Continental | Unveils Super Clean Electrified Diesel Tech
At the recent Vienna Motor Symposium, Continental presented system solutions for extremely low-pollutant diesel engines. The company’s newly developed 48-volt mild hybrid system not only reduces fuel consumption, and therefore CO2 emissions, but can also achieve significant reductions in pollutant emissions from diesel engines. By making various modifications to a Euro 6 Diesel standard vehicle, engineers at Continental were able to reduce nitrogen oxide emissions by 60 %.
“The diesel engine will continue to play an important role in meeting mobility needs for the foreseeable future,” said José Avila, President of the Powertrain Division and Member of the Executive Board of Continental. “So it is vital for us to develop the technology to support extremely low-pollutant diesel operation.”
The engineers implemented their clean diesel vision in several stages, starting by replacing the standard injection system with Continental’s PCRs5 piezo common rail injection system. This operates with maximum injection pressures of 2,500 bar. With highly dynamic valve timing, it is possible to perform multiple, very closely spaced and very precisely metered injections per cycle. In this way, a minute amount of fuel can be injected into the cylinder after the combustion event. This fuel is ignited only when it reaches the catalyst, thereby accelerating catalyst warm-up. This has important implications because the SCR catalyst has to reach a certain minimum operating temperature before it can begin converting nitrogen oxide emissions. Tests show that this single measure – post-injection – can cut the SCR catalyst light-off time by around eight minutes, resulting in a reduction in cumulative nitrogen oxide emissions under the future WLTP (Worldwide harmonised Light-duty Test Procedure) driving cycle of 37 %.
A 48-volt hybrid system, based on a belt-driven starter-alternator, is also used. The electric motor, with a rated output of around 15 kW, not only allows braking energy to be recuperated and stored as electricity in a small lithium-ion battery but can also assist the internal combustion engine during short, sharp bursts of acceleration. This reduces the peaks in nitrogen oxide emissions that are a feature of diesel engines under very sudden, heavy throttle application. By cutting the relative proportion of accelerating power that has to be supplied by the combustion engine, the 48-volt system can reduce nitrogen oxide emissions by a further 3 %. At the same time, CO2 emissions are cut back by an additional 3 % approximately.
The ‘Super Clean Electrified Diesel’ presented in Vienna also uses a Traffic Light Assist (TLA) function to achieve a further reduction of nitrogen oxide emissions as well as a reduction in fuel consumption. The TLA predicts when the next traffic light – which may not yet actually be visible to the driver – will be on red and can then use this additional information to improve coasting, recuperation and braking management.
In total, the measures featured on the test vehicle presented in Vienna deliver a very significant 60 % reduction in nitrogen oxide emissions, while at the same time achieving a slight drop in fuel consumption, which is down 2 % compared to a Euro 6 Diesel standard car.
HP Lubricants, Leo Burnett | Design Vehicle Management System
HP Lubricants and Leo Burnett India have jointly innovated for the implementation of what they claim is the world’s first anti-collision vehicle management system designed for India’s national highways. Named as RoadsThatHonk, the system has been conceptualised, designed and executed by Leo Burnett India and has been launched on NH1 in North India, along the Jammu-Srinagar Highway.
RoadsThatHonk adopts ‘SmartLife’ poles at sharp curves and hairpin bends, which employ advanced networked devices and combine wireless technology, radar systems, and an anti-collision warning system, powered by solar PV modules. SmartLife poles are placed on each side of key hairpin bends, detect speeds of oncoming vehicles and then communicate with each other to caution approaching vehicles on either side with a horn.
The functionality is achieved by transmitting an electromagnetic wave in 24 GHz frequency range (K-band), and measuring the frequency shift of the reflected electromagnetic wave. The frequency shift is caused by the Doppler effect of the moving target on the electromagnetic wave. As the relative speed between the radar sensor and the target increases, the detected frequency shift also increases, thus enabling the radar sensor to precisely determine the target speed.
The smart pole is a device created specifically to reduce the risk of accidents in hilly areas, funded and executed by HP Lubricants and Leo Burnett India. The aim is to observe the progress of the device and then further amplify the scale and magnitude of the project. The combination of communications infrastructure and technology provides a strong foundation and a way-forward towards smarter and safer mobility. Commenting on the project, Rajdeepak Das, Chief Creative Officer, Leo Burnett, South Asia, said, ‘2016 recorded numerous accidents across national highways and this is a major concern for local and state administration. We are glad to have been behind an innovation that harnesses the power of technology, and uses radar signals to intimate drivers. We are confident that RoadsThatHonk will significantly reduce accidents and save several lives every year.’
