Main process aims in powertrain development progress

QUALITY

Quality everywhere. In particular, what we do when we design, is to extend engine’s lifetime to its limits as per the production possibilities. As a result, produced engines can last up to their desired lifetime without any particular important damages.

COST EFFECTIVE

When we design, we aim at reaching desired production costs our customer wants. Consequently our designs are cost effective for cost effective engine development projects.

ENGINEERING SPEED

We design to time. It means that optimized engineering methods we use, reduces time resources. Therefore what we engineer will fit the desired time frame.

DESIGNED FOR PRODUCTION

From concept to SOP. When an engine is in designing progress, we take necessary actions for reaching SOP from the very beginning. What are  our principles? you can find them here. In addition, parts and tooling plans, assembly and sub assembly charts and documents along with other procedures will be made for perfect SOP.

Industries we can cover for powertrain development

We can develop powertrain and engines both gasoline and diesel and even bi-fuel which are widely used in different following industries.

  • Light vehicles and passenger cars diesel, gasoline and bi-fuel powertrains in automotive industry
  • Heavy load trucks and transportation vehicles diesel engines and bi-fuel powertrains
  • Construction machineries and agricultural vehicles diesel engines and bi-fuel powertrains
  • Mining industry, loaders and shovels and others diesel engines and bi-fuel powertrains
  • Light and ultralight aircraft ULTRA performance gasoline engines
  • Coastal and passenger ship engines and powertrains and propeller
  • Bulk carriers and tankers diesel engines and bi-fuel powertrains and propeller

Complete driveline development

When a complete driveline development is desired, we do also develop transmissions to fully match our powertrain. That will ensure optimized cost and full performance in lesser time. Make sure to check our transmission development page.

up to 3400 Hp

Engine power output

powerful enough or you need more ?

up to 16 cylinder

Engine configuration

Main powertrain project targets

Burg Germany like many other companies, aims at today’s needs when a project runs. Therefore every project is created carefully base on achieving the most of bellow said objectives.

Reduced Emissions

  • Reduced CO2, NOx emissions.
  • Use of bi fuels.
  • Catalyst converters.
  • Targeting Euro5 and 6 standards.
  • Future emission standards.

Best Performance

  • Best weight to power ratio.
  • Maximum performance with natural aspirated engines.
  • Maximum performance with Turbo Charger development and testing.

Fuel Economy

  • GDI and MPFI development.
  • New injector types selection and configuration.
  • Combustion design.
  • New engine parts for better fuel efficiency.

Low Noise

  • Engine and transmission noise and vibration test technology.
  • Sound isolation methods and solutions.
  • Low noise powertrain and driveline development.

Engine set up and design configurations

New systems and technologies in internal combustion engines can be developed to improve performance, fuel economy and emission reduction simultaneously.

  • Cylinder wall guided.
  • Air-guided.
  • Spray guided.
  • Double injector system.
  • Mono or Dual (Bi)
  • VGT – Variable Geometry Turbo Charger
  • Electric Turbo Charger
  • Mono or Dual for intake and/or exhaust
  • Continues or Discreet types.
  • Intelligent mechanism.
  • Servo or mechanical based systems.
  • Double Overhead Camshafts systems for engines with OHVs or older systems.

Engines consisting of :

  • GDI
  • Turbo Charged
  • DOHC

Engine control systems – ecu

Clean and environmentally friendly, high performance management systems for today’s powertrains

Hardware development

When we design the hardware, we ensure that individual components function perfectly. Individually and in the system as a whole. With intelligent electronics and todays technologies that work fast, we make a product secure and reliable. We also offer comprehensive solutions, from the concept to the product ready up to SOP. We support our customers during the final production of the relevant electronics components and even after it. This is hassle free engineering.

Software development

Burg Germany Engineering develops smart solutions and intelligent protocols for the powertrain and transmission. And we see to their implementation and accompany our customers up to series production. This way, vehicle manufacturers can rely on intelligent software, while at the same time, short innovation cycles become reality. Our innovative protocols run our engines safe, fuel efficient, powerful with minimized emissions.

Testing and calibration

If you look at today’s technologies you find them yet very complex and challenging. Our testing and calibration facilities and engineers look forward to intelligently, optimize the functions and performances in the fields of fuel economy, emission control and reliability. For sure the result will be cost effective and the safety is guaranteed.

