508 28馬力輪式拖拉機(jī)最終傳動(dòng)及驅(qū)動(dòng)軸設(shè)計(jì)（有cad圖+文獻(xiàn)翻譯）
508 28馬力輪式拖拉機(jī)最終傳動(dòng)及驅(qū)動(dòng)軸設(shè)計(jì)（有cad圖+文獻(xiàn)翻譯）,508,28馬力輪式拖拉機(jī)最終傳動(dòng)及驅(qū)動(dòng)軸設(shè)計(jì)（有cad圖+文獻(xiàn)翻譯）,28,馬力,輪式拖拉機(jī),最終傳動(dòng),驅(qū)動(dòng),設(shè)計(jì),cad,文獻(xiàn),翻譯
外文資料翻譯
Powering profits
How PSA is extracting more performance and profit from a new 2.2-litre engine
The ongoing success of the co-operation between PSA Peugeot Citroen and Ford (See Feature, page 38) is further illustrated by the introduction of an all-new 2.2-litre diesel engine for passenger cars. The inline four-cylinder engine was not included in the original framework agreement, signed in 1998. Its development suggests that the two groups are doing well out of the partnership.
The new 2.2-litre diesel engine resulting from the technical alliance between PSA and Ford was designed to meet an ambitious target. It had to offer the driveability of the best 2.5-litre engines on the market as well as better fuel efficiency and emissions levels.
The engine will be used on a number of platforms for upper mid-rang and executive cars produced by both manufacturers. The engineers also faced the challenge of improving pedestrian protection to meet incoming European legislation and to improve the engine’s noise characteristics.
Because downsizing had proved effective in earlier phases of their co-operation, PSA and Ford opted to keep the new engine small. They set the displacement at 2.2-litres to reduce fuel consumption and carbon dioxide emissions, without sacrificing any of its performance features.
The engine takes some interesting approaches in its design . Its “extreme conventional combustion system” (ECCS) features a combustion chamber design that reduces emissions by 30 percent while improving performance and noise.
The combustion chamber has a large diameter and low compression ratio, which produces a more uniform air/fuel mix. The size of the combustion chamber limits the amount of fuel in contact with the walls. This makes combustion more efficient.
The pistons’ geometry had to be altered to create a 25 percent larger diameter combustion chamber compared with the previous engine generation. To withstand the extra stress and heat, the pistons had to be aluminium. The metal has very high mechanical and thermal properties.
The special geometry also significantly reduced swirl in the combustion chamber, thereby reducing heat loss to the walls and improving the engine’s efficiency. As a result, fuel efficiency under all driving conditions improved by 2 percent compared to the previous generation.
Remarkably, the new ECCS system did not require any changes in the production tooling for PSA’s DW family of engines. Parts are common to the other engines produced in this plant.
The engine’s common rail is a third-generation Bosch system that operates at a pressure of 1800 bar. The system uses piezoelectric injectors with seven 135 nozzles. These can make up to six injections per cycle, make fuel dosing more precise. This in turn enhances management of the introduction rate, the ratio of the amount of diesel injected to the injection spray is finer, which reduces emissions, since the air/diesel mix is more uniform.
All the cars powered by the new engine will be equipped with maintenances-based filter technology, while Ford will use a catalyst-based filter.
To enhance drive ability, particularly the torque delivered at low revs, turbos were essential. PSA engineers developed two turbo charging systems for different versions of the engine in partnership with turbo firm Honeywell.
The more powerful 125KW version uses a parallel sequential dual turbo. This reaches a peak torque of 400Nm at just 1750rpm. Using a small, low-inertia turbo makes the same size kicks in at 2700rpm. Both turbos are controlled by the engine management system.
A second version, which can produce between 115 and 125 KW, uses a single variable geometry turbo. This reaches 400Nm at 2000rpm and will be used for applications that do not require the bi-turbo boost at low engine speed. Electrical control enables precise, fast management of the turbo’s variable geometry to optimize boost pressure across the entire operating range.
Despite the extra kit on the engine, the overall engine height is 40mm less than its predecessor. Its compact size will allow it to be used in a greater number of vehicles by the manufacturers. It also makes the engine less likely to injure a pedestrian in the event of an accident. Performance, rather than pedestrian safety was the main priority, however. The reduction an size is the result of extensive re-engineering work on the engine’s top end.
