internal combustion engine handbook basics components systems and perspectives pdf

Heinz Burtscher XVII Manager of Ignition Engineering, Beru AG, Ludwigsburg, Germany Business Unit Manager, Gates GmbH, Aachen, Germany Department Manager of Engines and Drive Systems, IA

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Internal

Combustion Engine

Handbook

Basics, Components,

Systems, and Perspectives

Edited by Richard van Basshuysen

and Fred Schafer

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www.TechnicalBooksPDF.com

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Internal Combustion Engine Handbook

Basics, Components, Systems,

and Perspectives

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Other SAE titles of interest:

Direct Injection Systems:

The Next Decade in Engine Technology

By Cornel Stan (Order No R-347) Engine Combustion Instrumentation and Diagnostics

By Hua Zhao and Nicos Ladommatos

(Order No R-264) Introduction to Internal Combustion Engines

By Richard Stone (Order No R-278) The Romance of Engines

By Takashi Suzuki (Order No R-188)

For more information or to order a book, contact SAE at

400 Commonwealth Drive, Warrendale, PA 15096-0001; phone 724-776-4970; fax 724-776-0790; e-mail CustomerService@sae.org;

website http://store.sae.org

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Internal Combustion Engine

Handbook

Basics, Components, Systems,

and Perspectives

Edited by Richard van Basshuysen

and Fred Schafer

s,•.,E lnternationar Warrendale, Pa

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All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE

For permission and licensing requests, contact:

Library of Congress Cataloging-in-Publication Data

Handbuch Verbrennungsmotor English

Internal combustion engine handbook: basics, components, systems, and perspectives I edited by Richard van Basshuysen and Fred Schiifer

p cm

Includes bibliographical references and index

ISBN 0-7680-1139-6

1 Internal combustion engines I van Basshuysen, Richard,

1932-11 Schiifer, Fred, 1948- Ill Title

TJ755.H2513 2004

621.43-dc22

Translated from the German language edition:

Handbuch Verbrennungsmotor by Richard van Basshuysen and Fred Schiifer

Copyright ® Vieweg Verlag, Wiesbaden, Germany, 2002

SAE Order No R-345

Printed in the United States of America

2004048172

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V

Foreword

The complexity of a modem internal combustion engine is certainly one of the reasons why one person is

no longer able to comprehensively present all the important interplays in their full depth Perhaps it is also one of the reasons why there has been no complete work on this subject to date Although a large number of technical books deal with certain aspects of the internal combustion engine, there has been no publication until now that covers all of the major aspects of the topic

The more than lOO-year development of the internal combustion engine has resulted in an enormous amount of important information and detailed knowledge on the different demands, the large number of components, and their interaction With a volume of almost 950 pages, more than 1250 illustrations, and nearly 700 bibliographical references, we believe that with this book we have now succeeded in covering all the main technical aspects of the internal combustion engine

It was, therefore, a particular endeavor of the publishers to place emphasis in all the right places and thus

to present a work that closes a significant gap in the technical literature Of particular note is the fact that this book was produced in just eighteen months and, therefore, effectively reflects the current high status of the present-day technical development

Apart from illustrating the latest level of knowledge in engine development, the editors were extremely keen to present theory and practice in a balanced ratio This was achieved, in particular, by winning the cooperation of more than 90 authors from science and industry With their help, a publication has been created that is a valuable source of information and advice in the day-to-day work of education, research, and practice

It is aimed, in particular, at specialists involved in science and practice in the automotive, engine, mineral oil, and accessories industry and at students for whom it is designed to provide valuable help throughout their studies Furthermore, it is intended to be a useful advisor for patent lawyers, the motor vehicle trade, government offices, journalists, and interested members of the general public

The question of the future of the internal combustion engine is reflected in many new approaches to the solution of the problems concerning fuel consumption and environmental compatibility Particularly under these aspects, by comparison with the alternatives, it is not difficult to predict that the reciprocating piston engine as the driving power for cars will probably remain with us in its fundamental elements for many years

to come New drive systems always have the problem of having to compete with more than 100 years of development with enormous development capacities worldwide Starting from the present-day status of motor development, it is important to answer the questions: In what direction is the internal combustion engine developing? What is its potential after more than 100 years of development? How is the fuel situation of the future to be assessed? Are there competing systems that could replace it in the coming years and decades? This book tries to give conclusive answers to these questions

Even though the main focus of the book is on the car engine, certain basic aspects also relate to the commercial vehicle engine It is also new that the different aspects of the gasoline engine as compared with the diesel engine in many areas are illustrated in this book Will there be any fundamental difference between the gasoline and the diesel engines in a few years? We have only to look at the growing approximation between gasoline and diesel engines: Gasoline engines with direct injection-in the future perhaps diesel engines with homogeneous combustion

Our special thanks go to all the authors for their collaboration and for their appreciation of this difficult task With their discipline they made it easy for us to coordinate more than 90 authors Of particular note is the punctuality of the authors that enabled the book to appear six months ahead of schedule-an almost unique occurrence

The editors know that the work on this book has often been at the expense of partners and families, and

so we express our thanks to them, too, for their understanding

A few improvements have been made to the second edition: Numerous illustrations have been enlarged, and the formulas improved

Thanks also to the Society of Automotive Engineers for its constructive and understanding cooperation Last but not least we thank Siemens V DO Automotive for the technical and material support in the creation of this work, without whose cooperation this book could never have been published

Fred Schiifer

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VII

Chapters, Articles and Authors

2 Definition and Classification of

Reciprocating Piston Engines

and Bore-to-Stroke Ratio

3.3 Rotational Speed and Piston Speed

4.3 Ignition and Injection Maps

5.5 Energy Balance in the Engine

Dipl.-lng Karl B Langlois

Dipl.-lng Markus Muller

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Vlll

Christof Harle Bernd Schreiber

Dipl.-lng Rolf Kirschner

Dipl.-lng Matthias Farrenkopf 7.19 Bearings in Internal Combustion Engines Dipl.-lng Ulf G Ederer

Dipl.-lng Wilhelm Kullen

Dr rer nat Hans-Peter Werner

9.3 Methods of Measuring Friction

9.4 Influence of the Operating State and

the Boundary Conditions

9.5 Influence of Friction on the Fuel

Consumption

9.6 Friction Behavior of Internal Combustion

Engines Already Built

Four-Stroke Engines

10.2 Calculating Charge Cycles

10.3 T he Charge Cycle in Two-Stroke Engines Dr.-lng Uwe Meinig

Dipl.-lng Wolfgang Stephan Prof Dr.-lng Wilhelm Hannibal 10.5 Pulse Charges and Load Control of Dr.-lng Alfred ElsaBer

Reciprocating Piston Engines Using Dipl.-lng Wolfgang Schilling

Dipl.-lng Kay Brodesser Dr.-lng Oskar Schatz www.TechnicalBooksPDF.com

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11.6 Additional Measures for Supercharged

