Browse Topic: Downsizing

Items (261)
Vibro-Acoustic Analysis for Modeling Propeller Shaft Liner Material2019-01-15606/5/2019
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 response. The second step is a boundary element simulation to calculate prop surface radiated noise under the excitation obtained from the first step. Finally, acceleration and acoustic test data are presented to assess the accuracy of the CAE method. The new CAE method can dramatically benefit driveline N&V integration, such as prop liner selection or prop mode tuning to reduce the driveline noise.
Jayaratne, Rajith R.Liu, YuGehringer, MarkRayce, JeffHill, Wallace
Model Verification of CAE with NVH-Test Acting on Downsized Car Engines2019-01-15506/5/2019
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 Cars in-line 4-cylinder VEA diesel engine in rig installation is the object for the paper of model verification. Method of this work has been to do simultaneously NVH measurements of vibrations, torque and cylinder pressure traces during different engine load conditions. Also bump test with a modal hammer has been done in order to find rigid body mode frequencies. The measured cylinder pressure is applied as input to the simulation model in order to have consistent input load between test and simulation. This is important when comparing the output vibrations. Verify and compare crank angle based time domain vibrations signals from CAE model with NVH-testing on a real engine. This is the results of the work.
Rönnqvist, UrbanRibarits, Janos
Reducing Vehicle Interior NVH by Means of Locally Resonant Metamaterial Patches on Rear Shock Towers2019-01-15026/5/2019
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 to be able to benchmark the solution, a test vehicle is chosen, which is equipped in its commercial version with a 1.46 kg tuned vibration absorber (TVA) on each of the rear shock towers as NVH solution. It is shown that the metamaterial solution allows to achieve similar interior NVH performance, while reducing the added mass by 48%. The metamaterial additions are realized through additive manufacturing and they are designed to be effective around 190 Hz, as was the case for the original solution. Both experimental results and numerical validation of a road test are presented.
Sangiuliano, LucaClaeys, ClausDeckers, ElkeDe Smet, JasperPluymers, BertDesmet, Wim
Colorado State University EcoCAR 3 Final Technical Report2019-01-03604/2/2019
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) including acceleration, energy consumption, and emissions. In this interest, the team focused on the areas of mass reduction, efficient powertrain operation as well as optimal engine and motor use. While there is incomplete evidence showing that targets have been met in these areas, this study definitively shows improvement from year to year of the competition and specifically during Year 4 when the vehicle was tested extensively. Mass reduction resulted in more acceleration. Efficient powertrain operation resulted in better energy consumption and emissions. Optimal engine and motor use increased our EV range and further improved fuel economy and emissions. Our study reveals that our efforts have made drivability smoother and more responsive, lowered energy consumption while elongating range, and decreased emissions over previous iterations of our vehicle.
DiDomenico, Gabriel ChristianBair, JamisonKukkala, Vipin KumarTunnell, JordanPeyfuss, MarcoKraus, MichaelAx, JoshuaLazarri, JeremyMunin, MatthewCooke, CoreyChristensen, EricPeltz, LoganPeterson, NathanWolfe, LoganVinski, ZachNorris, DanielKaiser, CorrieCollier, JacobSchott, NickWang, YiBradley, Thomas
Water Injection Benefits in a 3-Cylinder Downsized SI-Engine2019-01-00341/15/2019
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 stoichiometric air/fuel ratio engine operation, and hence both reduction in fuel consumption and full utilization of a three-way catalytic converter (TWC). Further information about effects of various water injection parameters is required. Thus, in this study, a 4-stroke, 1.5 liter, 3-cylinder turbocharged engine with direct fuel injection and port water injection was operated on 91, 95 and 98 RON gasoline fuel to assess effects of water injection on knock mitigation, combustion phasing, required air:fuel ratios and exhaust gas temperature control. Full- and part-load curves obtained with different fuels and water injection strategies are presented and discussed.