GKN | Reveals New Concept e-Drive
At the recent Auto Shanghai Motor Show in China, GKN Driveline showcased an advanced new concept for a fully-integrated eDrive system, all the components of which are contained within a bespoke housing, resulting in optimised packaging and simplifying the integration process for car manufacturers.
The GKN eDrive system features a sophisticated wireless setup that is about 15 % smaller, 10 % lighter, more efficient and more refined than electric vehicle systems that use separate components. Its fully-integrated design will enable advanced eDrive solutions to be supplied to OEMs at lower unit costs than current electric drivelines. GKN claims that this will pave the way for more affordable eDrive variants of mainstream vehicles.
The complete eDrive system packages the electric motor, power inverter and eAxle reduction gearbox within a single casing. The close proximity of the components results in significant improvements in both mechanical and electrical efficiency compared to today’s technology, it explained. The optimal packaging is also claimed to be more refined, as the housing helps to suppress noise and vibrations. The design means that the cooling requirements have been factored in from the start, leading to further efficiencies in the system.
Peter Moelgg, CEO, GKN Driveline AW&E Drive product stream, said the company constantly works in partnership with customers to make its technology smaller and lighter, while retaining high performance and efficiency. The eDrive concept is a perfect example of this, showcasing GKN’s expertise in complete mechanical and electrical systems that will enable the next-generation of electrified vehicles, he added.
BorgWarner | Showcases New Tech In China
BorgWarner recently showcased its extensive product portfolio for combustion, hybrid and electric vehicles at the 17th International Automobile Industry Exhibition in Shanghai, with special focus on solutions for 48-volt hybrid and pure electric vehicles. In addition to technologies such as the regulated two-stage (R2S) turbocharging system and Visctronic fan drive, BorgWarner showcased its electrification know-how, with solutions including the integrated electric drive module (eDM), eBooster electrically driven compressor and various products for P2-type hybrid vehicles.
Combining BorgWarner’s eGearDrive transmission and the high voltage hairpin (HVH) electric motor, the company’s eDM provides primary or secondary propulsion for P4-type hybrid vehicles or pure electric vehicles. Its compact housing structure simplifies installation and saves space while lowering overall weight and costs. The eBooster electrically driven compressor, which was recently brought into series production, complements conventional turbocharging systems. It makes use of 48-volt power supplies to deliver boost on demand for outstanding low-end torque with no perceptible turbo lag. As a result, this innovative technology enables downsizing for up to 35 % better fuel efficiency. BorgWarner has developed various products for P2-type hybrid vehicles, including disconnect clutches and control modules.
“We follow the same goal with all our products: to provide solutions for a cleaner, more energy-efficient world,” said Tom Tan, President, BorgWarner China. “Electrification is a major trend in China, with pure electric and plug-in hybrid vehicles forecast to grow rapidly for many years.”
Bosch, Daimler | Sign Up To Develop Autonomous Cars
Bosch and Daimler have announced that they are working together to take forward the development of fully-automated, driverless vehicles, with market launch expected by the start of the next decade. The companies have agreed to set up a development alliance aimed at making a system for fully automated (SAE-Level 4) and driverless (SAE-Level 5) vehicles a reality on city streets. The objective of the joint development, between Bosch and Daimler, is to work on software and algorithms for a fully autonomous driving system.
This joint-development project is expected to take vehicle expertise of Daimler and combine it with the systems and hardware expertise of Bosch. Objectives of this project include development and rollout of a production-ready system for automated taxis to navigate urban traffic. Bosch and Daimler are looking at improving urban traffic flows and enhance road safety through this project.
Bosch said that among other things, the technology will increase the attractiveness of car sharing. It added that it will allow people to make optimum use of the time they spend in cars, and open up new ways of being mobile to people without driver’s licenses. The project’s main aim is to make a driving system ready for production, as a result of which vehicles will be able to drive completely autonomously in cities. The idea behind it is that the vehicle will come to the driver, not the other way around, noted Bosch. Within a predetermined urban area, people can conveniently use their smartphones to book a car share or an urban automated taxi that comes to them ready to take them to their destination.