IAV Engine Design and Development

> Hardware Design > Calculation & Simulation > Engine Testing > IAV Processes > IAV Innovative Concepts

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Contents

Design 4

Calculation/Simulation 5
Engine Testing – Mechanical Development 6

IAV Engineering Processes 7

Innovative Concepts 8

Our Services 9

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3
Design

Crankcase/Oil Circulation

u Structure and base concept

u Liner-design
u Ventilation/aerating
u Oil pump development
u Detail design

Cylinder Head

u Cooling optimization
u Combustion chamber
u Charge-exchange ports
u Mounting/lubrication
u Integration valve train
u Oil drain/aerating
u Design of versions

Engine Mechanics

u Crankshaft, piston, conrod and bearing

u Cranktrain concepts
u Timing train
u Valve train, variable valve train
u Balance shaft system

Charge Exchange

u Charge exchange dimensioning

u Intake system/exhaust system
u Supercharging
 Calculation/Simulation

Structural Mechanics

u Strength/stiffness
u Material
u System analysis
u Thermo mechanics
u Optimization

Dynamics/Acoustics

u Vibrations
u Sound radiation
u Sound design
u Engine mounting
u Optimization

Fluid Mechanics 1D

u Charge-cycle
u Thermo dynamics
u Engine systems
u Supercharging
u Optimization

Fluid Mechanics 3D

u Intake system/exhaust system

u Cooling system
u Components
u Combustion system
u Optimization

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Engine Testing –
Mechanical Development

Mechanics

u Power loss
u Crank train
u Timing train
u Valve train

Lubrication/Cooling

u Cooling system
u Oil circuit
u Aeration
u Lubricant

Vibration/Acoustics

u Airborne-sound emission
u Sound-source-detection
u Structure borne sound transmission
u Psycho acoustics

Strength/Production Support

u Component strength
u Component deformation
u Durability test
u Wear analysis
 IAV Engineering Processes

Virtual Powertrain

u Methodology development
Digital Mock-Up
u Data strategy management
u Data integration into customer processes
u Process support/consulting

IAV Dimensioning Tools for Design,

Computation and Testing

u Engine mechanics (VENTIL, V.-ENGINE, ...)

u Dimensioning workflows
u Optimization, calculation of variants
u Uniform analysis of calculation results
and test results

IAV-Knowledge Data Base

u Knowledge network (vehicle, engine, gear ...)

u Knowledge based engineering for
Design, Computation and Testing
u Benchmark of engine parameters
u Hybrid module
u Bench mark of competition engines
u Approx. 3000 engines, 600 gears
(as of March 2007)

Frontloading-Methods

u Development systematics
u 3D-Tolerance simulation/costs
u Casting simulation in early stage
u Fitting simulation und assembly simulation

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Innovative Concepts

IAV-Variable Stroke System

and Variable Compression

Oil Supply On Demand With

the IAV Controlled Vane-Type Oil Pump

VVL-System
IAV-VARIOVALVE® and
Switchable Valve Train Systems

Modular Single Cylinder

Engines for Special Investigations
(Combustion, Fuel Injection ...)
Our Services

Development of new engines, Cylinder head

engine derivates or:

Valve train design and Port layout and design Crankshaft layout, design and
optimization (cam optimization optimization using IAV-tools and
and layout optimization, 3D CFD port optimization a proven development method
changeover bucket tappet to including FEM, fatigue and
roller finger follower) Port measurement and component testing
port benchmarking utilizing
Mass balance system IAV’s DGV measurement Plane bearing layout and
development with focus on method optimization using IAV-tools
system development (function, (HD) and EHD-calculations
mass, stiffness), manufacturing Water jacket and cooling
design and optimization Conrod design and optimization
System development pressure-
oil circuit/oil returns/aerating Integration of valve train Piston optimization
(oil pump layout and oil pump and oil system
development, dynamical oil Timing train layout and opti-
level und gas concentration, oil Layout and design of oil mization (chain drive, gear drive)
throwing, disposition to drain, ventilation and utilizing IAV-tools and other
freezing-up) separation calculation software packages
for dynamic simulation
New design and optimization Entire cylinder head design
of highly stressed cylinder and structural optimization Valve train layout and opti-
head (Otto, Diesel) - considering manufacturing mization (all types) utilizing
thermomechanics, cooling, demands IAV-tools and other
port development calculation software packages
Layout and optimization of for dynamic simulation,
New design and optimization of head-block compound measurements an test rig
cylinder crank cases (Al, GCI) considering thermo-
mechanical fatigue and Balance shaft system layout
System development engine gasket behavior and optimization
cooling (water pump, water
guidance, thermo-management)

Optimization of auxiliary posi-

tion and auxiliary function
(incl. startergenerator/belt
startergenerator concepts)

New design or optimization of

intake and exhaust manifolds
(with TC-Integration)

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Our Services

Engine systems Cylinder block IAV Software packages for

engine development

Charging system layout Structural layout and design IAV Engine and Hybrid
and optimization considering material demands and database
(1D; 3D) manufacturing demands
IAV VENTIL for valve train
Transient in-cylinder flow Liner design and optimization layout and optimization
investigation including spray of liner distortion (FEM and
analysis, FIE simulation measurement) IAV P-CRANK for crankshaft
and measurements on test layout and optimization
rig, combustion simulation Bulkhead optimization utilizing
(diesel/gasoline) FEM and hydro pulse testing IAV V-CD for chain drive
layout and optimization
Turbo charger system Ventilation optimization
integration, component IAV V.-ENGINE for holistic
development (calculation, layout and optimization
testing on hot gas test stand) of engine mechanics

Engine cooling system and Special features IAV V-SiTE for evaluation of
water pump layout and simulation and test results
optimization (1D/3D calculation IAV’s variable valve trains for
and testing) advanced combustion control, IAV EngineeringToolbox for
exhaust brake etc. integrated engine layout
High pressure oil system workflow and optimization
development, oil pump IAV’s map controlled variable technology
development incl. simulation oil pump system
and component tests for state-
of-the-art pumps and variable IAV’s variable compression
displacement pumps and variable displacement
concept
Engine ventilation, oil drain
and oil separation development IAV’s modular single cylinder
(calculation and testing) research engine

Engine freezing behavior

(testing)

Auxiliary drive layout

and tuning
Subject to change without notice. Effective: D 09/2008
IAV GmbH · Carnotstraße 1 · 10587 BERLIN · GERMANY · Phone +49 30 39978-0 · Fax +49 30 39978-9790 · · www.iav.com

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