Khatri, JayeshDenbratt, IngemarDahlander, PetterKoopmans, Lucien
Quasi-Dimensional Simulation of Downsizing and Inverter Application for Efficient Part Load Operation of Spark Ignition Engine Driven Micro-Cogeneration Systems2018-32-006110/30/2018
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 30% at 20% load, and reduced fuel consumption by over 50% at lower load. The co-generation potential was also evaluated, and it resulted practically the same from full to 50% load, while at low load the larger engine featured heat recovery potential up to two times larger compared to the smaller unit.
Irimescu, AdrianCatapano, FrancescoDi Iorio, SilvanaMerola, SimonaSementa, PaoloVaglieco, Bianca Maria
Effect of Mixture Formation and Injection Strategies on Stochastic Pre-Ignition2018-01-16789/10/2018
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 important contributor towards stochastic pre-ignition. The occurrence of pre-ignition, as shown by CFD calculations, is successful after completion of two stages. The first stage involves the formation of precursors from interactions between the fuel spray and oil on the cylinder liner. This is shown to be dependent upon the mass of the fuel impinging on the cylinder liner. The second stage involves the ignition of the precursor, which is shown to be dependent upon the temperature of the air-fuel mixture near top dead center.
Singh, EshanMubarak Ali, Mohammed JaasimIchim, AdrianMorganti, KaiDibble, Robert
On-Road Monitoring of Low Speed Pre-Ignition2018-01-16769/10/2018
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 tests have greatly increased the industry’s knowledge about LSPI, they may not accurately represent LSPI as it occurs while the vehicle is in actual service. This is because the industry tests are conducted on highly controlled engine dynamometers, often using special calibrations. In this work, a vehicle is fully instrumented with a high-speed data acquisition system to monitor LSPI. The vehicle is then operated on public roads with commercially available, pump gasoline for approximately 65,000 miles (104,607 km). Results indicate that LSPI, as it occurs in real world vehicle use, shows some similarities and differences from LSPI that occurs in laboratory engine tests. Additionally, the transient nature of the on-road testing presented a significant departure from the steady-state engine laboratory testing. This difference necessitates the development of a new method for identifying LSPI cycles in real world environments. Finally, results from this work will help the industry develop solutions to LSPI which are effective in the field.
Michlberger, AlexanderSutton, MikeKocsis, MichaelAnderson, GarrettVan Horn, Adam
Analysis of the Hardware Requirements for a Heavily Downsized Gasoline Engine Capable of Whole Map Lambda 1 Operation2018-01-09754/3/2018
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 that a HP EGR system, with the eSupercharger located downstream of the main compressor, has the greatest potential to enable lambda 1 operation at maximum power output. At this point an EGR flow rate of 15 % is required, which would require about 38 kW of EGR cooling capability.
Bassett, MikeVogler, ChristianHall, JonathanTaylor, JamesCooper, AdrianReader, SimonGray, KevinWall, Richard
The Development of Low Temperature Three-Way Catalysts for High Efficiency Gasoline Engines of the Future: Part II2018-01-09394/3/2018
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 paper summarizes work performed at Ford on the development of a catalyst formulation with significantly lower lightoff temperatures than a current production TWC after aging on a high temperature 4-mode durability cycle. The new catalyst consists of rhodium post-impregnated onto an overlayer of titanium deposited onto a silica-stabilized Al2O3 support. A rhodium loading study revealed that the lowest T90 s after 4-mode aging were obtained with 0.5% Rh. A titanium loading study showed that that the best performance after 4-mode aging was obtained with 8% titanium, which corresponded to the monolayer coverage of titanium. TEM analysis confirmed that the titanium monolayer remained well dispersed after the high temperature aging. A fresh sample of the optimized catalyst was evaluated after sulfur poisoning and after a stoichiometric desulfation.
Theis, Joseph R.Getsoian, Andrew (Bean)Lambert, Christine K.