Internal Combustion Engines

Related Systems

12.2 External Mixture Formation

12.3 Mixture Formation using Carburetors

Gasoline Injection

12.5 Mixture Formation in Diesel Engines Prof Dr.-lng Helm ut Tschoke

12.5.1 Injection Systems-An Overvie w

12.5.2 Systems with lnjection-Sychronous

Pressure Generation

12.5.3 Systems with a Central Pressure

12.5.4 Injection Nozzles and Nozzle-Holder Prof Dr.-lng Helmut Tschoke

Assemblies

12.5.5 Adapting the Injection System to the

Engine

Dipl.-lng Reinhold Bals

15.4 Two-Stroke SI Engines

Engine Management and Transmission

Shift Control

16.2 Stand-Alone Products (Separate Devices)

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16.6 Electronics in the Electronic Control Unit

16.8 Torque-Based Functional Structure Dipl.-lng Achim Koch

for Engine Management

17.2 The Motor-Vehicle's Longitudinal Dynamics

17.4 Power Level and Signal Processing Level

17.6 Integrated Powertrain Management (IPM)®

17.7 T he Integrated Starter-Motor/Alternator Dipl.-lng Peter Skotzek

19.1 Drives for Charge Controllers

19 2 Throttle Valve Actuators

19.3 Swirl and Tumble Plates

19.4 Exhaust Gas Recirculation Valves

19.5 Evaporative Emissions Components

20 Cooling of Internal Combustion Engines Dipl.-lng Matthias Banzhaf

20.3 Principles for Calculation and

21.3 Pollutants and Their Origin

21.5 Exhaust Gas Treatment for Spark-Ignition

Engines

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XI

21.5.1 Catalytic Converter Design and Chemical Dipl.-lng.Stefan Brandt

Reactions

21.5.2 Catalytic Converter Approaches for Dr Stefan Siemund/

21.5.3 Catalytic Converter Approaches for Dipl.-lng Stefan Brandt

21.5.4 Metal Catalytic Converter Substrates Dr Andree Bergmann

21.6 Exhaust Treatment in Diesel Engines

21.6.1 Diesel Oxidation Catalytic Converters Dr rer nat Peter Scherm

21.6.2 NOx Adsorbers for Diesel Passenger Cars Dr rer nat T ilman Beutel

Prof Dr Heinz Burtscher/

Dr Markus Kasper

24.1 Strength and Vibration Calculation Dr.-lng Werner Dirschmid/

Dr.-lng Erich BIOmcke

Dipl.-lng Jens Scholz Dipi.-Phys JOrgen Goller

Dr.-lng Erich BIOmcke

27.1 Basic Physical Principles and Terms Dr.-lng Hans-Walter Wodtke/

Emitted Noise

27.3 Sources of Emitted Noise

27.4 Emitted Noise-Reduction Provisions

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XII

27.5 Engine Noise in the Vehicle Interior

27.6 Acoustic Guidelines for the Engioe Designer

27.7 Measuring and Analytical Methods

Alternative Propulsion Systems

The Rationales for Alternatives

Prof Dr.-lng Ulrich Seiffert

Dr.-lng E.h Richard van Basshuysen

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Index of Companies and Universities

Index of Companies

Dr.-lng Werner Dirschmid

Dr Rudiger Teichmann

Dr Erich Winklhofer

Manfred Adolf Dipl.-lng Heinz-Georg Schmitz

Wetter

Dipl.-lng Armin Diez Dipl.-lng Eberhard Griesinger Dipl.-lng Uwe Georg Klump Dipl.-lng Wilhelm Kullen

Dipl.-lng Stefan Brandt Dipl.-lng Uwe Dahle Dipl.-lng Alfred Punke

Dr rer nat Peter Scherm

Dr Stephan Siemund Dr.-lng Susanne Stiebels

Dipl.-lng Markus Muller Dipl.-lng Frank Zwein

XIII

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XIV

Federal Mogul, Nuremberg

Federal Mogul, Wiesbaden

FEV Motorentechnik GmbH, Aachen

Freudenberg & Co KG, Weinheim

INA Motorenelemente, Hirschaid

IWIS GmbH & Co KG, Munich

Mahle Kolben und Motorkomponenten

GmbH, Stuttgart

Matter Engineering, Wohlen (CH)

Miba Gleitlager AG, Laarkirchen (A)

Mubea Muhr & Bender, Attendorn

Peiner Umformtechnik, Peine

Dipi.-Phys JOrgen Goller Dipl.-lng Jens Scholz Philippe Damour Dr.-lng Uwe Lehmann Dipl.-lng Bernd Haake Dr.-lng Franz Koch Dr.-lng Peter Waiters Dr.-lng Uwe Meinig Dr.-lng Manfred Arnold Dipl.-lng Matthias Farrenkopf

Dr Leopold Kniewallner

Dipl.-lng Andreas Knecht Dipl.-lng Wolfgang Stephan Dipl.-lng Reinhold Bals Dr.-lng Michael Fischer Dipl.-lng Michael Haas Dr.-lng Peter Bauer Dipl.-lng Kay Brodesser Dr.-lng Alfred ElsaBer Dipl.-lng Rolf Kirschner Dr.-lng Martin Lechner Dr.-lng Uwe Mohr Dipl.-lng Wolfgang Schilling Dipl.-lng Jan Schmidt Dr.-lng Olaf Weber

Dr Markus Kasper Dipl.-lng Ulf G Ederer Dr.-lng Rudolf Bonse Dipl.-lng Siegfried Jende

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Dr lng h.c F Porsche AG, Stuttgart Dipl.-lng Gunter Helsper

Dipl.-lng Karl B Langlois

Erling-Andechs

Dr.-lng Christof Lamparski Bernd Schreiber

Dipl.-lng Friedrich Graf Dipl.-lng Stefan Klockner Dipl.-lng Achim Koch Dr.-lng Robert Rehbold Dipl.-lng Rainer Riecke Dipl.-lng Peter Skotzek

Dr Michael Ulm

Dr Klaus Wenzlawski

Edenkoben

Index of Universities

Aargauische Fachhochschule, Windisch

University of Applied Sciences, Esslingen

University of Applied Sciences,

Giessen/Friedberg

University of Applied Sciences,

Sudwestfalen, lserlohn

Technical University of Dresden

Prof Dr Heinz Burtscher Prof Dipl.-lng Dr techn

Hartmut Bathelt Prof Dr.-lng Stefan Zima

Prof Dr.-lng Wilhelm Hannibal Prof Dr.-lng Fred Schafer Prof Dr.-lng Hans Zellbeck

XV

Ernst Pucher www.TechnicalBooksPDF.com

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Prof Dr.-lng Ulrich Spicher Dr.-lng Hanns Erhard Heinze Dr.-lng Detlef Hieber

Prof Dr.-lng Helmut Tschoke

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Index of Authors

Dr rer nat Dipi.-Phys Manfred Adolf

Dr.-lng Manfred Arnold

Dipl.-lng Reinhold Bals

Dipl.-lng Matthias Banzhaf

Prof Dipl.-lng Dr.-techn Hartmut Bathelt

Dipl.-lng Stefan Brandt

Dipl.-lng T homas Breier

Dipl.-lng Kay Brodesser

Prof Dr Heinz Burtscher

XVII

Manager of Ignition Engineering, Beru

AG, Ludwigsburg, Germany

Business Unit Manager, Gates GmbH, Aachen, Germany

Department Manager of Engines and Drive Systems, IAV Berlin, Germany Manager of Product and Process Development, Behr, Stuttgart, Germany Professor at University of Applied Sciences, Esslingen and former Manager of the Acoustics Department at AUDI AG, Neckarsulm, Germany

