2013

3.6L DOHC 4V V6 Direct Injection Engine

Florian CIVIER 04/11/2013

Content

Introduction ........................................................................................................ 2

Benefits of SIDI ................................................................................................. 2 Engine Coolant ................................................................................................ 2 oise ................................................................................................................. 3 !or"ue ............................................................................................................... 3 E#issions.......................................................................................................... 3

Econo#$ .............................................................................................................. 3

Cadillac ................................................................................................................. 4 I#%ro&e#ent of t'e (asic engine ................................................................. 4 )ir cooler integrated (oost ............................................................................ 4 *astegates actuated ($ &acuu# ..................................................................... +

Introduction
Direct in,ection engines - found in &e'icles ranging fro# s%orts cars to sno*#o(iles - are (eco#ing #ore co##on as #anufacturers loo. to i#%ro&e t'e internal co#(ustion engine ($ s"uee/ing out #ore 'orse%o*er0 less e#issions and (etter fuel efficienc$. Se&eral 12 engine fa#ilies %resentl$ use S%ar. Ignited Direct In,ection 3SIDI4 tec'nolog$0 including t'e 2.05 tur(oc'arged 46c$linder engine in t'e Saturn S78 and 9ontiac Solstice and t'e 3.:5 V: engine in t'e Cadillac C!S. So#e industr$ %ro,ections indicate t'at in a fe* $ears0 one in si; engines *ill (e (uilt *it' direct in,ection. !'e nu#(ers illustrate t'e &alue of t'e tec'nolog$< t'e 300 =9 3.:5 V: in t'e ne* C'e&$ Ca#aro is rated at an esti#ated 2> 291 'ig'*a$. Direct in,ection refers to t'e fact t'at t'e fuel is in,ected directl$ into t'e co#(ustion c'a#(er. Direct in,ection is not ne*. In fact0 it?s a (asic %rinci%le of t'e diesel engine. ) diesel engine de%ends on t'e 'eat of co#%ression to ignite t'e diesel fuel t'e instant it?s in,ected into t'e c$linder 3t'is is Co#%ression Ignited Direct In,ection or CIDI4. B$ co#%arison0 SIDI engines in,ect gasoline directl$ into t'e air in t'e c$linder and t'e resulting #i;ture is t'en ignited ($ a s%ar. %lug. !'e in,ection s$ste# used on SIDI engines differs fro# standard fuel in,ection in one i#%ortant *a$. @it' SIDI0 t'e fuel is in,ected at a #uc' 'ig'er %ressure 3u% to 201A: %si or 1+0000 .9a4 (ecause it?s in,ected directl$ into t'e co#(ustion c'a#(er rat'er t'an into t'e inta.e #anifold 3%ort in,ection4.

Benefits of SIDI
@'en co#%ared *it' %ort in,ection0 (enefits of SIDI include< B lo*er e#issions0 %articularl$ at startu% B 'ig'er co#%ression B (etter fuel econo#$ 3%articularl$ on tur(oc'arged engines4 B increased 'orse%o*er )ll gasoline engines de%end on ato#i/ing t'e fuel (efore co#(ustion. But *it' car(uretors0 t'rottle (odies0 and e&en %ort in,ection0 t'e ato#i/ation ta.es %lace at a distance fro# t'e co#(ustion c'a#(er. B$ t'e ti#e t'e ato#i/ed fuel and air reac' t'e co#(ustion c'a#(er0 so#e of t'e fuel 'as se%arated out and collects on inta.e

Engine Coolant
Cualit$ coolant and *ater are critical to *ater %u#% o%eration. Conta#inated coolant0 de%leted coolant0 and %oor *ater "ualit$ can result in corrosion and seal da#age.

SIDI eli#inates all of t'is ($ ato#i/ing t'e fuel directl$ in t'e co#(ustion c'a#(er. )s t'e fuel ato#i/es0 t'e air and fuel #i;ture are cooled0 ena(ling t'e use of a 'ig'er co#%ression ratio. Better ato#i/ation contri(utes to a reduction in %re6ignition and detonation0 *'ic' is *'$ t'e SIDI engine can o%erate at a 'ig'er co#%ression ratio and consu#e less fuel. SIDI allo*s t'e engine to run on a leaner #i;ture 3#ore air0 less fuel4 at full %o*er. SIDI also allo*s a 'ig'er co#%ression ratio0 *'ic' in turn %ro&ides (etter fuel econo#$ at %art and full t'rottle. Direct in,ection %er#its controlling a ric'er #i;ture around t'e s%ar. %lug0 #a.ing it easier to ignite *'en t'e engine is cold. !'e SIDI engine runs s#oot'er and generates lo*er e#issions during cold start and *ar#6u%

