Stepcom® – 2 Step Variable Compression Ratio System Integration & Industrialization

Authors

Dipl.-Ing. FH Manfred Pöpperl, Dr.-Ing. Sebastian Schilling, Dipl.-Ing. Dietmar Schulze, Hilite Germany GmbH, Marktheidenfeld;
Dr.-Ing. Daniel Henaux, Dr.-Ing. Knut Habermann, Dr.-Ing. Tolga Uhlmann, FEV Europe GmbH, Aachen

Summary

The integration of a new technology into an existing base engine design is a major challenge. This is even more valid when new engine designs are a limited number due to the future transition to electrified propulsion. The Hilite Stepcom® Variable Compression Ratio (VCR) system is providing a design solution to introduce a new technology with minimal impact on the existing base engine design. This also allows to utilize existing machining and engine assembly lines to build VCR engines side by side with conventional engines. Besides the benefits in terms of fuel consumption reduction VCR also provides further value with respect to upcoming RDE requirements given by the capability to operate higher specific power at stoichiometric condition. The first VCR system in production has been launched by Nissan in 2018.

This paper presents the compatibility of the Stepcom® system in combination with mild hybrid systems, system validation, electrical integration, actuation, design for cost optimization and production readiness.

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