Engine Components and Systems. Series Development and Manufacturing of Innovative Systems and Components for the Automotive Industry

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Series Development and Manufacturing

of Innovative Systems and Components for the Automotive Industry

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The innovative, global development partner and series supplier for the Automotive Industry

Content

The Company

₃

Camphasing Systems by Hydraulik-Ring

3 System Description Vane CAM

_®

4 Application

5 Light-weight construction concept aluminium

6 Light-weight Construction Concept Plastic

6 Improved Friction Moment

7 Minimal Leakage

7 Valves for Camphasing Systems

8 Increase of the Adjusting Speed

8 Types of Valves

9 Fast Phaser System

9 Locking in Predefined Intermediate Position

10 Use of Simulation Technology

10 UniValve

®

_{- Fully Variable Mechanical Valvetrain}

₁₁

Preface

In order to meet the constantly increasing demands for new engine generations as to performance, fuel consumption, emis-sion behaviour engine developers have to resort to variable valve control systems. Hydraulik-Ring develops and manufac-tures camphasing systems since the late 1980ies. Today this experience and many patented innovations put us in a position to tap and develop further potentials in engine technology.

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The innovative, global development partner and series supplier for the Automotive Industry

Camphasing Systems by Hydraulik-Ring

Porsche Variocam F1_®

The first series engine with camphasing is used in Porsche model 968. It was a two-step chain adjustment system with inte-grated chain tensioner which by shifting the chain geometry in the short camshaft drive could reposition the inlet camshaft in relation to the crankshaft.

The Company

Hilite International is an international components supplier for the automotive industry and has locations in the USA, France and Germany. Hilite International has specialised in the development and manufacturing of systems and compo-nents for engine and transmission appli-cations as well as of components in emis-sion systems. Hydraulik unloading valves and solenoid valves represent another range of products in which Hydraulik-Ring has many years of experience. The European Headquarters located in Marktheidenfeld near Würzburg is one of three plants in Germany. Here they de-velop and manufacture mainly hydraulic solenoid valves and system components for emission reduction.

In Nürtingen near Stuttgart Systems for engine and transmission applications are developed and produced in series.

The Seckach plant is located in the Odenwald-Neckar-Kreis and specialised in manufacturing pumps and valves. Be-sides they are specialised in the mecha-nical production of a variety of individual parts. The plant is equipped with the ma-chinery of the latest state of the art and a clean room.

Hydraulik-Ring GmbH offer to their cus-tomers an optimal environment and most modern equipment for their develop-ments, starting with a highly motivated team, the latest CAD- and simulation methods and fully equipped test work-shops covering all development phases from construction of prototypes to engi-ne testing, Hydraulik-Ring can provide all services.

Needless to say, that being an expe-rienced manufacturer of industrial series we have the know how to manufacture also your product/s in series.

Vane CAM

_®

Oscillating motor adjusters are the further development of chain adjusters which up to now have been in series in many VW, Porsche and Audi engines. The main ad-vantages of this system are considerably wider adjustable ranges and the possibi-lity to adjust both the inlet and the outlet camshafts.

Design chain adjuster

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The innovative, global development partner and series supplier for the Automotive Industry

System Description Vane CAM

_®

Nowadays camphasing systems are not only used in high volume spark ignition engines only; they have also become an essential part of small volume spark igni-tion engines.

The camphasing systems developed and made by Hilite/Hydraulik-Ring are well-known under their product designa-tion Vane CAM_® These systems work according to the principle of the oscilla-ting motor and use a rotor attached to the camshaft which effects the twist. The rotor blades on either side can be opera-ted hydraulically and are positioned in a way that allows them to twist. Depending on the twist the angular position of the camshaft varies in relation to the position of the crankshaft.

State of the art are camphasers which depending on the load and r.p.m. of the engine shift the relative angle of the camshaft variably.

The oil supply of the camphasers is ma-naged by the oil pump of the engine which should not use too much energy to control the angular position. Depending on the load and r.p.m. the system does not only control the angles of both cams-haft and crankscams-haft , but also the tem-perature of the engine oil. Camphasers should, whenever possible, also operate during “hot idling”, i.e. they should work at low oil pressure and at low viscosity.