The cylinder head has a single cooling flow, which also reduces heat loss, and is made from an aluminum-copper alloy. The properties of the material give better thermo-mechanical performance. The uniform water system cools the cylinder head precisely, reducing the amount of water used and simplifying the process.
A double-wall crankcase was developed for the project to reduce the noise radiated from the engine by three decibels; significant in terms of customer perception, says PSA. A fast response throttle intake system is actuated when engine is shut-off to avoid any vibration when the driver stops the car. And two counter-rotating balance shafts keep vibration on the inline unit to a minimum.
The engine will be manufactured at PSA’s tremery plant in France, the world’s largest diesel factory. In 2005, its 4637 engineers and production workers produced 1.2 million units.
The facility uses batch production to avoid assembly errors caused by changing from one model to another. The batches are very large with several hundred identical engines following each other on the line.
The 2.2-litre unit will be subject to the same “red card” sysem as others at the plant. Engines are checked after each assembly station. If a defect is spotted, the complete engine is scrapped. No reworking can be performed on the line, so that high quality is built into every engine from the outset. It sounds costly, but PSA’s research has shown that the reduction in warranty costs greatly outweighs any additional production costs.
The overall investment for designing and producing the new engine is EUR 212m (RMB 2.1bn). research and development costs came to EUR 127m (RMB 1.3bn). By using existing tooling with only specific technical improvements, production investment was limited to just EUR 85m (RMB 850m).
More than 300 people will be assigned to production of the engine. Built on the same line as PSA’s 2.0-litre engine, the use of existing tooling and processes meant that it took just 3300 hours of training for the operators to adapt their skills to the changes in their workstations.