Investigations on the Influence of Fuel Oil Film Interaction on Pre-ignition Events in Highly Boosted DI Gasoline Engines2018-01-14544/3/2018
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 understanding of the possible mechanisms leading to pre-ignition events it is important to know under which conditions splash effects on the film can cause droplet detachment. In this paper pre-ignition events in a 2.0 liter 4-cylinder production engine are analyzed regarding the different operating conditions of their occurrence. Parameters effecting splash conditions are injection timing and pressure (fuel impingement on liner), liner temperature, boiling curves of the fuel and lubricating oil viscosity. Conditions leading to increased pre-ignition rates are compared to a generic drop/wall film interaction experiment to evaluate whether splash events are a likely cause or not. The impact of a single drop onto a wetted wall using different liquids is investigated. A large parameter range is obtained by varying drop diameter, impact velocity, film thickness and fluid combinations of drop and wall film. Finally, a dimensionless number K * is defined in order to describe the splashing threshold. Typical K * numbers for various operating conditions of the engine are then computed and compared with results from generic drop impact experiments.
Kubach, HeikoWeidenlener, AlexPfeil, JuergenKoch, ThomasKittel, HannahRoisman, Ilia V.Tropea, Cameron
Adaptive Turbo Matching: Radial Turbine Design Optimization through 1D Engine Simulations with Meanline Model in-the-Loop2018-01-09744/3/2018
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 the exhaust boundary conditions and overall engine performance. Running the coupled engine-turbine model within an optimization framework, the optimal turbine design evolves. The methodology is applied to a Renault 1.2 L turbocharged gasoline engine, to minimize fuel consumption over given full- and part-load operating points, while meeting performance constraints. Despite the current series production turbine being a very good match already, and with optimization restricted to a few turbine geometric parameters, the full-load case predicted a significant cycle-averaged BSFC reduction of 3.5 g/kWh, while the part-load optimized design improved BSFC by 0.9 g/kWh. No engine design parameters were changed, so further efficiency gains would be possible through simultaneous engine-turbocharger optimization. The proposed methodology is not only useful for improving existing designs; it can also develop a bespoke turbine geometry in new engine projects where there is no previously available match. For these reasons, ‘adaptive’ turbo matching will become the standard approach in the automotive industry.
Kapoor, PrakharCostall, Aaron W.Sakellaridis, NikolaosHooijer, JochemLammers, RogierTartoussi, HadiGuilain, Stéphane
Downsized Gasoline Engine Cylinder Deactivation MiL Development and Validation Using Real-Time 1-D Gas Code2018-01-12444/3/2018
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 zero cylinder fueling applied to one or more cylinders to achieve the best possible fuel consumption. The real-time 1-D gas thermodynamic engine model is validated within the entire engine operating range against test data with/without deactivated cylinders. Moreover, further validation is done by running both the physical engine and the 1-D gas real-time code at transient load/speed cycles. The results from the steady-state and transient cycles show CO2 reduction. Using the MiL approach, the best cylinder deactivation strategy regions are identified. Additionally, the proposed MiL environment containing the 1-D gas real-time code and the engine control strategy can be further used for the development and calibration of advanced dynamic deactivation (known as skip-fire) strategies.
Kouba, AdamHnilicka, BohumilNavratil, Jiri
Development of High-Power-Density DC-DC Converter Using Coupled Inductors for Clarity Plug-In Hybrid2018-01-04584/3/2018
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 method of increasing the power density of the DC-DC converter. This circuit design reduced magnetic flux generated in the inductor cores by direct current, making it possible to reduce the size of the inductors. However, it was not possible to position electric devices such as current sensors close to the coupled inductors due to magnetic flux leakage to the exterior, making it challenging to increase the integration density of the components. In order to address this issue, a configuration of coupled inductors that reduces magnetic flux leakage was developed, making it possible to increase the integration density of the peripheral layout of the DC-DC converter. The application of the proposed coupled inductors has increased the continuous power density of the DC-DC converter approximately 2-fold in comparison with the conventional unit employed in previous Honda hybrids.
Komatsuzaki, AkitomoHashino, Satoshi
Development, Performance Analysis and Optimization of Parallel Hydraulic Hybrid System for City Bus Application2018-01-04194/3/2018
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, performance and optimization of hydraulic hybrid vehicle in city application. This paper deals with evaluation of simulation, integration, calibration and performance tests carried out at real world usage conditions. As a final proof of concept and performance, the hydraulic hybrid bus was tested back to back with conventional city bus of same configuration and results were analyzed and compared. This paper also deals on the scope of engine downsizing and major challenges faced in developing hydraulic hybrid system for extremely hot weather conditions such as South Asian countries.
