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Cylinder Deactivation: Manufacturer Type of Engine Valve Concept Status
Cylinder Deactivation: Manufacturer Type of Engine Valve Concept Status
Cylinder Deactivation: Manufacturer Type of Engine Valve Concept Status
Cylinder Deactivation
Torque
Road-resistance
curve
Figure 2 Operating data map and driving resistance curve: The operating ranges associated with the
lowest specific fuel consumption are approached in cylinder deactivation mode (graphic on
the right) and not when all cylinders are operating
Technical implementation
combustion
Source: MTZ "The New AMG 5.5-liter V8 Naturally Aspirated Engine with Cylinder Shut off“
Figure 4 Possible options for introducing a cylinder charge and their effects in cylinder deactivation mode
Valvetrain Systems 11 177
8
Consumption benefit in %
0
0.00
-4 -3.35
-8
-9.91
-12
-12.35
Figure 6 Different configurations for alternating cylinder deactivation in a fuel consumption comparison
Valvetrain Systems 11 179
Control of
AVS Actuators
Engine torque
Filling-target Cylinder filling
Actual filling
100 % 100 %
Ignition angle-
efficiency
50 %
Time
Must be
changed
ECU
Modifications
– Active requirements may be required
– Cycle control
– undetectable switching
– OBD-Function NVH measures
– Driver command prediction
Active
noise
cancellation
Exhaust system
Valve train
Accessory drive Torque-
converter
lockup clutch
Cam phaser /
(automatic
Timing drive
transmission)
Dual mass
flywheel
Engine mounts
reaches approximately 1,500 rpm, de- bly moderate outlay. The following options
pending on the engine concept, as this are available for this purpose:
will ensure the desired level of comfort for –– Switchable bucket tappets
passengers. In addition, cylinder deacti- –– Switchable finger followers
vation cannot be engaged if the engine oil –– Switchable pivot elements
has not reached operating temperature, –– Cam shifting systems
or engaging the mode would cause the –– Fully variable mechanical valve train
catalytic converter to drop below its light- systems based on detent cam gears
off temperature. –– Fully variable electrohydraulic valve
train systems such as the UniAir sys-
tem from Schaeffler
Design configuration of the shifting The benefit of this design lies in the short oil
oil circuit channels and small oil volume. Any oil foam-
ing that could occur would therefore be min-
Several solutions are conceivable for con- imal, which is why the system is highly insus-
trolling hydraulically actuated, two-stage ceptible to fluctuations in the shifting or
valve train components and arranging the switching times. This concept enables a
switching valves in the cylinder head. The switching time interval of approximately
positional arrangement of the switching 250 camshaft degrees, which equates to
valves and the design configuration of the a theoretical switching time of 28 ms at
oil channels produce different switch time 3,000 rpm. On engines with camshaft phas-
intervals and system-related constraints. ing units, the influence of the adjustment
The following depicts two different options range must also be factored into determining
for deactivating cylinders 2 and 3 in a four- the interval. By design, this variant can be
cylinder engine with an ignition timing se- enhanced or extended in such a way that all
quence of 1-3-4-2 and describes the inher- cylinders can be actively switch-controlled,
ent benefits and drawbacks in detail. which in turn means that in a four-cylinder
Figure 10 shows the variant with one engine application, the engine management
switching valve per cylinder, which means system can deactivate one, two, or three of
that one switching valve at each cylinder the four cylinders. One drawback, however,
controls the respective intake and exhaust is the comparably expensive design configu-
valves. ration associated with the oil channel be-
tween the intake
Intake and exhaust sides.
An alternative ar-
Cyl 1 Cyl 2 Cyl 3 Cyl 4 rangement is also
possible by control-
ling the oil circuit
Exhaust A A using one switching
valve on the intake
P T P T and exhaust sides
(Figure 11). The in-
take and exhaust
Figure 10 Oil circuit with one switching valve per cylinder valves are then ac-
tuated by two sep-
182
arate switching A
valves. The benefit of
this arrangement is P T
Intake
that the switching
time interval can be
governed indepen- Cyl 1 Cyl 2 Cyl 3 Cyl 4
dently of the adjust-
ment range of the
Exhaust
camshaft phasing
unit. In addition, the A
oil channels can be
designed in a more P T
simplistic manner,
and the switching Figure 11 Oil circuit with one switching valve per side
valves can be inte-
grated more easily. This design facilitates tion of the cylinder head and oil channels of
a switching time interval of approximately the target engine, whereby the main focus of
180 camshaft degrees, which corresponds the design work should be on maximizing
to a theoretical switching time of 20 ms at the switching time interval as far as possible
3,000 rpm. The longer oil channels do pose using justifiable levels of outlay.
a limitation, however, as they require a higher
oil volume, which in turn makes the system
more susceptible to fluctuations in the shift- Deactivation via switchable elements
ing or switching times as a result of the great-
er potential for oil foaming to occur. Finger followers
The shifting oil circuit and switching valve Since the design configurations for the
linkage can also be implemented in ways switchable finger follower can also be ap-
other than the ones described here. Critical plied to the switchable bucket tappet, we
design aspects that apply in this context are will not explore this topic any further.
the ignition timing sequence and configura- The solutions that are based on finger
followers or hinged-lever designs that can
be coupled with one another and have a
locking mechanism at the pivot point are
numerous. All systems that rely on oil pres-
sure require spring-actuated elements to
return the deactivated components to their
starting position after cam elevation (Figure 12).
