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All-New Small Diesel Engine w/ 400cc for future global requirements

Mega-Trend Downsizing - Transition to 1.6L Engines (I-4)
STEERING COMMITTEE

1.62 L
66-77-88 kW 1,2L - 1.6 L
54,3 kW/l 55-66-77 kW 1.59 L
48,1 kW/l 96 kW
1.59 L 60,3 kW/l
66-82 kW
51,6 kW/l

1.6 L
132/(164) kW
1.59 L
85/(105) kW/l
88 kW 1.46 L
55,1 kW/l 66/81 kW
55,4 kW/l
1.6 L
>100 kW
1.0L – 1.3L >65 kW/l
>70 kW
> 60 kW/l 1.6 L
66-85 kW
54,5 kW/l

1.1L 1.6 L
55 kW 94 kW
50 kW/l 58,7 kW/l
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Technology Roadmap Passenger Car Diesel Engines
New Engine Family Concepts – Options and Tendencies

Modern Engine Family Line-Up and Options - Commonality of Parts

Parent Family: Stroke/Bore identical

Modular Engine Architecture
1st Derivative Family: Bore identical / Stroke different
incorporates
2nd Derivative Family: Bore and Stroke different
– Base geometry of classical 500
Majority of Applications cc/cyl. Capacity with long-stroke
design
3,0L I-6 4V TCI
– Common cylinder unit philosophy
2,2L I-4 4V TCI for easy realization of various In-
Line versions (6-, 5-, 4-, 3-, 2-)
2,0L I-4 4V TCI
– Concepts can be adapted for EU-,
1,6L I-4 4V TCI US & BS Emission Norms
1,5L I-3 4V TCI
– Max. commonality of parts
– Upgrade possibility to higher
1,2L I-4 4V TCI
power versions by modularity of
equipment (FIE; TC) & cylinder
1,0L 2V TC(I)
head (2V), eventually materials
(t.b.d.)
50 kW 100 kW 150 kW 200 kW

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Technology Roadmap Passenger Car Diesel Engines
Small Diesel Engine Configuration in the 1,5/1.6L - Segment

REFERENCE I-3 I-4 REFERENCE I-4 (2,0 L)

Parameter I-4 (2,0 L) I-3 (1,5 L)
(1,5 L) (1,6 L) Combustion
I-4 (1,6 L)
110

100 100 98

Mechanics
Combustion 105

100
Mechanics 100* 95 100* 95

90

Cost Index
Compactness 100 106 97 85

Comfort Index 100 98 102

Cost Index 100 106 99

Comfort Index Compactness

SUM 100 101 99,2

* w/out mass balancing system

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Technology Roadmap Passenger Car Diesel Engines
Rated Power vs. Vehicle Weight
400
• 1.6L engines
Engine power
Status 02/2013 typically cover
all engine classes performance range
1.6l engines
300 2.0l engines
from 55….96 kW

• 1.2L derivates
engine power [kW]

usually deliver
performance
200
between 40 and 60
kW

100

Van Applications, e.g. VW

Multivan, Renault Traffic
0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
vehicle weight [kg]
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Technology Roadmap Passenger Car Diesel Engines
Maximum Torque vs. Vehicle Weight
900
• 1.6L engines typically
Maximum torque
800 Status 02/2013 offer torque range
all engine classes from 180….300 Nm
1.6l engines
700
2.0l engines
• 1.2L derivates ensure
maximum torque [Nm]

600 max torque of 140

and 180 Nm
500

400

300

200

100 Van Applications, e.g. VW

Multivan, Renault Traffic

0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800
vehicle weight [kg]
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Technology Roadmap Passenger Car Diesel Engines
Requirements Evolution of Power Density
CASE EXAMPLE
2-stage serial turbocharged HECS engine
120

Brake Power [KW/L]

100
100 80

Specific
Series Production Engines 60
105 kW/l
Concepts/Prototypes 40
80 20
Power Density [kW/l]

0
350
300

Torque [Nm/L]
60 250

Specific
200
37,7 bar
150
40 100

PERFORMANCE 50
260

Peak Pressure [bar]

240
20 220
EFFICIENCY
200
180
160
0 140
1930 1940 1950 1960 1970 1980 1990 2000 2010 2020 120
100
Model Year 1000 2000 3000 4000 5000

Realisation of 100 kW/l High End-Concepts expected in this decade Engine speed

Mainstream applications with lower power density (40-65 kW/ltr.)

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Medium-Duty & Heavy-Duty On-Road Engines Development Trends
Specific Engine Power Output

Specific power output will be further increased in the future

Specific power and average fuel consumption trends Comments

Based on advanced engine

technologies the specific power
of commercial engines has been
significantly increased in the last
30 years
At the same time fuel
consumption and emissions
have been significantly reduced
A further increase of specific
power output is to be expected
for the future

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Diesel Fuel Injection Technology
Injection Pressure Development (Passenger Car, Truck & Off-road)

High-efficient fuel injection system is key feature of modern Diesel engines

Fuel injection pressure development Comments

Significant increase of fuel

injection pressure from
~1500 bar up to ~2500 bar in the
last 15 years
Future developments target for
fuel injection pressures up to
3000 bar
Increased fuel injection pressure
provides additional potential for
emission and fuel consumption
reduction

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Diesel Fuel Injection Technology
Emission and CO2-Emission Potential

High-efficient fuel injection system is key feature of modern Diesel engines

EGR variation @ rated speed; 100% load Comments

Approximately 1% fuel
Baseline
consumption reduction possible
Fuel consumption

3000 bar
with advanced fuel injection
2 g/kWh systems with reduced high
pressure leakage
Increased fuel injection pressure
provides additional potential for
100 mg/kWh emission and fuel consumption
reduction
Additional peak cylinder
capability enables further fuel
consumption reduction potential

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