Camphasing system in the AMG V8 6.3l engine

1 Stator 2 Rotor 3 Camshaft 4 Camshaft sensor 5 Integrated Micro filter 6 Integrated return valve 7 Proportional valve 8 Proportional valve in tank

supply line 9 Oil filter

10 Motor oil pump 11 Oil temperature sensor 12 Air flow sensor 13 Throttle valve sensor 14 Coolant sensor 15 Crankshaft sensor 16 Motor control unit

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The innovative, global development partner and series supplier for the Automotive Industry

Application

Camphasing systems made by Hydrau-lik-Ring can be used in any type of en-gine construction, irrespective of the number of cylinders. Any drive concept, be it chain, belt or gearwheel, can be re-alised.

Vane CAM

_®

for V5 und V6 Engines

Vane CAM

_®

for W12 und W16

Vane CAM

_®

for V6 with belt drive

Vane CAM

_®

for V8 with gearwheel drive

Features of Vane CAM

_®

Camphasing

Increase of power and torque Reduction of fuel consumption and emissions

Improved idling performance Possibility to ”return exhaust fu-mes internally” in the overlapping range

Cost-efficient Simple to adapt

Adjustors on the inlet and the outlet side can be operated independently. • • • • • • •

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The innovative, global development partner and series supplier for the Automotive Industry

Light-weight construction concept aluminium

Light-weight Construction Concept Plastic

The use of aluminium allows to reduce the total weight of camphasing systems and particularly of the mass in motion. Particularly for small volume engines the-se are decisive criteria in favour of using such a system. A camphasing system with two steel adjustors and two hy-draulic proportional valves weighs about 2.2 kg. Whereas by using aluminium for the rotor housing, the rotor and the lids of the housing the weight can be reduced by approx. 900 g.

In the six-cylinder-engines of BMW, e.g. we use aluminium camphasers where the stator housing, the chainwheel and the one-piece rotor are made of sintered aluminium.

In order to meet the high demands as to wear, to which especially the chainwheel gearing is exposed, we have developed a sintered aluminium material with a high silica content.

The camphasing system goes without additional sealings between the rotor and the stator housing.

Due to the contact-free sealing and the narrower gap between the rotor and the

housing which can thus be realised, this construction – just like the comparable steel camphaser solution - results in the lowest system friction and subsequently in a spontaneous and quick adjusting of the camphasers.

Aluminium camphaser with aluminium chain wheel.

Additional reductions in the weight of in-dividual parts can be achieved by con-cepts using plastic material.

As you can see from the pictures stator, belt pulley and lid can be combined in one part. First tests made with combus-tion engines showed a positive long term running behaviour.

The weight advantage and at the same time the economic manufacturing of the components will be of great importance for future engine generations.

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The innovative, global development partner and series supplier for the Automotive Industry

Minimal Leakage

Improved Friction Moment

The friction moment rests against the adjuster which is subject to pressure and has to be overcome during the ad-justment. The diagram shows the friction moment of the adjuster solution offered by Hydraulik-Ring with a one-piece rotor construction, a narrow sealing gap and without any additional sealing elements. .

Starting from zero and after overcoming the initial breakaway torque the friction moments of the rotor when twisted in its housing will remain constant.

Due to this extremely low friction moment the solution offered by Hydraulik-Ring guarantees top functionality, even when the oil is hot and the supply pressure is low; this applies also for the r.p.m. range close to idle running.

Low losses resulting from leakage imply also lower requirements in oil at the oil pump. Hydraulik-Ring camphasers pos-sess due to their one-piece construction and their optimised sealing gap very low leakage values. The diagram shows the leakage flow in l/min at an oil temperature of 20°C and at the respective oil pressure at the rotor.

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The innovative, global development partner and series supplier for the Automotive Industry

Valves for Camphasing Systems

Another important compontent in the camphasing system is the proportional valve. It controls the pressurisation of the rotor with pressure oil. In order to clamp the rotor pressurised from both sides im-movably in an intermediate position, the system uses return valves.

As in the cylinder head ther is not always sufficient space for a return valve seat, Hydraulik-Ring has developed a valve into which this function has been integrated. Apart from that they also use valves with fine filters with integrated ring channels.

Electric connection

Min. spool diameter = 25 mm

3 fine filters

Integrated return

valve

Spool sealing

Apart from the above the check valve and the proportional valve are positioned close to the adjustor. This leads to a hig-her adjusting speed at low r.p.m.

The diagram shows the advantage of a check valve integrated in the hydraulic control valve. In the low speed range ad-justing speed can be increased consider-ably. In the range near idling run where the functioning of the camphaser also has to be ensured this advantage brought about by the integration is essential.

