Powertrain in Model Developing
Powertrain plays a crucial role in the model developing process. Powertrain design group includes engine and transmission tuning engineers. Powertrain development is closely linked to a vehicle’s overall performance, including fuel consumption, emissions and maneuverability. In light of future requirements for power performance, environmental protection and energy legislation, powertrain technology improves day by day. New technologies such as electronic throttle control, turbocharger, variable valve timing and exhaust gas recirculation are introduced into engine technology. Development of a matching transmission also aims at 6AT, and CVT technologies in order to comply with future requirements for fuel consumption regulations.
Powertrain Design and Development
Powertrain design mainly focuses on the compatibility of engines and vehicles, making sure that the design of engines matches the vehicle layout, while taking vibration noise, maintainability, safety and dynamic clearance into consideration at the same time.
1. Engine concept and design
Engine conceptual design includes 15 main systems, which are cylinder head, cylinder block, lubrication system, valve system, breather system, active components, cooling system, ignition system, accessories system, intake system, exhaust system, timing system, fueling system, EMS system and turbocharger system.
2. Analysis of competitors’ engines
Analyzing and comparing tests of competitors’ engines: Mainly by analyzing design features, advantages and weaknesses of the products from competitive international manufacturers, the design group takes them as references for further development of products, and achieves the goal of understanding competitors and their own company.
3. Engine design
Detail design analysis of the engine is mainly based on conceptual design and power performance. That includes 3D conceptual design, 2D detail design, CAE analysis, control system design and overall vehicle matching design. Engines currently under development are all equipped with a turbocharging system to satisfy the demand for vehicle power performance. Owing to this, a durable exhaust manifold becomes crucial. The thermal stress analysis of an exhaust manifold and turbocharger confirm that the material strength complies with the full load engine running temperature and stress.
4. Transmission matching
In order to successfully equip various transmissions to the complete vehicle and reach the optimum balance between fuel consumption and power performance, related matching confirmation and design are required.
5. Powertrain Lab
Various developing equipment and resources are introduced for developing, tuning and durability testing of the powertrain and the overall vehicle power performance. Verification by tests ensures the requirements for both quality and reliability. Current testing resources include Rig/Bench test equipment, Engine lab, vehicle exhaust pollution and fuel consumption lab, etc.
6. Powertrain tuning
Powertrain tuning is necessary after complete vehicle powertrain matching for satisfying power performance, cooling thermal effect, fuel consumption, pollution, driving ability and legal requirements for the sales market.
The purpose of powertrain tuning is to decide the appropriate A/F ratio and spark advance according to various controlling strategies, engine running conditions and transmission shifting times and thus improve powertrain performance and reduce total fuel consumption and exhaust pollution.
Powertrain tuning is divided into two major parts: Tuning of the Engine Management System (EMS) and the Transmission Management System (TMS). Apart from separate basic tuning of engines and transmission units on dynamometer, the scope of vehicle tuning also examines the combination of engines and transmissions under various running conditions and checks for efficient energy consumption and optimum performance of powertrain under various working conditions. Powertrain tuning of a vehicle includes exhaust gas pollution and fuel consumption tuning, subjective and objective driving ability tuning, three extreme conditions field tuning test (High temp, High dust, High altitude) and extreme cold and an emissions regulation endurance test.
Chassis system design and development at HAITEC involves the following main areas: Chassis package design, chassis analysis, layout design, part design, prototyping and test assembly, design verification, and new technology/template R&D. Development cost, delivery time and quality management are also practiced for chassis components.
The complete R&D process from chassis design through to actual vehicle testing at HAITEC is shown in the design and integration of the suspension system, steering system, braking system,transmission system and suspension provides a demonstration of R&D expertise. These areas are summarized below:
1. Suspension system design and integration
An appropriate suspension arrangement is designed to meet the specified performance, space and cost requirements. CAE virtual prototyping, DMU's package and dynamic gap validation, installation and maintenance procedure validation, and mule prototyping are used to design a suspension system that delivers the required vehicle performance along with the ride and controllability expected for the vehicle variant.
2. Steering system design and integration
The steering system must meet requirements for ergonomics, collision safety, space restrictions, field of view, targeted performance of steering stability, maneuverability, handling and minimum turning radius. The suspension system and engine room layout controllability and engine compartment layout are then taken into account to design a steering system and geometric arrangement that meets safety characteristics and NVH requirements.
3. Braking system design and integration
The braking system must meet the requirements for regulations of the individual market, and driving comfort of ergonomics, stepping feedback and stiffness. Efforts are made at reducing braking noise and vibration sensitivity while ABS anti-locking brakes are fitted as standard to deliver the design for a safe, reliable and controllable braking system.
4. Transmission, gearshift and pedal mechanism design and integration
The transmission system must provide a suitable joint between the engine and the gear box. The design of the pedal mechanism must meet layout regulations, collapse requirements during collision as well user comfort requirements while also being strong, safe, comfortable and cost-effective. In designing the gearshift mechanisms, appropriate styles must be developed for automatic and manual transmissions as well as one that provides precise gear shifting and feedback.