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From prechamber to BLUETEC

* Diesel technology from Mercedes-Benz: A history of innovations

* From stationary engine to refined automotive drive

* BLUETEC: The diesel technology of the future


The diesel engine draws much of its appeal from the history of the Mercedes-Benz brand. It “learned to walk” in the motor vehicle at Benz & Cie. – at the beginning of the twentieth century, design engineer Prosper L’Orange developed a vehicle propulsion unit from Rudolf Diesel’s engine, and in 1923 the world’s first diesel truck originated in Mannheim. Finally, in 1936 Mercedes-Benz built the world’s first diesel passenger car. Since that time there has been an unending succession of innovations to every aspect of the compression-ignition engine in the vehicles of the Stuttgart-based brand.

BLUETEC is the latest innovation for low emission levels and is going to further advance the powerful but low-emission drive towards the future. These high-tech vehicles, which make good ecological sense and are blessed with attractive driving qualities, provide an answer to the questions of the vehicle concepts of tomorrow. In the modular BLUETEC system, Mercedes-Benz has put together a technology package for coming vehicle generations.
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Chrysler Group 5.7-liter HEMI® and 3.0-liter V-6 Turbo Diesel Take Two Spots in Ward’s 10 Best Engines Awards

* HEMI wins for fifth consecutive year
* DaimlerChrysler advanced diesel technology recognized by industry experts
* Both Chrysler Group winning engines available in 2007 Jeep® Grand Cherokee


Auburn Hills, Mich., Dec 12, 2006 –

For the fifth year in a row – and every year since its 2003 re-introduction — Chrysler Group’s famous 5.7-liter HEMI® engine has earned a place on Ward’s 10 Best Engines list. Joining the HEMI in winning the award is DaimlerChrysler’s 3.0-liter V-6 Turbo Diesel, available in the 2007 Jeep Grand Cherokee.


“We are pleased that Chrysler Group has delivered two engines among Ward’s 10 prestigious winners,” said Bob Lee, Vice President — Powertrain, Chrysler Group. “The HEMI continues to impress as an engine that offers the combination of power and fuel efficiency our customers demand, while the 3.0-liter V-6 CRD Turbo Diesel boasts an unsurpassed blend of acceleration, torque and fuel economy.”

First introduced in the 2003 Dodge Ram, the 5.7-liter HEMI V-8 achieves power, fuel economy and emissions goals with a design that is elegant and cost effective. The engine is available in the Chrysler 300, Chrysler Aspen, Jeep Commander, Jeep Grand Cherokee, Dodge Charger, Dodge Durango, Dodge Magnum and Dodge Ram.
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Virtually painted

* Simulation of painting processes optimizes production

* Early planning cuts costs

* Complex calculations reduce testing


Stuttgart, Dec 11, 2006
The DaimlerChrysler researchers are developing special calculation methods to optimize painting processes. Even prior to production start-up, they can thus determine how a vehicle body can be painted as efficiently as possible or how an existing painting process can be improved. This early planning helps cut costs and enhances planning reliability.

No commercial program package is yet available on the market that can make predictions about painting processes. The DaimlerChrysler researchers are therefore using models to emulate the various systems and their dynamic processes. The findings from these simulations can be transferred to reality.

Toward practical application

With this tool, the production planners and developers can already test a newly designed vehicle body’s suitability for the painting process at an early stage. Complicated, expensive tests can be largely dispensed with, since the calculations provide reliable data. With their help, the planners are able to determine in advance the requirements for production and can design the processes accordingly. Modeling and numerical simulation are excellently suited for optimizing the existing infrastructure even in the ongoing production process. Paint robots, for example, can be adapted more rapidly and precisely to the task at hand.

Painting and spraying
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New diesel variant with V8 power: The S 420 CDI flagship diesel model makes its debut with 235 kW/320 hp and 730 Nm of torque

New diesel variant with V8 power: The S 420 CDI flagship diesel model makes its debut with 235 kW/320 hp and 730 Nm of torque

Stuttgart, Dec 06, 2006

Mercedes-Benz is extending its S-Class range with another diesel variant, the S 420 CDI. The new eight-cylinder model is powered by a
state-of-the-art V8 CDI engine developing 235 kW/320 hp and 730 newton metres of peak torque. This latest addition to the model line-up means that the luxury saloon range from Mercedes-Benz now encompasses two diesel engines, six petrol models and two body variants, along with the new 4MATIC all-wheel-drive system. The new S 420 CDI is available to order now, with deliveries to customers due to start in December 2006. The short-wheelbase model is priced at € 84,448 (net price € 72,800) and the long-wheelbase version at € 92,104 (net price € 79,400).

