2011 Mercedes Benz CLClass will debut a Fuel Efficient Next…

28 Янв 2015 | Author: | No comments yet »

2011 Mercedes Benz will debut a Fuel Next Gen V8 Engine

Press : Considerably less fuel but a much higher output was the of the development work for the new Mercedes-Benz generation, which will as an 8-cylinder in the 2011 CL-Class in autumn.

Mercedes-Benz developed the new motors since optimized combustion engines continue to specific advantages over drive systems with to operating range, refueling and costs, while offering the short-term potential to achieve fuel savings in day-to-day An internal combustion engine is the centerpiece of a hybrid drive and of decisive importance for improved

The new Mercedes-Benz engine family is based on modularization and innovative and replaces a very successful series. It allows the use of a start/stop 4MATIC all-wheel drive and with a hybrid module.

The V8 is in a new of its own

While the new V8 is based on its predecessor and has the distance between the cylinders, it has substantial reengineering in every

For example, it has a 15-percent smaller (4663 cc rather than cc) but generates 429 hp and therefore around 12 more output than the unit (382 hp). estimated that this new will achieve a fuel improvement of 22 percent. CO2 emissions likewise fallen by 22 percent an outstanding improvement for this class. At the same time has been raised from 391 to 516 lb-ft — an increase of 32

In the new V8, Mercedes-Benz engineers primarily a high output for a lower by using twin turbochargers one for each bank of cylinders. The air is forced into the eight chambers at an overpressure of up to 0.9 bar, the turbine blades rotating at up to rpm. The turbochargers and their hot gas are mounted on the outsides of the cylinder This enabled the intercooler with its air/water intercooler and distributor to be located inside the V of the

The chargers were configured to high torque even at low speeds — compared to the engine, the result is an increase by than 45 percent at 2000 No less than 443 lb-ft is between 1600 and 4750

The engine is based on a further of the previous engine’s … aluminum crankcase with aluminum/silicon (Silitec) cylinder

Basic and connecting rod journal were adopted from the engine, while for load the piston compression height was by just under four By reducing the lift and shortening the rod by 2 millimeters, it was possible to retain the height of the crankcase. As a remarkable the high compression ratio of remains unchanged versus the aspirated preceding engine, the high efficiency of the new, V8 when configured for premium

Key figures for the new V8 engine

No. of cylinders     V8

(cc)     4633

Bore     92.9

Stroke (mm)     86

ratio     10.5:1

Output (hp at     429 at 5250

Torque at rpm)     516 from

Innovative technology makes V8 fit for the future

The new V8 from Mercedes-Benz has an crankcase, pistons and cylinder The crankshaft, connecting rods and are of special forged steel.

has achieved this considerable in efficiency with the use of innovative — including newly third-generation direct gasoline with spray-guided combustion, injection and multi-spark ignition. this new generation of V-engines, is clearly demonstrating that substantial further development, combustion engines still a great deal of potential, and V8 engines with their running refinement are fit for the future.

The package in the new engine generation a number of new developments that are in this combination:

In combination multi-spark ignition, third direct fuel injection with spray-guided combustion and injectors offers further for fuel savings — by of an improved, homogeneous combustion

In conjunction with start/stop shift point adjustment and friction-reducing measures, improvements in fuel consumption by more 20 percent are possible.

Power by accessory units has been These include an optimized pump with second thermal management, a demand-controlled oil a volume-controlled high-pressure fuel and an intelligent generator management

Lightweight construction techniques and improvements have also in-engine friction considerably to the previous engine.

Third direct gasoline injection

gasoline injection with combustion, an industry first by Mercedes-Benz, has been developed as a third generation. The system is up to 200 bar, the pressure being optimized according to the engine’s map. Completely new piezo-electric allow up to five injections per … for the best possible formation.

The crystalline structure of the changes in microseconds under an voltage, and with a precision of a few thousandths of a millimeter. The central of a piezo-electric injector is the piezo-stack, directly controls the metering With a response time of 0.1 milli-seconds, the fuel injection can be sensitively and precisely adjusted to the load and engine speed, a beneficial effect on emissions, consumption and combustion noise.

The injections even in tiny made possible with injection technology were by Mercedes-Benz engineers to control a characteristic map with the efficient process, and to provide the conditions for functions:

 As the first new operating mode, engineers have developed stratified combustion (HOS). As the implies, HOS is a combination of homogeneous and classic stratified combustion. The injection is sprayed into the …, forming a homogeneous mixture. Actual stratified takes place during the … before ignition, and is a or double injection depending on the map.

