Browse Topic: Downsizing

Items (300)

Design & analysis of Dual Mass flywheel during Engine startup condition in 3 Cylinder Gasoline application

2026-26-03491/16/2026

Modern automotive powertrains are increasingly adopting engine downsizing and down speeding to meet stringent emission regulations and improving fuel efficiency However, these changes result in higher torsional vibrations and excitation amplitudes makes more challenge in NVH (Noise, Vibration, and Harshness) refinement. With growing customer expectations for premium driving experiences conventional clutch are no longer sufficient. To meet the NVH performance targets of the vehicle Dual Mass Flywheels (DMFs) are used In DMF due to lower stiffness and inertia separation there is a great advantage on torsional filtration in normal drive and idle condition. but the resonance frequency of the connected DMF is lower than the idle RPM. Engine startup is a key drawback with DMF equipped vehicles. The proper tuning of starter motor performance & DMF stiffness is required to cross the resonance zone faster otherwise it will lead to DMF to stay in the resonance zone for a longer time leading to

Jayachandran, Suresh kumar, Vijayaragavan, Thirupathi, M, DEVAMANALAN, Kanagaraj, Pothiraj, ahire, Manoj, Vellandi, Vikraman

Development of the Mild Hybrid System for Off-Road Machinery

2024-32-00674/18/2025

In recent years, the importance of achieving carbon neutrality has been highlighted in response to the escalating severity of climate change. In the leading automobile market, the share of electric vehicles is gradually expanding, especially in passenger car sector. However, it is not same in commercial vehicle sector. In the off-road machinery market, as with electrification in commercial vehicles, the factors such as the need to install charging infrastructure and the requirement for large batteries to expand operating duration are significant challenge to full electrification. As one of the realistic solutions toward carbon neutrality for off-road machines, methods to utilize both internal combustion engines (ICE) and their applied products are being reconsidered. Under the circumstances, we have developed a mild-hybrid (MH) system for small off-road machinery. This system adopts a 48V power supply in order to minimize size of the system offers as a “Drop-in” package solution. This

Koyama, Kazuaki, Kimura, Ryota, Nagamori, Yuko, Horita, Tatsuhiko, Nosaka, Kento

angular upgrade test

SAE-PP-078284/11/2023

testing upgrade

Rickard, Christopher

SAE-PP-0779411/16/2022

testing 123

Rickard, Christopher, SintzUSER, Jeneane

Bacon jmsauto testauto testauto testauto testauto test

SAE-PP-076579/15/2022

solutions

Rickard, Christopher

jms demo testauto testauto testauto test

SAE-PP-071869/8/2022

blah blah blah

Rickard, Christopher, SintzADMIn, Jeneane

testing collections assignment

SAE-PP-030347/8/2022

blah blah blah collections

Rickard, Christopher

Perspectives and limitations of a fully electric 48 Volts propulsion architecture

2022-01-08013/29/2022

In the context of CO2 emissions reduction, investigations are currently made in various directions among the automotive sector: internal combustion en gine efficiency improvement, downsizing, electrification, vehicle weight reduction. Meanwhile, a new type of ve hicle is emerging in the automotive sector. This study analyses the perspectives and limitations of a low volt age electric vehicle (<60V), with only two people ca pacity. One of the main challenges of this new type of vehicle is to identify the bestsuited powertrain ar chitecture, given the different constraints and needs (power, mass, acceleration, range, etc.). With the ad vantage of reducing the safety constraints linked to high voltage applications, but with the expense of higher currents when power level increases, a proper power train components sizing is mandatory, therefore limit ing the advantages of such architecture. To better eval uate the evolution of the powertrain parameters, a sim ulation tool has been built to

Miliani, El Hadj, El Ganaoui-Mourlan, Ouafae, Couillandeau, Matthieu, TBATOU, Ayoub, JIPA DRAGAN, Vlad Costin, Guia, Mateus

Interior Noise and Tactile Vibration Refinement of Commercial Vehicle Through Experimental Analysis

2021-01-10738/31/2021

Noise & Vibration refinement of automotive vehicles is becoming important parameter due to its influence on environmental aspect and comfort perceived by occupants. NVH parameters are driving factors in current vehicle design strategy. Drivers comfort is extremely important, and driver’s expectations from commercial and heavy-duty trucks are as good as refined passenger cars. Other trends in commercial vehicle segment such as engine downsizing, weight, cost reduction and meeting stringent emission norms have influenced vehicle design dynamics. These parameters are critical and often contribute to vehicle NVH issues. Considering these new trends in commercial vehicle segment, it becomes challenging for an NVH engineer to provide optimized solutions. NVH issues could be related to the various subsystems such as driveline, axle, transmission steering wheel etc. in the vehicle and its resonant frequencies. In commercial vehicles, driveline design parameters, power train mounting system and

Sankpal, Kiran, Thakur, Sunil, Kunde, Sagar, Wagh, Sachin, Sharma, Vijay

Opportunities for Medium and Heavy Duty Vehicle Fuel Economy Improvements through Hybridization

2021-01-07174/6/2021

The objective of this study was to evaluate the fuel saving potential of various hybrid powertrain architectures for medium and heavy duty vehicles. The relative benefit of each powertrain was analyzed, and the observed fuel savings was explained in terms of operational efficiency gains, regenerative braking benefits from powertrain electrification and differences in vehicle curb weight. Vehicles designed for various purposes, namely urban delivery, utility, transit, refuse, drayage, regional and long haul were included in this work. Fuel consumption was measured in regulatory cycles and various real world representative cycles. A diesel-powered conventional powertrain variant was first developed for each case, based on vehicle technical specifications for each type of truck. Autonomie, a simulation tool developed by Argonne National Laboratory, was used for carrying out the vehicle modeling, sizing and fuel economy evaluation. Performance based sizing rules implemented in Autonomie