CONCEPT TO SOP

It all starts from concept. It will be tailored base on customer’s needs. High tech methods and cost effective solutions will be provided toward complete manufacturing processes.

COMBUSTION DESIGN AND DEVELOPMENT

The most important part of any engine design is the combustion of fuel in internal combustion engines. We understand it, master it are able to develop it. That’s the key to performance.

Combustion design in other words

Injector

Fuel injector selection is a very important part of combustion development progress. Hence the created spray pattern configuration or injection speed will guaranty a uniform and homogenous flame in combustion chamber for maximum performance. Our engineering team ensures the optimum performance, fuel economy and controlled emmisions by perfectly selecting and configuring the right injectors.

GDI

High speed injectors we use, will carry out today’s demand for GDI configurations. In addition, our GDI fuel management system relies solely on how direct injection is performed especially in high revs in comparison with MPFI (multi port fuel injection). As a result, engines we design carry a very sophisticated fuel and combustion technology to ensure best fuel consumption in GDI systems along with maximum performance.

Bi Fuels

Nowadays, many engines rely on mixed fuels or switchable fuels like LPG, E10 or even CNG. When designing a Bi Fuel engine there will be more challenges to be taken cared of. To begin with, high temps, lack of fuel lubricants and corrosions cause by non purified natural gases are those that makes the injector performance and injection development more complicated.

Bi Injectors

In some cases and  for special engines, there will be added injectors. Spending on what result we are looking for, we add more injectors to our designs. As a result, we achieve the desired performance with high tech engineering and fuel injection management.

Valves

Valve shape and mechanism and its movement plays a crucial role in ICE performance.

Intake Valve Bounce Back

One of the very important problems occurs in ICE is the Intake Valve Bounce Back problem. Because of that, many engines loose pressure when air is compressed at high revs. Therefore there will be loss of power as well. Our designs completely covers all major problems and assures best smooth valve train performance.

VVT and VVL

For much better performances and better engine functionality, we can develop VARIABLE VALVE TIMIG and VARIABLE VALVE LIFTING systems to the engine. These technologies are very accurate and sophisticated. They can be developed either for intake or for both intake and exhaust valves. Undoubtedly, correct technologies will push engines to its perfect performance.

Piston

What compresses the air and creates power in an engine is the piston. It creates the pressure, holds it and transfer it. Therefore when we design an engine, we put a lot of attentions to it.

Piston Head Shape

Compression ratio, perfect fuel and air flow inside combustion chamber all rely on piston shape. This is one of our very important parts of performance that we put a lot of efforts on it.

Blow By

In milliseconds, when air is going to be compressed by a piston, there will be air leakage from around the piston where it contacts with cylinder. It not only lowers the compressed pressure, but also pushes more air inside engine block and creates other problems. In our engines, the blow by time is longer than the compression time hence, in high revs, engine will not loose that much of pressure. In this case, the compression will be faster than blow by time.

Flow and Compression

In combustion chamber, air flow and fuel-air compression management and lost control is a key to performance. What we do is to optimize flow and decrease compression lost all the way down to exhaust.

Gas flow and heat analysis

An example of gas flow and valve heat and stress analysis all together.

Air Flow Management

Our engines come with very high precision air flow management technologies. The amount of flow as well as its speed and turbulence effects, drastically changes the engine performance. Therefore in the development progress, we calculate total air flow system inside engine from its beginning to its end for maximum performance.

Turbo Charging

When we turbocharge an engine, we increase the volume of air which goes into the cylinder. That means more air in fraction of second goes in and more pressure will be created when piston compresses. But all that change and pressure creates many challenges which needs to be taking cared of. The latter also creates more heat than in non turbo charged engines. Hence designing fully matched turbo charger with managed thermal issues, ensures perfect torque and power at all engine speeds.

Example of cylinder simulation of 3 Valve engine-Heat and stress analysis.

Ignition

In our designs we ensure that a spark which ignites the fuel is right on time and is at its perfect place. furthermore with its right amount of fuel. We will ignite a perfect homogeneous correct amount of fuel in the engine’s combustion chamber for perfect performance and optimized fuel consumption.

Combustion simulation

As the most important part of any engine design which is the combustion of fuel in internal combustion engines, the selected spray pattern of fuel and firing sequence and combustion will be simulated to achieve the prefect performance.