Another new operating is known as Homogeneous Split In this homogeneous combustion more than 95 percent of the is singly or multiply injected, by a very small ignition to stabilize combustion. This is when combustion conditions are

The V8 engine is operated homogeneously the entire characteristic map, but high load homogeneous or HSP is used to improve smooth characteristics:

Multi-spark ignition for efficiency

The third-generation direct system also features multi-spark ignition (MSI). the first spark discharge and a combustion period, the coil is recharged and another spark is The MSI system enables up to four to be discharged in rapid succession one millisecond, creating a plasma a larger spatial expansion conventional ignition. Controlling rapid multi-spark ignition both the time lapse the next spark and the combustion for the relevant operating point to be adjusted. This provides for optimizing the center of combustion and residual gas compatibility, especially stratified charge operation. consumption can be reduced by roughly two in this way.


Fuel of up to four percent are possible by the use of piezo-electric injection technology in with multi-spark ignition, on the driving cycle.

Cylinder with new camshaft adjuster

On the of the previous engine’s architecture, engineers developed the variable, vane-type camshaft adjusters for the and exhaust sides. These now a larger adjustment range of 40 with reference to the crankshaft. were also able to the functionality, achieving a 35-percent adjustment speed and adjustability at an oil as low as 0.44 bar. Despite the performance, this new development with significantly smaller and low weight. For this reason the space on the longitudinal and vertical of the engine was able to be reduced by 0.6 inches.

Two-stage chain for low noise

The extreme compactness of the adjusters was achieved by the new, chain drive. This short secondary chains one per cylinder bank

— via a chain and an intermediate gear. All chains can be individually adjusted via a tensioner. This results in low forces and low chain dynamics, consistent timing and outstanding properties, with friction even further. In short, the new drive is compact and ensures operation.

Controlled oil pump with two stages

A fourth chain drives a completely new variable oil pump. The pump operates two pressure stages, depending on the map. At low engine speeds and the pump runs at a low pressure of two At this time the oil-spray for piston cooling are switched The high-pressure stage is activated at the load and engine speed Thanks to this control the lubrication and cooling points of the can be supplied with significantly drive energy than be possible with an uncontrolled

New coolant ducting and 3-phase management

The coolant ducting in the head is also completely The water mantle has a two-piece to improve flow. This to specific increases in flow and heat dissipation at certain accompanied by a reduction in pressure the coolant circuit. This has it possible to reduce the power of the water pump despite the engine output.

As it warms up, the of coolant is regulated by a 3-phase management system so that it reaches normal operating Initially the coolant remains at in the engine. It then circulates in the circuit, but without the radiator. a temperature of 221 degrees Fahrenheit has reached in normal operation degrees under high the vehicle’s radiator is included in the The water supply to the interior system is separately controllable.

weights have also reduced by the judicious replacement of and steel by plastics, e.g. for the belt pulley, wheel, valve and hydraulic lines.

function with direct-start

The new system operates with direct-start. This means when the engine is switched the attitude of the crankshaft is registered by a new sensor so that the engine unit knows the positions of the pistons. On restarting, it can then the cylinder that has the most piston position for first After the starter has briefly over the engine, reliable ignition and combustion is immediately

Minimized friction

Particular was paid to reduced friction in the new This was primarily achieved by a in flow through the oil and water low-friction pistons, piston and cylinder walls, plus the new management system and chain

Fit for the future thanks to modular

The new V-engines from Mercedes-Benz are fit for the They can not only be combined a start/stop function, but also with the 4MATIC four-wheel system or integrated into a drive system.

The new engines all worldwide emissions regulations. The use of generation, direct gasoline with spray-guided combustion and injectors provides a particularly basis for increased stringency in the

Development, trials and test technology:

Endurance test for the new

52,000 hours of test trials

Over 4 million of test drives

Mercedes-Benz CL-Class

2 million hours of computer calculation per

Before the new V8 engines were onto the roads, they had passed a series of torturous for example on the engine test of the test facility in Untertürkheim. 24 of the latest engine test are installed on each floor of imposing three-storey building. 72 test benches operate day and otherwise it would be impossible to the demanding test programs Mercedes-Benz engineers subject all

A wide range of road and situations can be simulated on the test reflecting every conceivable profile such as hot and cold stop-and-go and long-distance driving very varied conditions. All in the new V8 engines from Mercedes-Benz and auxiliary units were to pass 52,000 test of which 27,000 were runs.