Nieto Prada, Daniela, Vijayagopal, Ram, Costanzo, Vincent

Cold Idle Gear Rattle in Manual Transmission Passenger Car-Temperature Based Phenomenon

2020-01-22459/15/2020

Gear rattle is due to impact noise of unloaded gears in transmission having freedom to move in backlash region. Engine order vibrations in the presence of backlash in meshing pairs induce the problem. It is a system behavior wherein flywheel torsional vibrations, the pre-damper characteristics and transmission drag torque plays a vital role in an engine idle condition (hot & cold). Idle rattle is a severe issue, which is highly noticeable in cold condition or after 1st engine crank. Gear rattling observed in idle condition is idle gear rattle or neutral gear rattle, specifically in cold condition is a “Cold idle rattle” and this is one of the critical noise parameters considered for entire vehicle NVH. Damper mechanism in the clutch, is used to serve better isolation (by reducing the input excitation to transmission parts) of vibrations between engine and transmission their by reducing gear rattle intensity. Engine firing order, engine downsizing, down speeding (means high peak torque

Kapse, Ravi Ramesh, More, Vivek, Gangane, Swapnil

Reducing Vehicle Interior NVH by Means of Locally Resonant Metamaterial Patches on Rear Shock Towers

2019-01-15026/5/2019

Stringent regulations for CO2 emissions and noise pollution reduction demand lighter and improved Noise, Vibration Harshness (NVH) solutions in automotive industries. Designing light, compact and, at the same time, improved NVH solutions is often a challenge, as low noise and vibration levels often require heavy and bulky additions, especially to be effective in the low frequency regime. Recently, locally resonant metamaterials have emerged among the novel NVH solutions because of their performant NVH properties combined with lightweight and compact design. Due to the characteristic of stop band behavior, frequency ranges where free wave propagation is inhibited, metamaterials can beat the mass law, be it at least in some tunable frequency ranges. Previously the authors demonstrated how metamaterials can reduce the vibrations in a simplified shock tower upon shaker excitation. In this work, the authors apply the metamaterial concept on the real rear shock towers of a vehicle. In order

Sangiuliano, Luca, Claeys, Claus, Deckers, Elke, De Smet, Jasper, Pluymers, Bert, Desmet, Wim

Model Verification of CAE with NVH-Test Acting on Downsized Car Engines

2019-01-15506/5/2019

Today’s trend of combustion engine development for cars is characterized with; high torque, low engine speed, low weight, high degree of cyclic irregularity, low excitation frequency due to fewer cylinders active e.g. 4-cylinder or less. This implies in respect of vibrations that it is crucial to control powertrain rigid body modes and place these were they cannot be reached and induced by the low exciting harmonic frequencies for low engine speeds or idling. It is also important to control the overall flexible vibration modes. A mathematical CAE model is created in simulation software AVL-EXCITE in order to handle the vibration phenomenon as a first step. But it is absolutely necessary to “verify” these models with real measurements in respect of NVH and if needed upgrade the CAE model if there are detected deviations. The NVH-test is done with testing tool DEWESoft. The purpose of below paper is to do model verification on a concrete example in respect of powertrain vibrations. Volvo

Rönnqvist, Urban, Ribarits, Janos

Vibro-Acoustic Analysis for Modeling Propeller Shaft Liner Material

2019-01-15606/5/2019

In recent truck applications, single-piece large-diameter propshafts, in lieu of two-piece propshafts, have become more prevalent to reduce cost and mass. These large-diameter props, however, amplify driveline radiated noise. The challenge presented is to optimize prop shaft modal tuning to achieve acceptable radiated noise levels. Historically, CAE methods and capabilities have not been able to accurately predict propshaft airborne noise making it impossible to cascade subsystem noise requirements needed to achieve desired vehicle level performance. As a result, late and costly changes can be needed to make a given vehicle commercially acceptable for N&V performance prior to launch. This paper will cover the development of a two-step CAE method to predict modal characteristics and airborne noise sensitivities of large-diameter single piece aluminum propshafts fitted with different liner treatments. The first step is the use of a traditional CAE software to calculate prop surface

Jayaratne, Rajith R., Liu, Yu, Gehringer, Mark, Rayce, Jeff, Hill, Wallace

Colorado State University EcoCAR 3 Final Technical Report

2019-01-03604/2/2019

Driven by consumer demand and environmental regulations, market share for plug-in hybrid electric vehicles (PHEVs) continues to increase. An opportunity remains to develop PHEVs that also meet consumer demand for performance. As a participant in the EcoCAR 3 competition, Colorado State University’s Vehicle Innovation Team (CSU VIT) has converted a 2016 Chevy Camaro to a PHEV architecture with the aim of improving efficiency and emissions while maintaining drivability and performance. To verify the vehicle and its capabilities, the CSU Camaro is rigorously tested by means of repeatable circumstances of physical operation while Controller Area Network (CAN) loggers record various measurements from several sensors. This data is analyzed to determine consistent output and coordination between components of the electrical charge and discharge system, as well as the traditional powertrain. The aim is to improve drivability and efficiency as measured by vehicle technical specifications (VTS