Noise
12?s goal *as to ac'ie&e 9FI le&els of noise fro# t'e 'ig' %ressure fuel s$ste#. @it' DI t'e in,ectors and 'ig' %ressure %u#% are #ounted directl$ to t'e c$linder 'eads and t'erefore trans#it noise to t'e rest of t'e engine. Ru((er isolators and s%ring loaded *as'ers *ere de&elo%ed to isolate t'e fuel in,ectors. )dditionall$ t'e fuel in,ectors0 fuel rail and fuel %u#% *ere surrounded ($ noise insulating foa#. !'e engine co&er and (ell$ %anel *ere also designed *it' sound deadening #aterial to a(sor( radiated noise. Fuel %u#% control soft*are *as #odified to #ini#i/e t'e energ$ to dri&e t'e %u#% and reduce t'e action of t'e %u#% at idle.

Torque
!'e 12 3.:5 DD=C V: is a direct in,ected 4 &al&e engine. It retains full$ inde%endent &aria(le inta.e and e;'aust ca#s'afts. !'e increase in co#%ression ratio is a #a,or contri(uting factor to t'e #an$ (enefits o(ser&ed. !'is ne* engine o%tion for t'e C!S/S!S deli&ers 304 'orse%o*er 322A .@4 at :0400 r%#0 *'ic' is an increase of 1:E o&er t'e 9FI &ersion and 3A0 # of tor"ue at +0200 r%#0 *'ic' is an increase of FE o&er t'e 9FI &ersion.

Emissions
) #a,or ena(ler for t'e lo* e#issions is t'e ca%a(ilit$ of DI to run in =S9 #ode during catal$st lig't6off after cold start. During =S9 t'e fuel in,ected is s%lit into t*o in,ections. !'e first %ortion is ti#ed suc' t'at a lean #i;ture is distri(uted t'roug'out t'e co#(ustion c'a#(er. !'e second %ortion for#s an enric'ed cloud around t'e s%ar. %lug to allo* late ignition and co#(ustion *'ic' results in ele&ated e;'aust te#%eratures. Figure 23 s'o*s a (asic se"uence of t'e e&ents during =S9. ) DDE *as used to o%ti#i/e t'e control %ara#eters during =S9. S#oot'er o%eration and a reduction of '$drocar(on e#issions ($ a%%ro;i#atel$ 2+E during t'e cold6start and initial *ar#6u% *ere reali/ed using =S9.

Economy
Fuel econo#$ goals *ere e;ceeded on t'is %ro,ect 'a&ing ac'ie&ed 1A #%g E9) Cit$ and 2: #%g E9) =ig'*a$ &ersus goals of 1+.2 Cit$ / 2+.4 =ig'*a$. !'is *as acco#%lis'ed using FA octane regular fuel. Ena(ling t'is fuel econo#$ *ere t'e 'ig'er co#%ression ratio0 c'arge cooling0 ad&anced ignition ti#ing0 reduced *all *etting0 reduced start fuel and (etter fuel %re%aration.

Cadillac
Cadillac 'as announced details of a ne* !*in 6!ur(o V: engine and eig't6s%eed trans#ission 6 first re&ealed features of t'e ne* 2014 Cadillac C!S sedan *'ic' *ill de(ut ne;t *ee. at t'e )uto S'o* in e* 8or. . Rated a certified 420 'orse%o*er 3 313 .ilo*atts 4 and a tor"ue of +F3 # %o*er0 it is t'e #ost %o*erful V: e&er de&elo%ed ($ 1eneral 2otors. !'e ne* engine is an u%dated 3.:5 DD=C V: offered in t'e SRG 0 G!S and )!S currentl$ for sale . =o*e&er0 al#ost all t'e co#%onents are uni"ue. e* features include t'e follo*ing< e* engine (loc. and c$linder 'eads reinforced rods 2ac'ined alu#inu# %istons do#ed u%%er seg#ent *it' su%%orting steel for e;tra strengt' Co#%ression ratio of 10.2<1 S$ste# air intercooler integrated *it' air %i%es co#%act !*o tur(oc'argers *'ic' %roduce a %ressure of F0 .9a @astegates dri&en Co#%letel$ ne* direct in,ection s$ste# Resonators o%ti#i/ed inta.e and e;'aust 0 roc.er alu#inu# and ot'er s$ste#s to reduce noise.

