Mazda interview discussing inline-6

Some interesting comments from Mazda in this interview posted today.


At least in this application, the straight-six is not simply a lengthened version of Mazda's four-cylinder, as the bore and stroke dimensions aren't the same. Still, one imagines there's a lot of commonality between the two engines, because, well, why wouldn't there be?

Jay Chen, powertrain head at Mazda North America Operations, explains the straight-six was the right mill to propel the company’s luxury aspirations. The new rear-drive architecture provided the CX-90 enough length to use a straight-six, and the engine's narrow dimensions also allowed for double-wishbone suspension, the ideal layout for great ride and handling. Chen says the straight-six also allowed more room for crash structure.

Perhaps most notable is the engine’s 12:1 compression ratio, unusually high for a production turbocharged mill. That compression ratio is higher than the 10.5:1 of Mazda's 2.5-liter turbo four and even the 11:1 of BMW's B58 straight-six. Nissan's neat variable-compression turbo engine can run as high as 14:1, but as low as 8:1. Generally speaking, higher compression boosts power and efficiency, though obviously, those increases subject the engine’s components to greater stress overall.

For the CX-90, Mazda offers the 3.3-liter with two outputs. The first produces 280 hp and 332 lb-ft. Turbo S models make 340 hp and 369 lb-ft. From a hardware perspective, the engines are identical. The lower output engine is meant to run on standard 87-octane fuel. As such, the turbo only provides 14.0 psi of boost. (If you put higher-octane fuel in, it won't make a difference). The Turbo S engine requires 93 octane to deliver its full output, running 19.1 psi of boost. If you put 87 in a Turbo S, power output reduces to 319 hp while torque remains the same. Chen says he'd likely run the Turbo S on lower-octane fuel, as the real-world performance differences are insignificant.

Mazda says that despite bucking the trend toward engine downsizing, this relatively big six-cylinder provides better fuel economy at a given torque figure than its smaller-displacement cousins. Generally, a six-cylinder will provide more torque at lower revs than a four-cylinder, so the six isn't working too hard to heft the CX-90 around. Via its variable valve-timing system, this engine can also switch between the traditional Otto and Miller cycles, wherein the intake valve is held open slightly longer during the compression stroke to allow some fuel-air mixture back into the intake manifold. This increases the expansion ratio, the difference in cylinder volume between top dead center versus bottom dead center—essentially the opposite of compression ratio—providing a nice efficiency boost.

This is not the engine’s final form, Chen says. Think of this straight-six as something of a platform unto itself. It was designed with flexibility in mind, so Mazda can tailor its specifications to future products, ones smaller than the CX-90. The CX-70 should soon follow the CX-90. Chen also suggests this engine will end up in a sedan of some sort (just don't call it a Mazda 6).
 
That reads like an Advertorial bought by Mazda:

1. Somewhat interesting fact about engine.
2. GUESS WHAT ELSE HAS AN INLINE 6? BMW. MERCEDES.
3. Repeat ad nauseum.

On the other hand, I'm glad Mazda's marketing department appears to be actually doing something for a change. I just wish they got better product for their advertising money. There are a few things that are not quite correct:

1. "...the change of direction as pistons reach top and bottom dead center is mirrored by pistons on the other side of the engine, canceling out first order vibrations." So does a inline 4 and a V8. What they were going for here is that an inline six has perfect secondary balance, which is why it is smoother than the alternatives.

2. "From a hardware perspective, the engines are identical." Another poster has used the parts website to determine that the higher output version has a different intercooler setup.

3. "Via its variable valve-timing system, this engine can also switch between the traditional Otto and Miller cycles, wherein the intake valve is held open slightly longer during the compression stroke to allow some fuel-air mixture back into the intake manifold. This increases the expansion ratio, the difference in cylinder volume between top dead center versus bottom dead center—essentially the opposite of compression ratio—providing a nice efficiency boost." The valvetrain reduces the effective compression ratio by delaying the intake valve closure, it doesn't do anything to the expansion ratio at all.
 
3. "Via its variable valve-timing system, this engine can also switch between the traditional Otto and Miller cycles, wherein the intake valve is held open slightly longer during the compression stroke to allow some fuel-air mixture back into the intake manifold. This increases the expansion ratio, the difference in cylinder volume between top dead center versus bottom dead center—essentially the opposite of compression ratio—providing a nice efficiency boost." The valvetrain reduces the effective compression ratio by delaying the intake valve closure, it doesn't do anything to the expansion ratio at all.

If you read the definition of the miller cycle: « Efficiency is increased by having the same effective compression ratio and a larger expansion ratio. »

Opening the valve effectively reduce the compression stroke, while keeping the expansion stroke it’s original length. So the expansion stroke is effectively longer than the compression stroke and thus the expansion ratio is longer.

Potatoes and potâtoes, but the article is technically correct here.
 
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If you read the definition of the miller cycle: « Efficiency is increased by having the same effective compression ratio and a larger expansion ratio. »

Opening the valve effectively reduce the compression stroke, while keeping the expansion stroke it’s original length. So the expansion stroke is effectively longer than the compression stroke and thus the expansion ratio is longer.

Potatoes and potâtoes, but the article is technically correct here.

I am well aware of the definition. This engine does not have the same effective compression ratio - it is reducing it by delaying the intake valve closure. So, despite bragging about having 12:1 (mechanical) compression in the paragraph before, it's not really achieving this level when approximating the Miller cycle. When there's no boost, the motor swaps the valve timing to a traditional Otto cycle to increase efficiency and drivability prior to the turbo spooling.
 
All I am saying is that you said the article was wrong. I only have access to what was copied pasted above, but it isn’t really wrong by saying the expansion ratio is longer. It is missing information for sure.

If like you said the Otto cycle is used when there is no boost (full unboosted 12:1 compression ratio), and the miller cycle is used under boost, then the boosted air can be used in the miller cycle to create the same effective compression ratio. The intake valve is opened longer, but the charged air increase the pressure to the same effective compression ratio than the 12:1 unboosted compression ratio. Of course this miller cycle compression ratio would be less than a boosted Otto cycle, but we don’t know how the 12:1 compression ratio was measured.

I am honestly not sure this is how the mazda engine works, but if it works that way the article would be correct
 
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2. "From a hardware perspective, the engines are identical." Another poster has used the parts website to determine that the higher output version has a different intercooler setup.

So I think this may not be true, there were parts of the diagrams that were not clear via the diagrams and after spending more time, it looks like the sub-radiator is actually tied to additional cooling capacity based around towing capacity.

I need to go update that post.
 
I6 makes so much sense for turbo applications. You've got a hot side and a cold side. Also, from a modularity perspective, Mazda's future 4 could share a lot of components with the 6 (similar to the BMW B58 and B48). The current 4 seems to be based on the existing (legacy?) 2.5
 
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