DiDomenico, Gabriel Christian, Bair, Jamison, Kukkala, Vipin Kumar, Tunnell, Jordan, Peyfuss, Marco, Kraus, Michael, Ax, Joshua, Lazarri, Jeremy, Munin, Matthew, Cooke, Corey, Christensen, Eric, Peltz, Logan, Peterson, Nathan, Wolfe, Logan, Vinski, Zach, Norris, Daniel, Kaiser, Corrie, Collier, Jacob, Schott, Nick, Wang, Yi, Bradley, Thomas

Mechanism Analysis on the Effect of Fuel Properties on Knocking Performance at Boosted Conditions

2019-01-00351/15/2019

In recent years, boosted and downsized engines have gained much attention as a promising technology to improve fuel economy; however, knocking is a common issue of such engines that requires attention. To understand the knocking phenomenon under downsized and boosted engine conditions deeply, fuels with different Research Octane Number (RON) and Motor Octane Number (MON) were prepared, and the knocking performances of these fuels were evaluated using a single cylinder engine, operated under a variety of conditions. Experimental results showed that the knocking performance at boosted conditions depend on both RON and MON. While higher RON showed better anti-knocking performance, lower MON showed better anti-knocking performance. Furthermore, the tendency for a reduced MON to be beneficial became stronger at lower engine speeds and higher boost pressures, in agreement with previously published modelling work. A new method of interpreting octane appetite is presented which relates the

Kassai, Masaharu, Aksu, Cagdas, Shiraishi, Taisuke, Cracknell, Roger, Shibuya, Masahiko

Water Injection Benefits in a 3-Cylinder Downsized SI-Engine

2019-01-00341/15/2019

With progressing electrification of automotive powertrains and demands to meet increasingly stringent emission regulations, a combination of an electric motor and downsized turbocharged spark-ignited engine has been recognized as a viable solution. The SI engine must be optimized, and preferentially downsized, to reduce tailpipe CO2 and other emissions. However, drives to increase BMEP (Brake Mean Effective Pressure) and compression ratio/thermal efficiency increase propensities of knocking (auto-ignition of residual unburnt charge before the propagating flame reaches it) in downsized engines. Currently, knock is mitigated by retarding the ignition timing, but this has several limitations. Another option identified in the last decade (following trials of similar technology in aircraft combustion engines) is water injection, which suppresses knocking largely by reducing local in-cylinder mixture temperatures due to its latent heat of vaporization. Addition of adequate water can lead to

Khatri, Jayesh, Denbratt, Ingemar, Dahlander, Petter, Koopmans, Lucien

Quasi-Dimensional Simulation of Downsizing and Inverter Application for Efficient Part Load Operation of Spark Ignition Engine Driven Micro-Cogeneration Systems

2018-32-006110/30/2018

Within the context of distributed power generation, small size systems driven by spark ignition engines represent a valid and user-friendly choice, that ensures good fuel flexibility. One issue is that such applications are run at part load for extensive periods, thus lowering fuel economy. Employing an inverter (fitted between the generator and load) allows engine operation within a wide range of crankshaft rotational velocity, therefore improving efficiency. For the purpose of evaluating the benefits of this technology within a co-generation framework, two configurations were modeled by using the GT-Power simulation software. After model calibration based on measurements on a small size engine for two-wheel applications, the downsized version was compared to a larger power unit operated at constant engine speed for a scenario that featured up to 10 kW rated power. Indeed, the downsizing concept was found to ensure an electrical efficiency improvement of around 10% at 50% load, over

Irimescu, Adrian, Catapano, Francesco, Di Iorio, Silvana, Merola, Simona, Sementa, Paolo, Vaglieco, Bianca Maria

On-Road Monitoring of Low Speed Pre-Ignition

2018-01-16769/10/2018

To meet increasingly stringent emissions and fuel economy regulations, many Original Equipment Manufacturers (OEMs) have recently developed and deployed small, high power density engines. Turbocharging, coupled with gasoline direct injection (GDI) has enabled a rapid engine downsizing trend. While these turbocharged GDI (TGDI) engines have indeed allowed for better fuel economy in many light duty vehicles, TGDI technology has also led to some unintended consequences. The most notable of these is an abnormal combustion phenomenon known as low speed pre-ignition (LSPI). LSPI is an uncontrolled combustion event that takes place prior to spark ignition, often resulting in knock, and has been known to cause catastrophic engine damage. LSPI propensity depends on a number of factors including engine design, calibration, fuel properties and engine oil formulation. Several engine tests have been developed within the industry to better understand the phenomenon of LSPI. While data from these

Michlberger, Alexander, Sutton, Mike, Kocsis, Michael, Anderson, Garrett, Van Horn, Adam

Effect of Mixture Formation and Injection Strategies on Stochastic Pre-Ignition

2018-01-16789/10/2018

Stochastic pre-ignition remains one of the major barriers limiting further engine downsizing and down-speeding; two widely used strategies for improving the efficiency of spark-ignited engines. One of the most cited mechanisms thought to be responsible for pre-ignition is the ignition of a rogue droplet composed of lubricant oil and fuel. This originates during mixture formation from interactions between the fuel spray and oil on the cylinder liner. In the present study, this hypothesis is further examined using a single cylinder supercharged engine which employs a range of air-fuel mixture formation strategies. These strategies include port-fuel injection (PFI) along with side and central direct injection (DI) of an E5 gasoline (RON 97.5) using single and multiple injection events. Computational fluid dynamic (CFD) calculations are then used to explain the observed trends. Overall, this study reinforces that interactions between the fuel spray and oil on the cylinder liner can be an

Singh, Eshan, Mubarak Ali, Mohammed Jaasim, Ichim, Adrian, Morganti, Kai, Dibble, Robert

Nano-Unmanned Aerial Vehicle

TBMG-329059/1/2018

FLIR Systems Wilsonville, OR 503-498-3547

Material Brings Optical Communication onto Silicon Chips

TBMG-324988/1/2018

An increase in computing performance has been achieved by squeezing ever more transistors into a tighter space on microchips. This downsizing has also meant packing the wiring within microprocessors ever more tightly together, leading to effects such as signal leakage between components, which can slow down communication between different parts of the chip. This delay, known as the “interconnect bottleneck,” is becoming an increasing problem in high-speed computing systems.