PSA has reserved a capacity of 200000 2.2-litre units a year on the line. Considering that the current 2.2-litre engine is only produced at levels of 70000 a year, the French carmaker’s confidence in its latest creation must be high.
改進(jìn)動(dòng)力系統(tǒng)帶來利潤
標(biāo)志雪鐵龍集團(tuán)如何從一種新型2.2升發(fā)動(dòng)機(jī)獲取更多性能及利潤
轎車全新式2.2升柴油機(jī)的問世進(jìn)一步闡明了標(biāo)志雪鐵龍集團(tuán)與福特公司之間合作的成功（參閱特別報(bào)道，第38頁）。直列四缸動(dòng)機(jī)不包括在1998年簽署的原始框架協(xié)議之內(nèi)，它的開發(fā)表明雙方合作關(guān)系良好。
源于標(biāo)志雪鐵龍集團(tuán)與福特公司技術(shù)合作的新型2.2升柴油機(jī)為實(shí)現(xiàn)宏偉目標(biāo)而設(shè)計(jì)。它必須具有市面上2.5升最佳發(fā)動(dòng)機(jī)的驅(qū)動(dòng)性能，同時(shí)還具有較好的燃料效率及排放標(biāo)準(zhǔn)。
該發(fā)動(dòng)機(jī)將用于雙方制造商的中高級(jí)汽車等多種平臺(tái)。工程師也面臨著提高行人保護(hù)措施，從而符合即將來臨的歐洲立法及改善發(fā)動(dòng)機(jī)噪聲性能的難題。
由于其早期合作證明規(guī)?？s小十分有效，標(biāo)志雪鐵龍集團(tuán)與公司決定仍將新型發(fā)動(dòng)機(jī)設(shè)計(jì)為小型發(fā)動(dòng)機(jī)。他們?cè)诓粨p失其任何性能特點(diǎn)的基礎(chǔ)上，將2.2升排量的發(fā)動(dòng)機(jī)設(shè)計(jì)為可減少燃料消耗及二氧化碳排放物的形式。
該發(fā)動(dòng)機(jī)在其設(shè)計(jì)過程中采用了一些有趣的方案。它的“極其傳統(tǒng)的燃燒系統(tǒng)（ECCS）”具有一個(gè)燃燒室結(jié)構(gòu)，該結(jié)構(gòu)能夠在改善其性能及噪聲的基礎(chǔ)上減少30%的排放物。
該燃燒室較大的直徑及較低壓縮比，這能夠生成更加均勻的空氣與燃料混合物。燃燒室的尺寸能夠限制與內(nèi)壁接觸的燃料數(shù)量。這能夠使燃料更加有效。
與先前發(fā)動(dòng)機(jī)類別相比，活塞的幾何結(jié)構(gòu)不得不改動(dòng)以形成一個(gè)直徑比原來大25%的燃燒室。為承受額外應(yīng)力及熱量，活塞必須采用鋁制結(jié)構(gòu)。因?yàn)樗哂蟹浅８叩臋C(jī)械及熱性能。
這一特殊的幾何結(jié)構(gòu)也大大降低燃燒室中的渦流，從而減少了內(nèi)壁熱損失并改善了發(fā)動(dòng)機(jī)效率。因此，與上一代發(fā)動(dòng)機(jī)相比，所有驅(qū)動(dòng)下的燃料效率提高了2%。
最顯著的特點(diǎn)是新型ECCS系統(tǒng)無須改變標(biāo)志雪鐵龍集團(tuán)DW系列發(fā)動(dòng)機(jī)的生產(chǎn)工裝。其零件與在該工廠生產(chǎn)的其他發(fā)動(dòng)機(jī)相同。
該發(fā)動(dòng)機(jī)的共軌采用了第三代博世系統(tǒng)，這一系統(tǒng)可在1800巴壓力下運(yùn)行。該系統(tǒng)采用了壓電噴油嘴及七個(gè)135微米的噴嘴。這些裝置每個(gè)循環(huán)可形成六次噴射，能夠保證燃料噴射量更加精確。這也同時(shí)提高了對(duì)引入率的控制或柴油噴射量與噴射時(shí)間的比率。噴射射流較細(xì)有利于減少排放物，因?yàn)榭諝馀c柴油混合物更均勻。
所有由這種新型發(fā)動(dòng)機(jī)驅(qū)動(dòng)的汽車都將配備無須維護(hù)的柴油顆粒過濾器。標(biāo)志雪鐵龍集團(tuán)將采用一種基于添加劑的過濾器技術(shù)，而福特公司將采用一種基于催化劑的過濾器。
為了提高驅(qū)動(dòng)性能，特別是提高低轉(zhuǎn)速時(shí)的扭矩，渦輪是必須的裝置。標(biāo)志雪鐵龍集團(tuán)的工程師與霍尼韋爾渦輪公司合作，針對(duì)不同版本的發(fā)動(dòng)機(jī)開發(fā)了兩種渦輪增壓系統(tǒng)。
功率較強(qiáng)的125KW版本的發(fā)動(dòng)機(jī)采用了一個(gè)平行連續(xù)復(fù)式渦輪。這使發(fā)動(dòng)機(jī)僅在1750轉(zhuǎn)時(shí)就可達(dá)到400Nm的峰值扭距。采用一種小型，低慣性的渦輪使發(fā)動(dòng)機(jī)即使在較低轉(zhuǎn)速時(shí)也可響應(yīng)。因?yàn)樗∫灾劣跓o法覆蓋發(fā)動(dòng)機(jī)整個(gè)工作范圍，第二個(gè)同樣大小的渦輪可以在2700轉(zhuǎn)/分鐘時(shí)沖入。兩個(gè)渦輪都由發(fā)動(dòng)機(jī)操縱系統(tǒng)控制。
