Originally posted by: Zenmervolt
Originally posted by: mariok2006
Originally posted by: Zenmervolt
Originally posted by: mariok2006
What you didn't consider is throttle opening. Even though the rpm is lower, if the throttle opening is greater, teh car will use more fuel. If at 3000rpm the throttle opening is less than it is at 2100rpm to maintain 70mph, the car will get better mileage at 3000rpm.
Actually, you have it bass-ackwards.
RPM is the single largest driver in the fuel consumption equation. In the situation you describe, the car with the engine running at 2,100 RPM with a larger throttle opening will get better mileage than the car running at 3,000 RPM with a smaller throttle opening assuming that all else is equal.
ZV
As a decent example, let's take my car into account, even though fuel efficiency wasn't a large factor when the car was designed.
If your statement is correct, then I'd be getting better hwy mileage if I was cruising at 2500rpm at 70mph instead of 3700rpm than it does currently, which I don't believe to be the case.
I usually get worse mileage when I cruise below 3000rpm because I need to have a larger throttle opening to maintain speed. My torque curve directly reflects this. There's literally nothing below 3000rpm, even though it's linear.
Assuming you are correct, which you usually are...
Out of ignorance, why don't more cars (economy cars or cars meant for fuel efficiency) cruise at the lowest possible rpm without lugging the engine? Yes it would sacrifice passing power, but that's not the point.
In this one instance, fleabag has actually given the main reasons why low RPM + large throttle opening is more efficient, albeit in a more convoluted way than is necessary.
To move a given car at a given speed, a specific amount of power is require. Typically this is on the order of 20-30 hp to move a car at ~65 mph on a flat asphalt road without a significant head or tail wind.
As you have acknowledged, engines are most efficient at turning fuel into power when they operate near WOT (in modern EFI design there is usually mixture enrichment at WOT that increases fuel consumption, but we'll ignore that for a theoretical discussion). Since the HP requirement at a given speed is known and fixed, the most efficient way to cruise is to operate the engine under the conditions for which it most efficiently turns fuel into that specific amount of power. Generally this is at or near WOT at low RPM.
When the throttle is only partially open, a certain amount of addition hp is required to pull air past the restrictive throttle. This extra horsepower is effectively "thrown away".
So, if we know that the car itself needs, say 25 hp to cruise at 65 mph and that at WOT only 1 hp is consumed by the engine to overcome friction but that at 25% throttle 4 hp additional hp is consumed to overcome pumping losses, you can see that a higher RPM with a smaller throttle opening is going to require more power in total than a lower RPM with WOT. (These numbers are all made up for illustrative purposes.) More power required and less efficient at producing that power all conspire to make the high-rpm small throttle opening option consume more fuel.
The best example of this in real-world practice is the Chevrolet Corvette, which uses an incredibly tall 6th gear to drop the engine to very low RPM on the freeway and thereby achieve rather stunning highway mileage given the engine's size and power output.
You actually answer your own question when you point out that gearing economy cars to cruise at the lowest possible RPM without lugging the engine would sacrifice passing power, though you're right that it's not that simple.
Firstly, varying loads on the car affect when an engine will lug; with the car empty of everything but the driver the gearing could be taller than if the car were loaded to the full GVWR. Not only that, but it's essentially certain that people will load cars beyond the GVWR rating with reasonable frequency. Because of this, there needs to be enough leeway to prevent the engine from lugging in top gear even if the car is stuffed to the gills with NFL Defensive Linemen.
Also, there are hills and strong headwinds encountered in real-world driving and no-one wants to drive a car that requires a downshift every time the road starts to incline even slightly, so more leeway must be built in.
Additionally, there are demographic concerns. The majority of small cars are bought by people who don't do large amounts of long-distance freeway travel; most of these cars spend the majority of their time at 55mph or below and as a result tend to be geared such that they can be in their top gear by about 45 or 50 mph. This means that at freeway speeds of 65-75 mph the cars are already well above the minimum speed for their top gear. This sacrifice is acceptable because the gains in fuel mileage at lower speeds are far greater than the sacrifice in highway mileage. The cost of adding an additional gear to the manual transmission is generally judged not to be worth it.
Finally, there's just general feel. When the gap between two gears is too great it creates a negative impression on the driver, especially if the engine doesn't make much torque. If 5th gear in economy cars were designed to have a minimum speed of 65 mph, there would be two options: 1) space out the lower gears more widely which would make the car feel sluggish in most situations, or 2) leave gears 1-4 as normal and have a huge gap between 4th, which could be used by 35-40 mph, and 5th, which would mean either lugging the engine at 55-60 mph or revving abnormally high in that speed range. That's a gap that would be noticeable and annoying to drivers.
I'm sure there are other reasons as well, but those seem to be the main ones that come readily to mind.