Fuel and Injection System DevelopmentFrom Component Expertise to Overall System

Our German operations:BerlinChemnitzDresdenFriedrichshafenGifhornIngolstadtKasselLudwigsburgMunichNeckarsulmNeustadtNurembergRegensburgRostockRuesselsheimWeissach

T

Detroit

Shanghai

Seoul

São Paulo

Germany

Tokyo

London

Modena

Pune

Beijing

Mexico City

MoscowParis

IAV’s worldwidedevelopment expertise

We Make Things Move

IAV – Your Partner for AutomotiveEngineeringOur engineering is at the heart of vehiclesacross the globe. As one of the leadingdevelopment partners to the automotiveindustry, IAV offers more than 30 years ofexperience and a range of skills second tonone. With our expertise in the entirevehicle, and the passion to match, weprovide technically perfected solutions that balance both rational and emotionalaspects. Employing 5,000 members of staff and first-class facilities, we assistmanufacturers and suppliers in carrying out their projects wherever they are in theworld – from concept to start of production:Your goals are our mission.

PhilosophyIAV specializes in the entire process ofdeveloping fuel and injection systems fordiesel and gasoline engines. In particular,

we concentrate on designing, optimizingand testing hydraulic components. Our aimis to provide further impetus for improvingmixture formation and clean combustiontechnologies with a focus on future genera-tions of fuel and injection systems.

Incorporating combustion, electronics, the engine as well as the overall vehicle, IAV provides a start-to-finish approach inreaching the best possible solution thatmeets future vehicle consumption andemission requirements. To make sure itdoes, we work closely with our customersevery step of the way.

This brochure gives you an idea of theservices we offer in developing injectionsystems. But as competent consultants, thesupport we can give extends much further.

Do not hesitate to get in touch with us. Wewill be pleased to get down and discuss thespecific challenges you are facing.

Contact:

Ralf Marohn

+49 5371 80-51339

3

Contents

From Concept to Production 4

From Tank to Nozzle – Fuel Supply System (FSS) Diesel, Gasoline, SCR 6

From Tank to Nozzle – Fuel Injection System (FIS) 8

From Small to Gigantic, From Local to Global 10

Sub

ject

to c

hang

e w

itho

ut n

otic

e, e

ffec

tive:

M 0

2/2

01

4

S wift progress in fuel injectiontechnology over the years hasplayed a key part in developing

engines with higher fuel efficiency andlower emissions. The injection system itselfis highly complex, and each step forward

(e.g. higher injection pressure) pushesmaterials and functions ever further towardtheir limits. At the same time, the injectionsystem also has a significant effect on thecombustion process as well as exhaust-gasquality and emission standards.

Our experts adopt a start-to-finishapproach in identifying and satisfying thedemands placed on the entire powertrain.This way, consideration is not restricted tooptimizing internal engine aspects but alsocovers the entire fuel supply system.

From Concept to Production Global approach to development

Development processsupported by IAV

4

Concepts • Concepts for new injectors / pumps

and systems• Material innovations• Extremely high pressures• Analysis and feasibility studies• Benchmarking• Specifications for new concepts• Injection strategies• Expertise in all relevant processes and

technologies for fuel injection systems

Design• New designs for pumps and injectors• Hydraulic and mechanical layout• Packaging• FEM• Production support• Assembly processes

Simulation• 1D simulation for hydraulic component

and fuel injection systems• 3D simulation of flows

5

Testing influences, such as market andcountry-specific fuels, complements ourglobal approach.

In addition to its widely ranging testfacilities, IAV utilizes special measurement

technology that is constantly advanced and adapted to meet changing customerrequirements – e.g. for evaluating massflowrate.

Prototyping• Setting up prototypes• Prototype construction by specialized

partners

Testing• Detailed component tests and

assessment• System validation (hydraulic and

optical)• Test methodology• High-performance test benches• Capability of using real fuels

(diesel, gasoline, E85 etc.)• Testing at variable ambient

temperatures• Endurance tests, followed by

component assessments

Production• Assessment of production processes• Development of production processes• End-of-line test support• Supplier sourcing

E ver-tighter emission legislationmeans injection systems needto become even more efficient.

This can only be done if the injectionsystems operate within narrow tolerancesin relation to pressure, fuel quality etc. Fuel supply systems play a particularlyimportant part in this context.

The electric fuel pump and fuel filter inparticular must give the injection system alevel of stability that is so high as to ensureperformance continuity and durability.When it comes to testing components inextreme climate conditions, IAV uses testbenches that are capable of reproducingtemperature situations ranging from -40°Cto +140°C. IAV also provides customerswith support during field tests when resultsneed obtaining from the real-worldenvironment.

