Issue: Apr 2006


FEV Showcases New Technologies and Services at SAE



FEV Engine Technology will feature several emerging technologies and a new concept vehicle in its display at the SAE 2006 World Congress, in Detroit April 3-6

by Rob White

Advanced engine and vehicle technologies on display will include a new turbocharged, DI (direct-injection) gasoline engine; the latest development status of the opposed-piston, opposed-cylinder opoc(TM) engine; the new Mercedes-AMG 6.3L engine; a new diesel-electric hybrid CUV (crossover utility vehicle) concept vehicle, and a mild-hybrid electronics display.

New service offerings from FEV in the vehicle packaging, integration and calibration and motorsports fields also will be featured.

"The demands on our industry today are greater than ever," notes Robert Last, FEV vice president of operations and communications. "Success is now measured not by our ability to innovate new technologies, but our ability to bring those new technologies to the street."

"Harnessing and directing the innovation process to bring new ideas into production is the key enabler for competitive success in the North American automotive market," says Gary Rogers, FEV president and chief executive officer. "In the global marketplace, where engine concepts are increasingly complex and variable, innovative ideas and proven results are essential."

TurboDISI Engine

One of FEV's exhibits is a new turbocharged, gasoline direct injection (TurboDISI) engine that offers impressive low-end torque, smooth transient torque rise, and the excellent fuel economy typically associated with diesel engines.

"FEV engineers took a step-wise look at moving from a PFI (Port Fuel Injection) gasoline engine toward operating in the homogenous, DI mode by combining the latest turbocharging technology, adapted-charge motion, optimized compression ratio and variable-valve timing with gasoline direct injection," Rogers says. "The result provides the best fuel economy, torque and power output in a true, downsized 1.8-liter engine concept. The new TurboDISI engine can replace larger, heavier naturally-aspirated engines and still meet emissions."

Compared to a much larger 2.6-liter naturally aspirated engine, the TurboDISI engine produces the same rated power, but avoids much of the turbo- lag issues of conventional turbocharged PFI engines and offers better specific fuel mileage throughout the engine map.

opoc(TM) Engine

Another technology on display is a new version of the opoc(TM) engine. Originally introduced by FEV and Advanced Propulsion Technologies, Inc. at the SAE 2005 World Congress, this motor was noted for having a power density of more than one horsepower per pound combined with greater than 40 percent efficiency. This year, FEV will exhibit the tandem version of the opoc(TM) engine, initially targeted for defense applications.

The opoc(TM) engine's unparalleled power density meets design requirements for both land vehicles and aircraft. When combined with its high fuel efficiency and ability to operate on fuels available in the battlefield, it becomes the ultimate powertrain.

Designed to be modular, more cylinders can be added to the opoc(TM) engine so it can generate greater power for specific applications. By using a modular displacement clutch, one module can be completely shut down when less than half the engine power is required. This "cylinder deactivation" feature ensures that power is available on demand yet allows excellent operating range beyond that provided by powertrains currently used in such applications.

The dual-module engine is designed to deliver 450 hp from sea level to an altitude of 15,000 feet for a specific aircraft application. The opoc(TM) engine has the thermodynamic capability to produce 650 hp at sea level for aircraft and could be modified to have similar power output for ground vehicles.

FEV also will display the opoc-s(TM) engine concept, which offers exceptional specific power and high power density. The engine has several potential applications, including as an auxiliary power unit (APU) in commercial and military applications and as a primary power source for small, unmanned air vehicles (UAVs).

The intellectual property and trademarks relating to the original opoc(TM) design are owned by Advanced Propulsion Technologies, Inc. (APT). FEV has an exclusive agreement with APT to support opoc(TM) development.

Mercedes-AMG 6.3L V8

Also on display is the new Mercedes-AMG 6.3-liter V8 that is the first in the world to combine a high-revving concept with a large displacement engine to generate 514 hp at 6,800 rpm. With a maximum torque of 630 Nm (465 ft-lb), this new power pack is the world's most powerful naturally aspirated eight- cylinder production engine. FEV supported AMG with a wide variety of services, ultimately leading to the production release of this high- performance engine in 2006 in three different vehicles being marketed all over the world.