Yaser, K U Syed TajBakatwar, RupeshBhargava, AashishTiwari, Sanjay
Development of Electric Powertrain for CLARITY PLUG-IN HYBRID2018-01-04154/3/2018
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 a standard unit employed in a hybrid vehicle. The IPU contains 17 kWh high-capacity battery modules and a 12 V DC-DC converter. A coolant-cooling method has been adopted to respond to the increased power of the battery, boosting cooling performance. The battery modules are positioned below the front and rear seats, and the high-voltage wiring is positioned between the modules, in the center of the vehicle. This layout has made it possible to fit the IPU below the floor of the vehicle, helping to enable the realization of a spacious and comfortable cabin seating five passengers, as well as a useful amount of trunk space. The use of a high-power VCU and a high-capacity IPU has made it possible to realize EV operation in the high-speed range with no need to start the engine, giving the vehicle an adequate all-electric range (AER) for everyday use. During hybrid operation, increasing both the VCU power and the battery power helps ensure quietness while also allowing the engine to be downsized from 2.0 to 1.5 liters. The developed electric powertrain realizes a long AER of 47 miles and extremely quiet hybrid operation with a high level of fuel economy at 42 mpg.
Yamagishi, TomoyaIshikura, Takashi
Simulation Study of 1D-3D Coupling for Different Exhaust Manifold Geometry on a Turbocharged Gasoline Engine2018-01-01824/3/2018
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 study focus on the influence of 3D part on system. (e.g influence of intake or exhaust manifold on flow in cylinder in co-simulation).The objective of this study includes two aspects, one compares the difference between 1D and the 1D/3D coupling, the other studies the influence of the 4-1 and 4-2-1 exhaust manifold on in-cylinder residual fraction gas (RGF) based on the proposed 1D and 3D co-simulation approach. It describes a detailed analysis of the integrated 1D-3D simulation for two different exhaust manifold geometries on a turbocharged gasoline engine. The research results show that the induction process of the original 1D model and the co-simulation model were nearly equal, but the exhaust pressure of the coupled model was smoother than that of the original 1D model. The 4-1 exhaust manifold has a larger residual gas fraction due to the more severe pulse interference and the 4-2-1 exhaust manifold is able to mitigate this phenomenon by separating the runner 1/runner 4 with runner 2/runner 3. Furthermore, by added a spacer plate at exit port of 4-2-1 manifold, it can further reduce in-cylinder RGF and enable more uniformity among four cylinders. Therefore, the 4-2-1 exhaust manifold can be used to enhance the engine performance to achieve the concept of downsizing and down-speeding, and also it can be adopted to optimize the fuel efficiency by advancing the spark timing.
Zhang, ChaolinHu, Bolai, ChenguangZhang, HailinQin, LingLeng, XiaoliHuang, Wenpeng
The Effect of Swirl on the Flow Uniformity in Automotive Exhaust Catalysts2017-01-238410/8/2017
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 exists where the flow is most uniform. To gain further insight into the mechanisms controlling flow redistribution, numerical simulations have been performed using the commercial CFD code STARCCM+. With no swirl, the central jet transverses the diffuser, and a drastic flow redistribution takes place near the monolith face due to its high resistance. Immediately downstream of the sudden expansion, the flow separates from the diffuser wall forming a separation zone around the central jet. Increasing swirl reduces the size of this separation zone, and eventually leads to the formation of the central recirculation zone characteristic of high swirl flows. At intermediate swirl levels, the size of the wall separation zone is reduced considerably, while the axial adverse pressure gradient is insufficient to cause a central recirculation. Such a flow regime occurs at relatively low swirl levels (S ~ 0.23). This may have positive implications for aftertreatment system design with low residual swirl levels from the turbine, which might be tuned by adjusting the distance between the turbine and the catalyst or employing guide vanes. The findings can be directly transferred to other aftertreatment systems with a catalyst or particulate filter. Moreover, swirling flows with an obstruction or a high resistance device downstream (e.g. a heat exchanger or filter) are present in many other applications such as cooling flows, combustion and turbomachinery. Therefore the results are relevant to a much wider research and industrial community.