At running speeds between n = 1,000 up to 1,250 1/min the adjusting speed can be doubled.

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The innovative, global development partner and series supplier for the Automotive Industry

Types of Valves

Cartridge valve to be screwed in with ring channels

Cartridge valve with ring channels O-Ring sealings, flange mounting and lead connection

Cartridge valve with position-oriented bo-rings, aluminium, flange mounting and lead connection, angular connector

Cartridge valve with flange mounting, ring channels and straight connector

Fast Phaser System

Another new adjusting system of Hydraulik-Ring is the „Fast Phasing“ which allows a faster adjusting, particu-larly in the range of low engine speeds and with hot oil.

This system also uses in a patented so-lution for intelligent oil management the torque of the camshaft from the resulting shares of the valve spring power.

Another advantage of „Fast Phasing“ is the reduced requirement of oil which allows to design and use a smaller oil pump.

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The innovative, global development partner and series supplier for the Automotive Industry

Locking in Predefined Intermediate Position

Use of Simulation Technology

The significance of simulation technolo-gy for camphaser design has increased. Apart from standard durability tests for the design of adjusting components by means of the finite element method mo-dern CFD-applications also allow to map the oil stream within the system three-di-mensionally. To shape the basic design of the adjusting geometry consisting of volumes, flow sections and affected are-as the entire oil circuit of the camphare-asing system as well as the hydraulic on/off val-ve can be dimensioned by using a simu-lation of the hydraulic circuit. This helps to shorten the development time consi-derably. Prototypes close to series and test results can be realised quicker. The locking system of Hydraulik-Ring al-lows to lock the camphasers for the star-ting operation of the engine on the inlet and/or the outlet side in a predefined an-gular position.

Preferably these positions can be the late endposition on the inlet side and the early final angular position on the outlet side. Thus the valve overlap is negative and the starting of the engine becomes easier. For some combustion engines, however, it is desirable to have a locked start of the engine in a predefined intermediate posi-tion of the rotor.

Independent of the angular position ob-tained when shutting off the engine the adjuster is switched to the defined lo-cked position, before ignition. This leads to exactly defined start conditions. The diagram shows an extract from a misuse test during start of the engine.

Before the start the adjuster is in the early position (red line) which it can take at the shut off of the engine. Already in the ramping up phase and before the first ignition the adjuster can be securely locked in an intermediate position as desired and defined by the OEM

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The innovative, global development partner and series supplier for the Automotive Industry

In the UniValve® System the fully va-riable valve train is achieved by two in-termediate rocker levers mounted on a shaft with a roller running on needle- roller bearings. The roller runs in a gate connected with the cylinder head. A shaft links the two intermediate levers so that they form a fork.

They are actuated by the camshaft. The intermediate lever performs a tilting movement around the eccentric shaft. The height of the valve lift is determined by rotating the eccentric shaft in order to displace the tilting point of the intermedi-ate lever.

Draft for UniValve® _{patent application}

Methods of varying valve lifts

4 Cylinder test cylinder head with UniValve®_{system and}

camphasing system

System Features:

Combining camphasing system and UniValve®_means:

Load control for spark ignition engines and Swirl control for diesel engines

Control of NOx exhaust gas emissions Improvement of fuel

consumption

Modular valve control concept

Increase of driving dynamics. • • • • • •

Test setup 4-cylinder engine

UniValve

®

_{- Fully Variable Mechanical Valvetrain}

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www.hilite.com - www.hydraulik-ring.de - info@hydraulik-ring.de

Engine Applications

Transmission

Applications

Components for

Emission Systems

Valves

Europazentrale Plant Marktheidenfeld: Am Schlossfeld 5 97828 Marktheidenfeld Tel.: +49 (0) 9391 911- 01 Fax: +49 (0) 9391 911- 121 Plant Nürtingen: Weberstr. 17 72622 Nürtingen Tel.: +49 (0) 7022 9226 - 0 Fax: +49 (0) 7022 9226 - 298 Plant Seckach: In der Au 10 74743 Seckach Tel.: +49 (0) 6292 709-0 Fax: +49 (0) 6292 709-50

Sales Office in USA: 2701 Cambridge Court Suite 218

Auburn Hills, Mi. 48326 Tel.: 248.475 - 4580 Fax: 248.475 - 4581