Passenger Car Handling Characteristics Associated with Space-Saver Spare Tires

2018-01-50277/12/2018

Space-saver spare tires have become near-standard equipment in passenger cars, replacing full-size spares. The properties of space-saver spare tires (cornering stiffness, self-aligning torque, etc.) exhibit some differences when compared to standard size tires. We examine potential handling changes when a space-saver tire is installed on the vehicle by examining steady-state behavior, initial step steering response, and vehicle understeer gradient as functions of the mounting location of the space-saver tire (front or rear axle). Results show that space-saver spare tires perform well and are quite capable in low-ay, linear handling maneuvers.

Metz, L. Daniel

Peelable Heat Shrinkable Tubing Enables Next-Gen Miniaturization

TBMG-291136/1/2018

When it comes to the cardiovascular procedures, small is indeed beautiful. With the need for minimally invasive procedures and increasing moves to deliver therapies to hard-to-reach areas such as the brain, miniaturization is a niche that demands significant focus. Procedures are rapidly changing, creating a need for new technologies that can help address unmet needs. Nevertheless, as with all medical devices, the proof is in the application, and this requires supporting evidence pointing to successful outcomes.

Investigations on the Influence of Fuel Oil Film Interaction on Pre-ignition Events in Highly Boosted DI Gasoline Engines

2018-01-14544/3/2018

Premature and uncontrolled flame initiation, called pre-ignition (PI), is a prominent issue in the development of spark-ignited engines. It is commonly assumed that this abnormal combustion mode hinders progress in engine downsizing, thus inhibiting development of more efficient engines. The phenomenon is primarily observed in highly turbocharged spark ignited (SI) engines in the full load regime at low engine speeds. Subsequent engine knock induces extremely high peak pressures, potentially causing severe engine damage. The mechanisms leading to this phenomenon are not completely understood; however, it is quite plausible that a multiphase process is responsible for the pre-ignition. One effect could be the interaction between injected fuel drops and the oil film on the cylinder liner. Under certain conditions, droplets of oil or oil/fuel mixture can detach or splash from the film, leading to pre-ignition at the droplet surface towards the end of the compression phase. To gain further

Kubach, Heiko, Weidenlener, Alex, Pfeil, Juergen, Koch, Thomas, Kittel, Hannah, Roisman, Ilia V., Tropea, Cameron

Adaptive Turbo Matching: Radial Turbine Design Optimization through 1D Engine Simulations with Meanline Model in-the-Loop

2018-01-09744/3/2018

Turbocharging has become the favored approach for downsizing internal combustion engines to reduce fuel consumption and CO2 emissions, without sacrificing performance. Matching a turbocharger to an engine requires a balance of various design variables in order to meet the desired performance. Once an initial selection of potential compressor and turbine options is made, corresponding performance maps are evaluated in 1D engine cycle simulations to down-select the best combination. This is the conventional matching procedure used in industry and is ‘passive’ since it relies on measured maps, thus only existing designs may be evaluated. In other words, turbine characteristics cannot be changed during matching so as to explore the effect of design adjustments. Instead, this paper presents an ‘adaptive’ matching methodology for the turbocharger turbine. By coupling an engine cycle simulation to a turbine meanline model (‘in-the-loop’), adjustments in turbine geometry are reflected in both

Kapoor, Prakhar, Costall, Aaron W., Sakellaridis, Nikolaos, Hooijer, Jochem, Lammers, Rogier, Tartoussi, Hadi, Guilain, Stéphane

Analysis of the Hardware Requirements for a Heavily Downsized Gasoline Engine Capable of Whole Map Lambda 1 Operation

2018-01-09754/3/2018

MAHLE has developed a heavily downsized demonstrator engine to explore the limits, and potential benefits, of engine downsizing. The 1.2 litre, 3-cylinder, MAHLE downsizing (Di3) engine, in conjunction with an Aeristech 48 V electric supercharger (eSupercharger, eSC), achieves a BMEP level of 35 bar and a specific power output in excess of 160 kW/litre. The eSupercharger enables high specific power output, good low speed torque and excellent transient response. The resulting heavily downsized engine has been installed into a demonstrator vehicle that also features 48 V mild hybridization. At specific power output levels above 90 kW/litre the engine is operated with excess fuel in order to protect the turbine from excessive exhaust gas temperatures. In this analytical study, the boosting system requirements to maintain lambda 1 fuelling, via the use of EGR, across the entire engine operating map for the eSupercharged version of the MAHLE Di3 engine, have been explored. It has been found

Bassett, Mike, Vogler, Christian, Hall, Jonathan, Taylor, James, Cooper, Adrian, Reader, Simon, Gray, Kevin, Wall, Richard