Key Account Manager, IWIS, Munich, Germany

Emitec, Lohmar, Germany Senior Chemist, Engelhard Technologies, Hannover, Germany

Department 1/EK-6, Audi AG, lngolstadt, Germany

Manager of the Valve Train Business Unit, Muhr & Bender, Attendorn, Germany

Project Manager of Lean S.l Engines, Engelhard Technologies, Hannover, Germany

Former Head of Development for the Business Unit Special Seals, Elring Klinger, Dettingen, Germany

Division Manager for Testing and Advanced Design, Mahle, Stuttgart, Germany

Instructor at the Institute for Signals and Sensors at Aargau Polytechnic in Windisch, Switzerland

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Dipl.-lng Friedrich Graf

Dipl.-lng Eberhard Griesinger

Dipi.-Phys Jurgen Goller

Project Engineer for Lean S.l Engines, Engelhard Technologies, Hannover, Germany

Chief Engineer for Bearing Shells and Connecting Rods, Federal Mogul, Wiesbaden, Germany

Development Manager for the Business Unit Cylinder Head Seals, Elring Klinger, Dettingen, Germany

Department 1/EK-61, Audi AG, lngolstadt, Austria

Manager of Advanced Development of New Technologies, Miba Gleitlager, Laakirchen, Austria

Project Manager for Air Cycle Valves, Mahle, Stuttgart, Germany

Technical Director, Gates GmbH, Aachen, Germany

Divisional Manager for S.l Engines, IAV, Berlin, Germany

Director of the Research and Development Department, TRW, Barsinghausen, Germany Scientific Assistant to the Chair for Automotive Engineering and Vehicle Propulsion Systems at the Brandenburg University at Cottbus, Germany

Siemens VDO Automotive, Regensburg, Germany

Manager of Applied Engineering, Elring Klinger, Dettingen, Germany

Manager of Technical Calculations for Pistons, Federal Mogul, Nuremberg, Germany

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Dipl.-lng Bernd Haake

Dipl.-lng Michael Haas

Prof Dr.-lng Wilhelm Hannibal

Christof Harle

Dr.-lng Hanns Erhard Heinze

Dipl.-lng GOnter Helsper

Dr.-lng Detlef Hieber

Dr.-lng Rolf Jakobs

Dipl.-lng Siegfried Jende

Dr Markus Kasper

Dipl.-lng Rolf Kirschner

Dipl.-lng Stefan Klockner

Dipl.-lng Uwe Georg Klump

Dipl.-lng Andreas Knecht

XIX Project Manager, FEV, Aachen, Germany Manager of Variable Valve Trains, INA Motorenelemente, Hirschaid, Germany Manager of the Laboratory for Construction and CAE Applications and the CAD Laboratory at South Westfalia University

of Applied Sciences, lserlohn, Germany

Manager of Testing, SHW, Bad Schussenried, Germany

Scientific Assistant at the Institute for Machine Metrology and Piston Machines

at the University of Magdeburg, Germany

Developer of Engine Drive Systems,

Dr lng h.c F., Porsche AG, Stuttgart, Germany

Scientific Assistant at the Institute for Machine Metrology and Piston Machines

at the University of Magdeburg, Germany

Manager of Research and Development for Piston Rings, Federal Mogul, Burscheid, Germany

Plant Management at Peiner Umformtechnik, Peine, Germany Managing Director, Matter Engineering, Wohlen, Switzerland

Advanced Design and System Design for Valve Train Systems, Mahle, Stuttgart, Germany

FEM Department, Elring Klinger, Dettingen

Manager of Development for Engine Technology, Hydraulik-Ring GmbH, NOrtingen, Germany

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Dipl.-lng Markus Muller

Manager of the Research and Development Department, Fischer Fahrzeugtechnik, Schaffhausen Department Manager for Construction and Engine Mechanics, FEV, Aachen, Germany

Manager of the Development Department, Bleistahl, Wetter, Germany Developmental Engineer for the Business Unit Special Seals, Elring Klinger, Dettingen

Manager of Development, SHW, Bad Schussenried

Development of Engine Propulsion Systems, Dr lng h.c F Porsche AG, Stuttgart, Germany

Manager of Advanced Design, Mahle, Stuttgart, Germany

Manager of Technical Calculations for Friction Bearings, Federal Mogul, Wiesbaden, Germany

Manager of Technology, TTM, Niederrohrdorf, Switzerland Manager of Development, Freudenberg Spezialdichtungsprodukte, Weinheim, Germany

Manager at the Institute for Technical Combustion at the University of Hannover, Germany

Manager of the Research and Development Center, Mahle, Stuttgart, Germany

Manager of Cylinder Product Development, Federal Mogul, Burscheid, Germany

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Dipl.-lng Hubert Neumaier

Dipl.-lng Rainer Riecke

Prof Dr.-lng Fred Schafer

Dr.-lng Oskar Schatz

Dr rer nat Peter Scherm

Dipl.-lng Wolfgang Schilling

Dipl.-lng Jan Schmidt

Dipl.-lng Heinz-Georg Schmitz

Dipl.-lng Jens Scholz

Dipl.-lng Johann Schopp

Manager of Product Development, Tenneco Automotive-Heinrich Gillet, Edenkoben, Germany

XXI

Team Manager for S.l Engine Drive Systems for Passenger Cars, AVL List, Graz, Austria

Institute for Internal Combustion Engines and Automobile Construction at the Technical University of Vienna, Austria Manager of New Technologies, Engelhard Technologies, Hannover, Germany

Professor at University of Applied Sciences, South Westfalia for Motor Engines and Machines

Manager at Schatz T hermo Engineering, Gauting, Germany

Project Manager for Diesel Oxidation Catalytic Converters, Engelhard Technologies, Hannover, Germany Electronics Developer, Mahle, Stuttgart, Germany

Control Software Developer, Mahle, Stuttgart, Germany

Developer of Cold-Start Systems, Beru

AG, Ludwigsburg, Germany Principal Scientist for Materials, Federal Mogul, Nuremberg, Germany

Department Manager for Construction and Mechanical Testing, BMW AG, Munich, Germany

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XXII

Bernd Schreiber

Dipl.-lng GOnter H Seidel

Prof Dr.-lng Ulrich Seiffert

Dr Stephan Siemund

Dipl.-lng Peter Skotzek

Prof Dr.-lng Ulrich Spicher

Prof Dr.-lng Peter Steinberg

Dipl.-lng Wolfgang Stephan

Former Manager of Development, ARAL

AG, Bochum, Germany

Managing Member of WiTech Engineering, Professor at Braunschweig Technical University

Project Manager of T hree-Way Catalytic Converters, Engelhard Technologies, Hannover, Germany

Manager of the Institute for Piston Machines at the University of Karlsruhe, Germany

