Sample project – Camshaft phaser locking

• Prevention of unwanted phase setting immediately after engine start
• Precise control of unlocking time possible
• Unlocking function independent of chamber pressure
• Unlocking takes place via rise in control oil pressure, which affects the front of the main slider
• OBD monitoring for the phaser during engine start is no longer necessary, because the phaser is mechanically locked

Sample project – Cost-optimized camshaft phaser

• Conventional shape
• Cost-optimized solution

Sample project – Construction of valve operation components

• Optimization for mounting at cylinder head
• Optimization of production and assembly
• Cast design and optimization
• 3D modelling

CAD Software @ hofer:

• UG, Pro-engineer, Catia, V-5, ...

FEM

• Amsys, ProMechanika,

Sample project – Cast magnesium

Aluminium:	Magnesium:

Sample project – Testing

Engine test bench experiment: Testing turbocharger NFZ

Test bench equipment:

• 2 test benches set up as containers
• Load unit eddy-current brakes
• Test subjects placed on pallets
• P_max=440 kW; n_max=10.000 1/min; M_max=1.600 Nm
• Additional machine for pulling (30 kW max)

Application and analysis tools: INCA, CANape, …

Sample project:

• Endurance testing and rigidity testing of turbocharger
• Carbonization endurance testing
• Oil consumption tests

Further projects in test-bench sector:

• Function structures for gear drive and toothed belt
• Camshaft phasing test and valve lift adjustment
• Leakage tests
• Operation with special fuels
• Vibrational analyses
• Cold-run tests (engine in cold room up to –40°C)
• Analysis of structural tension via DMS
• Preparation of special structures (e.g. Plexiglas windows)

Sample project – Optimization of camshaft phasing

Control unit application / Function optimization

• Measurement and evaluation of optimization requirement
• Analysis of control parameters
• Optimization via DOE
• Testing

Application and analysis tools: INCA, CANape, ...

Sample project:

• Optimization of valve operation control times
• Optimization of running smoothness
• Controller adjustment / optimization of parameters and data feed
• Efficiency increase (performance, torque, fuel consumption)
• Monitoring of actuator technology – adapted diagnostics
• Fault diagnostics implementation