Rusli, Ijhar H.Aleksandrova, SvetlanaMedina, HumbertoBenjamin, Stephen F.
Exploitation Strategies of Cabin and Galley Thermal Dynamics2017-01-20379/19/2017
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 electrical system are used to assess and compare these different strategies. Potential impacts on passenger comfort are discussed. Additionally, the gained performance is compared to more conventional storage elements like electrical batteries. Finally, the potential of fuel reduction will be quantified using a reference aircraft model and the optimal strategy is selected.
Schlabe, DanielZimmer, DirkPollok, Alexander
Tribodynamics of a New De-Clutch Mechanism Aimed for Engine Downsizing in Off-Road Heavy-Duty Vehicles2017-01-18356/5/2017
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 hydraulic pressure is applied behind the piston to initiate the engagement. The angular motion of the plates is supported by friction torque between the plates and friction linings. The conjunctions between paper-based linings and steel plates are designed to be dry. Friction (the most significant tribological feature of the linings in torque transmission) is measured in a pin-on-disc tribometer and mapped into the dynamics model in MSC ADAMS. The pin-on-disc tribometer is able to capture the variation of friction coefficient with contact pressure and sliding velocity. The surface topography is obtained experimentally to examine the consistency of surface properties. The normal pressure and tribology of the contacting components determines the engagement time, clutch capacity and dynamic behaviour of the clutch.
Dolatabadi, NaderRahmani, RaminTheodossiades, StephanosRahnejat, HomerBlundell, GuyBernard, Guillaume
Impact of the Future Fuel Economy Targets on Powertrain, Driveline and Vehicle NVH Development2017-01-17776/5/2017
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 will begin with an introduction of the legislative framework with respect to fuel economy and CO2 targets for light duty vehicles. Key megatrends of engine, transmission, driveline, and electrified propulsion systems will be examined, following which the NVH behavior of each sub-system will be illustrated. A combination of experimentally measured data and simulations will be used to demonstrate key NVH challenges such as high levels of combustion noise, increased driveline torsional excitation, start-stop refinement, shift quality, and high-frequency whine noise from motors/generators in electrified propulsion systems. Examples of component-level and system-level NVH countermeasures will be discussed. Finally, the use of advanced test and simulation-based methodologies for smooth NVH refinement of future propulsion systems will be illustrated using case study examples.
Wellmann, ThomasGovindswamy, KiranTomazic, Dean
Model Based Approach by Combination of Test and Simulation Methodologies for NVH Investigation and Improvement of a Rear Wheel Drive Vehicle2017-01-17746/5/2017
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 and predict vehicle behavior with respect to the drivetrain torsional oscillations and low frequency booming noise and vibration. For this purpose, the procedure was divided in two phases: testing and modelling. The testing phase was used to get insight into the vehicle behavior, noise sources and noise transfer paths, using operational measurements. Moreover, dedicated component tests were carried out to obtain parameters to be used in the modelling phase, with the CPVA being the most complex and important component. The modelling phase used the test results as input to build a full vehicle model and to validate the booming noise results. The final model was fit for sensitivity studies and was also used to evaluate the performance of the CPVA, which is dedicated to the reduction of lock-up booming noise. Such an approach is a first step which can accelerate the SDPD (system driven product development) into a consolidated MBSE (model based system engineering) framework.