"The unique abilities of our vehicle packaging, integration and calibration personnel were highlighted by this successful program," says Rogers. "We sent engineers all over the world -- to Spain, Sweden and South Africa as well as the U.S. to support our customer as they readied this."

Asia-Pacific Ford Ranger

A Ford Ranger for the Asia-Pacific market will be displayed at FEV's exhibit. It represents a truly international vehicle integration and calibration effort between Ford, Mazda and FEV.

FEV supported Ford Motor Company with engineering to integrate an existing Ford automatic transmission and Mazda 4-cylinder diesel engine into the Ford Ranger vehicle, primarily for the Asian and European markets. FEV resources were integrated into the Ford development organization and FEV worked closely throughout the project with Mazda and Ford resources and facilities worldwide. FEV performed development work at FEV and Ford facilities on three continents. Its range of activities included powertrain integration, simulation, emissions, performance and driveability calibrations, NVH development.

Diesel-hybrid CUV

A concept vehicle on display is a new diesel-hybrid CUV (crossover utility vehicle) concept that was co-developed by FEV and Ssangyong of Korea. This vehicle is equipped with a 5-cylinder, 2.7-liter turbocharged diesel engine mated to an automatic transmission with an integrated 34-kilowatt synchronous electric motor. The result is a CUV with excellent low-end torque and a greater than 24 percent improvement in fuel economy compared to a baseline diesel vehicle. This represents a likely improvement over today's conventional gasoline vehicles of about 50 percent.

The CUV diesel-hybrid concept uses start/stop operation as part of the operating strategy. Also, engine run time is reduced, dramatically reducing particulate emissions and cutting nitrous oxide emissions below the baseline vehicle's levels. Using the electric motor also results in a 25 percent increase in the 0-60 miles-per-hour performance of the vehicle. The diesel- hybrid CUV offers a 20-30 percent improvement in mid-speed acceleration.

Hybrid Electronics and Controls

FEV's SAE exhibit will highlight hybrid electronics and control system development capabilities. A hybrid electronics display demonstrates mild- hybrid technology that enables fuel consumption reductions while providing good vehicle performance. This is enabled by an operating strategy to support a "downsized" internal combustion engine with an electrical boost. The concept has been verified in a technology demonstrator vehicle developed by FEV.

FEV Racing Team

The FEV Racing Team develops high-performance engines and optimizes them for power, torque and fuel consumption. Currently, FEV is optimizing an internally-developed, 4.0L V8 engine with a flat crankshaft, based on an existing production engine.

For this race engine, FEV will handle design, component procurement, cooling and lubrication system optimization, combustion system development in a test cell, dynamic engine tuning on the test track, support for engine installation, and customer support during testing and race events (data recording, telemetry and lap time simulation with GT-Drive).

"The vehicle exhibits we're showing this year do a great job of demonstrating the wide range of vehicle services that FEV offers to its customers," says Last. "FEV is actively helping OEMs meet the latest round of OBD legislative requirements. Our services are critical in this regard and include (among others) algorithm development, production calibration, certification, rate-based monitoring and production vehicle evaluation, as well as resolving warranty and recall issues."

Along with its exhibit of innovative new technologies and services, the company also is sponsoring the FEV Powertrain Innovation Forum at the 2006 Congress, a series of panel discussions and technical sessions on topics ranging from motorsports to hybrid-electric powertrains and new transmission technology, to thought-provoking discussions on the future fuel mix in the transportation industry, throughout the four days of the SAE Congress.

FEV is an independent engine and powertrain systems research, design and development company, headquartered in Aachen, Germany. Globally, it provides complete concept-to-production (C2P(TM)) support to the transportation industry, commercial engine manufacturers and the emerging fuel-cell industry. The company designs, prototypes and develops advanced gasoline-, diesel- and alternative-fueled engines, as well as advanced vehicle powertrain concepts, electronic control systems and hybrid-electric vehicles. FEV also is a global supplier of advanced test cell, instrumentation and test equipment. Please visit http://www.fev.com/ for additional company information.

Visit FEV at SAE Booth #1817.

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