Optimization Of 1.6L PFI Gasoline Engine Piston Assembly And Its Effect On Fuel Consumption

In 2015,China launched and forced the implementation of the fourth phase of "Corporate Average Fuel Consumption(CAFC)" regulations.It requires that the CAFC of the automobile enterprises need to achieve 5.0L/100 km in 2020.This requirement has brought tremendous pressure to China automobile enterprises.In order to meet this requirement,DPCA decided to optimize the design of the existing 1.6L naturally aspirated gasoline engine.It’s required that reduce the friction loss,improve the air charging efficiency to improve engine efficiency and reduce fuel consumption based on little overcost.Because the friction loss of the piston assembly is one of the important factors that affect the engine efficiency,the design optimization scheme for reducing the friction loss of the piston assembly is discussed in this paper.The design optimization mainly includes five aspects,such as the lightweight of the piston assembly,the optimization of the contact surface between the piston component and the cylinder bore,the reduction of the piston ring elasticity,the optimization of the piston and piston ring coating,and the optimization of the cylinder clearance.The first step is the study of theoretical analysis of main parameters related to the fuel consumption of the piston assembly,study the potential direction of improvement;the second step is the study of the existing piston assembly parameters related fuel consumption,making optimization design solutions;third step using the Finite Element Analysis to make theoretical calculation and analysis,list the main parameters of improved piston components compared to the original piston components,demonstrate the improved effect;fourth step is that produce optimized piston assembly prototype,making friction torque test,engine bench test and vehicle road test.The optimization design of this research,compared with the original engine fuel consumption is reduced by 2%,it bring 0.083L/100 km CAFC benefits to DPCA,to help DPCA meet the requirements of fourth stage corporate average fuel consumption limits and regulations.In this paper,a cost effective and feasible fuel consumption reduction technology is discussed.Making design optimization based on the existing engine,realize the fuel consumption target,and the overcost is not high,little influence on the structure of the existing engine,and keep the engine performance.This research provides important reference value for the current automobile enterprises to improve the average fuel consumption and meet the requirements of national laws and regulations.