In parallel with extensive practical trials started in all the climatic zones of the — in the winter cold of the and the merciless heat of Death (USA), in desert sands and the air of Alpine regions or in tropical The program also included laps on e.g. the high-speed in Nardo (Italy) and Papenburg, as as stop-and-go driving in busy areas. All in all, the different vehicles with the new V8 engine over 4 million miles very varied conditions.

the development process began before these real-world — namely on the computer of the development engineers. This is the fundamental design calculations made with the help of computers. All the mechanical functions conceived and refined here, as the oil and coolant circuits, the various for intake air ducting, the charging combustion chamber geometry the intake and exhaust duct, as as the multiple injection system. All created and calculated on-screen.

computer cores provided the computing power for this process. More than two core hours were to calculate and verify all the engine and components for the best possible

Without the very latest it would not have been to explore technical boundaries and use new such as multiple injection. is because the engineers not only this enormous computing for design calculations, but also for the and testing of all engine functions.

the engineers used PCs to establish the possible configurations for all components, so they met precisely formulated and could be approved for production of the prototypes. After this verification process, the first in the new V-engine generation from immediately ran reliably and met all expectations on the bench.

A short history of injection

Mercedes-Benz is a pioneer in direct injection

The legendary 300 SL was the trailblazer

gasoline engine with direct injection and spray-guided

In 1954 Mercedes-Benz equipped the 300 SL with a four-cylinder engine direct gasoline injection as a first for series production Since then, the company has direct gasoline injection for cars with ongoing development and improvements.

In 1994, the and engineers at Mercedes-Benz entered new territory when they the development of a spray-guided combustion In the view of specialists, this the greatest potential for mastering two of the automotive engineering challenges of the namely further reductions in consumption and exhaust emissions.

At the end of Mercedes-Benz presented a new development in direct gasoline injection the new 1.8-litre CGI four-cylinder engine only). CGI stands for Stratified Gasoline Injection.

The second-generation CGI reached a new level in the CLS350 CGI in Europe in 2006: the four-door featured the world’s first engine with piezo-electric injection and spray-guided combustion. six-cylinder unit achieved a saving of around ten percent the V6 gasoline engine with injection.

The present state of the art is now by the new V8 engines with third-generation injection and multi-spark ignition. combine a high output excellent economy and environmental and offer refinement at the highest

Engine Production

The cradle of design

A success story the outset

State-of-the-art engine

Exemplary approach to environmental at the plant

Bad Cannstatt has a long and history as the birthplace of Mercedes-Benz For it was here that 125 years ago Daimler and Wilhelm Maybach their grandfather clock the world’s first single-cylinder It was to become a pioneering invention simultaneously marked the birth of mobility. Today, just a throw from Daimler’s green-house — the original of these activities — is the most recent sub-plant of the plant, the V-engine factory at Bad

This factory of the future was opened in 1997. For the first the all-new engine series for 6 and engines was produced using the state-of-the-art production facilities. then, the objective was to achieve production using as many components as possible for the variants of the new series. With a high output, this meant costs — which also benefited the customer. The to locate to Bad Cannstatt at the time an investment worth approximately 1 Deutschmarks, 700 million DM of which earmarked for plant construction and alone.

In 2004 the original area of 217,500 square was expanded by around 60,000 feet to 277,000 square With a workforce of around 900 the specialist V-engine production is today a key part of the production Since its official opening, four million V-engines come off the assembly lines at the plant. And this success is set to continue with production of the new In addition to pure engine Cannstatt is also responsible for the processing of key com-ponents such as crankshafts, con rods and cylinder

Envirtonmental protection as a matter of

Even at its official opening the plant was considered proof efficient production, ecological and attractive jobs were not mutually exclusive. Here, energy requirements went in hand with the optimum use of all This involved, for example, waste materials and recycling fluids and chips from processing. With its closed-loop recycling systems, Cannstatt is completely free of wastewater and materials, and the plant falls within legal limits for gas values.

The Bad Cannstatt plant has set new with approaches that the utilization of waste heat and recovery with an advanced system. The solar paneling which covers an area of square feet and at the time was one of the systems found anywhere in the — generates an an-nual output of 350,000 kWh. is sufficient to meet the electricity of more than 120 homes. The generated is fed directly into the grid.

For production of the new series the adopted the award-winning principle of quantity lubrication, which mixing minimum quantities of with cold air instead of conventional cooling lubricant. The new uses a fraction of the volume of lubricant previously used.

these substances are manufactured petroleum and demand both and cost intensive preparation, the of minimum quantity lubrication an enormous cost advantage and a contribution to environmental protection.

In a true eco-paradise has been on the outskirts of the plant. The Neckar bed concept was developed in collaboration environmental and nature conservation After replicating a Neckar over an area of 13,000 feet — complete its own characteristic heat islands and microclimate — it has been that 40 species of wild bee now found a new habitat.

Mercedes-Benz CL-Class

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