Dongfeng Motor has announced and certified an achievement that could fundamentally change its position on the world technology map: the new Mach 1.5T gasoline engine, designed specifically for hybrid vehicles, has officially become the first internal combustion engine with a thermal efficiency exceeding 48%.
The record was certified by the authoritative CATARC (China Automotive Research Center), which issued the engine with the “Energy Efficiency Star“ certificate. The registered value is 48.09% - a number that was previously considered science fiction in mass automotive construction. To give you an idea, thermal efficiency is the key to economy: it shows how much of the fuel energy is converted into useful work, and not wasted as heat. While conventional gasoline engines typically operate in the 35-40% range, and the best hybrid units barely exceed 41-43%, Dongfeng raises the bar almost to the sky.
Dongfeng engineers explained that this leap is the result of three fundamental technological changes implemented in the new generation of the engine.
First, the team has developed an entirely new, highly efficient combustion system. Through a combination of a high compression ratio (over 15.5), a precise piston stroke to cylinder diameter ratio (over 1.45), direct fuel injection under extremely high pressure of 500 bar, and an ultra-powerful ignition system, they have managed to ensure complete and rapid combustion of every drop of gasoline. It is as if you are forcing the engine to “squeeze” every last joule of energy.
The second key area was the thorough modification of the intake system and turbo. Especially for the needs of the hybrid architecture, the Mach 1.5T received a VGT turbocharger with variable geometry, a sleeveless valve design and a modern electric drive for the variable gas distribution system. These solutions ensure that the engine “breathes“ freely and efficiently in any operating mode, without any “choking“. The result is a noticeably faster and more stable response to gas supply, even in difficult conditions.
The third, but not least, block of improvements focuses on the drastic reduction of mechanical losses. By implementing more than ten innovative solutions – including an electric oil pump and thermal spraying technology (Thermal Spraying) on the cylinder walls – a significant reduction in internal friction has been achieved. Less friction means that less energy is wasted on overcoming internal resistance and more power is transferred directly to the wheels.
The end result of these changes is a remarkable expansion of the engine's effective operating range. Dongfeng claims that the updated Mach 1.5T provides a noticeable reduction in fuel consumption in all conditions: from busy city driving to long highway trips.
Thanks to this wider “green zone“ of high efficiency, the hybrid system can constantly keep the car in optimal fuel economy. The manufacturer boldly predicts that the new engine will allow for approximately 100 kilometers more on a single tank compared to the previous generation, and the overall fuel economy reaches about 10%.