Schaeffler: Thermal Management Module

Published:  13 February, 2018

The job of a modern water pump is so much more than circulating coolant through the engine cooling system. Advances in technology have led to the water pump having a direct effect on CO2 by controlling coolant flow around the turbo, gearbox and intercooler, as well as the battery pack inside hybrid vehicles.

Schaeffler’s Thermal Management Module (TMM) uses sensor-controlled rotary slide valves to manage the temperature balance inside the vehicle’s drivetrain, allowing the engine and transmission to reach optimum temperature quickly. This generates a greater energy efficiency and life of the drivetrain’s components.

The TMM allows the ideal operating temperature of the internal combustion engine to be reached in the shortest possible time; consequently, fuel consumption and CO2 emissions are reduced by up to 4%.

The cold-running phase begins from when the engine is started. The TMM (1) ensures that the engine’s cooling jacket (3) is blocked off; therefore, the engine warms up faster and the cold-running phase is significantly shortened.

The warm-up phase is when the engine has reached its best operating temperature. The TMM (1) opens the water circuit and uses the available heat to regulate the temperature of the engine, transmission (4), heating system (5) and other system components.

www.schaeffler.co.uk

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  • 888... Lucky for some 

    With this month’s focus in Aftermarket on cooling, I thought a look at how technology has affected one of the oldest systems of the internal combustion engine. For illustration, I have chosen the Volkswagen Auto Group’s en888 engine, built in Mexico, Hungary and China hence the 888 insignia; It is their lucky number.

    Its one of Audi’s high-performance variants. Its fitted in my Seat Cupra 2ltr, producing 400bhp with stock mechanicals. So, what are the benefits of advanced cooling systems? Heat derived from combustion, transferred by conduction and convection into cooling and the environment is in effect wasted energy. Controlling and where necessary containing it improves efficiency, not forgetting reductions in emission pollution.

    Efforts
    They have made stringent efforts in the mechanical design of the 888 to achieve savings in efficiency. Reducing engine weight, minimising internal friction, increasing power and torque, current with fuel economy initiatives.

    The cylinder block wall is reduced from 3.5mm to 3.00mm. Internal friction is reduced with smaller main bearing journals, revised timing chain design, incorporating a dual pressure lubricating system. The balance shaft has roller bearings, piston cooling jets further improve thermal stability. The jets have PCM mapped control, while extra oil cooling is provided adjacent the filter housing, close to the activation solenoid and twin oil pressure sensors.

    The engine can theoretically reach Lambda 1 from cold within 20-30 seconds.

    Further technical innovations include reduced oil level, reduced tension force in the auxiliary chain mechanism, down shifting achieved with variable valve lift and twin scroll direct mount turbo design.

    Advances
    You will now appreciate that it is no longer possible to separate mechanical design, power delivery, emissions, and all-round efficiency, treating cooling as an afterthought.

    Take the cylinder block design, which possibly has the biggest advances reserved within the cylinder head and coolant control module (water pump). The exhaust manifold is housed completely within the cylinder head casting. This ensures very effective conductance of heat. The emphasis is now on increase, maintain, reduce, thanks to an advanced dual valve PCM controlled coolant control module. The module is mounted at the rear of the engine block, belt-driven with a cooling fan to keep the belt cool.
    By manipulating the two rotary valves, flow and temperature can be effectively controlled within very carefully controlled limits. The rotary valves are manipulated by a PWM 1000hz motor with SENT position feedback (single edge nibble transmission), a method used by the latest air mass meters.

    Heat transfer into and from the turbo is much more efficient due partly to the direct mount and integrated cooling galleries surrounding the exhaust tracts.

    The piston to wall clearance has been increased, with a special coating on the piston thrust side complimenting a direct gudgeon pin to rod contact, the DLC coating removes the need for a bearing bush.

    The cylinder head porting incorporates ignition sequence separation, thus ensuring preceding exhaust pulses do not impede the energy from the current. This in combination with advanced turbine design further improves torque range and downshifting. Cooling control priority is applied to the occupants, then the transmission, further reducing frictional losses.

    Complexity
    Although not directly related to the cooling system, a dual injection system is fitted with its main function being emission reduction. Cold start is provided with three direct injection events, followed by port injection warm up. These systems do not run in tandem. Two thirds of the load range is controlled by port injection, with full load above 4,000 rpm delivered by induction stroke direct fuel delivery.

    From a practical point of view, previous low-tech tasks like replacing coolant components and bleeding now requires electronic support through the serial interface. Using the correct antifreeze is now essential if premature corrosion is to be avoided. As a warning, capillary coolant invasion within wiring looms is well known in some French and GM vehicles, as some of you will be aware.
    It is also worth mentioning that Volkswagen has modified the software controlling cooling in some of their diesel vehicles as part of the emission recall programme.

    Predictably due to their complexity, I can foresee cooling systems being neglected during routine servicing , so expect to see faults as these systems age in the pre-owned market.


  • Steel Seal 

    Steel Seal can permanently seal blown head gaskets, warped heads and cracked engine blocks. Simply pour Steel Seal into the radiator of a cold engine.  When the engine is started and reaches its operating temperature the mixture is drawn into the damaged areas by the heat and pressure caused by the head gasket fault, which then seals the cracks with a thermo-chemical bonding process. Once the bonding process is complete and the engine has been allowed to cool the chemicals become inert, so there is no reaction when other products are added to the cooling system. Steel Seal also offers a lifetime money back guarantee
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  • TOTAL QUARTZ 9000 FUTURE FGC 5W-30 

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