Design and Optimization of Composite Horizontal Axis Wind Turbine (Hawt) Blade

2018-01-10344/3/2018

Wind energy is clean and renewable source of energy that is an attractive alternative to non-conventional sources of energy. Due to rapid increase in global energy requirements, this form of energy is gaining its share of importance. Unlike nuclear power or tar sand oils, wind energy does not leave a long-term toxic legacy. Using MATLAB algorithms, multi-optimization of wind turbine design can be achieved. Therefore, an aerodynamic mathematical model is developed to obtain the optimal chord length and twist angle distribution along the blade span. Further, a promising generic blade design is used to initialize a detailed structure optimization wherein leading edge panel (LEP), Spar cap, Shear web, Trailing edge panel (TEP) reinforcement are sized using composite laminates so that the blade is according to the intended design standard. Initially blade airfoils are analyzed on 2D platform and then the results are used to construct 3D model of Horizontal Axis Wind Turbine (HAWT) blade

Brella, Rohan, Sehgal, Mayank, Kumar, Naveen

An Optimal Design of Vehicle Swing Door Using Metamodeling Techniques

2018-01-10224/3/2018

In side-closures’ design, mass reduction provides numerous benefits in addition to reduced cost. This paper presents a Meta model based non-linear durability optimization to develop a lightweight structure for vehicle swing door. A surrogate model developed is using Kriging methodology and the thickness of the door components are given as input design variables. Adaptive Multi-Objective Genetic Algorithm (AMGA), a nonlinear optimization technique, is used in this study, to formulate the mass minimization under durability constraints. The optimized swing door design shows the overall mass saving of ~10% over initial design in terms of frame and sag deflection. The present investigation shows better effectiveness and practical applicability to develop the lightweight structure for the vehicle swing door. From the comparative study, Kriging method is found to be more effective in terms of measuring the accuracy, robustness and efficiency of the results than the Radial basis function (RBF

Zaman, Thoheer, Kumar, Arun, Valiyaveettil Nazir, Fazil, Velu, Jayaprakash, Appana, Kameshwara rao

Simulation Study of 1D-3D Coupling for Different Exhaust Manifold Geometry on a Turbocharged Gasoline Engine

2018-01-01824/3/2018

One-dimensional (1D) simulation tools, the computing speed of which is relatively fast, usually solve simple complexity problems. The solving process of 1D simulation is mostly based on one-dimensional dynamic equations and empirical laws and thus in some cases it cannot obtain a similar accuracy with the time-consuming three-dimensional (3D) simulation tools. The 1D-3D co-simulation, which combines the advantages of the two simulation tools while minimizes the disadvantages, is a method that integrates and runs the two simulation tools concurrently. The coupled simulation can offer a 3D analysis for which a detailed information is needed while offer system level information in the rest of the whole system where averaged results are sufficient. The approach not only minimizes the computational cost, but avoids demand for imposing accurate boundary conditions to the 3D simulation. But nowadays, a lot of paper only use the approach to obtain boundary condition from 1D environment, few

Zhang, Chaolin, Hu, Bo, lai, Chenguang, Zhang, Hailin, Qin, Ling, Leng, Xiaoli, Huang, Wenpeng

Development and Validation of a Three Pressure Analysis (TPA) GT-Power Model of the CFR F1/F2 Engine for Estimating Cylinder Conditions

2018-01-08484/3/2018

The CFR engine is the widely accepted platform to test standard Research Octane Number (RON) and Motored Octane Number (MON) for determining anti-knock characteristics of motor fuels. With increasing interest in engine downsizing, up-torquing, and alternative fuels for modern spark ignition (SI) engines, there is a need to better understand the conditions that fuels are subjected to in the CFR engine during octane rating. To take into account fuel properties, such as fuel heat of vaporization, laminar flame speed and auto-ignition chemistry; and understand their impacts on combustion knock, it is essential to estimate accurate cylinder conditions. In this study, the CFR F1/F2 engine was modeled using GT-Power with the Three Pressure Analysis (TPA) and the model was validated for different fuels and engine conditions. The finite element cylinder model was applied to better estimate heat transfer and cylinder wall temperatures of the cast iron combustion chamber (piston, cylinder, and

Choi, Seungmok, Kolodziej, Christopher P., Hoth, Alexander, Wallner, Thomas

Development of High-Power-Density DC-DC Converter Using Coupled Inductors for Clarity Plug-In Hybrid

2018-01-04584/3/2018

Honda has developed an electric powertrain for a 2017 plug-in hybrid vehicle using its second-generation SPORT HYBRID i-MMD powertrain system as a base. The application of the newly developed powertrain system realizes a long all-electric range (AER), allowing operation as an EV for almost all everyday driving scenarios, with dynamic performance making it possible for the vehicle to operate as an EV across the entire speed range, up to a maximum speed of 100 mph. The amount of assist provided by power from the batteries during acceleration has been increased, helping to downsize the engine while also balancing powerful acceleration with quietness achieved by controlling racing of the engine. In order to realize this EV performance with the second-generation SPORT HYBRID i-MMD system as the base, it was necessary to increase the power output of the DC-DC converter, taking restrictions on space into consideration. An interleaved circuit design using coupled inductors was employed as the

Komatsuzaki, Akitomo, Hashino, Satoshi

Development of New Hybrid Transaxle for Mid - Size Vehicle

2018-01-04294/3/2018

The new P710 hybrid transaxle for a mid-size 2.5-liter class vehicle was developed based on the Toyota New Global Architecture (TNGA) design philosophy to achieve a range of desired performance objects. A smaller and lighter transaxle with low mechanical loss was realized by incorporating a new gear train structure and a downsized motor. The noise of the P710 transaxle was also reduced by adopting a new damper structure.

