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magdy m.s · #**848** 23-02-2012, 04:56 AM

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Very cool: Two rotary valves control the powertrain's cooling circuit

Schaeffler has developed an innovative thermal management unit for Audi�s latest 1.8-litre turbocharged gasoline engine. The unit ensures rapid warm-up of the engine and transmission and cuts CO2 emissions by 2.5g/km.

The plastic module features an integrated water pump and uses two rotary valves to control coolant flow throughout the entire powertrain and HVAC system.
The Audi engine features an integrated exhaust manifold. This enables higher output and reduced consumption but cooling is challenging and means greater heat rejection to heat exchangers. The OEM approached Tier One Schaeffler for a solution. Development work began in 2007.
Michael Weiss, Schaeffler�s director of engine systems thermal management, said: �Electronically controlled thermostats are a cheap, known technology. But when engines become more complex, you might need two and you have more and more parts. Then it makes sense to integrate everything in one module.
�And when you have high power density, as in the Audi engine, reaction time is critical. We don�t have the 5-6s delay that a thermostat takes to open. Our module is connected to the throttle � as soon as you demand more power the valves open.�

The module features two rotary slide valves driven by an electric motor and gearbox, and a belt-driven plastic water pump. When valve one is closed, there�s standing water in the cylinder block; coolant only heats up in the cylinder head, ensuring rapid warm-up of engine and cabin. When it opens, coolant flows through the second valve. The valve has four ports: one for the engine, radiator and transmission oil cooler, and one to the engine oil cooler. This enables complete control of the entire cooling circuit.
The main development challenges were managing the tight positional tolerances between the water pump and the cylinder block and finding a motor able to cope with the high vibration loads. �We couldn�t use metal for the housing material because of the manufacturing complexity so we needed a plastic able to cope with the temperatures and vibrations. The tooling is extremely complex � 27 pistons on four layers to make the moulding,� said Weiss.
The module is made from PPS with 40% glass-fibre reinforcement and weighs around 1.2kg. Schaeffler has three other programmes for the technology in both gasoline and diesel applications. The Audi 1.8 develops 125kW/320Nm and launches in the A4 and A5.

Schaeffler integrates cooling system control

The unit ensures rapid warm-up of the engine and transmission and cuts CO2 emissions

Schaeffler is helping to unlock new potential through the optimization of internal combustion engines with the new thermal management module. This innovative module is the key to reducing fuel consumption and CO₂ emissions by up to four percent.
The thermal management module is a temperature control unit for the entire drive train. It is integrated in a compact component manufactured from high-strength plastic and combines numerous functions. Where as engine temperature has been controlled until now in a rudimentary manner by a thermostat located close to the engine, the new modern thermal management module controls the temperature conditions in the vehicle precisely and enables operation in the optimal temperature window in the fastest possible time. This means on the one hand that the cold running phase is significantly reduced by completely blocking off the cooling jacket. On the other hand, the individual components can be operated at higher temperatures than would be possible with a system controlled by a thermostat. The engine temperature can also be reduced under full load and the tendency for knocking and enrichment of the mixture under full load can be reduced.
The opportunities for precisely controlling temperature in order to increase efficiency range from both the engine and heating to the transmission and turbocharger. Controlling the temperature of alternators, hybrid modules and batteries is one of a range of possible tasks that can be performed by this sensor controlled component � they can be efficiently cooled and heated according to requirements using the thermal management module from Schaeffler.
Precise control by means of a rotary slide valve enables the ideal temperature window for the engine and transmission to be reached rapidly. This has an effect on both the energy efficiency and the life of components in the drive chain. The turbocharger can also be included in the components whose temperature is controlled by the thermal management module. Individual control ensures aftercooling of the thermally stressed exhaust gas turbine.
�The performance of the thermal management module makes this component particularly suitable for use in engines for start-stop operation�, says Prof. Peter Pleus, Member of the Executive Board responsible for engine systems at Schaeffler. The individual components of the module are also optimized for friction in accordance with Schaeffler�s high requirements in terms of energy efficiency. This means that the thermal management module can be connected directly to the engine control unit without additional power stages thanks to its low power consumption.
The thermal management module also releases developers from the constraint of having to fit the component in close proximity to the engine block � as was always the case with a thermostat located on the engine. Standardized, non-interchangeable hoses reduce assembly times and ensure a high level of seal integrity. This means that Schaeffler�s thermal management module makes a valuable contribution to quality.