For this reason, extremely strong, aviation-grade stainless steel was chosen for the two triangular longitudinal frames and the box-shaped rear axle carriage frame. The heart and soul of the Veyron is the 8-liter W16 engine with four turbochargers, which initially generated 1, PS, and an incredible 1, PS in later models.
The engine is fully capable of operating under a continuous full load, a feat that engines designed for use in motor racing cannot achieve. These scoops direct a flow of air into the two air filters, each of which supplies two turbochargers. The air end on each turbocharger compresses the air before feeding it through the two intercoolers and throttle valves into the two inlet manifolds. The exhaust gases, in turn, power the four turbochargers and pass through the catalyzers into the liter titanium exhaust system.
From there, the exhaust gas is vented out into the open air through four tailpipes — two visible on the vehicle tail and two concealed in the rear diffusor.
The Bugatti Veyron engine is designed in a so-called W configuration. Unlike other W engines made by Volkswagen, it has a 90 degree bank angle.
Each bank has eight cylinders in a VR arrangement, ensuring optimum use of the available space. The crankshaft has eight large-end bearing sockets, with two large-end bearings per socket.
In contrast to the usual positioning of auxiliary units on the engine, with the W16 engine they are positioned in a separate ancillary system holder behind the engine. This makes optimum use of the available space and protects the ancillary systems from excessive heat from the turbochargers and catalyzers.
Each cylinder has four valves: two supply it with inlet air and two more vent out exhaust gases. Four chain-driven overhead camshafts operate the valves of which there are 64 in total. The Veyron is equipped with the dual-clutch gearbox DSG , which is the fastest gearbox in the world. Bugatti was the first manufacturer to use a seven-speed variant of the DSG. Designed specially for the new sports car, this gearbox has a job which any other gearbox would balk at, i.
The seven-speed dual-clutch gearbox comprises two clutches with four gears each: one for the even and reverse gears, and the other for the odd gears. The actuator block, which controls the clutches and valves, is located between the two clutches. The downforce is transmitted to the rear axle along the right-hand side relative to the direction of travel.
The shaft runs from here to the rear axle differential between the turbochargers and engine block. The downforce is transmitted to the cardan shaft, and hence the front axle, via the front end of the gearbox. The even and reverse gears are located in the front section of the gearbox housing and are connected to the dual clutch via a long shaft. The gears 1, 3, 5 and 7 are located in the rear section of the gearbox housing.
A short, coaxial hollow shaft encompasses the drive shaft for the even gears, connecting them to the dual clutch. A dual-clutch gearbox is, to all intents and purposes, an automatically operating manual gearbox. This means that automatic hydraulic systems are not only used to open and close the two clutches but also to select individual gears. The requisite clutch and valve actuator is located in a central block between the two clutches.
The actuator performs functions such as shifting the shift dogs in order to switch the seven gears. In a high-performance vehicle such as the Veyron, it is essential that the engine is always supplied with constant fuel pressure. The adaptive boost-pressure fuel injection system constantly monitors inlet pressure and injects fuel into the combustion chambers at a constant level of excess pressure to ensure optimum atomisation and carburation, achieving maximum power with minimum fuel.
Although the Bugatti has two visible filler flaps on the outside, only the flap on the right-hand side is used for refueling; the left-hand flap is used for checking and refilling the engine oil tank.
A fuel pipe channels the fuel to the base of the fuel tank, preventing the outgassing that uncontrolled fuel influx would cause. At around the halfway point, the emergency fuel pipe branches off from this fuel pipe in order to ensure that, when refueling from a five-liter canister as specified in law , both catch tanks are adequately filled so that the engine will start.
Four ejectors — two in each half of the saddle tank — pump a large volume of fuel into a collecting tank at low pressure. The collecting tank then distributes the fuel to the two catch tanks. A secondary feed flow supplies the ejectors with a small quantity of fuel at high pressure, which draws large quantities of fuel out of the main feed pumps by means of the Venturi effect.
The main feed system comprises two AC main feed pumps. They both have a dedicated control device which analyzes data on the current inlet pressure and the engine requirements in order to calculate and set the required rotational speed for the main feed pumps.