Alongside fuel supply, the SCR system hasbecome increasingly relevant to meetingtoday’s emission standards. Besides theAdBlue® tank, this system also incorporatesa system for injecting the AdBlue® into theexhaust system. The demands it needs tosatisfy are as rigorous as those required ofthe supply system, making packaging andtesting equally as sophisticated as for thewhole fuel supply system.

Fuel Tank (Including Filler Inlet)• Performance testing • Assessment

Electric Fuel Pump• Component testing • Stability testing

(e.g. supply rate, durability)• Packaging (e.g. in-tank, in-line)

From Tank to Nozzle Fuel Supply System (FSS) Diesel, Gasoline, SCR

Fuel Filter• Filter concept• Component testing

(e.g. filter, housing, line)• Performance testing (e.g. plugging,

water separation, durability using FAME)• Freezing tests down to -30°C• Activated carbon canister testing

High-Tech Systems and Methods• Test benches for a wide

temperature range • Automated test benches for

endurance tests• Use of real-world fuels

(diesel, gasoline, gaseous)• Validation of components at vehicle tests

Components and installationof the fuel supply system

7

Injectors and spray patterns (swirl and multi-hole) used for GDI

SCR System• Preliminary development / simulation

- Concept (ventilation, fluid-level indication)

- Packaging (design verification plan)• Component testing

- Heater- Supply module- Fill-level detection- Quality sensor- Reservoir- Dosing line

• Vehicle testing and calibration- Verification of all functions under

extreme conditions- Behavior around the AdBlue®

freezing point- Accoustic behaviour

• Production Support

Water separation

Activated carbon canister

SCR system

Hydraulic test bench

Extreme conditions on test benches

From Tank to Nozzle Fuel Injection System (FIS)

IAV Injection Analyzer Optical analysis

T o avoid making developmentmistakes with far-reaching conse-quences, it is important to optimize

the injection system with all its componentsat an early stage. To do this, IAV takes intoaccount both the engine manufacturer’srequirements and the supplier’s situation.Our engineers are experts in resolvingtrade-offs, aiming at all times to meet thedemands of minimizing cost, emissions andfuel consumption while maximizingdurability.

This integrated view of the fuel and injectionsystem coupled with profound componentexpertise creates the ideal basis for thecompetent support we provide. The resultwe arrive at is validated by the use of high-precision measuring systems, such as theIAV Injection Analyzer for injection rates andquantity, or the pressure chamber foroptically analyzing injection events.

The overriding goal is to enhance thequality of combustion, reduce fuelconsumption and emissions as well asimprove the power and harmony of theengine itself.

High-Pressure Pumps (HPP)• Component testing • Endurance testing • Testing with poor-quality fuels• Design and packaging of new pumps

Rails and Pressure-Control Valves• Performance testing • Stability testing (pressure)• Development of control strategies

Injectors• Injector concepts • Nozzle concepts• System concepts • Design and packaging• Component testing • System testing

High-Tech Systems and Methods• Test benches for wide temperature range • Automated test benches for

endurance tests• Optical spray visualization

(Schlieren, MIE etc.)• Measuring system developed in-house

(IAV Injection Analyzer)• Use of real-world fuels

(diesel, gasoline, gaseous fuels)

Combustion Principles• Focus on mixture formation• Support in relation to combustion

principles • Close meshing with engine and

vehicle tests

Spray analysis

9

Components and installation ofthe fuel injection system

Our PortfolioOur activities do not stop at passengercars or commercial vehicles. They alsocover off-highway and marine applications.This means we can provide our broadknowledge and experience for whatever the application.

For example, IAV has developed injectionsystems for off-highway usage – fromconcept to simulation, prototyping andtesting right through to mass production.Implementing new and optimizedapproaches, IAV uses its experiencegathered from projects on applications

and engines of various sizes. New combina-tions of materials and innovative coatingsincrease robustness and prolong servicelife. Newly developed ECU algorithmsensure stability over vehicle life, with OBDensuring compliance with legislation. To make injection measurements com -parable for all applications, we use the IAV Injection Analyzer, a measuring systemdeveloped in-house.

Not only available at our headquarters inGermany, IAV’s expertise and state-of-the-art test facilities are at your service acrossthe globe.

Germany (Gifhorn, Lower Saxony)Our main development center is located inGermany. This is where we provide all of theservices described for developing andtesting fuel supply systems, SCR systemsand fuel injection systems.

France (Guyancourt, Île-de-France)At Guyancourt we develop and test fuelinjection systems using our specialhydraulic test benches.

USA (Northville, Michigan)At Northville we use component testbenches for developing and testing fuelinjection systems.

From Small to Gigantic,From Local to GlobalEngine optimization with Design of Experiments

Operation range from Passenger Carsto naval application

10

11

IAV injection systemsites around the world

IAV GmbHCarnotstrasse 110587 BerlinGERMANY

Tel. +49 30 3997-80Fax +49 30 3997-89790

www.iav.com