07. October 2013

FEV GmbH highlights friction reduction as a baseline powertrain technology

Multi-disciplinary optimization approach is unique in the industry

Aachen, Germany, October 7, 2013 – A reduced-friction gasoline engine mock up will be making its debut at the Aachen Colloquium for Automobile and Engine Technology, 7 – 9 Oct., 2013.  The low friction engine was created by Aachen, Germany-based FEV GmbH, (FEV), a leading developer of advanced powertrain and vehicle system technologies.  FEV used its friction database — the world’s largest — in-house software and other engineering tools to cost effectively reduce CO2 emissions and improve fuel economy.

These friction reduction measures, which can be applied to the crankshaft and pistons, valvetrain, lubrication and cooling circuits as well as transmission, tend to be much less expensive than electrification while providing a large fraction of the benefit. Data from FEV’s floating liner single-cylinder test engine is combined with advanced CAE simulations to create an optimization menu that engineers can choose from to develop the best methods for achieving largest friction reduction results at lowest cost.  The friction database serves as a continuous benchmark against which FEV engineers measure development progress.

“By following a multi-disciplinary approach that combines direct measurement, simulation and the world’s largest friction database, FEV engineers are able to optimize friction characteristics in the concept phase of engine design while considerably reducing development time and cost,” said Prof. Stefan Pischinger, CEO of FEV GmbH. “Plus, continuous improvement to our Virtual Engine software, visualization and simulation tools, and automated Design of Experiment (DOE) methods help FEV and its customers to achieve tough fuel consumption and CO2 targets quickly.”

The application of these and other friction reduction measures, via detailed optimization of both engine and transmission components, show that a fuel consumption reduction in the NEDC of more than 8% is possible for a C-class vehicle with a 1.8-liter turbocharged, inline, four-cylinder engine. Not only does this technology cost far less than hybridization, the friction reduction benefits that are gained through this process remain compatible with nearly all future vehicle technologies.