The optimization of combustion processes for commercial vehicle engines focuses on meeting emission standards while ensuring maximum system efficiency. Thermal management has also a significant part in balancing the overall system, including exhaust-gas aftertreatment. We have the expertise and up-to-date technical facilities to provide the best possible configuration for the engine and its particular field of application by optimizing supercharging assembly, charge motion, injection system and combustion-chamber geometry.
Coordinated Tool Chain
The development process is backed up by a closely interconnected tool chain. The combustion chamber geometry in particular is designed using special tools. In addition to accompanying simulations with varying levels of complexity and with statistical approaches, we also use component test rigs (injection test rig, optical pressure chamber, turbocharger test stand etc.) and our MPEC open prototype control unit that has been developed specifically for these requirements. This gives us flexibility in responding to demands and allows us to initiate iteration steps very quickly. Apart from open and closed-loop control algorithms, this also provides the capability of integrating sensors (e.g. charge sensing) and actuators (e.g. injectors, EGR actuator) of any type into the function environment and validating them on single-cylinder and full engines.
At IAV, the injection system is an integral part of developing combustion processes since it plays a key part in influencing emissions, fuel consumption and NVH. Alongside functionality, our focus is on injection-nozzle design (number, orientation and shape of holes) as well as on defining spray distribution by shaping main injection and multiple-injection events. Fuel quality and composition is also taken into account. Besides advancing the conventional diesel process, we also optimize combustion processes for alternative energy sources (CNG, LPG etc.) and applications (e.g. hybrid) to mass-production level.
In addition to the fuel side, the air path is a process-defining system. We meet the latest air-path requirements with facilities, such as a cutting-edge turbocharger test stand, and high-resolution 3D measurements of the velocity field in the combustion chamber (DGV). All individual tests are brought together on the basis of analytical approaches and are closely meshed with our design departments and prototype shop.
Our range of expertise:
- Combustion process concepts (conventional and alternative applications and energy sources)
- New combustion processes (e.g. PCCI)
- Combustion processes for alternative energy sources (CNG, LPG etc.)
- Components and combustion chamber design
- System analysis and simulation at all levels of complexity
- Algorithm development in rapid-prototyping environments
- Analysis of new sensors / actuators in existing systems including their actual functions
- Optimization of supercharging systems and gas exchange analysis
- Measurement, analysis and optimization of injection systems and components
- Development, design and production of prototype injection systems
- Design and set-up of prototypes of engine components and full engines
- Simulation tools (GT Suite, StarCD, OpenFoam, etc.)
- Flow rigs (DGV)
- Prototype control units
- HiL test rigs
- Turbocharger test stand
- Hydraulics rigs
- Optical pressure chambers for injection system characterization
- Single-cylinder test benches
- Fully transient engine dynamometers