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Analytical and Developmental Techniques Utilized in the Structural Optimization of a New Lightweight Diesel Engine
Abstract:
Jaguar Land Rover (JLR) has designed and developed a new inline 4 cylinder engine family, branded Ingenium. In addition to delivering improved emissions and fuel economy over the outgoing engine, another key aim from the outset of the program was to reduce the combustion noise.
This paper details the NVH development of the lead engine in this family, a 2.0 liter common rail turbo diesel. The task from the outset of this new program was to reduce the mass of the engine by 21.5 kg, whilst also improving the structural attenuation of the engine by 5 dB in comparison to the outgoing engine. Improving the structural attenuation by 5 dB was not only a key enabler in reducing combustion noise, but also helped to achieve a certified CO2 performance of 99 g/km in the all-new Jaguar XE model, by allowing more scope for increasing cylinder pressure forcing without compromising NVH.
To achieve this structural attenuation target, an intensive program of CAE analysis, rig testing and full powertrain measurements in an Engine Noise Test Cell (ENTC) were undertaken on three progressive levels of prototype engines. Details are included of the key hardware changes that were implemented to deliver the target attenuation, as well as the correlation that was achieved between CAE, rig and full powertrain testing.