FEV is an internationally recognized leader The company supplies some of the world’s in the design and development of internal most advanced engine testing systems ranging combustion engines and supplier of advanced from combustion analysis to fully automated test and instrumentation systems. Founded in test benches. 1978, the company today employs a staff of over 1300 highly skilled research and develop- FEV enjoys a close working relationship with ment specialists. FEV offers a complete range automotive, heavy-duty and industrial engine of engineering services, providing global sup- manufacturers, worldwide, as well as with port to customers in the design, prototyping their supply base. In addition, FEV supports and development of advanced gasoline, diesel the mineral oil industry, heating system ma- and alternative propulsion systems, e.g. fuel nufacturers and conducts advanced research cells. In addition, FEV provides engine integra- and development programs for governmental tion and vehicle calibration services. agencies.

We offer new technologies, which address World Headquarters and the European Tech- future emissions and fuel economy standards nical Center are located in Aachen, Germany. while fulfilling market demands for engine per- FEV’s North American Technical Center is formance and acoustics. In performing these located in suburban Detroit, Michigan. services, FEV meets customer requirements for shorter development schedules, high quality and reduced costs.  Full range engineering service supplier for gasoline and diesel engines as well as advanced powertrains  Large database of over 200 modern engines (benchmarking programs)  Supplier of advanced test facilities including end-of-line test benches  Close working relationship with germany‘s largest technical university FEV designers have access to more than 90 To support a quick and cost effective deve- fully equipped design workstations using all lopment process, most engine designs today important CAD systems on several platforms. conducted as 3D CAD designs. This enables In today‘s marketplace, innovative designs can provides the requested geometry models for be implemented only if they can be manufactu- different analysis tasks, e.g. structural analysis red efficiently and at reasonable cost. or CFD calculations, plus enables to deliver 3D geometry information to pattern makers early As a consequence, FEV evaluates manufactura- in a development project. Accordingly, modern bility issues as well as the potential for reuse of analysis and rapid prototyping tools are fully high investment cost tooling. These studies are integrated into the design process at FEV. part of the design and development process. To guide and confirm the concept and design work, FEV applies many years of proven pro- ject management and quality control process experience. Especially for large bore Diesel en- gines, the design for six sigma process (DFSS) has been applied successfully in the past. The design teams are working worldwide in close cooperation with the suppliers of com- ponents and they are also responsible for the procurement of prototype components.

In order to provide our customers with excel- lent development support, FEV has developed a new large bore single cylinder test engine, which is used for the investigation of advanced combustion system technology, as well as me- chanical development of engine components. Today‘s product engineering and development Early in the development of a new structure, market demands rapid analysis, advanced Finite Element Analysis (FEA) provides a means development capabilities and extremely high of optimizing the design with regard to thermal levels of precision. and mechanical loading, deformation, weight and material choice. FEV works to ensure Model-based structural analysis has become results by combining the designers‘ geomet- the standard approach in an industry where rical input with information about the proper development time has become a driving factor. boundary conditions that are provided by FEV‘s Where many structural features were traditio- process simulation teams. In addition, FEV nally verified through empirical testing, today‘s maintains an extensive database of engine and analysts routinely apply state-of-the-art analyti- component test data, which can be applied to cal tools in their work. ensure the accuracy of the predictions. FEA is used extensively in the thermal and me- FEV uses a variety of engineering software chanical analysis of the cylinder head, liner and packages that have been widely adopted by the crankcase. For the layout and dynamic calcu- automotive and related industries. Every effort lation of connecting rods, pistons, crankshafts is made to perform analyses for our customers and bearings, the use of advanced simulation to their own specifications. tools like MBS in combination with EHD today is inevitable. FEV is continually investing in its infrastructure to ensure that state-of-the-art computing plat- Design calculations within FEV‘s technical forms are available for performing advanced community are enhanced by extensive practical analysis and engineering work. experience with a large number of different types of engines.

Realistic FE calculation results require detailed consideration of the non-linear behavior of en- gineering materials as well as the temperature dependencies. Within the comprehensive gear and valvetrain development procedure, cinematic calculations as well as dynamic simulations provide the ne- cessary information about the load and stress levels. Finite element techniques, commercial multi-body simulation tools and FEV-owned calculation routines support the different deve- lopment tasks.

The layout and design of the fluid systems The real geometry of each fluid system and the requires quick and powerful simulation tools to hydraulic and thermal characteristics of the support the design of new engines right from relevant components are reflected by predefi- the start of the development. ned functions or based on measurements by polynomal expressions. Complex one-dimensional simulation models also allow the investigation of various virtual concepts and assist in the decision to develop the most promising concept. FEV‘s NVH department is structured into func- Proven methodologies and development tional teams, corresponding to the variety of targets are agreed upon before launching a noise and vibration problems, e.g. engine noise project; as the project proceeds, modeling and dynamic structural analysis. techniques and parameters are discussed in advance with the client‘s design and develop- FEV‘s CAE-based dynamic analysis of the exci- ment teams. tation mechanism and structural behavior has been developed during more than 10 years of FEV can ensure practical and reliable design experience on more than 100 different engines improvements as program deliverables, which and powertrains. Close cooperation in aggres- directly address the project goals. sive joint development programs with various manufacturers and suppliers has resulted in the evolution of specialized techniques for pro- blem solving and rapid evaluation of potential solutions. The best NVH designs are achieved when joint cooperation is ensured at a very detailed level during the earliest phases of the propulsion system development process. By designing for best-in-class NVH from the beginning, FEV helps customers avoid modifications once the design is near production.

