Optimization of the combustion engine reduces CO2 emissions by up to six percent

Two approaches for the basic engine are optimizing friction and preventing oil from entering the combustion chamber. CO2 emissions can be reduced by up to six percent (WLTC) with MAHLE technologies for optimized mechanics and lubrication in gasoline engines. These measures also demonstrate a sustainable impact on emissions and consumption in actual driving operation. MAHLE will showcase specific solutions for the optimization of the combustion engine at IAA Cars 2017 from September 14 to 24, 2017 in Frankfurt/Germany.

◾Less CO2, lower emissions—the optimization of the combustion engine benefits footprint and actual operation
◾Sustainable impact: improved economic efficiency and carbon footprint thanks to lower particulate emissions

The combustion engine has already developed into a highly efficient and clean drive, especially in the past few years. As a result of this development, the complete system, comprising the powertrain and its peripherals, has become substantially more complex. Therefore, in order to achieve greater efficiency and lower emissions in this system, more and more interactions and relationships need to be taken into account. In many cases, inherently contradictory problems have to be overcome. Thanks to its comprehensive systems expertise, MAHLE has developed technologies that sustainably reduce consumption and emissions.

Reducing friction—less CO2 in every driving situation

Like waste heat, friction adversely impacts the performance of combustion engines. A decrease in friction has a noticeable effect at every operating point and in every driving situation, i.e., a drop

in fuel consumption. The heart of the engine, the power cell unit (PCU) from MAHLE consisting of piston, piston rings, and piston pin, achieves a direct decrease in friction thanks to optimized clearance design, low-friction surfaces, and a decrease in friction contact surfaces. An increase in specific output with no change to the basic geometric dimensions leads to an improvement in specific frictional loss. However, this requires the PCU components to have a more robust design. The latter consideration conflicts directly with the requirement for low component weight, which also contributes to efficiency. A key element of piston development is therefore topography analysis, which is used to determine at which points less material can be used without jeopardizing robustness. With the direct friction reduction in the PCU, MAHLE can reduce CO2 emissions by up to 2.5 percent (WLTC). At the same time, MAHLE has designed the new engine components to allow the use of low-viscosity oils and reduce the load on the oil circuit as the pistons require less cooling oil. As a result, the oil pump can be controlled on demand at every operating point. This saves additional fuel, particularly under real operating conditions. Overall, this results in up to six percent less CO2 emissions.

For further information, contact:
MAHLE GmbH
Ruben Danisch
[email protected]