Elektrohydraulische

Ventilsteuerung
EHVS
Electro-hydraulic
Valvetrain
System EHVS
FPNI Forum 2004, Bad Ischl

02.03.2004 | FPNI 2004.ppt

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS

FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution?
2. How does the EHVS work?
3. What components are used?
4. What results can be measured at the test bench?
5. Next steps?
02.03.2004 | FPNI 2004.ppt
Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

2
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Electro-hydraulic Valvetrain System EHVS

Expected Advantages for Gasoline Engines
Fuel consumption/Efficiency

Minimization of gas exchange losses (dethrottling, with manifold injection)

valve cutoff, cylinder cutoff, multi stroke operation
Reduce of idle speed (more stable due to less residual gas)

Torque curve/Power

Operating-point-dependent optimization of valve timing and

stroke

Exhaust gas

Operating-point-dependent variation of the charge motion

Variable internal exhaust gas recirculation (EGR)

Additional functions

more efficient engine brake

new starting strategies
less assembly groups
reduced size of the engine

02.03.2004 | FPNI 2004.ppt

103 408 144

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS

Requirements to a fully variable Valvetrain

The simultaneous and uncoupled optimization of the fuel consumption and

the emissions requires the independent control of fresh mixture, residual gas
and charge motion. For this the opening and closing angle and the stroke of
the individual gas exchange valves are to be controlled cycle to cycle
conform.

The systems fail safety, especially the fail safe position gas exchange valve
closed, is to be considered in the systems design.

In order to achieve a low-cost serial production with a high number of pieces

there is to be aimed a use of the control principle as well as the partial
components with all known engine types and combustion concepts.

All material, partial components and production processes necessary for the
systems assembly are to be selected in compliance with the criterions
availability and process safety.

The different engine types which are all to be covered with the same
principle require a broadly applicable range relating to the parameters
force, stroke and valve velocity.

02.03.2004 | FPNI 2004.ppt

103 635 442

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS

Titel des Kapitels
Specification

parameters combination:
high force (>1000N), velocity (2,5ms/10mm), stroke (>10mm)

valve velocity and braking behavior adapted to operating point

valve free travel is not always to be assumed

cylinder head with actuators, checkable as module

afterwards installation of the whole module on the engine block

exchange of individual actuators installed on the mounted cylinder head

temperatures between -40C ... 140C

02.03.2004 | FPNI 2004.ppt

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS

Technology Decision
gas
exchange

cylinder rotary
valve

flat rotary valve

flat seat
valve

camless valve train

systems with cam

pendulum systems

electromagnetic

electrohydraulic

single acting plunger,

counter spring

one 3/3 solenoid valve

02.03.2004 | FPNI 2004.ppt

ball valve

linear systems

electromagnetic

electrohydraulic

pneumatic

double acting plunger

(identical surface)

two 2/2 solenoid valves

electromotive

piezoelectric

differentialplunger

servo solenoid valve

103 448 149

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

magneto
-strictive

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Electro-hydraulic Valvetrain System EHVS

FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution?
2. How does the EHVS work?
3. What components are used?
4. What results can be measured at the test bench?
5. Next steps?
02.03.2004 | FPNI 2004.ppt
Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

7
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Electro-hydraulic Valvetrain System EHVS

Operating Principle of the Differential Piston
Gas exchange valves stroke depending on the control MV1/MV2
Stroke
MV 1

MV 2

opening

hold

closing

Gas exchange
valve

Valve
brake

closed

MV 1

open

Time

closed

Gas exchange valve

MV 2

Control for big stroke of gas exchange valve

Control for small stroke of gas exchange valve

02.03.2004 | FPNI 2004.ppt

Time

open

closed

IO

103 449 149

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copying and passing on to third parties.

IC

Time

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Electro-hydraulic Valvetrain System EHVS

Hydraulic Principle of Actuator V0.7
Every actuator includes:

Actuator
SD-Rail

DRV

2/2 solenoid valve currentless closed at

high-pressure side

RB

MV1

MV2

ND-Rail

2/2 solenoid valve currentless opened at

low-pressure side
Throttle for valve brake adjustable via
pilot pressure (-> variable valve brake)
two-stage differential piston drive
hydraulic length compensation

HD-Rail

Every actuator can be:

HDV
GWV

assembled or disassembled individually

at the engine
completely connected hydraulically via
the bearing surface

HD rail ........ High pressure supply (50 - 200bar)

