MAHLE Powertrain delivers new concept engine in less than 12 ...

Designing the Lubrication & Cooling SystemsFlowmaster is used throughout the design process. From the initial conceptstage, Flowmaster allows engineers to understand what is or isn’t feasible andidentify any problems long before the engine reaches the test bed.Flowmaster is used to build a full model of the lubrication and cooling systems tomeet the exact requirements of the engine. By understanding these requirements,along with the parameters and tolerances of the available components MAHLEhave been able to optimise the design of the engine, thus reducing powerlosses and ensuring high reliability. A downsized engine puts high demandson the lubrication system, therefore the accuracy and quality of information isparamount.Figure 2: Engine Oil Pressure GraphThe engine oil pressure must meet a series of critical targets to ensure correct operation of eachcomponent including hydraulic actuators, piston cooling nozzles and highly loaded crankshaft bearingcomponents.For the lubrication system design, engineers at MPT use Flowmaster to optimisethe pump capacity and drive ratio. At low engine speeds the oil pump pressurerelief valve (PRV) remains closed, forcing all of the flow from the pump to theconsumers. Under these conditions it is critical that the pump capacity matchesthe engine’s requirements and acceptable oil pressure targets are achieved.By optimising the combination of capacity and drive ratio MPT engineers canminimise the pump power consumption under normal driving conditions. Theefficiency of an automotive oil pump is extremely sensitive to speed, temperatureand pressure. The optimum arrangement is a balance between all these factorsand Flowmaster enables MPT to calculate the best configuration quickly andeasily.www.flowmaster.com

ResultsFigure 3: Oil Flow DistributionThe oil flow in the engine needs to be steered to the most critical components in strict priority. Anyflow through the pressure relief valve at low engine speeds results in wasted energy and increasedfuel consumption.By using Flowmaster to optimise the engine cooling, inter-cooling and exhaustgas recirculation (EGR) systems the concept vehicle installation requirementshave been met such that the powertrain’s overall fuel economy savings andemissions reductions can be maximised.Robert Corbishley, Senior Analysis Engineer for MPT explains how Flowmasterhas aided the development process. “Flowmaster shortens the time frameand provides much more detailed information at an early stage. We are ableto foresee any potential problems with the engine design much earlier, whichsaves considerable time and resource. The value for money Flowmaster offersis exceptional, being used throughout the development process. When youevaluate Flowmaster’s contribution to the overall project in time saving versuscost, the return on investment is excellent.”www.flowmaster.com