Future-Proof and Flexible

FEV develops non-road engine family for emerging markets

18. July 2016 | Engineering Service

The sales of construction and other non-road machinery has constantly increased over the past few years and will continue to expand in future. In particular, emerging markets are primarily responsible for this development; these markets require cost-efficient and robust engines that guarantee high reliability, even under difficult environmental or maintenance conditions. FEV has developed a non-road engine family that takes these challenges into account and considers the broad range of potential engine applications. Thanks to forward-looking design features, which constitute an ideal basis for a compact, cost-efficient, and friction-optimized base engine, the engine family offers the very best conditions for successful and future-proof use – globally and especially in emerging markets.

Base Engine and Future Development Stages

The new engine family includes an inline six-cylinder engine with a displacement of 7.3 liters and a four-cylinder engine derivative. While the base engine is equipped with single-stage turbocharging, uprated versions can be realized in the future with two-stage turbocharging or increased stroke. This variability has already been taken into account in the design to provide problem-free coverage of the broad power and application spectrum within the engine family.

Valentina ATZ

Modular Design, Friction Optimization, and Low Costs

In order to cover the large number of potential application versions with different flywheel sizes and PTO (Power Take Off) positions, modular design of the engine block was selected. For this purpose, the gear drive housing was realized as a separate component between the crankcase and flywheel housing. The flexibility that this achieves enables the adaptation of the engine to challenging installation conditions in various vehicles or machinery.

In order to optimize friction, various measures such as a cost-neutral crank off-set were integrated into the design.

Due to the particular cost pressure in this engine segment, the crankcase is designed with integrated cylinder liners (“parent bore”). This solution is inexpensive and presents additional advantages in terms of size and weight. Another cost optimization was achieved through the use of standard gray cast iron (GJL) for the crankcase and the cylinder head while simultaneously ensuring the required high peak firing pressure capability. Comprehensive FE calculations in accordance with the proven FEV methodology contributed to the positive result.

Customized Emissions Concept

The emission concept of the new engine family incorporates a combination of SCR and uncooled EGR. This combination is relatively inexpensive and durable. A common rail injection system enables the realization of flexible injection timing and quantity. Emissions, fuel consumption, and thermal management can thus be made possible. Good matching of combustion chamber geometry, valve timing, injection nozzle geometry, and swirl provide the basis for an optimized combustion process.

>> THE MODULAR DESIGN ENABLES MAXIMUM FLEXIBILITY FOR DIFFERENT APPLICATIONS

Non-road engine

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