Marques dos Santos, Fabio LuisEnault, TristanDeleener, JanVan Houcke, Tom
Topology Optimization and Fatigue Analysis for Lightweight Design of Vehicle Differential Case2017-01-13363/28/2017
In this advanced technological era, lightweight design for fuel efficiency and environmental friendliness is essential for both conventional and hybrid electric vehicles (HEVs), without sacrificing the durability which is an important design factor for vehicle safety. To achieve these objectives, reduction of the structural mass of the full vehicle plays a vital role. The scope of this paper is to describe design methodologies for the vehicle differential case applied to achieve light weight and to ensure product life. The focus of this paper includes two tasks. The topology optimization and fatigue analysis of a vehicle differential case are conducted. Finite element analysis (FEA) is used to simulate the stress with constraint. After that, optimization parameters (design variables, responses, objective functions and constraints) of a vehicle differential case are selected for lightweight design by solid isotropic microstructures with penalization (SIMP) method. The optimization results revealed that the SIMP method successfully achieved 25% mass reduction of vehicle differential case. Furthermore, the second task is the fatigue analysis which is usually used during the design phase to predict the future failure of components. The fatigue lives and damages of two lightweight cases obtained from topology optimization were analyzed and compared. Our proposed research methodology is expected to be useful in reducing mass and prolonging product life.
Shaikh, WaqasWang, LiangmoYang, SenXia, HanguanDong, Yi
Design Optimization of Vehicle Body NVH Performance Based on Dynamic Response Analysis2017-01-04403/28/2017
Noise-vibration-harshness (NVH) design optimization problems have become major concerns in the vehicle product development process. The Body-in-White (BIW) plays an important role in determining the dynamic characteristics of vehicle system during the concept design phase. Finite Element (FE) models are commonly used for vehicle design. However, even though the speed of computers has been increased a lot, the simulation of FE models is still too time-consuming due to the increase in model complexity. For complex systems, like vehicle body structures, the numerous design variables and constraints make the FE simulations based optimization design inefficient. This calls for the development of a systematic and efficient approach that can effectively perform optimization to further improve the NVH performance, while satisfying the stringent design constraints. In the present work, an efficient method to optimize the structural dynamic response is proposed considering the low-frequency NVH performances. As a first step, to reduce computational burden, a response sensitivity analysis is performed to detect the most important variables prior to the design optimization. Then an analytical approximation model of vibration resonance peak is constructed and coupled with the adaptive simulated annealing (ASA) algorithm to replace the time-consuming finite element analysis. Subsequently, an optimization of NVH performance considering dynamic response is formulated and carried out. The methodology aims at improving the NVH behavior of body structure by simultaneously suppressing several resonance peaks. Finally, the proposed method and its process are successfully illustrated through a vehicle body example. The results demonstrate that the proposed method of incorporating response surface model with ASA algorithm is feasible and cost-efficient in solving the vibration optimization problem.
Lu, JunZhan, ZhenfeiSong, HaozhanLiu, XuYang, XinYang, Junqi
Potentials of Electrical Assist and Variable Geometry Turbocharging System for Heavy-Duty Diesel Engine Downsizing2017-01-10353/28/2017
Diesel engine downsizing aimed at reducing fuel consumption while meeting stringent exhaust emissions regulations is currently in high demand. The boost system architecture plays an essential role in providing adequate air flow rate for diesel fuel combustion while avoiding impaired transient response of the downsized engine. Electric Turbocharger Assist (ETA) technology integrates an electric motor/generator with the turbocharger to provide electrical power to assist compressor work or to electrically recover excess turbine power. Additionally, a variable geometry turbine (VGT) is able to bring an extra degree of freedom for the boost system optimization. The electrically-assisted turbocharger, coupled with VGT, provides an illuminating opportunity to increase the diesel engine power density and enhance the downsized engine transient response. This paper assesses the potential benefits of the electrically-assisted turbocharger with VGT to enable heavy-duty diesel engine downsizing. A 1D engine simulation model of the Caterpillar 7.1L 6-cylinder diesel engine has been developed and validated against engine test data taken with ETA device fitted. Both steady state and transient engine performance are evaluated with different electric power levels, motor response time and VGT vane positions. The ETA technology gives transient response benefits over a range of transient events, but with diminishing returns at the higher levels of ETA power. Better transient response and fuel consumption could be achieved by combining ETA device with VGT versus a standard fixed turbine. The importance of ETA control with fast response time during transient maneuver is highlighted. This study also demonstrates the engine speed drop is less significantly affected than recovery time over block load test by employing ETA technology. This potential limit of the requirement to have sufficient initial excess boost for downsized engine could be addressed by controlling the VGT vane position. Finally, the capability of this optimized boosting system to enable downsizing from 9.3L to 7.1L is demonstrated.