第二個(gè)版本發(fā)動(dòng)機(jī)能夠生成115至125KW的功率，該發(fā)動(dòng)機(jī)采用了一種單式可變幾何渦輪。該渦輪可使發(fā)動(dòng)機(jī)在2000轉(zhuǎn)/分鐘時(shí)達(dá)到400Nm扭矩，而且它將被應(yīng)用于在較低發(fā)動(dòng)機(jī)轉(zhuǎn)速時(shí)無須雙渦輪增壓的領(lǐng)域。電動(dòng)控制系統(tǒng)能夠精確，快捷的控制渦輪的可變幾何結(jié)構(gòu)一邊在整個(gè)工作范圍內(nèi)增壓。
盡管該發(fā)動(dòng)機(jī)上設(shè)有額外裝置，但是整個(gè)發(fā)動(dòng)機(jī)高度比它上一代少40毫米。由于其具有尺寸緊湊的特點(diǎn)
因此它將被各個(gè)制造商應(yīng)用于大量車輛中。同時(shí)，如果發(fā)生事故時(shí)它也能夠保證發(fā)動(dòng)機(jī)不大可能傷及行人。然而，與行人安全相比，性能是首當(dāng)其沖需要考慮的事項(xiàng)。尺寸縮小是對(duì)發(fā)動(dòng)機(jī)頂端大量再設(shè)計(jì)的結(jié)果。
汽缸蓋具有一個(gè)同樣可減少熱損失的單式冷卻流道，該汽缸蓋由鋁銅合金制成。該合金材料的特性具有較好的熱量機(jī)械性能。均一的供水系統(tǒng)能夠精確的冷卻汽缸蓋，從而減少所使用的水量并簡化工序。
標(biāo)志雪鐵龍集團(tuán)表示，針對(duì)該項(xiàng)目開發(fā)的雙壁曲軸箱旨在將發(fā)動(dòng)機(jī)輻射出的噪音減少三分貝，這對(duì)客戶的感受非常重要。快速響應(yīng)的油門進(jìn)氣系統(tǒng)能夠在發(fā)動(dòng)機(jī)關(guān)閉時(shí)啟動(dòng)以免司機(jī)停車時(shí)出現(xiàn)任何振動(dòng)。而且兩個(gè)反轉(zhuǎn)平衡軸能夠?qū)⒅绷邪l(fā)動(dòng)機(jī)的振動(dòng)最小化。
這一發(fā)動(dòng)機(jī)將在標(biāo)志雪鐵龍集團(tuán)位于法國的特母利工廠生產(chǎn)，該工廠是世界上最大的柴油機(jī)工廠。2005年，該工廠4637名工程師及生產(chǎn)工人生產(chǎn)了120萬臺(tái)發(fā)動(dòng)機(jī)。
該工廠采用批量生產(chǎn)，以避免由一個(gè)模式向另一個(gè)模式轉(zhuǎn)變?cè)斐傻难b配錯(cuò)誤。這些批次都很大，每個(gè)生產(chǎn)線有數(shù)百臺(tái)相同的發(fā)動(dòng)機(jī)彼此接續(xù)。
這種2.2升發(fā)動(dòng)機(jī)將與該工廠生產(chǎn)的其他發(fā)動(dòng)機(jī)一樣受“紅牌”系統(tǒng)的控制。在每個(gè)裝配站裝配之后，發(fā)動(dòng)機(jī)都需檢驗(yàn)。如果發(fā)現(xiàn)有任何缺陷，整個(gè)發(fā)動(dòng)機(jī)將作廢。生產(chǎn)線上不能進(jìn)行任何返工工作，以便保證從開始每臺(tái)發(fā)動(dòng)機(jī)就具有較高質(zhì)量。盡管這聽起來成本很高，但是標(biāo)志雪鐵龍集團(tuán)的研究表明保修成本減少帶來的收益遠(yuǎn)大于任何附加生產(chǎn)成本。
設(shè)計(jì)及生產(chǎn)這種新型發(fā)動(dòng)機(jī)的總投資為2.12億歐元（人民幣21億元）。研發(fā)成本共計(jì)1.27億歐元（人民幣13億元）。采用現(xiàn)有的工裝及僅有專門的改造后技術(shù)，生產(chǎn)投資僅需8.5億歐元（人民幣85億元）。
將有300多人將被分配生產(chǎn)這種新型先進(jìn)的四缸發(fā)動(dòng)機(jī)。在標(biāo)志雪鐵龍集團(tuán)生產(chǎn)2.0升發(fā)動(dòng)機(jī)的生產(chǎn)線上生產(chǎn)，采用現(xiàn)有工裝及工藝，這意味著只需花費(fèi)3300個(gè)小時(shí)培訓(xùn)操作者將其技術(shù)適應(yīng)其工作站的變化。
標(biāo)志雪鐵龍集團(tuán)已儲(chǔ)備了每年生產(chǎn)線生產(chǎn)20萬臺(tái)2.2升發(fā)動(dòng)機(jī)的能力。鑒于目前2.2升發(fā)動(dòng)機(jī)每年僅生產(chǎn)七萬臺(tái)，這一法國汽車制造商必須對(duì)其最新創(chuàng)作具有很高的信心。
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