Matsumura, Mitsutaka, Shiozaki, Kazuya, Mori, Nobuhito

Development, Performance Analysis and Optimization of Parallel Hydraulic Hybrid System for City Bus Application

2018-01-04194/3/2018

One of the key requisites for a sustained mobility development is to have an efficient public transport system. Fuel efficiency and emission control are extremely important in this respect. By the very nature of city driving, it is obvious that city traffic results in frequent vehicle start and stops; which involves huge waste of vehicle kinetic energy. Every time vehicle moving from idle, needs a bigger input of power and every time the brakes are applied, all energy built up disappears again, wasted in the brake pads as heat. An effort has been taken to recuperate vehicle kinetic energy, hydraulically during braking events and utilize it to assist the vehicle during acceleration. Hydraulic based hybrid vehicle working on the principle of regenerative braking is one of the most fuel-efficient technologies for city application. Parallel hydraulic hybrid vehicle has been developed and optimized for fuel efficiency gain at vehicle level. Objective of this paper is to study behavior

Yaser, K U Syed Taj, Bakatwar, Rupesh, Bhargava, Aashish, Tiwari, Sanjay

Downsized Gasoline Engine Cylinder Deactivation MiL Development and Validation Using Real-Time 1-D Gas Code

2018-01-12444/3/2018

Cylinder deactivation has become common not only in large swept volume gasoline V-engines but also in cheaper highly downsized automotive engines. Cylinder deactivation strategy leads to a combination of reduced throttling and pumping losses and consequently, to CO2 emissions reduction. This is achieved by deactivation of some cylinders and by moving the operation point of the firing cylinders to higher loads to compensate for the deactivated cylinders. This paper focuses on the 1.4 litre direct injection gasoline 4-cylinder (inline) engine and the development of its deactivation strategy in the Model in the Loop (MiL) environment using the Ricardo 1-D gas real-time code ‘WAVE-RT’ as the virtual engine controlled by the engine control strategy. The engine control strategy can be easily flashed into rapid prototyping ECU and validated on the testbed. The engine does not include ‘expensive’ 2nd + 3rd valve closing technology and therefore, the deactivation feature is achieved just by

Kouba, Adam, Hnilicka, Bohumil, Navratil, Jiri

The Development of Low Temperature Three-Way Catalysts for High Efficiency Gasoline Engines of the Future: Part II

2018-01-09394/3/2018

It is anticipated that future gasoline engines will have improved mechanical efficiency and consequently lower exhaust temperatures at low load conditions, although the exhaust temperatures at high load conditions are expected to remain the same or even increase due to the increasing use of downsized turbocharged engines. In 2014, a collaborative project was initiated at Ford Motor Company, Oak Ridge National Lab, and the University of Michigan to develop three-way catalysts with improved performance at low temperatures while maintaining the durability of current TWCs. This project is funded by the U.S. Department of Energy and is intended to show progress toward the USDRIVE target of 90% conversion of hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx) at 150 °C after high mileage aging. The testing protocols specified by the USDRIVE ACEC team for stoichiometric S-GDI engines were utilized during the evaluation of experimental catalysts at all three facilities. This

Theis, Joseph R., Getsoian, Andrew (Bean), Lambert, Christine K.

Ultra-Light Weight Automotive Door: Design and Validation

2018-01-01114/3/2018

An Ultra-Light Door (ULD) has been developed that is 40% lighter than a baseline 2016 mid-size vehicle’s driver side door. The ULD scope encompasses the entire door, including the door-in-white (DIW), interior trim, glazing, hardware, wiring, etc. To achieve such a substantial mass reduction while still meeting the baseline vehicle’s performance metrics (including safety, durability, NVH, appearance, etc.) at a minimal cost increase, the door design relies on a comprehensive full system approach that includes a unique architecture in addition to lightweight materials and components. This paper details the ULD design concept, simulated performance results, the current status of vehicle level validation, and comparisons between component level CAE predicted performance and physical test results.

Reaburn, Timothy, Skszek, Timothy W.

Development of Electric Powertrain for CLARITY PLUG-IN HYBRID

2018-01-04154/3/2018

Honda has developed the 2018 model CLARITY PLUG-IN HYBRID. Honda’s new plug-in hybrid is a midsize sedan and shares a body platform with the CLARITY FUEL CELL and the CLARITY ELECTRIC. The vehicle’s electric powertrain boosts driving performance as an electric vehicle (EV) over Honda’s previous plug-in hybrid. The CLARITY PLUG-IN HYBRID’s electric powertrain consists of a traction motor and generator built into the transmission, a Power Control Unit (PCU) positioned above the transmission, an Intelligent Power Unit (IPU) fitted under the floor, and an onboard charger fitted below the rear trunk. The PCU integrates an inverter that drives the traction motor, an inverter that drives the generator, and a DC-DC converter to boost battery voltage (referred to as a “Voltage Control Unit (VCU)” below). The VCU employs an interleaved circuit configuration and a coupled inductor and realizes approximately three times the rated continuous power and approximately three times the power density of

Yamagishi, Tomoya, Ishikura, Takashi

Development of a Lightweight Third-Generation Advanced High-Strength Steel (3GAHSS) Vehicle Body Structure

2018-01-10264/3/2018

This article covers an application of third-generation advanced high-strength steel (3GAHSS) grades to vehicle lightweight body structure development. Design optimization of a vehicle body structure using a multi-scale material model is discussed. The steps in the design optimization and results are presented. Results show a 30% mass reduction potential over a baseline mid-size sedan body side structure with the use of 3GAHSS.

