Two-Stage Variable Compression Ratio

(VCR) System to Increase Efficiency in

Gasoline Powertrains
2014 CRC Advanced Fuel and Engine
Efficiency Workshop
Henning Kleeberg, Dean Tomazic, Steve Bowyer, FEV NA Inc.
Juergen Dohmen, Bernd Haake, FEV GmbH
Andreas Balazs, RWTH Aachen University

Baltimore, February 25th, 2014

Content
Introduction and Motivation
Layout of FEVs Two-Stage VCR System
CO2 Reduction Potential
Combination with Future Technologies
Summary and Conclusion

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

Introduction and Motivation

Principle Influence of Compression Ratio on Fuel Consumption

2000 rpm / WOT

BSFC [%]

high

2000 rpm / BMEP = 2 bar

100

VCR
low

CRbase

14

Compression ratio (CR) [-]

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

Introduction and Motivation

Classification of VCR Systems
Variable piston
TDC position
max
min

Unconventional
cranktrains

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

Variable distance
head - crankshaft

Variable
kinematic lengths

by FEV all rights reserved. Confidential no passing on to third parties

Layout of FEVs Two-Stage VCR System

Working Principle: Conrod

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

Layout of FEVs Two-Stage VCR System

Working Principle: Mechanical Actuation
View from top
horizontal
movement

valve body
functional surface

Cam disc carrier

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

Layout of FEVs Two-Stage VCR System

Transition Time During Load Step
high

2500

Accelerator Pedal [-]

CR [-]

2000
n = 2000 rpm
Oil temp. = 90C

1500

1000

Manifold pressure [mbar]

Full Load

500
Part Load

ideal CR

actual CR

low
-0.2

0.0

0.2

0.4

0.6

0.8

1.0

Time [s]
CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

Layout of FEVs Two-Stage VCR System

Influence of Oil Temperature
high

90C

CR [-]

n = 2000 rpm
BMEP = 8 bar
Oil temp.:
0C

CR low

high

CR high

low

low

0.0

0.2

0.4

0.6

0.8

1.0

Time [s]
CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

Two-Stage VCR System

CO2 Reduction Potential
US Emission Cycles based Simulations Boundary Conditions
Large Passenger Car (Vehicle Weight = 1670 kg)
7-speed Wet Dual-Clutch Transmission
2.0L-I4 Turbocharged GDI Engine
Max. Power = 180 kW
Max. Torque = 350 Nm (BMEP = 22bar)
Base CR
10.5 with Premium Fuel
10.0 with Regular Fuel

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

Two-Stage VCR System

CO2 Reduction Potential
US Emission Cycles based Simulations FTP 75 Results

195

Premium Fuel

FTP 75
Full size sedan
-4.5%

-5.3%

-6.0%

Regular Fuel

-6.5%

-5.6%

-4.8%

190
-2.8%

185

-3.9%

-4.8%

-2.8%

-4.0%

-4.8%

175

CR = 10

180
CR = 10.5

CO2 Emissions [g/km]

200

170
Baseline

CR = 9/12

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

CR = 9/13

CR = 9/14

CR = 10/12

by FEV all rights reserved. Confidential no passing on to third parties

CR = 10/13 CR = 10/14

10

Two-Stage VCR System

CO2 Reduction Potential
US Emission Cycles based Simulations FTP 75
24
Fuel share
in FTP75 [%]

22
Turbocharged DI 2.0L CR=10/14

20
18

BMEP [bar]

16

CR = 10

14
12

CR = 14

10
3

8
6

4
1

2
0

1000

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

2000

3000
4000
Engine Speed [rpm]

5000

by FEV all rights reserved. Confidential no passing on to third parties

6000

11

Two-Stage VCR System

CO2 Reduction Potential
US Emission Cycles based Simulations US06
24

Fuel share
in US06 [%]

22

BMEP [bar]

20

Turbocharged DI 2.0L CR=10/14

18

16

CR = 10

14

12

CR = 14

10
2

0.8

0.5

0.3

1000

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

2000

3000
4000
Engine Speed [rpm]

5000

by FEV all rights reserved. Confidential no passing on to third parties

6000

12

Two-Stage VCR System

Combination with Future Technologies
Alternative Fuels

Extreme
Downsizing

Gasoline Controlled
Auto Ignition (GCAI)

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

13

Combination with Future Technologies

Two-Stage VCR Combined with GCAI - Gasoline Controlled Auto Ignition
Base vehicle: 1372 kg, 1.8L

Load too high for GCAI

-4% CO2 in NEDC

Fixed CR = 9.8
Load too low for GCAI

GCAI operation area

Two-stage VCR CR = 9.8/13

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

-12% CO2 in NEDC

14

Two-Stage VCR System

Combination with Future Technologies
Two-Stage VCR Potential for Alternative Fuels

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

15

Two-Stage VCR System

Summary and Conclusions
VCR can help to resolve the conflict between part load and full load CR layout
especially for boosted downsized gasoline engines
The presented two-stage VCR system is based on a variable length conrod with
eccentric piston wrist pin suspension and can be adapted with moderate effort to
existing engines
Various CR settings can be chosen with small conrod design changes
The transition duration of the system with 0.6 seconds is sufficiently short
especially for boosted engines and is almost independent from oil temperature
CO2 reduction potential for moderately downsized GDI engines 5 7% within the
FTP75 cycle
Operating area of GCAI technology can be significantly enlarged resulting in up
to 12% CO2 reduction in combination with two-stage VCR in NEDC
The higher knock resistance of alternative fuels can be used via adaptation of the
VCR shift line in the map
CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

16

2014 CRC Advanced Fuel and Engine Efficiency Workshop

Two-Stage Variable Compression Ratio (VCR) System

Thank you for your attention!

CRC_AFEEworkshop2014_VCR_Kleeberg_20140225.pptx

by FEV all rights reserved. Confidential no passing on to third parties

17