MANN+HUMMEL Automotive Introduces Top-sys(R), a Breakthrough Concept In Air Induction Technology
10 September 1997
MANN+HUMMEL Automotive Introduces Top-sys(R), a Breakthrough Concept In Air Induction Technology
FRANKFURT, Germany, Sept. 10 -- MANN+HUMMEL Automotive will
unveil a new and original air induction system with several unique features
for enhancing performance, increasing fuel efficiency, and fine tuning
acoustics. Top-sys(R), as it is called, is a continuously variable induction
system incorporating all components from the fresh air inlet through to the
cylinder head. This first of its kind system will be introduced at the
Frankfurt Auto Show on September 10, 1997.
Induction systems for today's combustion engines are faced with the
challenge of meeting the ever-increasing demands of both customer and
industry. Among these demands are thermodynamics, fuel efficiency, acoustics
and packaging.
Thermodynamic factors of an induction system include the air temperature
and the management of the air flow through the system. Both factors play a
vital role in optimizing the performance of the engine.
Increasing gas prices and tougher CAFE requirements placed upon car makers
are driving the need for more fuel efficient vehicles. Greater responsibility
is being shifted from the manufacturer to the supplier to design and develop
engine components with fuel optimization in mind.
The move from traditional aluminum induction products to composite has
brought with it a concern regarding the acoustics of the product or system.
The challenge for the supplier is to design the induction product or system
minimizing Noise Vibration Harshness levels (NVH).
As the trend to build smaller, more efficient vehicles continues, the
engine compartment will in turn continue to decrease in size. These tighter
tolerances under-the-hood greatly impact the packaging of the induction
system. The geometry, orientation under-the-hood, and adjacent components are
all determining factors to be considered in the design of the product.
The result of extensive research and advanced development, the top-sys
induction system has been designed to face these demands head-on. There are
five advanced features which make up the revolutionary system that include:
* top-vario(R) -- continuously varies intake orifice diameter located in
the fresh air inlet duct. The orifice size is controlled by a diaphragm-like
device which continuously adjusts itself according to the engine RPM and load.
Purpose: Controlling the orifice size and, therefore, the volume of incoming
fresh air, directly influences the acoustics of the system.
* top-temp(R) -- manages air intake temperature. On the fresh air end,
the system includes both a cold air intake duct from outside air and a hot air
intake duct which draws hot air from above the exhaust manifold. The two
extremes come together at the air temperature optimizing device called top-
temp which senses the air temperature mixture and adjusts it according to both
outside air temperature and engine RPMs. If the temperature is too hot, more
air will be taken in from the cold air inlet and vise versa to achieve the
optimal air mixture. Purpose: Controlling the intake air temperature to
remain within a constant range allows for optimal air/fuel ratios which
reduces fuel consumption and enhances performance.
* top-phon(R) -- attenuates overall noise levels in the fresh air ducts.
When the fresh air leaves top-temp it enters a final duct on its way to the
air cleaner. It is in this duct that we find top-phon which is a section of
the duct that is perforated with small holes to allow air to pass into a small
connecting chamber. Purpose: Sound pressure levels which cause noise can be
attenuated over an entire frequency range through the use of top-phon.
* top-neck(R) -- constantly varies the resonating ability of the system.
Top-neck has an active switching device which changes the size of the orifice,
length and position of the resonater neck based on RPMs and load. Purpose:
Acoustic optimization. The ideal amount of sound pressure is released into
the resonater based on the engine speed, which allows for ideal noise
attenuation at varying frequencies.
* top-tube(R) -- continuously varies intake manifold runner lengths. Top-
tube utilizes a rotating "barrel concept" to continually adjust runner lengths
in correlation to changing engine needs. Current active manifolds function on
a long/short or on/off system whereas top-tube is constantly active. Purpose:
Continuously adjusting runner lengths based on the engine's needs translates
to enhanced engine performance.
The top-sys induction system demonstrates never before seen technology and
will almost certainly impact the future of induction systems. The individual
elements which make up the impressive system have produced amazing results,
however, the system as a whole adds up to more than the sum of its parts.
The results of the top-sys induction system are impressive. Some of the
benefits which can be easily measured include a decrease in fuel consumption
of 2% to 3% under normal driving conditions, a reduction in noise levels by 8
decibels, and a 10% increase in volumetric efficiency. Putting these results
into perspective, it can be said that top-sys achieves the same overall
results as seen with variable valve timing, however, with costs of up to 20%
less.
Though top-sys is currently a developmental prototype, it has been
packaged and extensively tested on a production vehicle. A compact car with a
1.4L engine was chosen to play host to top-sys, which was purposely designed
to meet the tight packaging requirements of today's vehicles.
MANN+HUMMEL Automotive is a division of MANN+HUMMEL GmbH. With sales of
$800 million annually, MANN+HUMMEL GmbH is organized into two divisions,
automotive and industrial. The automotive division, which serves both the OEM
and aftermarket, manufactures under-the-hood products including plastic intake
manifolds, air cleaners, resonaters, air, oil, fuel, and cabin filters and
complete air induction systems. The company employs approximately 8,000
people and has 20 manufacturing/sales locations worldwide.
SOURCE MANN+HUMMEL Automotive