Chair of Automotive Technology and Drive Systems at the Brandenburg University of Cottbus, Germany Manager of Development, Hydraulik-Ring GmbH, NOrtingen, Germany

Project Engineer for Three-Way Catalytic Converters, Engelhard Technologies, Hannover, Germany

Business Segment Manager of Indicating Systems and Sensors, AVL List, Graz, Austria

Manager at the Institute for Machine Metrology and Piston Machines at the University of Magdeburg, Germany Siemens VDO Automotive, Regensburg, Germany

Publisher of ATZ/MTZ

Manager of Central Development, Mann + Hummel, Ludwigsburg, Germany Siemens VDO Automotive, Regensburg, Germany

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Dr Erich Winklhofer

Dr.-lng Hans-Walter Wodtke

Dr.-lng Peter Waiters

Prof Dr.-lng Hans Zellbeck

Prof Dr.-lng Stefan Zima

Dipl.-lng Frank Zwein

Manager of Testing and Simulation, Elring Klinger, Dettingen, Germany

XXIII

Team Manager for Optical Procedures, Measuring and Testing Systems, AVL List, Graz, Austria

Manager of NVH, AFT Atlas Fahrzeugtechnik, Werdohl, Germany Division Head of Spark Ignition Engine Processes, FEV, Aachen, Germany Chair of Internal Combustion Engines at the Technical University of Dresden, Germany

Professor of Mechanical Engineering, Foundry Technology and Materials Engineering at the University of Applied Sciences, Giessen/Friedberg, Germany

Project Manager, Federal Mogul, Burscheid, Germany

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3 Characteristics 1 5

3 1 Piston Displacement and Bore-to -Stroke Ratio 1 5

3 2 Compression Ratio 16 3.3 Rotational Speed and Piston Speed 1 7 3.4 Torque and Power 1 8 3.5 Fuel Consumption 1 9 3.6 Gas Work and Mean Pressure 20

3 7 Efficiency 22 3.8 Air Throughput and Cylinder Charge 23 3.9 Air-Fuel Ratio 24

5.2 1 1 Constant Volume Cycle 37 5.2 1 2 Constant Pressure Cycle 37 5.2 1 3 Seiliger Process 37 5.2 1 4 Comparison of the Cyclical Processes 39 5.2.2 Energy Losses 39 5.3 Open Comparative Processes 39 5.3 1 Work Cycle of the Perfect Engine 39

5.3 1 1 Elements of Calculation 40 5.3 1 2 Work of the Perfect Engine 4 1 5.3 1 3 Effectiveness of the Perfect Engine 4 1 5.3 1 4 Exergy Loss in the Perfect Cycle 42 5.3.2 Approximation of the Real Working Cycle 42

5.3.2 1 Models to Determine Combustion Behavior 42 5.4 Efficiency 44 5.5 Energy Balance in the Engine 45

5 5 1 Balance Equation 45

6 Crank Gears 4 7

6 1 Crankshaft Drive 47

6 1 1 Design and Function 47

6 1 2 Forces Acting on the Cran kshaft Drive 5 1

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XXVI Cont ent s

6 1.4.2 I nertial Forces in a T wo-Cyl inder V Crank Gear 6.1.4.3 I nertial Forces and I nert ial Torque in Multicyl inder Crank Gears 6.1.4.4 Exampl e Mass Bal ancing 6.1.5.1 Bal ancing Single-Cyl inder Crank Gears 6.1.5.2 Bal ancing Multicyl inder Crank Gears 6.1.6 I nternal Torque 6.1.7 Throw and Firing Sequences Rotational O scill ations 6.2.1 Fundament al s 6.2.2 Reduct ion oft he Machine Syst em 6.2.3 N at ural Frequencies and Modes of Natural Vib rat ion 6.2.4 Exciter Forces And Exciter Work 6.2.5 Measures to Re duce Cran kshaft E xcursions 6.2.6 Two-Mass Flywheel s Engine Components

7 I P istons I Wristpins I Wristpin Circl ips

7 1.1 P ist ons

7.1.l.l 7.1.1.2 7.1.1.3 7.1.1.4 7.1.1.5 7.1.1.6 7.1.1.7 7.1.1.8 7.1.1.9 7.1.1.10 7.1.1.11

Requirement s and Functions Engineering Designs Off set ting the Boss Bore

I nstall ation P lay and Running Pl ay

P iston Masses Ope rating Temperatures

P iston Cool ing

P ist on Desi gns

P ist on Manufacture

P rot ection of Running Surfaces/Surfaces

P ist on Mat erials 7.1.2 Wrist pins

7.1.2.1 Functions 7.1.2.2 Designs 7.1.2.3 Requirement s and Dimensioning

7.2.5.1 Manufact uring t he Blank 7.2.5.2 Machining 7.2.6 Conrod M at erial s 7.3 P iston Rings 7.3.1 Emb odiment s

7 3.1.1 Compression Ri ngs 7.3.1.2 Oil Control Rings 7.3.2 Ring Combi nat ions 7.3.3 Characterizing Features

7 3.4 Manuf acturing

7 3.4.1 Shaping

7 3.4.2 Wear-P rot ection Layers

7 3.4.3 Surf ace Treatments 7.3.4.4 Contact S urface Shapes for Pi st on Rings 7.3.4.5 Mat erial s for P iston Ri ngs 7.3.5 L oading, Damage, Wea r, Fricti on 7.4 Engine Bl ock 7.4.1 Assignments and Funct ions

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7.4.2 E ng ine B lock Des ign

7.4.2 1 Types of Engine Blocks 7.4.3 Optimizi ng Acoustic Properties 7.4.4 Minimizing Engine Block Mass

7 4.5 Casting Processes for Engine Blocks

Cylinder Designs 7.5 1 1 Monolit hic Design

7 5 1 2 Insertion Technique 7.5 1 3 Bonding Tech nology Machini ng Cylinder Running Surfaces 7.5 2.1 Machining Processes Cylinder Cooling 7.5.3.1 Water Cooling

7 5.3.2 Air Cooling Oil Pan 7.6.1 Oil Pan Design Cra nkcase Venti ng 7.7.1 Conventional Crankcase Ventilation 7.7.2 Positive Crankcase Ve ntilation (PVC) System 7.7.3 Vacuum-Regulated Crankcase Ve ntilation Cylinder Head 7.8.1 Basic Design for the Cylinder Head

7 8.2.4 Cooling Concepts

7 8.2.5 Lubricating Oil Management 7.8.2.6 Engineering Desig n Details 7.8.2.7 Engineering in Construction Steps 7.8.2.8 Using CAD in Engineerin g 7.8.2.9 Computer-Assisted Design Casting Process 7.8.3.1 Sand Casting 7.8.3.2 Die Casting 7.8.3.3 Lost-Foam Process (Full Mold Process)

7 8.3.4 Pressure Die-Casting Process Model and Mold Cons tructio n Machining and Quality Assurance 7.8.5 1 Mass-Production Manufacture

