Professional Documents
Culture Documents
10
With the new 1.0l Kappa () gasoline engine, which can be found in the face-lifted Hyundai i10 and the
new Kia Picanto, Hyundai-Kia combines a three-cylinder concept with modern technologies such as the
initial application of variable valve timing within this displacement segment. The derivate with switchable
intake manifold delivers 60kW/82PS and achieves a maximum torque of 94Nm. Next to the gasoline engine
a bivalent version for the use of gasoline and liquefied petroleum gas (LPG) is already available; an ethanol
engine is under development.
autHorS central role in the companys efficiency are improved by reducing the
future small cars number of cylinders. Therefore, determin
ing the number of cylinders was crucial
Climate change and the influence of hu for development of the Kappa 1.0l engine.
mans on it are the subjects of world-wide Compared to a four-cylinder engine, a
discussion. The transportation sector, in three-cylinder engine has better perfor
cluding cars, trains, aircraft and ships, is mance and fuel economy, . Nevertheless,
Sunghoon Lee responsible for more than one-fifth of all a NVH (noise vibration harshness) prob
is Leader of Design for Kappa Engine global CO2 emissions. Hyundai-Kia is lem caused by increased unbalanced forces
Family at Hyundai Motor Company
(HMC) in Seoul (Korea).
meeting the challenge to lower emissions remained the weakness of the three-cylin
as required by legislation in all markets. der. However, through optimal design of
Such regulations, as well as rising energy the cranktrain, reinforcement of the engine
prices, lead to an increased interest in structure and optimizing the match with a
compact vehicles. The new 1.0l three- vehicle, NVH can be improved. Contrast
cylinder engine out of the Kappa family is ing with a three-cylinder engine, a two-
part of the Hyundai-Kia sustainable prod cylinder engine generally fitted to a motor
Youngsam Gu uct strategy and combines high achieve cycle cannot meet NVH quality without a
is Member of Design for Kappa ment with fuel efficiency. The selected balance shaft because of excessive un
Engine Family at Hyundai Motor
three-cylinder concept fulfils high acoustic balanced forces caused by reciprocating
Company (HMC) in Seoul (Korea).
requirements due to intensive detail opti mass. If the balance shaft is applied, the
mization. From the beginning of develop vibration of the C1 component will be
ment, the engine was designed with coun decreased. However, fuel economy will
try-specific requirements in mind. The become worse due to power loss. Also,
economic and eco-friendly Kappa engine applying a balance shaft increases cost
family will when flanked by additional and weight. Moreover, larger and longer
Dr. Taechung Kim derivates take over a central role in the intake and exhaust systems are necessary
is Leader of Engine Simulation at companys future small cars. to reduce low-frequency combustion noise,
Hyundai Motor Company (HMC)
the unique noise of a motorcycle. Even
in Seoul (Korea).
with the application of these technologies,
Concept Decision:
there are limits to combustion noise re
Number of Cylinders
duction in a two-cylinder engine. Adding
In the early phase of development, the an alternator, air conditioner compressor
four-cylinder engine was typical in the and a starter motor on a two-cylinder
1.0l class. However, owing to increasing engine body restricts design freedom. In
Dr. Joachim Hahn demands for improved fuel economy, conclusion, considering NVH quality, cost
is Leader of Design and Mechanical three-cylinder engines were launched; the and other factors, the three-cylinder con
Development at Hyundai Motor Europe development of a two-cylinder engine was figuration was determined to best for the
(HMETC) in Rsselsheim (Germany).
even reported. Friction loss and thermal Kappa 1.0l engine.
