis.
About FEV Group
The FEV Group is an internationally recognized powertrain and vehicle engineering company that supports the global transportation industry. FEV offers a complete range of engineering services, providing support across the globe to customers in the design, analysis, prototyping, powertrain and transmission development, as well as vehicle integration, calibration and homologation for advanced internal combustion gasoline-, diesel-, and alternative-fueled powertrains. FEV also designs, develops and prototypes advanced vehicle / powertrain electronic control systems and hybrid-electric engine concepts that address future emission and fuel economy standards. The company has expanded its engineering capabilities to include full vehicle systems and now offers broad expertise in electronics, telematics and infotainment system engineering.
The FEV Testing Solutions division is a global supplier of advanced test cell, instrumentation and test equipment. The FEV Group employs a staff of over 4,000 highly skilled specialists at advanced technical centers on three continents. FEV North America, Inc. employs over 450 personnel in its North American Technical Center in Auburn Hills, MI.
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