Savic, Vesna, Hector, Louis, Singh, Harjinder, Paramasuwom, Mahendran, Basu, Ushnish, Basudhar, Anirban, Stander, Nielen

Miniature “Pop-Up” Robot Combines Micrometer Precision and High Speed

TBMG-288164/1/2018

Because of their high precision and speed, Delta robots are deployed in many industrial processes, including pick-and-place assemblies, machining, and welding. Delta robots use three individually controlled and lightweight arms that guide a platform to move fast and accurately in three directions. The platform is either used as a stage — similar to those used in flight simulators — or coupled to a manipulating device that can, for example, grasp, move, and release objects in prescribed patterns. Over time, roboticists have designed smaller and smaller Delta robots for tasks in limited workspaces, yet shrinking them further to the millimeter scale with conventional manufacturing techniques and components has proven fruitless.

Catalytic Characteristic and Application Performance of Catalyzed DPFs Coated with Various Content of Precious Metal in China

2017-01-237910/8/2017

Recent toxicological and epidemiologic studies have shown that diesel emissions have been a significant toxic air contaminant. Catalyzed DPF (CDPF) not only significantly reduces the PM mass emissions (>90%), but also further promotes carrier self-regeneration and oxidize more harmful gaseous pollutants by the catalyst coated on the carrier. However, some ultrafine particles and potentially harmful gaseous pollutants, such as VOCs species, originally emitted in the vapor-phase at high plume temperature, may penetrate through the CDPF filter. Furthermore, the components and content of catalyst coated on the CDPF could influence the physicochemical properties and toxicity intensity of those escaping ultrafine particles and gaseous pollutants. In this work, (1) we investigated the influence of precious metal content as a variable parameter on the physicochemical properties and catalytic activities of the small CDPF samples. Dispersion of the precious metal on the fresh samples presented

Feng, Qian, Shen, Shu, Li, Mengliang, Li, Zhijun, Qin, Kongjian, Lou, Diming, Wang, Jiguang, Fang, Xiyu

The Effect of Swirl on the Flow Uniformity in Automotive Exhaust Catalysts

2017-01-238410/8/2017

In aftertreatment system design, flow uniformity is of paramount importance as it affects aftertreatment device conversion efficiency and durability. The major trend of downsizing engines using turbochargers means the effect of the turbine residual swirl on the flow needs to be considered. In this paper, this effect has been investigated experimentally and numerically. A swirling flow rig with a moving-block swirl generator was used to generate swirling flow in a sudden expansion diffuser with a wash-coated diesel oxidation catalyst (DOC) downstream. Hot-wire anemometry (HWA) was used to measure the axial and tangential velocities of the swirling flow upstream of the diffuser expansion and the axial velocity downstream the monolith. With no swirl, the flow in the catalyst monolith is highly non-uniform with maximum velocities near the diffuser axis. At high swirl levels, the flow is also highly nonuniform with the highest velocities near the diffuser wall. An intermediate swirl level

Rusli, Ijhar H., Aleksandrova, Svetlana, Medina, Humberto, Benjamin, Stephen F.

Automotive Engineering: October 2017

17AUTP1010/5/2017

ICE Breaker! Mazda's Skyactiv-X beats the big guys to market with a promising new production engine that marries Otto and Diesel attributes. Testing mmWave radars in the loop University of Texas researchers develop a real-time HIL testbed that beats the incumbents on cost, time and flexibility. Driverless cars and freeway traffic flow Analysis shows platooning and wave damping can reduce congestion. Editorial: EVs lack a robust charging grid SAE Standards News Mobility for everyone: Automated Driving Systems Supplier Eye The future on stage at Frankfurt The Navigator Time for standard naming of safety features Developing high-energy-density batteries for EVs U.S. Dept. of Transportation issues new autonomous-vehicle guidelines Federal-Mogul's cool solution for downsized engines Continental unveils new 3D display cluster Back to physics for Dayco's new vacuum assist Voltage spike at 2017 Frankfurt auto show For '18 models, GM quietly backs diesel-with quiet new diesel Cadillac plugs in

Exploitation Strategies of Cabin and Galley Thermal Dynamics

2017-01-20379/19/2017

The thermal inertia of aircraft cabins and galleys is significant for commercial aircraft. The aircraft cabin is controlled by the Environment Control System (ECS) to reach, among other targets, a prescribed temperature. By allowing a temperature band of ± 2 K instead of a fixed temperature, it is possible to use this thermal dynamic of the cabin as energy storage. This storage can then be used to reduce electrical peak power, increase efficiency of the ECS, reduce thermal cooling peak power, or reduce engine offtake if it is costly or not sufficiently available. In the same way, also the aircraft galleys can be exploited. Since ECS and galleys are among the largest consumers of electrical power or bleed air, there is a large potential on improving energy efficiency or reducing system mass to reduce fuel consumption of aircraft. This paper investigates different exploitation strategies of cabin and galley dynamics using modelling and simulation. Modelica models of the thermal and the