7 8.5.2 Prototype Manufactur ing 7.8.5 3 Quality Assura nce for Cylinder Heads Shapes Implemented for Cylinder Heads 7.8.6.1 Cylinder Heads for Gasoline Engines 7.8.6.2 Cylinder Heads for Diesel Engines 7.8.6.3 Special Cylinder Head Designs 7.8.7 Perspectives in Cylinder Head Tech nology Cran kshafts 7.9.1 Function in the Vehicle

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7.9.3 Ligh tweigh t Engineering and Future T rends

7.9.3.1 Hollow Cast Cranksha fts 7.9.3.2 ADI Aus tempered Ductile Iron 7.9.3.3 Increasing Component S treng th through Postcas ting Treatmen t Val ve Train Componen ts 7.1 0.1 Val ve Train

7 1 0 1 1 Direc t Dri ve Val ve Trains

7 I 0.1.2 Indirect Dri ve Val ve Trains

7 I 0.1.3 Hydraulic Val ve Play Compensa tion

7 I 0 1 4 Mechanical Val ve Play Ad jus tmen t

7 1 0 1 5 Future Trends

7 1 0.2 Bel t Tensioni ng Sys tems , Idler and Deflec tion Pulleys

7 1 0.2 1 In troduc tion

7 1 0.2.2 Au tomatic Belt Tensioning System for Synchronous Belt Dri ves

7 1 0.2.3 Idler and Deflection Pulleys for Synchronous Bel t Drives

7 10.2.4 Prospec ts for the Fu ture

7 1 0.3 Chain Tensioning and Guide Sys tems

7 1 0.3.3 Tensioning and Guide Rails

7 1 0.3.4 Sprockets Func tions and Explan ation of Terms and Concepts Types of Val ves and Manufacturing Techniques

7 1 1 2 1 Monome tallic Val ves

7 1 1.2.2 Bime tallic Val ves

7 1 1 2.3 Hollow Val ve Embodi men ts

7 1 1 3 1 Val ve Head

7 1 1 3.2 Valve Sea t

7 1 1 3.3 Val ve S tem Valve Mate rials

7 1 1 4 1 Hea t Treatment

7 1 1 4.2 Surface Finishing Special Val ve Designs 7.11.5 1 Exhaust Con trol Val ves Val ve Keepers

7 1 1 6 1 Tasks and Func tioning

7 1 1 6.2 Manufacturing Techniques Val ve Rota tion De vices

7 1 1 7.1 Function 7.1 1 7.2 Designs and Func tioning Val ve Sp rings Val ve Sea t Inserts

7 1 3 1 Introduction 7.13.2 Demands Made on Val ve Seat Inser ts

7 1 3 2.1 Loading on Val ve Sea t Inserts

7 1 3.2.2 Materials and Their Properties

7 1 3 2.3 Geometry and Tolerances

7 1 3.2.4 Cyl inder Head Geome try and Assembly Val ve Guides 7.14.1 Requirements for Val ve Guides 7.14.2

7 1 5 1 1 Inte rnal Gear Pump 7.15 1 2 Ex te rnal Gear Pump

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7 1 5.2.3 Regulation in the Clean Oil Stream

7 1 5.2.4 Two-Stage or Multistage Regulation

7 1 5 2.5 Two-Stage Regulation Pump 7.1 5.2.6 Regu lated Internal Gear Pump

7 1 5.2.7 Regulated External Gear Pump

7 1 5.2.8 Regulated Vane Pump Engineering Basics

7 1 5.3 1 Cranksha ft Pump

7 1 5 3.2 Sump Pump

7 1 5.3.3 Key Oil Pump Values Taken from Practice

7 1 5 3.4 Comparison bet ween Crankshaft and Sump Pumps 7.1 5.3.5 Cavitation and Noise Emissions Calculation

7 1 5.4 1 Numerical Simulation of Flow -C FD

7 1 5 4.2 One-Dimensional Simulat ion of Flow Grids

Camshaft Functions Valve Train Configurations Structure of a Camsha ft Technologies and Materials

7 1 6.6 Factors Influencing Camshaft Loading

7 1 6 7 Designing Cam Pro files

7 1 8 1 1 Synchronous Belt Drive

7 1 8 1 2 Synchronous Belt Drive System

7 1 8 1 3 Synchronous Belt Dynamics

7 1 8 1 4 Application Examples

7 1 8.2 Toothed V-Belt Drive to Power Auxiliary Units

7 1 8.2 1 Micro- V® Drive Belts

7 1 8.2.2 Auxiliary Component Drive System

7 1 8.2.3 Application Examples Bearings in Internal Combustion Engines

7 1 9.2.3 Elastohydrodynamic Calculation

7 1 9.2.4 Major Dimensions: Diameter , Width

7 1 9.2.5 Oil Feed Geometry

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7 1 9.4.4 Miba 'M Grooved Bearings

7 1 9.4.5 Sputter Bearing

7 1 9.5 Bearing Failure

7.1 9.5 1 Progress o f Damage

7 1 9.5.2 Types of Bearing Damage

7 1 9.6 Prospects for the Future Intake Systems 7.20 1 Thermodynamics in Air Intake Systems

7 20.2 Acoustics Sealing Systems 7.2 1 1 Cylinder Head Sealing Sy stems

7 2 1 1 4 Prospects for the Future Special Seals 7.2 1 2 1 Functional Description of the F lat Sea l

7 2 1 2.2 Elastomer Seals 7.2 1 2.3 Metal-Elastomer Seals

7 21 2.4 Special Metaloseal ® Gaskets 7.2 1 2.5 Prospects for the Future Elastomer Sealing Systems 7.2 1 3.1 Elastomer Seals 7.2 1.3.2 Metal-Elastomer Gaskets 7.2 1 3.3 Modules Development Methods 7.2 1 4 1 Finite Element Analysis 7.2 1 4.2 Simulation in the Laboratory -Testing Functions and Service Life Threaded Connectors at the Engine 7.22 1 High-Strength Threaded Connectors 7.22.2 Quality Requirements 7.22.3 Threaded Connectors

7.22.4

7.22.5

7.22.3 1 Head Bolt 7.22.3.2 Main Bearing Cap Bolt 7.22.3.3 Conrod Bolt

7 22.3.4 Belt Pulley Bolt 7.22.3.5 Flywheel Bolt 7.22.3.6 Camsha ft Bearing Cap Bolt 7.22.3.7 Oil Pan Attaching Screws Threaded Connections in Magnesium Components Screw T ightening Process 7.22.5 1 Torque-Controlled Tightening

7 22.5.2 Rotation-Angle Controlled Tightening 7.22.5.3 Tightening under Yield Point Control Exhaus t Manifold

7 23 1 Manifold Development Process 7.23.2 Manifolds as Individual Components

7.23.3

7.23.2 1 Cas t Manifold 7.23.2.2 Tube Manifold 7.23 2.3 Single- Wall, Half-Shell Manifold 7.23 2.4 Manifo lds with Air Gap Insulation (AGI Manifold) The Manifold as a Submodule 7.23.3 1 Integrated Manifold and Catalytic Converter

7 23.3.2 Integra ted Manifold and Turbochanger 7.23.4 Manifold Components Control Mechanisms for Two-Stroke Cycle Engines

