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The spray-guided BMW DI combustion system eliminates the most important disadvantages of the wall-and air-guided 1st generation DI combustion systems. With its central injector position, the spray-guided system provides a stratified mixture at the spark plug and reduces wall wetting significantly. The low spray penetration and high spray stability of the outward-opening piezo injector allow an extension of the stratified engine map to higher engine load and speed. The piezo drive permits an extremely fast opening of the injector needle, thus enabling multiple injections with very short delay times and high flexibility for the calibration strategy to supply a very efficient combustion with low unburnt hydrocarbon and carbon monoxide emissions. Compared to a conventional throttled SI engine, the spray-guided system shows a fuel consumption potential of about 20% in the NEDC.

The complexity of the mixture formation in direct injection engines requires - according to a suitable mixture transportation and vaporization of the fuel - detailed knowledge of the in-cylinder processes to reliably place an ignitable mixture at ignition timing near the spark plug for any speed and load. Two different optical measurement techniques were adapted to a single cylinder engine and the spray propagation was observed from the start of injection until ignition. 3-pentanone tracer-LIF signals (laser-induced fluorescence) and CN spark emission signals were detected simultaneously in order to get information about the local equivalence ratio at the spark plug and compare the two methods. While there is a good correlation for homogeneous operating conditions of the engine, the results diverge in the stratified mode.

To operate gasoline direct injection engines at part load and in stratified mode the mixture formation has to fulfil several requirements. The complexity of this process requires - regarding a suitable mixture transportation and vaporisation of the fuel - an adjusted design of the combustion chamber and the intake ports to reliably place an ignitable mixture at ignition timing near the spark plug at any speed and load. Due to the inhomogeneous mixture distribution during stratified operation, the first combustion period is very sensitive to cycle-to-cycle variations. A reproducible mixture movement with high kinetic energy is necessary for stable engine operation with low fluctuations in the combustion process. Because of the high relevance of these facts, the effects of an adjustable air guiding system in the inlet manifold on in-cylinder flow, ignition and combustion using optical measurement techniques were investigated.

To meet future emission standards with gasoline direct injection engines it is important to have a reliable process robustness during stratified charge operation. Especially engines with a wide spacing arrangement of fuel injector and spark plug which operate with an air-guided concept are very sensitive concerning misfire operation caused by cyclic variations of the mixture formation and transport. Primarily the turbulent in-cylinder gas motion and the interaction with the fuel injection indicate these fluctuations. To reduce these cycle-to-cycle variations and to generate a steady flow behavior an adjustable air-guiding system was developed and attached to the inlet port of a single-cylinder DI engine. The following examinations show that the air-guiding system can lead to a significant reduction of the cycle-to-cycle-variation of the in-cylinder air flow. As a result of these improvements, the deviation of imep in the fired engine decreases obviously.

With the increasing demands on commercial vehicles in the last few decades the air-brake system too has been continuously improved. As a supplement to the reliable valve technology, electronic systems such as ABS (Anti-lock brake system) and ASR (Automatic traction control system) have ensured safer driving in recent years. Further progress in the brake system will be achieved by increasing the brake-air pressure level and using disk brakes on all vehicle axles. In addition to this the performance, operating convenience and economic efficiency of the brake system can be increased by the use of an electro-pneumatic brake system in which compressed-air actuated wheel brakes are activated via electrical control signals and integrated pressure control circuits. Optimized ABS/ASR functions are integrated in the new system.