Schlabe, Daniel, Zimmer, Dirk, Pollok, Alexander

Optimizing Transmission Loss for Lightweight Body Structures

2017-01-18126/5/2017

In an effort to reduce mass, future automotive bodies will feature lower gage steel or lighter weight materials such as aluminum. An unfortunate side effect of lighter weight bodies is a reduction in sound transmission loss (TL). For barrier based systems, as the total system mass (including the sheet metal, decoupler, and barrier) goes down the transmission loss is reduced. If the reduced surface density from the sheet metal is added to the barrier, however, performance can be restored (though, of course, this eliminates the mass savings). In fact, if all of the saved mass from the sheet metal is added to the barrier, the TL performance may be improved over the original system. This is because the optimum performance for a barrier based system is achieved when the sheet metal and the barrier have equal surface densities. That is not the case for standard steel constructions where the surface density of the sheet metal is higher than the barrier. Therefore, it appears there may be some

Sorenson, Steven, Ebbitt, Gordon, Smith, Scott, Remtema, Todd

Tribodynamics of a New De-Clutch Mechanism Aimed for Engine Downsizing in Off-Road Heavy-Duty Vehicles

2017-01-18356/5/2017

Clutches are commonly utilised in passenger type and off-road heavy-duty vehicles to disconnect the engine from the driveline and other parasitic loads. In off-road heavy-duty vehicles, along with fuel efficiency start-up functionality at extended ambient conditions, such as low temperature and intake absolute pressure are crucial. Off-road vehicle manufacturers can overcome the parasitic loads in these conditions by oversizing the engine. Caterpillar Inc. as the pioneer in off-road technology has developed a novel clutch design to allow for engine downsizing while vehicle’s performance is not affected. The tribological behaviour of the clutch will be crucial to start engagement promptly and reach the maximum clutch capacity in the shortest possible time and smoothest way in terms of dynamics. A multi-body dynamics model of the clutch system is developed in MSC ADAMS. The flywheel is introducing the same speed and torque as the engine (represents the engine input to the clutch). The

Dolatabadi, Nader, Rahmani, Ramin, Theodossiades, Stephanos, Rahnejat, Homer, Blundell, Guy, Bernard, Guillaume

Magnetic Actuators for Active Powertrain Vibration Control

2017-01-18296/5/2017

The new fuel efficiency and emission standards have forced OEMs to put emphasis on different strategies such as engine downsizing, cylinder deactivation… Unfortunately these new technologies may lead to increased powertrain vibrations generated by the engine and transmitted to the chassis and the car cabin, such that their reduction or elimination has become a key topic for the automotive industry. The use of active engine mounts, acting directly on the fluid of an hydromount, or active vibration dampers, acting as an inertial mass-spring system, are very effective solutions, particularly when using electromagnetic based actuators. Nevertheless, all electromagnetic actuators technologies are not equals and the choice of such actuators must be considered carefully by taking into account the full performances and the overall cost of the solutions. This paper presents an electromagnetic actuator technology, that can be considered as the best tradeoff between performances and cost

Loussert, Guillaume

Model Based Approach by Combination of Test and Simulation Methodologies for NVH Investigation and Improvement of a Rear Wheel Drive Vehicle

2017-01-17746/5/2017

The increasing pressure on fuel economy has brought car manufacturers to implement solutions that improve vehicle efficiency, such as downsized engines, cylinder deactivation and advanced torque lock-up strategies. However, these solutions have a major drawback in terms of noise and vibration comfort. Downsized engines and lock-up strategies lead to the use of the engine at lower RPMs, and the reduced number of cylinders generates higher torque irregularities. Since the torque generated by the engine is transferred through flexible elements (clutch, torsional damper, gearbox, transmission, tire), these also impact the energy that is transferred to the vehicle body and perceived by the driver. This phenomenon leads to low frequency behavior, for instance booming noise and vibration. This paper presents a combined test and CAE modelling approach (1D/3D) to reverse engineer a vehicle equipped with a CPVA (centrifugal pendulum vibration absorber). The objectives were to fully understand

Marques dos Santos, Fabio Luis, Enault, Tristan, Deleener, Jan, Van Houcke, Tom

Impact of the Future Fuel Economy Targets on Powertrain, Driveline and Vehicle NVH Development

2017-01-17776/5/2017

The automotive industry continues to develop new technologies aimed at reducing overall vehicle level fuel consumption. Powertrain and driveline related technologies will play a key role in helping OEM’s meet fleet CO2 reduction targets for 2025 and beyond. Specifically, use of technologies such as downsized engines, idle start-stop systems, aggressive torque converter lock-up schedules, wide-ratio spread transmissions, and electrified propulsion systems are vital towards meeting aggressive fuel economy targets. Judicious combinations of such powertrain and driveline technology packages in conjunction with measures such as the use of low rolling resistance tires and vehicle lightweighting will be required to meet future OEM fleet CO2 targets. Many of the technologies needed for meeting the fuel economy and CO2 targets come with unique NVH challenges. In order to ensure customer acceptance of new vehicles, it is imperative that these NVH challenges be understood and solved. This paper

Wellmann, Thomas, Govindswamy, Kiran, Tomazic, Dean

New York auto show: Lincoln unveils all-new, aluminum-bodied 2018 Navigator

17AUTP05_135/1/2017

Ford's Lincoln luxury-vehicle unit revealed the 2018 Navigator fullsize SUV at the 2017 New York auto show by touting its blend of smart basic engineering and smart features. Like the recently-revealed Ford Expedition, its Lincoln counterpart is fitted with weight-saving aluminum bodywork to cut roughly 200 lb (91 kg) from the curb weight and help offset the mass of the new Navigator's copious luxury and advanced driver-assist features.

Visnic, Bill

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