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Contents XXXI

8.2 1 Lubrication 28 1 8.2.2 Components and Function 2 8 1

9 Friction 289

9 I Parameters 289 9.2 Friction States 289 9.3 Methods of Measuring Friction 290 9.4 Influence of the Operating State and the Boundary Conditions 291 9.4 I Run-In State of the Internal Combustion Engine 29 1 9.4.2 Oil Viscosity 29 1 9.4.3 Temperature Influence 292 9.4.4 Engine Operating Point 292 9.5 Influence of Friction on the Fuel Consumption 293 9.6 Friction Behavior of Internal Combustion Engines Already Built 294

9 6 1 Breakdown of Friction 294 9.6.2 Engine Power Unit 295

9.6.2 I Crankshaft 295 9.6.2.2 Conrod Bearing and Piston Group 296 9.6.2.3 Mass Balancing 297 9.6.3 Valve Timing ( Valve Train and Timing Gear) 297 9.6.4 Auxiliaries 297

9.6.4 1 Oil Pump 299 9.6.4.2 Coolant Pu mp 300 9.6.4.3 Alternator 300 9.6.4.4 Fuel Injection Pump 301 9.6.4.5 Air Conditioning Compressor 301 9.6.4.6 Radiator Fan 302 9.6.4.7 Power Steering Pump 302 9.6.4.8 Vacuum Pump 302

10 Charge Cycle 305

1 0.1 Gas Exchange Devices in Four-Stroke Engines 305

I 0 1 1 Valve Gear Designs 306

I 0.1.2 Components of the Valve Gear 307

1 0 1 3 Kinematics and Dynamics of the Valve Gear 3 1 2

1 0 1 4 Design of Gas Exchange Devices in Four-Stroke Engines 3 14 10.2 Calculat ing Charge Cycles 325

1 0.3 The Charge Cycle in Two-Stroke Engines 328

I 0.3.1 Scavenging 328

1 0.3.2 Ga s Exchange Organs 330

1 0.3.3 Scavenging Air Supply 331 10.4 Variable Valve Actuation 333

I 0.4 1 Camsha ft Timing Devices 335

1 0.4 1 1 Overview of the Functional Principles of Camshaft Timing Devices 335

1 0.4.1.2 The Effects of Camsha ft Timing Devices on Engines 337

I 0.4.1.3 Camsha ft Adjusters for Production Engines 338

1 0.4 1 4 Reflections about Camsha ft Adjusters 34 1

I 0.4.2 Systems with Stepped Variation of the Valve Stroke or Opening Time 342

1 0.4.3 Infinitely Variable Valve Actuation 344

1 0.4.3 1 Mechanical Systems 344

1 0.4.3.2 Hydraulically Actuated Systems 344 10.4.3.3 Electromechanical Systems 345 10.5 Pulse Charges and Load Control of Reciprocating Piston Engines Using an Air Stroke Valve 346

1 0.5 1 Introduction 346

1 0.5.2 Design and Operation of the Air Stroke Valve 346

I 0.5.3 Options for Influencing the Charge Cycle 347

10.5.3 1 Dynamic Supercharging in Induction Engines (Pulse Charge) 347

1 0.5.3.2 Supporting and Recharging Supercharged Engines 347

1 0.5.3.3 Throttle-Free Load Control 348

I 0.5 3.4 EGR Con trol 348 10.5.3.5 Hot Charging 348

1 0.5.3.6 Cold Charging Supercharged Engines 349

1 0.5.3.7 Cylinder Shutoff 349

1 0.5.4 Prototype for Engine Tests 349

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1 0.5.5 1 Increa sing Air Expenditure by Dynamic Supercharging 350

1 0.5.5.2 Increa sing Torque by Dynamic Supercharging 35 1

1 0.5.5.3 Required Air Stroke Valve Operating Time s in Dynamic Supercharging 352

1 0.5.5.4 Hot Charging 353 Summary and Outlook 354

11 Supercharging of Internal Combustion Engine 355

1 1 1 Mechanical Supercharging 355

1 1 2 Exhau st Ga s Turbocharging 356

1 1 3 Intercooling 358

1 1 4 Interaction of Engine and Compre s so r 359

1 1 4 1 Four-St roke Engine in the Compre s sor Map 359

12 Mixture Formation and Related Systems 373

1 2 1 Internal Mixture Formation 373

1 2.2 External Mixture Formation 373

1 2.3 Mixture Formation u sing Carburetor s 373

1 2.3 1 Mode of Operation of the Carburetor 373

1 2.3.2 De sign s 374

1 2.3.2.1 Number of lntake Air Duct s 374

1 2.3.2.2 Po sition of the Intake Air Duct 375

1 2.3.2.3 De sign s for Special Application s 375

1 2.3.3 Important Auxiliary Sy stem s on Carburetor s 376

1 2.3.4 Electronically Controlled Carburetor s 378

1 2.3.5 Constant Vacuum Carburetor 379

1 2.3.6 Operating Behavior 379

1 2.3.7 Lambda Clo sed-Loop Control 3 8 1

1 2.4 Mixture Formation by Mean s of Ga soline Injection 3 8 1

1 2.4 1 Intake Manifold Injection Sy stem s 3 8 1

1 2.4.2 Sy stem s for Direct Injection 382

1 2.4.2 1 Air-Supported Direct Injection 384

1 2.4.2.2 High-Pre s sure Injection 385

1 2.4.2.3 Injected Fuel Metering 389 12.5 Mixture Formation in Die sel Engines 390

1 2.5 1 Injection Sy stem s -An Overview 3 9 1

1 2.5.2 Sy stem s with Injection-Synchronou s Pre s sure Generation 395

1 2.5.2 1 Individual Pump Sy stem s with a Line 396

1 2.5.2.2 lnline Fuel Injection Pump s 396

1 2.5.2.3 Di stributor Injection Pump 398

1 2.5.2.4 Pump Nozzle Sy stem 40 1

1 2.5.3 Sy stem s with a Central Pres sure Reservoir 40 1

1 2.5.3 1 High-Pre s sure Pump 402

1 2.5.3.2 Rail and Line s 404

1 2.5.3.3 Injectors 405

1 2.5.3.4 Injection Nozzle 407

1 2.5.3.5 Electronics 407

1 2.5.3.6 Developmental Trend s 408

1 2.5.4 Injection Nozzles and Nozzle-Holder A s semblie s 408

1 2.5.5 Adapting the Injection Sy stem to the Engine 4 1 2

1 3 Ignition 4 1 7

1 3 1 Spark-Ignition Engine 4 1 7 13.1.1 Introduction to Ignition 4 1 7

1 3 1 2 Requirement s of the Ignition Sy stem 4 1 7

13 1 3 Minimum Ignition Energy 4 1 7

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Contents

1 3.2

1 3.3

X XXIII

1 3 1 4 Fundamentals of Spark Ignition

1 3 1 4 1 Phases of the Spark

1 3 1 4.2 Energy Transmission Efficiency

1 3 1 5 Coil Ignition System (Inductive)

