TECHNOLOGIES FOR IMPROVING THE FUEL ECONOMY OF PASSENGER CARS AND LIGHT-DUTY TRUCKS 37
tinue to accelerate. As a result, electromechanical IVT is advancing to the point where BMW has an- nounced the introduction of its so-called Valvetronic concept. When multipoint fuel injection is used, both the lift and timing of the intake valves can be con-
trolled to maintain the correct ratio without a throttle plate. This has the potential to essentially eliminate the pumping losses across the normal but- terfly throttle valve. Also important is the potential to use conventional three-way-catalyst (TWC) treatment technology and incorporate cylinder deac- tivation. However, significant cost and complexity in actuation, electronic control, and system calibration
are to be expected. Improvements in fuel consump-
tion of an additional 3 to 6 percent above VVLT are possible with this technology. Compared with
valve engines, total system improvements may ap- proach 6 to 12 percent.
Camless valve actuation A further evolution
of fast-acting, completely variable valve timing (not limited by the lift curve of a camshaft) is represented by electromechanical solenoid-controlled, mass valve (EMV) systems (Siemens, BMW, FEV) and high-pressure hydraulic-actuated valves with high-speed, digital control valve technology (Ford, Navistar). In addition to reducing pumping losses, this technology facilitates intake port and cylinder deactivation and allows the use of conventional
TWC aftertreatment. Technical challenges in the past for EMV have been to minimize energy con- sumption and achieve a soft landing of the valve against the seat during idle and low-speed, low-load operation, for acceptable noise levels. These issues appear to be solved through advances in sensor and electromagnetic technologies. EMV systems are ex- pected to see limited production within 5 to 7 years. Improvements in fuel consumption of 5 to per- cent relative to VVTL are possible with this tech- nology. Compared with fixed-timing, four-valve engines, total system improvements of 15 percent or more have been demonstrated (Pischinger et al., 2000).
Variable compression ratio (VCR) engines. Current
production engines are typically limited in compres- sion ratio (CR) to about 1 to 10.5:1 with the use of high-octane fuel, owing to knocking under high load. However, significant improvements in fuel consump- tion could be gained with higher CR under normal driving cycles. Many different VCR approaches that allow improved efficiency under low load with high CR (13- 14:1) and sufficient knock tolerance under full
load with lower CR are under development.
Saab appears to have the most advanced VCR proto- types. Automakers, suppliers, and R&D organizations are currently exploring many other approaches that are
applicable to both and Vee engine configura- tions. Several of these are expected to enter production within years. Compared with a conventional four- valve engine, improvements in fuel consumption of 2 to 6 percent are possible (Wirbeleit et al., 1990). The combination of VCR with a supercharged, downsized engine is likely to be effective, giving the maximum advantage of both systems and reducing total fuel consumption, at constant performance, by
to percent. However, the potential complexity of the hardware, system durability, control system development, and cost must be traded off for produc- tion applications.
Many additional engine technologies with good potential for improved fuel consumption are the subject of
Others are currently offered in markets with higher fuel prices (due to higher taxes) or exhaust emission standards more lenient than the upcoming federal Tier 2 emission stan- dards (or California’s SULEV standards, set to begin in model year 2004). A brief summary of these technologies is presented below, including reference to the areas of uncer- tainty and the need for further development.
Direct-injection gasoline engines. charge gasoline engines burning in a lean mode (when more air is present than required to bum the fuel) offer improved thermodynamic efficiency. However, the technology faces potential problems in controlling par- ticulate emissions and NO,. Trade-offs between the maximum operating range under lean conditions ver- sus stoichiometric operation (when the exact amount
of air needed to bum the fuel is present) with early injection must be developed. Although lean-burn DI engines of the type offered in Europe could improve fuel consumption by more than 10 percent, NO,-con-
requirements that necessitate stoichiometric op- eration and the use of limit the potentia1 fuel consumption improvement to between 4 and 6 percent (Zhao and
Direct-injection diesel engines. The application of small (1.7- to high-speed tur- bocharged, direct-injection diesel engines has seen tre- mendous expansion in passenger cars and light-duty trucks in Europe. Increasing power densities
liter), achieved through the application of advanced, high-pressure, common-rail fuel injection systems; variable geometry turbochargers; and advances in noise, vibration, and harshness (NVH) control tech- nologies, combined with high-efficiency, lean-burn combustion systems and practically smokeless and odorless emissions, have greatly improved customer acceptance in Europe. The high low-speed torque and relatively flat torque curve also offer significant drivability improvements. Fuel consumption
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