Elektrohydraulische Ventilsteuerung EHVS Electro-hydraulic Valvetrain System EHVS FPNI Forum 2004, Bad Ischl

02.03.2004 | FPNI 2004.ppt Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution? 2. How does the EHVS work? 3. What components are used? 4. What results can be measured at the test bench? 5. Next steps?
02.03.2004 | FPNI 2004.ppt Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Expected Advantages for Gasoline Engines Fuel consumption/Efficiency

Minimization of gas exchange losses (dethrottling, with manifold injection) valve cutoff, cylinder cutoff, multi stroke operation Reduce of idle speed (more stable due to less residual gas)

Torque curve/Power

Operating-point-dependent optimization of valve timing and stroke

Operating-point-dependent variation of the charge motion Variable internal exhaust gas recirculation (EGR)

Exhaust gas

more efficient engine brake new starting strategies less assembly groups reduced size of the engine

Additional functions

02.03.2004 | FPNI 2004.ppt

103 408 144 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Requirements to a fully variable Valvetrain

The simultaneous and uncoupled optimization of the fuel consumption and the emissions requires the independent control of fresh mixture, residual gas and charge motion. For this the opening and closing angle and the stroke of the individual gas exchange valves are to be controlled cycle to cycle conform. The systems fail safety, especially the fail safe position gas exchange valve closed, is to be considered in the systems design. In order to achieve a low-cost serial production with a high number of pieces there is to be aimed a use of the control principle as well as the partial components with all known engine types and combustion concepts. All material, partial components and production processes necessary for the systems assembly are to be selected in compliance with the criterions availability and process safety. The different engine types which are all to be covered with the same principle require a broadly applicable range relating to the parameters force, stroke and valve velocity.
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02.03.2004 | FPNI 2004.ppt

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Electro-hydraulic Valvetrain System EHVS Titel des Kapitels Specification

parameters combination: high force (>1000N), velocity (2,5ms/10mm), stroke (>10mm) valve velocity and braking behavior adapted to operating point valve free travel is not always to be assumed cylinder head with actuators, checkable as module afterwards installation of the whole module on the engine block exchange of individual actuators installed on the mounted cylinder head temperatures between -40C ... 140C

02.03.2004 | FPNI 2004.ppt Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Technology Decision

gas exchange

flat seat valve

flat rotary valve

cylinder rotary valve

ball valve

systems with cam

camless valve train

pendulum systems

linear systems

electromagnetic

electrohydraulic

electromagnetic

electrohydraulic

pneumatic

electromotive

magneto -strictive

piezoelectric

single acting plunger, counter spring

double acting plunger (identical surface)

differentialplunger

one 3/3 solenoid valve

two 2/2 solenoid valves

servo solenoid valve

02.03.2004 | FPNI 2004.ppt

103 448 149 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution? 2. How does the EHVS work? 3. What components are used? 4. What results can be measured at the test bench? 5. Next steps?
02.03.2004 | FPNI 2004.ppt Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Operating Principle of the Differential Piston Gas exchange valves stroke depending on the control MV1/MV2
Stroke
MV 1 MV 2

opening

hold

closing Valve brake

Gas exchange valve closed

Time

MV 1

open

Gas exchange valve

closed open

Time

MV 2

Control for big stroke of gas exchange valve Control for small stroke of gas exchange valve

closed

IO

IC

Time

02.03.2004 | FPNI 2004.ppt

103 449 149 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Hydraulic Principle of Actuator V0.7

Actuator SD-Rail RB

Every actuator includes:

2/2 solenoid valve currentless closed at high-pressure side 2/2 solenoid valve currentless opened at low-pressure side Throttle for valve brake adjustable via pilot pressure (-> variable valve brake) two-stage differential piston drive hydraulic length compensation

DRV

MV1

MV2

ND-Rail

HD-Rail HDV GWV

Every actuator can be:

assembled or disassembled individually at the engine completely connected hydraulically via the bearing surface