Impro ement of t!e "asic engine

)s Cadillac !*in 6!ur(o engine is (ased on t'e sa#e arc'itecture as t'e e;isting 3.:5 V:0 it 'as #an$ %ro&en tec'nologies suc' as dual o&er'ead ca# 'ead0 &aria(le &al&e ti#ing and direct in,ection. !'e #ain c'aracteristics of t'e #otor (ase are< ) forged steel cran.s'aft t'at contri(utes to greater fle;i(ilit$ at 'ig' s%eed ) friction reducing coating %ol$#er on t'e %iston s.irts 0 as *ell as full$ floating %iston %ins t'at reduce friction Cooling no//les of %istons actuated ($ oil %ressure )n oil su#% stiffer cast alu#inu# to i#%ro&e t'e rigidit$ of t'e %o*er unit and reducing &i(rations of t'e &e'icle. !'e engine (loc. is uni"ue (ecause it includes connections for t'e coolant and oil fro# t'e tur(oc'arger0 and s%ecific cran.case &entilation %assages. !'e engine includes t'e cran.s'aft (earing ca%s nodular iron for greater strengt' to 'andle 'ig'er c$linder %ressures t'at co#e fro# t'e t*o6stage tur(oc'arging. !'e 'eads offer design inlets i#%ro&ing tu#(le for #ore efficient co#(ustion. Val&e seats e;'aust cured )R20 are used for t'eir te#%erature resistance0 *'ile t'e 'eads %ro&ide sealing t'roug' its design in se&eral la$ers stac.ed steel.

#ir cooler integrated "oost

)not'er feature of t'e Cadillac V: !*in 6!ur(o is its treat#ent of t'e c'arge air t'roug' t'e c$linder 'eads to t'e co#(ustion c'a#(er. Dne (utterfl$ located a(o&e t'e engine control air c'arge fro# (ot' tur(oc'argers after t'e te#%erature is reduced in t'e air cooler . !'is design %ro#otes a (etter res%onse

ti#e of t'e cou%le0 for a greater feeling of %o*er de#and and reduces co#%le;it$ ($ eli#inating t'e need for a (utterfl$. @it' t*o s#all tur(oc'argers 0 t'e s#aller tur(oc'arger re&s *'en t'e load de#and and t'e second tur(o (oost 0 slig'tl$ (igger ta.es o&er as soon as t'e flo* increases . !'e integrated Cadillac V: !*in 6!ur(o s$ste# cooler air cooler also 'el%s i##ediate res%onse ti#e 0 (ecause t'e tu(ing (et*een t'e co#%ressor and cooler are &er$ s'ort.

$astegates actuated "y acuum

!'e *astegates 3or relief &al&e 4 actuated ($ a &acuu# 6 ($ a tur(oc'arger 6 and controlled recirculation &al&es are used in t'e 3.:5 !*in 6!ur(o for a (etter #anage#ent of t'e (oost %ressure and engine tor"ue t'roug'out t'e range diet . ) *astegate is used to control t'e engine (oost %ressure . It allo*s e;'aust gases to ($%ass t'e tur(ine *'eel of t'e tur(oc'arger 0 and to (e reintroduced into t'e e;'aust strea# 6 &ia a (ranc' %i%e 6 to .ee% a #a;i#u# &elocit$ across t'e tur(ine s%eed range . Bot' *astegates t'e t*in tur(o Cadillac V: are controlled inde%endentl$ on eac' side of t'e V of t'e engine in order to (alance t'e %ressure %roduced ($ t'e co#%ressors . !'e *astegates *or. toget'er *it' t'e recirculation &al&es to eli#inate %u#%ing tur(os 6 a condition t'at can lead to t'e re&ersal of t'e flo* of air0 as i##ediatel$ after t'e closing of t'e t'rottle . In addition *astegates actuated ($ &acuu# &al&es and recirculation 0 t'e engine uses t*o air flo* sensors and sensor te#%erature / 'u#idit$ of t'e inta.e air 0 a co#%ressor inlet %ressure sensor and (ot' %ressure sensors inta.e #anifold .