ND rail ........ Low pressure supply (<5bar)
SP rail ......... Pilot pressure supply (5 - 20bar)
MV1/MV2 ... Solenoid valves
02.03.2004 | FPNI 2004.ppt

HPV ......... High pressure pump for valvetrain system

DRV ......... Pressure control valve for pilot pressure
RB ........... adjustable valve brake
GWV......... Gas exchange valve

103 611 350

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copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS

Measured Valve Lift Curves for Actuator V0.7
mm
11.0

Variation of brake

10.5
10.0
9.5
9.0

Pressure:
Oil temp.:

100 bar
82 C

8.5
8.0
7.5
7.0
6.5
6.0

Measured velocities:
v_maxopening: 3,0 m/s
v_maxclosing:
3,2 m/s
vbrake:
0,05 .. 0,5 m/s

5.5
5.0
4.5
4.0
3.5
3.0
2.5

(inlet valve)

2.0
1.5
1.0
0.5
0.0
-0.5
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
ms

02.03.2004 | FPNI 2004.ppt

103 617 350

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS

Measured Valve Lift Curves for Actuator V0.7
mm
12

Cycle/cycle jitter

11
10

Pressure:
200 bar
Oil temp.:
86 C
Number of cycles: 50
Measured velocities:
v_maxopening: 4,5 m/s
v_maxclosing:
5,2 m/s
vbrake:
0,55 m/s
(inlet valve)

9
8
7
6
5
4
3
2
1
0
-1
0

10

11

12

13

14

15
ms

02.03.2004 | FPNI 2004.ppt

103 618 350

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

11
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Electro-hydraulic Valvetrain System EHVS

FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution?
2. How does the EHVS work?
3. What components are used?
4. What results can be measured at the test bench?
5. Next steps?
02.03.2004 | FPNI 2004.ppt
Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

12
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Electro-hydraulic Valvetrain System EHVS

Description of the System (4V Combustion Engine)
pressure and temperature sensor
pressure relief valve

EHVS- actuator

cylinder head with

hydraulic adapter modul,
thermodynamic modul

Signals for :
rpm
pedal position
temperatures
crankshaft position

viskosity sensor
high pressure pump

02.03.2004 | FPNI 2004.ppt

103 600 341

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

oil filter
(inflow of engines
oil circle)

high pressure
oil pressure of engine
reflow
leakage

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Electro-hydraulic Valvetrain System EHVS

EHVS-Actuators, different types

V0.5 (Diesel Engine)

V0.4 (Gasoline Engine)
02.03.2004 | FPNI 2004.ppt

V0.7 (Gasoline Engine)

103 627 641

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copying and passing on to third parties.

14
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Electro-hydraulic Valvetrain System EHVS

EHVS-Actuators, different types
V 0.4
Features

V 0.5

V 0.7

- Covers the complete gasoline

engine operating range

- Covers the complete diesel

engine operating range

- Covers the complete gasoline

engine operating range

- actuator can be assembled

independently on engine

- actuator can be assembled

independently on engine

- actuator can be assembled

independently on engine

- valve brake

- valve brake

- variable valve brake

(pilot pressure controled)

- Stand alone test of the cylinder

head possible

- Stand alone test of the cylinder

head possible
- high forces during complete
stroke

- Stand alone test of the cylinder

head possible
- two-stage differential piston drive
- hydraulic length compensation
- uses common engine valves

Size (LxW xH)

98 x 38 x 83 mm

99 x 38 x 87 mm

86 x 36 x 83 mm

Moved mass

76 g

103 g

75 g

10 (8) mm

10 (8) mm

12 (10) mm

Opening force (200bar)

EV: 835 N; IV: 400 N

EV: 1360 N; IV: 670 N

EV: 1690 N; IV: 840 N

Closing force (200bar)

EV: 475 N; IV: 480 N

Max. (usable) stroke

Engine
) N
V0.5 (Diesel
EV: 765
N; IV: 960

EV: 4,8
m/s; IV:)4,8 m/s
V0.4 (Gasoline
Engine

Max. Opening speed (200bar)

Max. Closing speed (200bar)
02.03.2004 | FPNI 2004.ppt

EV: 2,4 m/s; IV: 4,2 m/s

EV: 450 N; IV: 450 N

EV: 4,4 m/s; IV: Engine
4,5 m/s )
V0.7 (Gasoline

EV: 4,0 m/s; IV: 3,8 m/s

EV: 2,2 m/s; IV: 3,8 m/s

103 628 441

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copying and passing on to third parties.