1 3 1 6 Other Ignition Systems

1 3 1 7 Summary and Outlook Spark Plugs

1 3.2 1 Demands on Spark Plugs

1 3.2.2 Design

1 3 2.3 Heat Range

1 3.2.4 Required Voltage for Ignition

1 3.2.5 Ignition Characteristic (and Mixture Ignition)

1 3 2.6 Wear

1 3 2 7 Application Diesel Engines

1 3.3 1 Autoignition and Combustion

1 3 3.2 Diesel Engine Cold Starts

1 3.3.2.1 Important Influential Parameters

1 3.3 2.2 Start Evaluation Criteria

1 3.3.3 Components for Supporting Cold Starts

1 3 3.4

1 3.3.3 1 Glow Plug Systems

1 3.3.3.2 Heating Flange Outlook

1 3 3.4 1

1 3.3.4.2

1 3.3.4.3

Combined Systems Measurement of Ionic Current Regulated Glow Plug Systems

1 4.3 Combustion in Diesel Engines 446

1 4.3 1 Mixture Formation 447

14.3 1 1 Phenomenology 447 14.3 1 2 Fuel Jet Propagation 448 14.3.2 Autoignition 449

1 4.3.3 Combustion Process 45 1

14.3.3 1 Phenomenological Description 451 14.3.3.2 Equivalent Combustion Curves 452 14.4 Heat Transfer 453

1 4.4 1 Heat Transfer Model 453

1 4.4.2 Determination of Heat Transfer Coefficients 454

IS Combustion Systems 457

1 5.1 Combustion Systems for Diesel Engines 457

1 5.1 1 Diesel Combustion 457

1 5 1 2 Diesel Four-Stroke Combustion Systems 462

1 5 1 2 1 Methods using Indirect Fuel Injection (ID I) 463

1 5 1 2.2 Direct Fuel Injection Method (DI) 465

1 5 1 2.3 Comparison of Combustion Systems 466

1 5 1 2.4 Special Methods and Features 468

1 5.2 Spark-Injection Engines 470

1 5 2 1 Combustion Processes in Port Fuel Injection (PFI) Engines 470

1 5.2.2 Combustion Process of Direct Injection Spark Ignition (DISI) Engines 479

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1 6 3 Connecting Approaches 16.4 Integrated Products (MTM = Mechatronic Transmission Module) 16.5 Electronic Design, Structures, and Components 16.5.1 Basic Structure 16.5.2 Electronic Components

1 6.5.2.1 IC Knocking Input Filter Component 16.5.2.2 Driver Stage Component

1 6.5 2.3 Microcontroller

1 6.5.2.4 Voltage Regulator 16.6 Electronics in the Electronic Control Unit

1 6.6.7 Electronics for Transmission ECUs 16.7 So ftware Structures 16.7 I Task o f the Software In Controlling Engines

1 6.7.2 Demands on the Software 16.7.3 The Layer Approach to Software 16.7.4 The Software Development Process 16.8 Torque-Based Functional Structure for Engine Management

"On-Board" Diagnosis (OBD)

1 6.9.5 1 Self-Diagnosis Tasks

1 6.9.5.2 Monitoring the Catalytic Converter Safety Approaches The Powertrain

17 1 Powertrain Architecture 17.2 The Motor- Vehicle's Longitudinal Dynamics

1 7.3 Transmission Types

1 7.4 Power Level and Signal Processing Level 17.5 Transmission Management 17.5 1 Functions

1 7.5 1 1 Overview

1 7.5 1 2 Driving or Gearshift Strategy

1 7.5.1.3 Automatic Transmissions with Planetary Gears and Torque Converter 17.5 1 4 Automated Stick-Shift Transmissions

1 7.5 1 5 Continuously Variable Transmissions (C VT) 17.6 Integrated Powertrain Management (IPM ®)

1 7.7 The Integrated Starter-Motor/Alternator (ISO)

1 7.7.1 ISO: A System Overview

1 7.7 1 1 Torque Structure in a Motor Vehicle

1 7 7 1 2 Starter-Motor/ Alternator Structure 17.7 1 3 Description of the Starter-Motor/Alternator's Most Important

Modes of Use

1 7.7.2 Converters (Powertrain Management and Voltage Converters)

1 7.7.2 1 Requirements Made on the Electronics from a System Viewpoint 17.7.2.2 Function Groups and Design Criteria

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1 8.4 1 Normal Pressure Sensors 539

1 8.4 1.1 Piezoresisti ve Measurement Pr inciple 540

1 8.4 1 2 Capaciti ve Measurement Principle 540

1 8.4.2 Medium Pressure Sensors 540

1 8.4.3 High-Pressure Sensors 54 1

1 8.4.3 1 Technical Boundary Conditions 54 1

1 8 4.3.2 Signal Transmission 54 1

1 8.4.3.3 Measuring Precision 54 1

1 8.5 Air Mass Sensors 54 1

1 8.5 1 Comparison of Air Mass-Controlled and Intake Manifold Pressure-Controlled Systems 542

19 1 Dri ves for Charge Controllers 545

1 9 1 1 Pneumatic Dri ves 545

1 9 1 2 Electric Dri ves 545

1 9 2.5 Charge Pressure Control 548

1 9.2.6 Vacuum/Prethrottle Actuators 548 19.3 Swirl and Tumble Plates 548 19.3 1 Swirl Plate Actuators (Swirlffumble Actuators) 548

1 9.4 Exhaust Gas Recirculation Val ves 549

1 9.5 E vaporati ve Emissions Components 55 1

1 9 5 1 Canister-Purge Val ves 5 5 1

1 9.5.2 E vaporati ve Emissions Diagnostics 553

1 9.5.2 1 Tank Diagnostics with Pressure 553

1 9.5.2.2 Tank Diagnostics with Vacuum 553

20 Cooling of Internal Combustion Engines 555

20 1 General 555 20.2 Demands on the Cooling System 555 20.3 Principles for Calculation and Simulation Tools 555

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21 Exhaust Emissions 565 21.1 Legal Regulations 565 21.1.1 Europe 565 21.1.2 Califo rnia, USA 565 21.1.3 Japan 567

21 1 4 Harmonizing Exhaust Emission Regulations 568 21.2 Measuring Exhaust Emissions 569

2 1 2 1 Measuring Techniques for Certifying Automobiles 569 21.2.2 Measuring Technology for Engine Development 569 21.3 Pollutants and Their Origin 574 21.3.1 Spark-Injec tion Engines 574

21.3 1.1 Restricted Exhaust E mission Components 574 21.3 1.2 Unrestricted Ex haust Components 576 21.3.2 Diesel Engines 576

21.3.2.1 Restricted Exhaust Components 576 21.3.2.2 Unrestricted Exhaust Emission Components 578 21.4 Reducing Pollutants 578 21.4 1 Engine-Related Measures 578

2 1 4.1.1 Spark-Injection Engines 578 21.4.1 2 Diesel Engines 580 21.5 Exhaust Gas Treatment for Spark-Ignition Engines 582 21.5.1 Catalytic Converter Design and Chemical Reactions 582 21.5.2 Catalytic Converter Approaches for Stoichiometric Engines 583