HD rail ........ High pressure supply (50 - 200bar) ND rail ........ Low pressure supply (<5bar) SP rail ......... Pilot pressure supply (5 - 20bar) MV1/MV2 ... Solenoid valves
02.03.2004 | FPNI 2004.ppt

HPV ......... High pressure pump for valvetrain system DRV ......... Pressure control valve for pilot pressure RB ........... adjustable valve brake GWV......... Gas exchange valve

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Electro-hydraulic Valvetrain System EHVS Measured Valve Lift Curves for Actuator V0.7
mm 11.0

Variation of brake
Pressure: Oil temp.: 100 bar 82 C

10.5 10.0 9.5 9.0 8.5 8.0 7.5 7.0 6.5 6.0

Measured velocities: v_maxopening: 3,0 m/s v_maxclosing: 3,2 m/s vbrake: 0,05 .. 0,5 m/s
(inlet valve)

5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 -0.5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ms

02.03.2004 | FPNI 2004.ppt

103 617 350 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Measured Valve Lift Curves for Actuator V0.7
mm 12

Cycle/cycle jitter
Pressure: 200 bar Oil temp.: 86 C Number of cycles: 50
Measured velocities: v_maxopening: 4,5 m/s v_maxclosing: 5,2 m/s vbrake: 0,55 m/s
(inlet valve)

11 10 9 8 7 6 5 4 3 2 1 0 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ms

02.03.2004 | FPNI 2004.ppt

103 618 350 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution? 2. How does the EHVS work? 3. What components are used? 4. What results can be measured at the test bench? 5. Next steps?
02.03.2004 | FPNI 2004.ppt Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Description of the System (4V Combustion Engine)
pressure and temperature sensor pressure relief valve EHVS- actuator

cylinder head with hydraulic adapter modul, thermodynamic modul

Signals for :
rpm pedal position temperatures crankshaft position

oil filter (inflow of engines oil circle)

viskosity sensor high pressure pump

high pressure oil pressure of engine reflow leakage

02.03.2004 | FPNI 2004.ppt

103 600 341 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS EHVS-Actuators, different types

V0.5 (Diesel Engine) V0.4 (Gasoline Engine)

02.03.2004 | FPNI 2004.ppt

V0.7 (Gasoline Engine)

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Electro-hydraulic Valvetrain System EHVS EHVS-Actuators, different types

V 0.4
Features
- Covers the complete gasoline engine operating range - actuator can be assembled independently on engine - valve brake - Stand alone test of the cylinder head possible

V 0.5
- Covers the complete diesel engine operating range - actuator can be assembled independently on engine - valve brake - Stand alone test of the cylinder head possible - high forces during complete stroke

V 0.7
- Covers the complete gasoline engine operating range - actuator can be assembled independently on engine - variable valve brake (pilot pressure controled) - Stand alone test of the cylinder head possible - two-stage differential piston drive - hydraulic length compensation - uses common engine valves

Size (LxW xH) Moved mass Max. (usable) stroke Opening force (200bar) Closing force (200bar) Max. Opening speed (200bar) Max. Closing speed (200bar)
02.03.2004 | FPNI 2004.ppt

98 x 38 x 83 mm 76 g 10 (8) mm EV: 835 N; IV: 400 N EV: 475 N; IV: 480 N

99 x 38 x 87 mm 103 g 10 (8) mm

86 x 36 x 83 mm 75 g 12 (10) mm EV: 1690 N; IV: 840 N EV: 450 N; IV: 450 N EV: 4,4 m/s; IV: 4,5 m/s V0.7 (Gasoline Engine) EV: 5,0 m/s; IV: 5,2 m/s

V0.5 (Diesel765 N; IV: 960 N EV: Engine)