EV: 5,0 m/s; IV: 5,2 m/s

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Electro-hydraulic Valvetrain System EHVS

Header of section
4 Cylinder Head

Cylinder head with:

- EHVS actuator
- Adapter module

02.03.2004 | FPNI 2004.ppt

103 596 349

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

16
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Electro-hydraulic Valvetrain System EHVS

Solenoid Valves
MV2
currentless opened
delay opening
delay closing
opening cross-section
pressure compensation:
flow compensation

320s
380s
3mm
inlet

MV1
currentless closed
delay opening
delay closing
opening cross-section
pressure compensation:
flow compensation
02.03.2004 | FPNI 2004.ppt

280s
330s
3,4mm
inlet/outlet

103 589 349

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copying and passing on to third parties.

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Electro-hydraulic Valvetrain System EHVS

Hydraulic Pump Unit (next generation)

HPV5
Axial piston pump
Output
Max. rpm
Pressure range

02.03.2004 | FPNI 2004.ppt

5 pistons
5 cm/rev.
6000 1/min
20-250 bar

103 595 349

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

18
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Electro-hydraulic Valvetrain System EHVS

FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution?
2. How does the EHVS work?
3. What components are used?
4. What results can be measured at the test bench?
5. Next steps?
02.03.2004 | FPNI 2004.ppt
Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

19
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Electro-hydraulic Valvetrain System EHVS

Test Engine

Test engine:
Combustion engine
4 cyl.,16 valves

= 11

Peff
Md,max

MPFI

= 120 kW
= 200Nm
= 11

Euro-Super ROZ 95
3-way-catalyst
EU IV, SULEV certificated
16 valves with EHVS
Hydraulic pump integrated
Hydraulic oil: engine oil 0W40

02.03.2004 | FPNI 2004.ppt

103 601 348

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

20
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Electro-hydraulic Valvetrain System EHVS

Fuel Consumption (Dyno Results)
Messungen in Kooperation mit

Fuel Economy Improvement [%]

8

180 km/h

BMEP [bar]

7
6

55

10
10

160 km/h
NEDC

4
15

3
2

35
30
25
20
15
10
5
0

15

1
0
1000

20
30
2000

Customer Relevant
Reduction of
Fuel Consumption

3 to 17 %
Idle 0.31 kg/h

25

EHVS 16-Valve

EHVS cylinder deactivation

15

3 to 35 %
NEDC average 17%

35
3000

4000

5000

Engine Speed [rpm]

6000
Measurments with:

02.03.2004 | FPNI 2004.ppt

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

Actuator V0.4
Pump HPV7

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Electro-hydraulic Valvetrain System EHVS

Dyno results at 2000rpm
Messungen in Kooperation mit

2000 rpm

EHVS V0.4, HPV7, Full Engine at

500

Base Engine
EHVS 16V
EHVS Cyl. cut off

460

BSFC [g/kWh]

EHVS = 1, BSFC Status 09/03:

420

Fuel Reduction

Low Load: - 35% to - 12%

z
z

380

4 Cyl. 2000 rpm / 2 bar: 332 g/kWh

Cut off 2000 rpm / 2 bar: 305 g/kWh

High Load: - 12% to - 8%

2000 rpm / 7 - 10 bar:

241 g/kWh

340

300

Increase of max. Load:

260

Base Engine:

10,3 bar

EHVS Engine:

11,4 bar

220
0

10

12

10

12

BMEP [bar]
02.03.2004 | FPNI 2004.ppt

Measurments with:

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

BMEP [bar]

Actuator V0.4
Pump HPV7

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Electro-hydraulic Valvetrain System EHVS

FPNI Forum 2004, Bad Ischl

Agenda
1. Why a hydraulic solution?
2. How does the EHVS work?
3. What components are used?
4. What results can be measured at the test bench?
5. Next steps?
02.03.2004 | FPNI 2004.ppt
Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

23
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Electro-hydraulic Valvetrain System EHVS

Hydraulic circuit

Difference EKS / ZKS

Present system

EKS - one circuit system

engine oil / EHVS hydraulic
z
z

open hydraulic system

common with engine oil

High pressure pump

= psurrounding

Engine oil pump

Next system

ZKS - two circuit system

z

closed EHVS hydraulic system

separate fluid

in small portions mixable fluids

High pressure
pump

plow

Engine oil pump

02.03.2004 | FPNI 2004.ppt

Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as
copying and passing on to third parties.

Feed pump

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