25. April 2013

FEV GmbH displays downsizing capabilities at Vienna Motor Symposium

FEV exhibit shows its expertise in increasing fuel economy, reducing emissions Exhibit also includes information on full capabilities

Aachen, Germany, April 25, 2013 – 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 34th International Vienna Motor Symposium, 25 - 26 April 2012 at the Congress Center Hofburg, Vienna. FEV also announced its participation as a presenter in the event. The announcement was made by FEV GmbH president and CEO Prof. Stefan Pischinger.

"It is at events like the Vienna Symposium where we find the technologies of the future,” said Prof. Pischinger. “As a leader in the development of traditional and alternative propulsion powertrains, it is important that FEV exhibits its most recent vehicle technologies and view other technologies in order to determine, as an industry, the best solutions for future transportation.”

These and other technologies will be exhibited at FEV’s exhibit:

FEV will present on and show an animation of a downsized gasoline engine. The mock-up features a number of innovations that result in a small and fuel efficient, yet powerful engine. Some features include:

  • A roller bearing cranktrain that uses a hybrid bearing concept with a 3.3 percent fuel efficiency potential. The roller bearing supported crankshaft results in reduced friction losses, while plain bearings support the connecting rods.
  • A 2-stage variable compression ratio with a 6 percent fuel efficiency potential (relative to a 2.0L TC gasoline engine)
  • An integrated exhaust manifold that significantly reduces full load fuel consumption. With this manifold, the engine operates at lambda 1 across the entire speed range. It also provides improved engine warm-up due to heat rejection to coolant. Improved packaging results in weight and cost reduction.

In integrating a downsized engine into a demonstrator vehicle, FEV also developed active engine mounts that solve the conflict of high static stiffness for weight and torque support, and low dynamic stiffness for vibration isolation, also enhancing NVH.

Several development techniques were used that enable the engine, including the use of a triple-image endoscope to analyze pre-ignition location and soot formation, an optical spark plug for detection of cycles with pre-ignition and knock detection, telemetric piston temperature measurement using a proprietary FEV measurement technique, and turbocharger optimization.

Fuel Cell Range Extender
At the event, FEV will exhibit a Fuel Cell Range Extender Module Prototype, which includes a FEV-developed Controller Module consisting of a battery management system, a cell voltage measurement unit and a battery module. The technology was developed as part of the Breeze! project, a publically funded, collaborative effort between FEV, the Graebener Group, the Institute for Combustion Engines (VKA) at the RWTH Aachen, and ZBT GmbH. FEV was also responsible for vehicle integration into a Fiat 500 demonstrator vehicle, and the design of several components in conjunction with VKA.

FEV will be showing a new liquid-cooled high-performance battery module. One typical configuration of this module is an arrangement of 8 sets, featuring a peak power of 200 kW (continuous power = 80 kW) and providing a capacity of 10.4 kWh. The module also includes an FEV-developed integrated BMS slave unit capable of cell voltage and temperature measurement, cell balancing functions, and cell monitoring functions.

Reduced Emissions
FEV’s Variable Valve Train (VVT) for diesel engines demonstrates a technology package aimed to provide solutions as stringent emission legislation approaches. The VVT features the integration of a 2-stage variable valve lift on intake valves. When valve lift is reduced, and in combination with seat swirl chamfer, variable swirl is enabled. The VVT also features the integration of a phaser on the exhaust camshaft and internal exhaust gas reduction through advanced exhaust valve timing.

Transmission Development
FEV has developed a dry, dual-clutch transmission that features a low complexity gearset with only 3 synchronizer units. The 7-speed DCT (patent pending) has an input torque of 280 Nm, and installation length is just 350 mm, which is a new benchmark. Also a new benchmark, the DCT weighs just 64 kg (dry). It features electro-mechanical acutation and a mechanical park-lock mechanism. FEV developed the concept and used 3D and 2D plus CAE in the design. Software design and bench testing are ongoing.

Also in the area of transmission development, FEV has developed the P-REX1 transmission for plug-in hybrids. The transmission provides two-speed pure electric driving, and can be integrated with a combustion engine range extender with parallel mode for efficient highway driving. The transmission has a highly flexible CVT mode during which a vehicle can launch and creep without the clutch slipping, and e-boost is provided during launch, even with an empty battery. The transmission has been successfully shown in a demonstrator vehicle.

FEV will also be presenting several technical papers at the Symposium; one concerning the development and matching of double entry turbines for next generation highly boosted gasoline engines, and the other on the effect of fuel and the combustion system of the pre-ignition of a boosted SI engine.