Xue, XingyuRutledge, John
Research on the Application of Micro-Channel Evaporator in R134a Roof-Top Bus Air Conditioner2017-01-01613/28/2017
This study investigates the cycle performance and potential advantages of the replacement of fin-and-tube evaporator with parallel flow micro-channel evaporator, in R134a roof-top bus air conditioner (AC) system. The heat exchangers for bus AC system are featured by a stringent space height limitation. The configuration of inclined four piece or six piece micro-channel evaporators was proposed to satisfy this space requirement, instead of original two piece fin-and-tube evaporators. Additionally, the individual superheat control method with thermostatic expansive valve (TXV) in each evaporator was adopted to improve refrigerant distribution. Three kinds of micro-channel evaporators were designed and equipped in an 8-m roof-top bus AC system. Except the replacement of evaporators, TXV and connecting pipes, other cycle components were kept same. Comparison experiments were carried out to evaluate the cycle performance with micro-channel evaporator configuration in psychometric calorimeter test facility at rated cooling condition. Experiment results, including R134a refrigerant charge, superheat performance, cooling capacity and system coefficient of performance (COP) were compared between micro-channel evaporator system and fin-and-tube evaporator system. Results show that individual superheat control method improved the superheat distribution uniformity among multiple evaporators, and enhanced the system cooling capacity. Besides, the optimum micro-channel evaporator configuration achieved equal cooling capacity and COP with fin-and-tube evaporators. Furthermore, potential advantages including refrigerant charge reduction, cost saving, system mass reduction, and compact installation were also discussed for the application of micro-channel evaporator in roof-top bus AC system.
Wang, DandongLiu, CichongChen, Jiangping
Experimental and Numerical Study of the Water Injection to Improve the Fuel Economy of a Small Size Turbocharged SI Engine2017-01-05403/28/2017
In this work, a promising technique, consisting of a liquid Water Injection (WI) at the intake ports, is investigated to overcome over-fueling and delayed combustions typical of downsized boosted engines, operating at high loads. In a first stage, experimental tests are carried out in a spark-ignition twin-cylinder turbocharged engine at a fixed rotational speed and medium-high loads. In particular, a spark timing and a water-to-fuel ratio sweep are both specified, to analyze the WI capability in increasing the knock-limited spark advance. In a second stage, the considered engine is schematized in a 1D framework. The model, developed in the GT-Power™ environment, includes user defined procedures for the description of combustion and knock phenomena. Computed results are compared with collected data for all the considered operating conditions, in terms of average performance parameters, in-cylinder pressure cycles, burn rate profiles, and knock propensity, as well. Finally, the validated model is applied to investigate the full potential of water injection in reducing the knock tendency and improving the fuel economy in a wide load range. The numerical results highlight that WI technique involves significant Brake Specific Fuel Consumption (BSFC) advantages, especially at the medium-high loads. These benefits are limited by the maximum allowable levels for the in-cylinder pressure, while additional advantages are obtained in terms of reduced turbine inlet temperature, turbocharger speed, and boost pressure. The developed numerical procedure, based on validated combustion and knock sub-models, is able to take into account the complex interactions among different parameters, which affect the engine behavior. It is hence believed to realistically forecast the WI-related BSFC advantages and constraints, induced by thermo-mechanical stresses. Simultaneously, it underlines the need of a partial engine redesign to fully exploit WI potential.