For more than a decade, FEV‘s Engine Ther- FEV routinely conducts analyses in support of modynamics department has supported its the effort for layout of base engine geometry. clientele with a team of skilled engineers, each Once all of the possible factors influencing dedicated to serving the individual needs of our the outcome of a design effort have been diverse client base. assessed, the potential advantages and disa- dvantages concerning fuel consumption, per- In the Concept Phase, the major technical formance, complexity and transient behavior features of the final product are defined. In this are quantified and a reliable technical basis for phase, FEV‘s Engine Thermodynamics depart- a decision, in keeping with market trends, is ment supports its clients by assessing the presented to the customer. potential benefits of multiple boosting concepts and carefully analyzing market trends to predict In the Design Phase, FEV‘s Engine Thermody- the viability of a new design or product. Alter- namics department provides a detailed layout native engine concepts can also be demonst- of the complete intake and exhaust systems of rated. Any charging system can be intensively the engine. This layout can include numerous examined from state-of-the-art turbocharging efforts: Advanced boosting systems with super to controlled two-stage turbocharging or com- and turbochargers are matched with GT Power bined turbocharging systems. or CATS. The optimization of the gas exchange process and valve timing are carried out in accordance with the specifications of the client. Problems, for which a one-dimensional simula- tion is insufficient, are solved by an integrated calculation that uses the 3D code, Star CD and GT Power. Any complex gas flow within an engine can Using indicated pressure traces and approp- be simulated by CFD. Optimization of coolant riate mean values, a very detailed calculation water jackets simulations are conducted with model is adjusted to match expected prototype 3D simulations of the coolant water flow. This behavior. Afterwards, the gas exchange pro- analysis is closely coupled with FEV‘s FEM ana- cess and charging system is fine-tuned to the lysis. To support swirl and flow optimization on customer‘s expectation. Detailed analyses of the flow test bench, the intake port and the in- existing engines are carried out to detect weak cylinder flow are calculated with 3D code, Star points and to show further areas of potential CD. This transient flow field is the basis for improvement. subsequent investigations of spray penetration, mixture formation, ignition and combustion. All The combustion process is analyzed in detail the layout work is simultaneously engineered with regard to heat release rate, thermal losses in close cooperation with either FEV‘s or the and nitrous oxide formation. clients Design, NVH and Mechanical Develop- ment departments.

In the Experimental Development Phase, FEV‘s Engine Thermodynamics department provides its clients with detailed thermal analyses and fine-tuning of gas exchange systems. FEV has been involved in the development FEV also provides special services, such as of Diesel combustion systems for more than engine certification and emission deterioration 20 years. In the past, the main focus was the measurements. improvement of performance and fuel efficien- cy. Whereas today, the effort is concentrated Starting with the first sketch for a new com- on the reduction of exhaust emissions while bustion system layout, FEV engineers are maintaining or even improving specific power focusing on optimum bowl design and fuel output and fuel efficiency. injection system characteristics, to achieve little spray-wall-interaction for low soot emis- A central task of the Diesel combustion deve- sion and a fast, but well balanced burn rate. lopment is the investigation of new injection Since NOx reduction is a major requirement for strategies, such as pilot, split, and multi-event- the improvement of Diesel exhaust emissions, injection, which requires modern, highly flexib- water injection and water emulsified fuels have le injection systems. always received attention from engine devel- opers. Today, FEV can offer its clients a com- The test cell investigations on the fired engine prehensive knowledge of technical solutions are supported by intensive analyses utilizing for using water injection/water emulsified fuels simulation tools for combustion process inter- and provide feasible solutions for the specific pretation, such as burning function and heat requirements and problems of water emulsion. release calculation as well as fuel spray penet- ration computations. FEV, by tradition, has always been involved in Large bore Diesel engines for stationary, lo- the development of gas engine combustion comotive and marine propulsion systems will systems. Due to their excellent exhaust emis- soon need to comply with the same reduced sion quality, these engines have achieved a exhaust emission standards that high-speed high degree of acceptance for stationary power truck and industrial Diesel engines have to systems and for city bus applications. meet today. In order to provide our customers with excellent development support, FEV has Based on long-term research and development developed a new large bore single cylinder programs and with the expert knowledge of test engine, which is used for the investigation numerous gas engine development projects, of advanced combustion system technology, FEV offers high level support for all gas en- providing both excellent fuel efficiency as well gine related development tasks. Apart from as reduced exhaust gas emission targeting the prechamber combustion, a system called ATAC emission standards of 2008 and beyond. (Advanced Turbulence Assisted Combustion) has been developed, which provides the poten- tial to achieve full load performance similar to Diesel engines and combined with extremely low exhaust emission levels. FEV Motorentechnik GmbH FEV Engine Technology, Inc. Neuenhofstraße 181 4554 Glenmeade Lane 52078 Aachen ∙ Germany Auburn Hills, MI 48326-1766 ∙ USA Telefon +49 (0) 241/ 56 89 - 0 Phone +1 (0) 248 / 373- 60 00 Fax +49 (0) 241/ 56 89 -119 Fax +1 (0) 248 / 373- 80 84 E-Mail [email protected] E-Mail [email protected] Internet http://www.fev.com Internet ttp://www.fev-et.com