0 7 - 0 8 I 2 0 1 1 Volume 72 11
coVer story THREE-CyLINDER ENGINES
12
Influence of crankshaft offset on friction fuel efficiency and performance by opti
mizing valve timing. It continuously alters
inlet/outlet valve timing depending on
driving conditions to reduce pumping loss
and increase volumetric efficiency. With
Dual-CVVT technology the Kappa improves
fuel economy by up to 3% and perfor
mance significantly compared to a non-
CVVT engine. Also, it decreases emission
gases such as NOx and HC by the effect of
the internal Exhaust Gas Recirculation
(EGR). Moreover, the internal EGR helps
to achieve cost reduction, because catalyst
jewelry weight is reduced. The Kappa is
developed with Mechanical Lash Adjuster
(MLA) tappet of the direct acting type, ,
for reducing inertial mass of the valve sys
tem and saving costs. The MLA tappet is
coated with Diamond Like Carbon (DLC)
to improve fuel efficiency. DLC coating
overcomes the disadvantage of increasing
Optimized conrod friction due to sliding contact between
camshaft and tappet. In comparison with
Other engines 1.0 l engine nitrification coating, the DLC coating gets
700 0.3% better fuel economy by reducing
valvetrain friction. The friction of the DLC-
600 coated tappet is improved relatively better
at low-engine speed than at high-engine
500
Weight [g]
0 7 - 0 8 I 2 0 1 1 Volume 72 13
Cover Story T hree-cylinder Engines
Combustion chamber shape and layout of cylinder head exhaust manifold. The increased content
of silicium enables the Kappa to resist
oxidation under high-temperature condi
tions and to improve the catalyst durabil
ity. The new engine fulfils the latest Euro
5 standard.
Operation Strategy
Optimization of Engine
and Vehicle Acoustics
14
160
CO2 is reduced by 5% while power is
dline improved as much as in the gasoline vari
Tren
140 ant. The Kappa LPI Bi-Fuel engine is
equipped with both gasoline and LPG
injector. And because of poor conditions
Dry mass [kg]
60
800 1000 1200 1400 1600 1800 2000 2200 2400 Results
Displacement [cm3]
With the application of the latest tech
Dry mass of new 1.0 l engine in comparison to competitor engines nologies, such as Dual CVVT and the
switchable intake manifold (VIS), the new
Kappa 1.0l engine achieves the best-in-
class performance. The same technologies
structure is analyzed and modified by because of the shortage of LPG infrastruc in combination with a carefully detailed
using extensive CAE. Also, to improve ture, demands on the development of optimization particularly in the field of
engine NVH, a high-strength aluminium Bi-Fuel engine which consumes both the engine mechanics allow partial-load
engine block and ladder frame are used. gasoline and LPG fuel are increasing. fuel consumption to represent a new
The circular matching structure allows the To meet these needs, Hyundai-Kia has optimum within the competitor engines
powertrain to be stiffened. Additionally, developed the 1.0l LPI Bi-Fuel version of (=1 and Non-EGR) with a value of only
compact and strong accessory packaging the Kappa. Volumetric efficiency of the 375 g/kWh at 2000/min and 2bar. By
is applied by directly mounting both the Kappa 1.0l Bi-Fuel engine is improved by using various technologies to decrease
alternator and air conditioning compres applying a Liquid Petroleum Injection noise, the Kappa improves NVH quality
sor on engine block. To reduce radiated (LPI) system. This injects LPG into each about 2 to 3dB over competitive engine
noise, the vibration path from piston to cylinder head ports entrance and controls at whole engine running zones. To reduce
ladder frame is optimized and radiation the rate of fuel flow accurately. Therefore, weight, the Kappa uses an aluminium
from radiation surfaces such as head
cover, chain cover and in/exhaust is
reduced.
100 Performance and
shows the analytical results of reduc
-1.0 l engine (3-cyl) torque curve of the new
tion of vibration and radiated noise from
1.0 l engine
a chain cover and a head cover by using -1.0 l engine (4-cyl)
CAE. To reduce rumble noise from the (predecessor)
80
engine partial load operation conditions,
ECU data, such as spark timing, are opti
mally matched. To decrease both whine
and ticking noise of the chain drive a
Pressure Regulation Valve (PRV) is 60
applied to the chain tensioner. Also, cool
Power [PS]
20 80
0 7 - 0 8 I 2 0 1 1 Volume 72 15
Cover Story T hree-cylinder Engines
200
Other vehicles
180
Kia Picanto
CO2 emission [g/km]
160
140
120
100
Gasoline (95 g/km)
Bi-fuel (90 g/km)
80
800 900 1000 1100 1200 1300 1400 1500
Displacement [cm3]
16
Heavy-Duty, On- and
Off-Highway Engines
Concepts for the future www
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