21.5.2 1 Three-Way Catalytic Converter 583

2 1 5.2.2 Oxygen Storage Mechanism 584 21.5.2.3 Cold Start Strategies 585 21.5.2.4 Deactivation and Its Effect 587 21.5.3 Catalytic Converter Approaches for Lean-Burn Engines 589

21.5.3.1 Options for NO, Reduction in Lean Exhaust Gas 589

2 1 5.3.2 The NOx Storage Catalytic Converter 591 21.5.3.3 System with a Precatalytic Converter and NOx Adsorber 596 21.5 4 Metal Catalytic Converter Substrates 597 21.6 Exhaust Treatment in Diesel Engines 60 I 21.6.1 Diesel Oxidation Catalytic Converters 60 I

21.6 1 1 Pollutants in Diesel Exhaust 601 21.6.1.2 Characteristics of Diesel Oxidation Catalytic Converters 601

2 1 6.1.3 Deactivating the Catalyst Surface 601

2 1 6 1 4 Evaluating Diesel Oxidation Catalytic Converters 603

2 1 6.2 NOx Adsorbers for Diesel Passenger Cars 604

21.6.2.1 Operating Range of Storage Catalytic Converters 605

2 1 6.2.2 Desulfurization 605 21.6.2.3 Regeneration Methods 607 21.6.3 Particle Filters 607

2 1 6.3.1 Particle Definitions and Particle Properties 607

2 1 6.3.2 Goals of Particle Filtration 609 21.6.3.3 Requirements for Filter Media and Technical Solutions 610 21.6.3.4 Deposition and Adhesion 611 21.6.3.5 Regeneration and Periodic Cleaning 6 1 4 21.6.3.6 Regenera tion Emissions and Secondary Emissions 6 1 7

2 1 6.3.7 Pressure Loss 618

2 1 6.3 8 Installation Area and System Integration 619 21.6.3.9 Damage Mechanisms, Experience 619

2 1 6.3.10 Quality Criteria 620 21.6.3.11 Performance Test, lYpe Test, OBD, Field Control 620

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22 1 1 1 Diesel Fuel Components and Composition

22 1 1 2 Characteristics and Properties

22 1 1 3 Additives for Diesel Fuel

22 1 1 4 Alternative Diesel Fuels

22 1 2 Gasoline

22 1 2.1 Gasoline Components and Composition

22 1 2.2 Characteristics and Properties

22 1 2.3 Alternative Gasolines 22.2 Lubricants

22.3

22.2 1 Types of Lubricants 22.2.2 Task of Lubrication 22.2.3 Types of Lubrication 22.2.4 Lubrication Requirements 22.2.5 ViscosityNiscosity Index (V.I.)

22.2.5 1 Influence of Temperature on Viscosity 22.2.5.2 Influence of the Pressure on the Viscosity 22.2.5.3 Influence of Shear Speed on Viscosity 22.2.6 Basic Liquids

22.2.6 1 Mineral Basic Oils 22.2.6.2 Synthetic Basic Liquid 22.2.7 Additives for Lubricants

22.2.7 1 V.I Improvers 22.2.7.2 Detergents and Dispersants 22.2.7.3 Antioxidants and Corrosion Inhibitors 22.2.7.4 Friction and Wear Reducers (EP/AW Additives) 22.2.7.5 Foam Inhibitors 22.2.8 Engine Oils for Four-Stroke Engines

22.2.8 1 SAE Viscosity Classes for Engine Oils 22.2.8.2 Single-Grade Engine Oil 22.2.8.3 Multigrade Oils 22.2.8.4 Fuel Economy Oils 22.2.8.5 Break-In Oils 22.2.8.6 Gas Engine Oils 22.2.8.7 Methanol Engine Oils 22.2.8.8 Hydrogen Engine Oils 22.2.8.9 Performance Classes 22.2.8 1 0 Evaluating Used Oil 22.2.8 1 1 Racing Engine Oils 22.2.8 1 2 Wankel Engine Oils 22.2.9 Engine Oils for Two-Stroke Engines

Filtration of Operating Fluids

23 1 Air Filter

23 1 1 The Importance of Air Filtration for Internal Combustion Engines

23 1 2 Impurities in Engine Intake Air

23 1 3 Data for Assessment of Air- Filter Media

23 1 4 Measuring Methods and Evaluation

23 1 5 Requirements Made on Modern Air- Filter Systems

23 1 6 Design Criteria for Engine-Air Filter Elements

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24 Calculation and Simulation 70 1

24 1 Strength and Vibration Calculation 70 I

24 1 1 Procedures and Me thods 70 I 24.1.2 Selected Examples of Applications 703

24 1.3 Piston Calculations 705 24.2 Flow Calcula tion 7 1 3 24.2 1 One- and Quasidimensional Methods 7 1 3 24.2.2 Three-Dimensional Flow Calculation 7 1 5 24.2.3 Selected Examples of Application 7 1 7

25 Combustion Diagnostics 723

25 1 Discussion 723 25.2 Indicating 723 25.2 I Measuring Sys tems 724 25.2.2 Quality Criteria 725 25.2.3 Indicating: Prospects 726 25.3 Visualization 726 25.3 1 Functions and Discussion 726 25.3.2 Visualiza tion Methods for Real Engine Operation 727

25.3.2 1 The Radiant Properties of Gas, Gasoline, and Diesel Flames 727 25.3.2.2 Flame Spectroscopy 727 25.3.2.3 Flame Propagation i n Premixed Charges with Supplied Igni tion 728 25.3.2.4 Flame Propaga tion in Diffusion Combus tion in a Diesel Engine 728 25.3.3 Visualization of Combustion in Real Engine Opera tion by the

Flame's Intrinsic Luminescence 728 25.3.3 1 Technical Exploi ta tion: Flame Propaga tion 728 25.3.4 Visualization of Illuminated Processes 732

25.3.4.1 Visualization of Mix ture Distribution 733 25.3.4.2 Visualization of Velocity Fields 733 25.3.5 Visualization: The Future 734

26.2.3.1 The Lean-Burn Engine Concept and Direct Injection 742 26.2.3.2 Variable Val ve Timing 743 26.2.3.3 Ignition 744 26.2.4 Cylinder Shutoff 745

26.2.4.1 Concept for Reduction of Fuel Consump tion 745 26.2.4.2 Consumption Benefits in the Par t-Load Range 746 26.3 Transmission Ra tios 746 26.3 1 Selection of Direct Transmission 746 26.3.2 Selection of Overall Transmission Ratio in the Highest Gear 747 26.4 Dri ver Beha vior 748 26.5 C02 Emissions 749 26.5 1 C02 Emissions and Fuel Consumption 749 26.5.2 The Influence of Engine Use on C02 Emissions 750 26.5.3 The Trend in Global C02 Emissions 750

Tiêu đề	Internal Combustion Engine Handbook Basics, Components, Systems, and Perspectives
Tác giả	Richard Van Basshuysen, Fred Schafer
Trường học	SAE International
Chuyên ngành	Internal Combustion Engines
Thể loại	handbook
Năm xuất bản	2004
Thành phố	Warrendale

Định dạng
Số trang	874
Dung lượng	48,92 MB