Tribologia

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Challenges on Interaction between Lube Oil
and PCU on Modern Engines

Rafael Antonio Bruno
Product Technology
MAHLE Jundiai Tech Center

MAHLE France SAS, EED1L, 17-June-2011

© MAHLE

Challenges on Interaction between Lube Oil and PCU on Modern Engines

Table of Content

1. Engine Demands and New Technologies

2. Effects on PCU components

3. Experimental Results – FrictionFocus

4. Final Considerations

2

MAHLE France SAS, EED1L, 17-June-2011

© MAHLE

Challenges on Interaction between Lube Oil and PCU on Modern Engines

Table of Content

1. Engine Demands and New Technologies

2. Effects on PCU components

3. Experimental Results – Friction Focus

4. Final Considerations

3

MAHLE France SAS, EED1L, 17-June-2011

© MAHLE

Challengeson Interaction between Lube Oil and PCU on Modern Engines

TREND
TREND

• reduced friction
components
• improved efficiency
• low weight
• thermal mgt
• downsize and boosting
• low oil viscosity
• direct injection (GDI,
EDI)
•VVT
• High EGR
• Extended oil change

ENGINE
SYSTEM

Low Fuel consumption
(CO2 emission) and
general emissions

ENGINE DEMAND

New Engine Demands4

Hybridization

• start stop controls
• smaller and
dedicated engines
(range extender)

• higher mechanical loads
• lower lubricity (quantity
or longer use)
• reduced noise

MAHLE France SAS, EED1L, 17-June-2011

Increase Power
Output

• Diesotto/HCCI
concepts
• Dowsizing
• Turbo charge

Alternative Fuels
or Fuel Quality

• Ethanol (E85 in
NAFTA, E100 in
Brazil)
•Hydrogen (fuel
cell Vs. ICE)
• Natural gas
• Flex fuel
• High S, Water
content on Diesel
• Biodiesel
• Regulation on
different regions

• higher structural resistance
• low mass demand
• new geometries to support engine
technology

Low Cost
Concepts

• NA
• MPFI
• Low power density

• higher load carrying capacity
• higher corrosion resistance
• higher wear resistance
•increased asperity contact
© MAHLE

Challenges on Interaction between Lube Oil and PCU on Modern Engines

Modern SI Engine Demands

Engine Demands
•Higher efficiency
•More compact engines (Downsizing)
Engine Technologies
•Emissions reduction
•Lower fuel consumption
•PCP increase (20%-30%)
•More fuel injection (+30%)

Higher
Efficiency

Friction

Downsizing

•Spark timechanged
•Flex-fueled engines
•Stop-start operation
•Low viscosity oils
•Direct Injection (GDI, EDI)
•Turbocharged applications

PCU Impact
•Higher Loads
•Tribological Severity Increased
•Lower oil film thickness
•Boundary condition operation
•Less lubrication (fuel dilution)

MAHLE France SAS, EED1L, 17-June-2011

Challenges on Interaction between Lube Oil and PCU on Modern EnginesBlow-by

Modern SI Features

REQUIREMENTS
Increasing Components Durability
Maintaining Blow-by Level
Maintaining Low Oil Consumption Level

Friction
Durability
Oil Consumption

PCU Impact

MAHLE France SAS, EED1L, 17-June-2011

•Higher Loads
•Tribological Severity Increased
•Lower oil film thickness
•Boundary condition operation
•Less lubrication (fuel dilution)
© MAHLE Challenges on Interaction between Lube Oil and PCU on Modern Engines

Modern SI Features - Combustion Cylinder Pressure
Cylinder Pressure @ WOT (bar)
120
110
100
90
80
70
60
50
40
30
20
10
0

NA
Turbo

-360

Intake

-180

Compression

0

Expansion

180

Exhaust

Ring Pack – Piston design to
reduce blow-by (PCV design,
Lubricant corrosion/degradation)

RingPack – Piston design to
avoid Oil Consumption at low load
(idle – Mega City driving) or during
transient operations

360

Cylinder Pressure @ No Load (bar)
3

PCU Impact
Pressure (bars)

Intake
Manifold
Vaacum

2

Atmospheric
Pressure

1

0
-360

Intake

-180 Compression 0

Expansion

180

Exhaust

360

Crank Angle

7

System Approach

Top Ring...
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