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3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance.

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Presentation on theme: "3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance."— Presentation transcript:

1 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

2 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Baseline Engine Performance Baseline engine = 1,6L-5V 74kW - A2Jetta, FAW-VW Official performance –74kW @ 5800 r/min –150Nm @ 4000 r/min Tested by VWSA –Engine as received, 10 hr run-in –Standard Inlet and Exhaust System A2 Jetta –Standard E.C.U. Engines received by VWSA from FAW-VW do not meet this specification

3 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Baseline Engine Performance

4 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Baseline Engine Performance Official: 150Nm, 74kW Average: 143Nm, 71.5kW VWSA currently investigating: –Volumetric Efficiency –Friction Tests –Full Engine Characterisation China Bora Target: 150Nm, 78kW

5 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

6 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Pistons / Compression Ratio N.B. Rumpfmotor is AUDI Responsibility. Choice of 10.3:1 made based on VWSA testing –Performance –Sensitivity –Exhaust temperature with high spark retard. Concern: Cylinder head volumes larger than drawing  10.5:1 possible  10.5 -0.5 :1 specification? –Knock tests? –Performance specification? –Sensitivity study? –Exhaust Temperature? AUDI supply heads: top of specification

7 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

8 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Inlet Manifold Design: History Pre-Development (before last project meeting) –Targets and restrictions –Computer modeling –Preliminary testing –Development prototypes (composite) Last project meeting: VWSA –Pistons not yet available –Timing of calibration vital  Aluminum Prototypes 5 weeks. –Flow-design freeze necessary

9 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Inlet Manifold Design: Parameters Length –maximum (as 1,8L-5V) –longer would have been preferable (torque at lower speed) Diameter –Smaller - lower torque peak, less power (first order) –37mm, 39mm and 41mm prototypes tested Trumpet (diffuser) Design –Improve peak power on smaller diameter manifolds

10 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Inlet Manifold Design: Diameter

11 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Inlet Manifold Design: “Trumpet”

12 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Inlet Manifold Design: Prototypes Sand Cast available 18 May 2000 “Flow correct” for calibration, preliminary testing

13 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

14 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Manifold Selection: Overview Two Options : –Cast: 1,6L-5V A2 Jetta –Tube: 1,8L-5V Considerations –China Localisation (No Difference) –Part Cost (Similar) –Complexity of Heat Shields tubular: 6 parts cast: 1 part –Tubular: heat shields foul with inlet manifold bracket: new bracket would be necessary –Performance... Williams

15 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Manifold Selection Williams

16 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Manifold Selection: Decision Cast as 1,6L-5V A2 Jetta Williams

17 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

18 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Camshaft Selection Camshafts to exist within group Williams

19 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Camshaft Selection Williams

20 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Camshaft Selection Williams

21 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Camshaft Selection: Decision COP 1,6L-5V A2 Jetta Best compromise torque/power –Best torque peak –Power only 1-2kW from best –Still meets power targets Currently in production

22 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-Pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

23 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Down-pipe Selection IAV responsibility (ZP7) Specified: –1,8L-5V Audi A3 COP –With modifications (catalyst changes) Torque targets: Longer secondary length needed –1,6L-2V 74kW Bora COP considered –Modifications also needed Williams

24 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Down-pipe Selection Williams

25 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Down-pipe Selection Williams

26 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Down-pipe Selection 1,6L-2V 74kW Bora COP/modified Changes needed: –Flange Different (1,8L-5V) –Alignment with rear section (35mm too low) –Interference with cross-member. Agreed : IAV Vorderwagen meeting KW23 Drawing to VWSA KW24 Firma Gillet: prototypes KW25 Williams

27 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-Pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

28 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Rear Section Selection IAV Responsibility Originally specified 1,8L-5V Bora COP 1,6L-2V 74kW Bora COP as option VWSA Tested Both Considerations: –Performance –Acoustics –Back Pressure –China Commonisation Williams

29 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Rear Section Selection Williams

30 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Rear Section Selection Williams

31 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Exhaust Rear Section Selection Considerations: –Performance: 1,8-5V COP better –Acoustics: Not yet tested (1,8-5V Probably better) –Back Pressure: only 1,8L-5V within specification (250mBar) –China Commonisation: 1,8L-5V Preferable VWSA Preference : 1,8L-5V COP Williams

32 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-Pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

33 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Variable Valve Timing (VVT) VVT considered as option –Torque Targets –Weight of Bora –Chinese driving requirements Benefit vs Cost... Williams

34 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Variable Valve Timing (VVT) Williams

35 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Variable Valve Timing (VVT) Williams

36 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Variable Valve Timing (VVT) Cost: 90Dm / vehicle. FAW-VW to make decision. (Before Calibration) Williams

37 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-Pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

38 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Full Load Enrichment: Overview Torque Target 150Nm <4000rpm Engines under specification - 145Nm Spark Advance curve shows big “dip” @ 4000rpm VWSA experimented… Performance increase with “over-fueling” at full load around 4000rpm Only effective on some engines Obvious effect on Fuel Consumption (at full load) Williams

39 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Full Load Enrichment: Performance Williams

40 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Full Load Enrichment: Ignition Curve Williams

41 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Full Load Enrichment: Fuel Consumption Williams @N pmax <=300 @N Mdmax <= 285

42 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Full Load Enrichment: Decision Need Decision for Calibration

43 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-Pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

44 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 M1.5.4 vs ME7.5 Williams

45 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Williams Power & Torque Development. 1. Baseline Performance 2. Pistons / Compression Ratio 3. Inlet Manifold Design 4. Exhaust Manifold Selection 5. Camshaft Selection 6. Exhaust Down-Pipe Selection 7. Exhaust Rear Section Selection 8. Variable Valve Timing (VVT) 9. Full Load Enrichment 10. M1.5.4 vs ME7.5 11. Final Performance

46 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 Final Performance Williams

47 3rd Project Meeting: 1.6l-5V in Bora for FAW-VW, China Bosch Technical Centre Korea20 June 2000 3rd PROJECT MEETING: 1.6l 5V in BORA for FAW-VW Robert Bosch Technical Centre Korea

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