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Variable Intake Manifold in VR Engines: P N - M 9550 (KW)
Variable Intake Manifold in VR Engines: P N - M 9550 (KW)
P [kW]
M [Nm]
nM
P=
[kW]
9550
n [min-1]
212_020
NEW
Important
Note
Table of contents
Power and torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air channelling in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
The principle of resonance charging . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
212_010
P = n M [kW]
9550
M = torque [Nm]
9550
L =
mL
mth
Exhaust
Air filter
Throttle valve
Air
212_004
Resonance pipes
Collector
212_005
Resonance pipe
Collector
212_006
Pressure wave
Resonance pipe
Collector
212_007
Pressure wave
Resonance pipe
212_008
Ram-effect charging
t=
[ms]
High-pressure wave
s
212_009
Power collector
Resonance pipes
Torque collector
Change-over
barrel actuator
Intake manifold,
lower part
VR5
VR6
Torque pipes
700
770
Power pipes
330
450
For assembly reasons, the variable intake manifold is divided into an upper and a lower part.
The injectors and fuel rail with pressure regulator
are integrated into the lower intake manifold
part.
The upper intake manifold part contains the
resonance pipes, the power collector, the
change-over barrel with actuator, the torque
collector and the throttle valve positioner, which
is attached to the torque collector.
Torque collector
212_011
Torque position
(long pipes)
1,0
Volumetric efficiency
0,9
0,8
0,7
1000
2000
3000
4000
Engine speed
212_012
Power collector
Torque collector
Effective length of
power pipes
212_013
VR5
VR6
4200
3950
Power position
(shorter pipes)
1,0
0,9
0,8
0,7
4000
5000
6000
212_014
10
140
120
100
80
60
250
230
M (Nm)
40
210
20
190
170
1000
2000
3000
4000
5000
6000
n (min-1)
M = Torque
P = Power
n = Engine speed (rpm)
212_015
Power with variable intake manifold
Power without variable intake manifold
Torque with variable intake manifold
Torque without variable intake manifold
Gain in power and torque
11
Full load
Torque M (Nm)
200
150
100
Change-over barrel
Switching point -
in torque position
50
0
1000
2000
3000
4000
5000
6000
7000
12
Advantages!
Lower fuel consumption
Smoother combustion
Improved acoustics
Change-over barrel
212_017
200
M (Nm)
225
175
Air gap
0,27 mm
150
0,42 mm
0,58 mm
0,72 mm
125
2000
4000
6000
n (min-1)
212_018
The influence of the air gap of the change-over
collector on torque in the VR5 engine.
Maximum torque shifts to a higher rpm range.
In the power range (open power pipes), the air
gap cannot have any significance.
13
Power collector
A reminder:
Closed change-over barrel = torque position
Torque pipe
212_003
Power pipe
555o CA
cylinder
2
1
605o CA
575o CA
cylinder
1
2
212_002
635o CA
212_021
Example of current progression in collector.
At a crankshaft angle of 555o, the current moves from No. 3
cylinder 3 to No. 1 cylinder.
Beginning at about crankshaft angle 605o, the intake phase
of No. 2 cylinder leads to a reversal of the current direction.
Decimal points represented by commas in graphic.
14
Manifold/
torque collector
Intake manifold
change-over valve N156
Vacuum line
To other
consumers
Vacuum reservoir
Check valve
Pneumatic switching
212_019
Operating rod
Compression spring
Connection from
solenoid valve line
212_023
Vacuum unit
The tension of the compression spring is overcome and the membrane together with the connecting rod is pulled downwards.
The change-over barrel is rotated 90o.
The torque position comes into effect.
15
Atmospheric pressure
Foamed plastic filter
Magnetic coil
Magnet
(Valve)
To vacuum unit
Valve plate
212_022
Emergency operation
If there is no signal, the vacuum line to the
vacuum unit remains closed. The shorter intake
path in the variable intake manifold remains
open. A substitute function is not planned.
J17
Self-diagnosis
Self-diagnosis is performed with the following
functions:
S
N156
Electrical circuits
J17
J220
N156
S
16
J220
212_001
Service
The variable intake manifold and its actuator are
service-free.
If the engine is shown to have power deficits, the
operation of the variable intake manifold is easy
to test:
V.A.G - EIGENDIAGNOSE
01 - Motorelektronik
HELP
1 2 3
4 5 6
HELP
7 8 9
C 0 Q
Via self-diagnosis
The intake manifold change-over valve data
is available under the functions 02 - Read out
fault memory and 03 - Final control diagnosis.
Visual inspection of the 90o rotation at the
vacuum unit with the help of the engine
speed.
203_026
90ochange-over movement
Idling/power
positions
212_025
V.A.G 1390
212_027
17
1.
2.
Consequently, the first principle is the basis for the concept of a variable change-over
intake manifold
with .................... intake pipes in the low engine speed range
for .................... ..................... .
with .................... intake pipes in the high engine speed range
for power production.
3.
4.
One characteristic of the variable intake manifold on the VR engines is the change-over barrel.
It
A.
B.
C.
18
212_024
5.
A.
B.
C.
6.
The high torque achieved with the variable intake manifold permits frequent use of upper gears in
low and middle engine speed ranges without loss of pulling power.
A.
B.
C.
This improves the service life of the change-over barrel because it is operated less.
This is bad for the operation of the change-over barrel because it is operated less.
Frequent change-over motion is good for the self-cleaning of the change-over barrel.
Therefore the change-over concept was extended by an additional change-over point
in the low engine speed range.
7.
8.
A compression spring in the vacuum unit holds the change-over barrel in the power position.
A compression spring in the vacuum unit holds the change-over barrel in the torque position.
Actuating the vacuum unit switches the manifold to the power position.
Answers
A.
B.
C.
19
Service.
212