EV: 1360 N; IV: 670 N

EV: Engine V0.4 (Gasoline 4,8 m/s; IV:)4,8 m/s EV: 2,4 m/s; IV: 4,2 m/s

EV: 4,0 m/s; IV: 3,8 m/s EV: 2,2 m/s; IV: 3,8 m/s

103 628 441 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Header of section 4 Cylinder Head

Cylinder head with: - EHVS actuator - Adapter module

02.03.2004 | FPNI 2004.ppt

103 596 349 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Solenoid Valves

MV2
currentless opened delay opening delay closing opening cross-section pressure compensation: flow compensation 320s 380s 3mm inlet

MV1
currentless closed delay opening delay closing opening cross-section pressure compensation: flow compensation
02.03.2004 | FPNI 2004.ppt

280s 330s 3,4mm inlet/outlet

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Electro-hydraulic Valvetrain System EHVS Hydraulic Pump Unit (next generation)

HPV5
Axial piston pump Output Max. rpm Pressure range 5 pistons 5 cm/rev. 6000 1/min 20-250 bar

02.03.2004 | FPNI 2004.ppt

103 595 349 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution? 2. How does the EHVS work? 3. What components are used? 4. What results can be measured at the test bench? 5. Next steps?
02.03.2004 | FPNI 2004.ppt Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Test Engine

Test engine:
Combustion engine
4 cyl.,16 valves

= 11
= 120 kW = 200Nm = 11

Peff Md,max MPFI

Euro-Super ROZ 95
3-way-catalyst EU IV, SULEV certificated 16 valves with EHVS Hydraulic pump integrated Hydraulic oil: engine oil 0W40

02.03.2004 | FPNI 2004.ppt

103 601 348 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Fuel Consumption (Dyno Results)

Messungen in Kooperation mit

Fuel Economy Improvement [%]

8 7

180 km/h

BMEP [bar]

6 5 4 3 2 1 0 1000 15 15 20 30 2000 25 35 3000 4000 15 10 10

5 5

160 km/h NEDC

35 30 25 20 15 10 5 0

Customer Relevant Reduction of Fuel Consumption

EHVS 16-Valve

3 to 17 % Idle 0.31 kg/h

EHVS cylinder deactivation

3 to 35 % NEDC average 17%

5000 6000
Measurments with: Actuator V0.4 Pump HPV7

Engine Speed [rpm]

02.03.2004 | FPNI 2004.ppt copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Dyno results at 2000rpm

EHVS V0.4, HPV7, Full Engine at
500 460 420 380 340 300 260 220 0 2 4 4 6 8 8 10 10 12 12

2000 rpm

Messungen in Kooperation mit

Base Engine EHVS 16V EHVS Cyl. cut off

EHVS = 1, BSFC Status 09/03:

Fuel Reduction
Low Load: - 35% to - 12%
4 Cyl. 2000 rpm / 2 bar: 332 g/kWh Cut off 2000 rpm / 2 bar: 305 g/kWh

BSFC [g/kWh]

High Load: - 12% to - 8%

2000 rpm / 7 - 10 bar: 241 g/kWh

Increase of max. Load:

Base Engine: EHVS Engine: 10,3 bar 11,4 bar

BMEP [bar]
02.03.2004 | FPNI 2004.ppt copying and passing on to third parties.

Measurments with:

Actuator V0.4 Pump HPV7

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as

BMEP [bar]

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Electro-hydraulic Valvetrain System EHVS FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution? 2. How does the EHVS work? 3. What components are used? 4. What results can be measured at the test bench? 5. Next steps?
02.03.2004 | FPNI 2004.ppt Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS Hydraulic circuit

Difference EKS / ZKS

Present system EKS - one circuit system engine oil / EHVS hydraulic
open hydraulic system common with engine oil
High pressure pump

= psurrounding

Engine oil pump

Next system ZKS - two circuit system

closed EHVS hydraulic system separate fluid
in small portions mixable fluids
High pressure pump Feed pump
plow

Engine oil pump

02.03.2004 | FPNI 2004.ppt Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties.

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