The new V8 model’s strengths are effortlessly superior performance combined with moderate fuel consumption. The S 420 CDI powers from 0 – 100 km/h in 6.6 seconds and goes on to reach 250 km/h (electronically governed), all while returning fuel consumption figures below the magic ten litre threshold, burning just 9.4 to 9.6 litres of diesel per 100 kilometres on the NEDC cycle. With a fuel tank capacity of 90 litres, this equates to ranges approaching the 1000 kilometre mark.

Such impressive figures are down to the highly advanced eight-cylinder turbodiesel engine under the bonnet: from its 3996 cc displacement, the CDI unit with four-valve-per-cylinder technology delivers a maximum output of 235 kW/320 hp at 3600 rpm and a peak torque of 730 newton metres, which is on tap from 2000 rpm. Third-generation common-rail high-pressure injection technology with a maximum injection pressure of 1600 bar and an ignition pressure of 175 bar ensures efficient combustion. Optimised flow dynamics for the best possible gas cycle and twin turbochargers with variable-nozzle turbines promise high power and torque delivery. As many as five injections of diesel fuel per injection cycle, special orifice nozzles, piezoelectric injectors and highly effective exhaust gas recirculation all help to lower emissions significantly. The new V8 powerplant is equipped as standard with a maintenance-free diesel particulate filter to cut untreated emissions even further, and also complies with the EU4 emissions standard. The engine development team was able to reduce noise levels by optimising the chain drive and fitting a rigid crankcase with large engine bearings as well as extra acoustic covers. The square bore-to-stroke ratio combines with a counter-rotating balancer shaft for outstandingly smooth operation.
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Global Development

Clear definitions for complex requirement profiles

Stuttgart, Nov 30, 2006
Vehicle electrical and electronic systems are not only becoming more comprehensive; they’re also growing increasingly complex, especially in terms of their functions. This development is being driven by automakers’ ability to precisely define which requirements a certain component must meet in order to ensure that it can subsequently be integrated as desired into the overall system. For a component or system to even be suitable for cross-platform applications, a very sophisticated approach is needed — a new culture of vehicle development that demands more than simply specifying technical processes.


Anyone who thinks a blinker is only a simple light, or says that a tachometer can hardly be considered a complex instrument, can expect a vociferous rebuttal from Frank Houdek. The DaimlerChrysler researcher needs only a few minutes to convince even the most uninformed lay person that such notions are all wrong. “I myself am time and again amazed by how complex the definitions of requirements have to be, even for components I had thought were very simple,” he reassures his novice visitor.
Houdek works in the Software Process Design department led by Bärbel Hörger in Ulm. The sign on his office door says “Requirement Engineering Processes,” because there’s no succinct German translation for this area of research. The focuses of the work performed by Hörger’s department include a process central to the overall task of vehicle development — specification. To the experts, the term means precisely describing all the requirements that must be fulfilled by simple components like LEDs, by more complex systems such as the vehicle dynamics system ESP, or even by the entire vehicle with all of its various functions.
And in this field, “precise” means “unambiguous.” In practice, “unambiguous” in turn means that “Anton,” a development engineer responsible for a control unit, is able to understand a requirement definition in exactly the same way as does his colleague “Boris,” whose tire pressure sensor sends a signal to Anton’s component. And the two of them must understand the specification document in exactly the same way as “Claude,” an engineer working for a supplier who is responsible for developing the tire pressure display for the instrument cluster of the planned model.
Clarity also means that development engineers “Osamu” at Fuso in Tokyo, “Beth” at Freightliner in Portland and “Kurt” at Mercedes-Benz in Stuttgart all have exactly the same understanding of a jointly formulated requirement definition — for a new multifunctional display that is to be installed in the respective instrument clusters of the heavy-duty trucks from these three brands, for example.
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Short Circuits Cut Down on Friction

Stuttgart, Nov 30, 2006
The introduction of electric arc wire spraying in engine production has made it possible to build very low-friction cylinder running surfaces in aluminum engines.

The new 6.3-liter V8 engine developed by engineers at DaimlerChrysler’s AMG subsidiary is the world’s most powerful eight-cylindery naturally aspirated engine. It delivers an output of 386 kW (525 hp), and 630 Nm of torque at the crankshaft, and is now being used in various AMG models, most recently the Mercedes-Benz CL 63 AMG high-tech coupe. The fully aluminum engine has 32 valves, a cylinder bore of 102.2 millimeters, and a stroke of 94.6 millimeters. It achieves its impressive power not only from its large displacement and favorably streamed intake and exhaust system, but also by means of a unique innovation deep in its interior: The running surfaces of the light-metal cylinders consist of an “EAS coating” that ensures extremely low-friction operation.
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