Germany develops plastic camshaft module to reduce engine weight/reduce carbon dioxide emissions
Geshi Automotive News The use of plastic in cars can reduce vehicle weight. However, at present, the camshaft module, a key component of the power system, is still made of aluminum. According to foreign media reports, a research team from the Fraunhofer Institute for Chemical Technology ICT in Germany worked with partners to create a camshaft module using fiber-reinforced thermosetting polymers. This lightweight design element helps reduce the weight of the engine and reduce assembly costs, and it is currently only a functional demonstration product.
(Picture source: Fraunhofer Institute of Chemical Technology)
Camshaft can ensure internal combustion engine The inflation valve opens and closes reliably and accurately. This type of valve is located in the camshaft module, and the standard manufacturing material is still aluminum. However, automakers and suppliers are vigorously implementing lightweight designs for power systems and their components. Reducing weight is also one of the most effective ways to reduce carbon dioxide emissions. Researchers at the Fraunhofer Institute of Chemical Technology are using a camshaft module made of thermosetting composite materials to support the automotive industry. The light camshaft module was developed by ICT in cooperation with MAHLE Group, Daimler AG, SBHPP/Vyncolit NV and Georges Pernoud. The German Federal Ministry of Economic Affairs and Energy (BMWi) has also been providing financial support for the project .
When choosing the right polymer, the project’s partners chose a high-strength, fiber-reinforced thermosetting polymer, because this polymer can withstand high temperatures, as well as synthetic motor oils and coolants. Mechanical and chemical pressure. Thomas Sorg, a researcher at ICT, said: 'We provide expertise on how to design component geometries to adapt to materials and processes so that the components can ultimately meet all requirements. The camshaft module is located in the cylinder head and is usually installed on top of the power system. Therefore, it is very important to reduce its weight, because it can also lower the center of gravity of the vehicle.'
Aluminum castings need to be reworked many times after casting, so the cost is high. Fiber-reinforced thermosetting polymers can realize near-net-shape (near-net-shape) manufacturing. Relatively speaking, there is almost no need to rework, which can reduce production costs. In addition, the service life of thermosetting polymer injection molds is significantly longer than that of aluminum high-pressure die-casting molds. Compared with aluminum, the carbon dioxide emissions of high-fiber plastic parts are also much lower, so the manufacturing process of this kind of light metal (aluminum) consumes a lot of energy.
This kind of polymer also has the advantage of being able to meet the requirements of automobile manufacturers to minimize noise emissions. A rattling car is not only annoying for passengers, but also an obvious competitive disadvantage. Therefore, NVH (noise, vibration, and roughness) is also an important factor in evaluating vehicle quality. The polymer has good damping characteristics and can be optimized Acoustic performance of the camshaft module.
(Picture source: Fraunhofer Institute of Chemical Technology)
This camshaft module It adopts an integral design with integrated bearings. Due to the integrated production, the assembly time of the engine manufacturing plant is reduced. The car manufacturer receives a pre-assembled module from the supplier, which can be installed on the engine with a few simple operations, eliminating the need to spend time separately installing the camshaft. This innovative solution has another advantage: the aluminum insert in the high stress area of u200bu200bthe camshaft bearing absorbs direct forces.
In the initial test of the camshaft on the engine test bench, the researchers observed that it has good working performance and reduced weight compared with aluminum reference parts. The researchers said: 'Compared with the use of light metals to make camshaft modules, we can use thermosetting polymer materials to make camshaft modules more easily, and in the injection molding process, it can be produced in a more economical way.' Simulation technology is also used to design and verify product prototypes before the manufacturing process begins. 'Although the stiffness of thermosetting polymer is only one-fourth that of aluminum, the design method we have adopted has achieved the maximum allowable deformation.' After 600 hours of testing on the engine test bench, the camshaft module equipped in the most advanced internal combustion engine Lightweight design elements are adopted to show perfect functions. With the help of the fuel injection test plan, the project partner wanted to prove the function and NVH characteristics of the camshaft module, taking into account the gas force during the combustion process.
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