The shift mechanism must be designed in
such a way that the entire valve stroke is
traveled when no oil pressure is present
(zero-pressure lock), since this safeguards
operation in limp-home mode and is re-
quired for cold-starting the engine.
Although cylinder deactivation brings
with it many benefits, the concept also has
several drawbacks. The additional contact
Figure 12 Switchable finger follower points and increased number of compo-
Valvetrain Systems 11 183
nents, for example, reduce rigidity as com- valve inadvertently opens in the direction
pared to a standard finger follower and opposing the valve spring pressure.
negatively affect the vibration of the valve
train. The added components also increase Support element
the mass moment of inertia of the follower, The switchable pivot element also lends it-
which in turn means that stronger valve self to being deactivated. Similar to the
springs need to be fitted, and the valve train switchable roller tappet, the inner part of the
assembly encounters higher levels of fric- element can be telescopically extended into
tion as a result. Potential space restrictions the outer part (Figure 13). Here too, a spring
necessitate narrower rollers, a design that or spring assembly is required to return the
inherently increases the surface contact moving part to its starting position. The oil
pressures between the roller and camshaft. pressure, which is controlled by an up-
Switchable finger followers that brace stream switching valve, is also used to actu-
themselves against a zero-stroke cam in ate the coupling mechanism. The distance
deactivation mode create a more stable traveled by the oil to this mechanism is
system than the variant that does not pro- shorter, however. The same restrictions that
vide for this effect. The only drawback is apply to the switchable finger follower with
that the camshaft then requires two differ- regard to the oil pressure also hold true for
ent profiles per valve. If a zero-stroke cam is this application.
not provided, the acting forces must be pre- The rigidity of the valve train is only re-
cisely coordinated with each other; in the duced by the structural integrity of the cou-
decoupled state, the lost-motion spring pling point in the switchable pivot element.
needs to be strong enough to prevent “infla- The geometry (with the exception of the
tion” or “pump-up” (undesired elongation) of valve contact surface) and mass moment of
the support element. On the other hand, the inertia of the finger follower are unaffected.
spring must not be so rigid that the motor As a result, the valve spring pretension force
Oil
pressure
outlay than switchable elements, since in cylinders. This setup also facilitates the inte-
four-cylinder engine applications, both gration of an alternating cylinder deactiva-
camshafts must be equipped with a deacti- tion pattern [3].
vation function – a design aspect that also
affects positional elements that are not Cylinder deactivation via UniAir
switchable. Consequently, the cam shifting
system is a commercially viable option for UniAir not only controls and regulates
cylinder deactivation if an existing two- valve stroke travel in a fully variable fashion,
stage system for varying the valve stroke is but can also completely deactivate any
enhanced to include a third stage dedicated cylinder (Figure 16). This deactivation is
to the cylinder deactivation process (refer to achieved by actuating the system‘s integrat-
Figure 15). ed switching valves as required. In its cur-
Theory-based investigations conducted rent version, UniAir actuates both valves in a
by Schaeffler indicate that a three-stage uniform manner. As a result, both intake
system can offer further significant potential valves are always closed in deactivation
compared to a two-stage solution in con- mode. The operating state of the valve train
sumption testing cycles carried out under can thus be easily determined with the Uni-
higher load conditions. When the cam shift- Air system as well. When UniAir is only used
ing system is designed so that all intake and on the intake side, switchable support ele-
exhaust valves can be deactivated, it is pos- ments can be fitted in the relevant positions
sible to deactivate any desired number of on the exhaust side (as is the case with the
fully-variable me-
chanical system).
Schaeffler is cur-
rently working on ad-
ditional valve stroke
configurations that
approach the poten-
tial afforded by cyl-
inder deactivation
while making it pos-
sible to forego valve
deactivation on the
exhaust side. The
genuine appeal of
this type of configu-
ration is that it allows
any number of cylin-
ders to be deacti-
vated without having
to implement further
design measures.
Detailed informa-
tion is provided in
an additional article
[4] in this book.
Figure 16 Electrohydraulic, fully-variable UniAir valve train system
186