We develop system components for diesel and gaseous-fuel engines. In optimizing commercial-vehicle engines, the main focus is on meeting emission limits while maximizing system efficiency. Thermal management also plays a key part in balancing the overall system, including exhaust gas aftertreatment. We have the expertise and the technical facilities to define the best possible overall configuration for a particular engine and application by optimizing supercharger group, charge motion, injection system, combustion chamber geometry and calibration.
Engine mechanics and combustion process
Computational analysis, component layout and simulation of strength / stiffness, kinematics / kinetics, dynamics, material behavior, acoustics, gas exchange, process analysis, cooling system, intake system, mixture formation and exhaust system are firmly established as integral components in the engine development process at IAV.
Our activities in developing engine mechanics focus on optimizing structures, saving weight and reducing friction between engine components. Today, the development trends in heavy-duty engines are downsizing and downspeeding and hence higher cylinder peak pressures. Here, we offer our clients design solutions.
Our development process is backed up by a closely interconnected tool chain. In particular, we use special tools for designing combustion chamber geometry. In addition to accompanying simulations involving varying levels of detail and statistical approaches, we also use component test rigs (injection test rig, pressure chamber, turbocharger test rig etc.) and our MPEC open prototype control unit developed specifically for these requirements. This gives us flexibility in responding to development demands and allows us to initiate iteration steps very quickly. Apart from open-loop and closed-loop control algorithms, this also provides the capability of integrating sensors (e.g. charge sensing) and actuators (e.g. injectors, EGR controllers) of any type into the function architecture and of validating them on single-cylinder or full engines.
Injection system and supercharging
At IAV, the injection system is an integral part of developing combustion processes since it has a major influence on emissions, fuel consumption and engine noise. Alongside functionality, our focus is on injection nozzle design (number, orientation and shape of holes) as well as on defining spray distribution by shaping the main injection event and multiple injection events. Fuel quality and composition are also taken into account. Besides advancing conventional diesel combustion, we also optimize combustion processes for alternative fuels (CNG, LPG etc.) and drive systems (e.g. hybrid) to the point of manufacturing readiness.
In addition to the fuel side, the air path is the second system to define the combustion process. We meet the growing demands in this domain with facilities, such as a cutting-edge turbocharger test bench and high-resolution 3D measurements of the velocity field in the combustion chamber (DGV). All tests are brought together on the basis of analytical approaches and closely meshed with our design and prototyping departments.