The fuel runs from the two main feed pumps into the Krontec module, which comprises the fuel filters, pressure relief valves, rollover valves and secondary flow regulators. The carbon canister for venting the tank is located behind the right-hand rear wheel. It filters toxic gases that can result from outgassing of the fuel and, together with inlet air obtained from the outside, channels them to the engine to be burned.
At the time, the brakes on the Veyron were by far the most powerful brake system in the automotive industry. The ceramic discs, with a diameter of mm and 38 mm thickness at the front axle, and a diameter of mm and 36 mm thickness at the rear, were pioneering technology at the time in terms of material, size and structure for further developments in the super sports car area. The materials and design of the brake disc are of particular importance if one wants to implement very high performance in a street-legal vehicle.
The advantage of titanium is that its thermal expansion is very similar to the very low thermal expansion of a ceramic disc, unlike any other metal, and also features a superior ratio of both stiffness and strength to weight which holds up well even at very high temperatures. When it was developed, no other manufacturer had comparable technology. In a high-performance vehicle such as the Veyron, it is essential that the engine is always supplied with constant fuel pressure. The fuel tank also had to be redesigned.
Bugatti turned to the world of motorsport, but had to rebuild the conventional fuel tank used in racing, which is not permitted for road vehicles, to ensure that it would be approved. Bugatti consulted engineers in the aerospace industry, and the outcome was a fuel tank with an external Teflon coating which provides the fuel pumps with a constant supply of fuel in every situation, up to a residual capacity of three liters and maximum lateral acceleration of 1.
Cooling is an extremely important aspect of the Veyron. During combustion, some 2, PS of additional heat is generated for 1, PS of drive power. To cope with this, the Bugatti engine has two water circuits. The larger circuit contains 40 liters of coolant water in three radiators in the front section of the vehicle to keep the engine at operating temperature.
The second, a low-temperature circuit with a separate water pump, contains 20 liters of coolant water.
This system cools the charged air and helps, for instance, to prevent the car from overheating in slow traffic, which is a common problem in high-performance sports cars. The production tires can be used for all speed ranges, which means that the Veyron does not require a different set of tires when being driven at maximum speed. One exciting detail of tire development is the new tire pressure sensor that had to be developed for the Veyron.
This required extensive tests on a test stand used for aircraft gas turbines in order to simulate the high speeds of the Veyron wheels.
At the time, this kind of system was not available in the automotive industry. Bugatti developed a high-performance braking system featuring many unique components in order to control the powerful forces effectively and bring the vehicle to a halt safely and quickly.
Certain components were designed in conjunction with development partners from the aerospace industry. Combined with the simultaneous application of the airbrake, an aerodynamic braking function integrated into the rear wing, the Veyron generates breathtaking deceleration values. Bugatti chose carbon-ceramic as the preferred material for the brake discs, a Bugatti first, in order to achieve maximum braking performance and to withstand brake disc surface temperatures of up to 1, degrees.
In addition, titanium was used for the brake disc hub instead of the usual stainless steel. As a result, the Veyron had by far the strongest braking performance in the automotive industry and motorsport at the time.
The shape and style of the Veyron are strongly based on the historical design DNA of the brand. The strict requirement to stick to the design of the car did not always make life easy for the developers, and this was also the case in relation to the aerodynamics, which are an essential element of a supercar. The most important technical element on the Veyron in this regard is the rear wing. Adhering to the the Guiness World Record restrictions an unprecedented The guiding principle of the genius car designer Ettore Bugatti, who came from a family of artists, was to always encase perfect technology in an aesthetically appealing exterior.
This commitment lives on today: the designers gave the Veyron Instead of bonnet scoops, the cylinder engine is ventilated by two NACA ducts in the roof. All the modifications serve to create a more powerful vehicle with even more agile handling.
The increased performance of the cylinder engine is primarily due to the use of four larger turbochargers and intercoolers. The main spring rates were slightly increased and the stabilizers were strengthened. In conjunction with the newly developed dampers, adapted from motorsport models, this enables perceptibly more precise control of the wheels and the vehicle.
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