De Bellis, VincenzoBozza, FabioTeodosio, LuigiValentino, Gerardo
Dynamic Downsizing Gasoline Demonstrator2017-01-06463/28/2017
Gasoline engine downsizing is already established as a technology for reducing vehicle CO2 emissions. Further benefits are possible through more aggressive downsizing, however, the tradeoff between the CO2 reduction achieved and vehicle drivability limits the level of engine downsizing currently adopted by vehicle manufacturers. This paper will present the latest results achieved from a very heavily downsized engine, and resulting demonstrator vehicle, featuring eSupercharging in combination with a conventional turbocharger. The original 1.2 litre, 3-cylinder, MAHLE downsizing engine has been re-configured to enable a specific power output in excess of 160 kW/litre. Of key importance is a cost effective, efficient and flexible boosting system. The Aeristech eSupercharger, operating at 48 V, enables the transient response and low speed torque to be more than recovered, enabling both very high specific output and specific torque characteristic with excellent transient response and drive-ability characteristics, clearly demonstrating eSupercharging as a key technology for enabling further engine downsizing. The resulting heavily downsized engine has been installed into a demonstrator vehicle that also features an advanced 48 V lead-carbon battery pack and a 48 V belt-driven integrated starter generator (BISG). The battery and BISG have been selected to enable the continuous high-output (6 kW) operation of the eSupercharger to support prolonged operation of the engine at low speed and high-torque output. The fuel consumption of the resulting demonstrator vehicle has been analysed over a number of drive-cycles and the benefits of the downsized engine in conjunction with the complete mild-hybrid system have been assessed.
Bassett, MichaelHall, JonathanCains, TonyUnderwood, MarkWall, RichardRichards, Bryn GR
A Miller Cycle Engine without Compromise - The Magma Concept2017-01-06423/28/2017
The Magma engine concept is characterised by a high compression ratio, central injector combustion system employed in a downsized direct-injection gasoline engine. An advanced boosting system and Miller cycle intake-valve closing strategies are used to control combustion knock while maintaining specific performance. A key feature of the Magma concept is the use of high CR without compromise to mainstream full-load performance levels. This paper focuses on development of the Magma combustion system using a single-cylinder engine, including valve event, air motion and injection strategies. Key findings are that Early Intake Valve Closing (EIVC) is effective both in mitigating knock and improving fuel consumption. A Net Indicated Mean Effective Pressure (NIMEP) equivalent to 23.6 bar Brake Mean Effective Pressure (BMEP) on a multi-cylinder engine has been achieved with a geometric compression ratio of 13:1. Comparison of weighted key point cycle predictions for the downsized Magma concept vs a contemporary baseline engine, indicates fuel consumption savings over WLTC and FTP-75 of 12.5% and 16.4% respectively. The cost / benefit trade-off is currently being refined, but the position in terms of cost per gram per mile of CO2 benefit appears to favour a Magma solution over other options. Part of the benefit arises from the current assumption that a 2.0 litre L4 engine is replaced with a 1.5 litre L3 which is enabled by the higher specific rating of the Magma concept. The reduction in base engine cost offsets some of the additional air handling equipment.
Osborne, RichardDownes, TrevorO'Brien, SimonPendlebury, KenChristie, Mark
Development of New IGBT to Reduce Electrical Power Losses and Size of Power Control Unit for Hybrid Vehicles2017-01-12443/28/2017
One way to improve the fuel efficiency of HVs is to reduce the losses and size of the Power Control Unit (PCU). To achieve this, it is important to reduce the losses of power devices (such as IGBTs and FWDs) used in the PCU since their losses account for about 20% of the total loss of an HV. Furthermore, another issue when reducing the size of power devices is ensuring the thermal feasibility of the downsized devices. To achieve the objectives of the 4th generation PCU, the following development targets were set for the IGBTs: reduce power losses by 19.8% and size by 30% compared to the 3rd generation. Power losses were reduced by the development of a new Super Body Layer (SBL) structure, which improved the trade-off relationship between switching and steady-state loss. This trade-off relationship was improved by optimizing the key SBL concentration parameter. Size was reduced by adopting a new environment-friendly IGBT surface electrode structural design that enabled double-sided solder packaging. This approach ensured thermal feasibility caused by the higher current density due to the smaller design. A REduced SURface Field (RESURF) structure was adopted for edge termination. To improve the robustness of the breakdown voltage, an optimum RESURF concentration balance was designed which also contributed to the IGBT’s downsizing. These developments successfully reduced both the loss and size of the IGBTs, thereby reducing the size and loss of the new PCU, and helping to improve the fuel efficiency of Toyota’s 4th generation HVs.
Kimura, KeisukeRahman, TasbirMisumi, TadashiFukami, TakeshiHara, MasafumiKawaji, SachikoMachida, Satoru
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