Browse Topic: Energy conservation

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Development of the Mild Hybrid System for Off-Road Machinery2024-32-006704/18/2025
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
Studying the Lean Burn Operation in Two-Wheelers to Increase Fuel Efficiency and Investigate the Use of Lean NOx Trap Catalyst (LNT) for Lean Burn System2024-32-005804/18/2025
This study offers an overview of the impact of lean burn technology in two-wheeler vehicles, specifically concentrating on enhancing the fuel economy and addressing the challenges associated with its adoption. Lean burn systems, characterized by a fuel-air mixture with a higher air content than stoichiometric ratio. The study focuses on technology which meets stringent emission standards while enabling the optimization of fuel efficiency. The lean burn system employs strategies to optimize air-fuel ratio using electronic fuel injection, ignition timing control, and advanced engine control algorithms like - updated torque modulation control algorithm for drivability, lambda control algorithm for rich and lean switch and NOx modelling algorithm for LNT catalyst efficiency tracking. The challenges related to lean burn systems, includes issues related to combustion stability, nitrogen oxide (NOx) emissions, and their impact on drivability, is summarized in the study. Mitigation strategies
Somasundaram, Karthikeyan, Sivaji, Purushothaman, John Derin, C, Vishal, Karwa, Manoj Kumar, S, Maynal, Rajesh
Development of Cylinder Deactivation Control during Idle for Conventional Engines2024-32-001904/18/2025
This report examines the advancement and utilization of cylinder deactivation technology that enhances fuel efficiency in conventional engines without hardware modifications. It operates by halting fuel supply to some of the cylinders in multi-cylinder engines and increasing the output power of the remaining active cylinders to maintain an idle state. By implementing this technology in the mass-produced 90° V-twin engine, the U502, and deactivating one of its two cylinders, fuel consumption during idling is reduced by over 30%. The focus of this study is on the technology developed to minimize engine speed fluctuations during the transition to cylinder deactivation and reactivation for the engine. By making various modifications to the fuel injection control sequence and optimizing the throttle opening of each cylinder in idle and driving conditions, engine speed fluctuations were minimized. This allows users to reduce fuel consumption while maintaining the engine’s original
YANAGIDA, Shoji
Analyses of Cold Thermal Energy Storage Systems Using Eutectic Mixtures of Inorganic Hydrated Salts as Phase Change Materials2025-01-500301/23/2025
Cold thermal energy storage using phase changing materials is being researched to find freezing and thawing points. The use of inorganic hydrated salts, a type of phase changing material (PCM) used in cold energy storage systems without the use of existing renewable energy systems, allows for a longer cooling effect and saves energy. A high volumetric storage density and relatively high thermal conductivity make hydrated salts suitable materials for thermal energy storage. They can be used only as inorganic mixtures or else they can also be used as eutectic mixtures, which involve mixtures of inorganic–inorganic salts or simply a combination of two or more inorganic salts. This research deals with eutectic mixtures, which are 4% KNO3 + 96% H2O, 4% NaHCO3 + 96% H2O, and 2% KNO3 + 2% NaHCO3 + 96% H2O. Three different novel eutectic mixtures were examined and found a suitable mixture for a cold thermal energy system. An efficient phase change approach involving 2% KNO3 + 2% NaHCO3 + 96
Vasanthkumar, P., Santhoshkumar, A., Gopika, P., Murali, M., Meera, C.
SAE TOMORROW TODAY: Reshaping Air Freight with Blended Wing Body Design1349401/06/2025
For more than 60 years, the air freight industry has adapted passenger aircraft for cargo fleets resulting in limited capacity and diminished fuel efficiency. However, a long-overdue shift toward a volume-optimized blended wing body (BWB) design is enabling freight aircrafts to carry 40-50% more in cargo capacity per trip while also reducing greenhouse gas emissions. Leading the way is Natilus, a company that develops hyper-efficient cargo and passenger BWB aircraft that dramatically improve aerodynamic efficiency and provide a powerful increase in internal volume. The result? Less fuel burn, lower emissions, higher payloads, and lower operating costs. To learn more, we sat down with Aleksey Matyushev, CEO and Co-Founder, to discuss how Natilus' next-generation BWB aircraft design can improve economic efficiency and sustainability, as well as the company's foray into the passenger aircraft space. We'd love to hear from you. Share your comments, questions and ideas for future topics and
Hineman, Marcie
Cost-effective techniques for SCEV to improve performance & life of battery and motor by using efficient thermal systems2024-26-027501/16/2024
The automotive world is moving towards electric powertrain systems. The performance of an electric powertrain and its electric components majorly depends on the operating temperature of the components. In the small commercial vehicle segment overall vehicle cost is a very sensitive parameter while competing in the market. This paper presents advanced efficient cost-effective thermal techniques for small commercial electric vehicles (SCEV) to improve the performance & life of major electric components. It is observed that from the literature survey, this technology is a novel technology for small commercial electric vehicle applications. The one-dimensional (1D) simulation approach is employed to evaluate the performance of the battery and traction cooling system during battery charging and vehicle driving scenario for different ambient conditions. The proposed thermal management techniques consist of simple and cost-effective thermal architectures having 3-way & 4-way valves which help
Chormule, Suhas Rangrao, Warule, Prasad, Jadhav, Vaibhav, Nagpure, Rahul
Fuel Cell Electric Train Concept – Zero Emission Rail Transport Solution for India2024-26-017901/16/2024
Indian cities are among the most polluted in the world. The transportation sector is one of the major source of gaseous pollutants. In recent years, also the effects of climate change and global warming have been felt across the globe. India has therefore committed at the CoP26 summit to reduce its CO2 emissions 45% by 2030. The Indian automotive sector is already addressing the problem with implementation of stricter BS VI, CAFÉ & Stage V standards and pursuing rapid electrification with application of zero emission vehicles. India also has the largest rail network of Asia, and a significant proportion of greenhouse gases also comes from this sector. Deployment of zero emission fuel cell trains would be one of the solutions to meet India's emission reduction targets. Indian Railways has already started its journey towards zero emissions and has set a target to launch hydrogen fuel cell trains on some routes by 2023 as part of the "Hydrogen for Heritage" initiative. In this study, the
Emran, Ashraf, Mertes, Simon, Garg, Shivam, Wick, Maximilian, Gautam, Anirudh, Schmidt, Marvin, Wagh, Sachin, Sharma, Vijay, Walters, Marius
Dynamic Spark Advance Technology for Gasoline Fuel Blends2024-26-007401/16/2024
Fuel efficiency is one of the most important customer requirement in Indian market as well as very crucial to meet the upcoming regulation like CAFÉ for Indian Automotive manufacturers. Most of the technology changes to meet this challenge, always come with a cost penalty with hardware addition. To counter the above challenge, we identified a strategy in the EMS software, without any hardware change, that will dynamically adapt the spark timing based on fuel quality. This strategy has resulted in fuel efficiency improvement on MIDC as well as on-road as per customer driving pattern. Going forward the availability of Ethanol Blended Fuels are going to increase multifold, to take advantage of this, the dynamic spark advance strategy has been proposed in this paper. This paper elaborates on the work done to develop and validate the EMS Strategy as well as the test results with different Ethanol Fuel Blends.
Tyagarajan, Sethuramalingam, Kavekar, Pratap, Suna, Bhagyashree, Agarwal, Nishant, Shaikh, Wasim
Engine Modelling with Smart Online DoE2024-26-033801/16/2024
The implementation of TREM/CEV 5 emission norms on farm equipment will bring in cost pressure due to the need for exhaust after treatment systems. This cost increase needs to be reduced by bringing in more efficient and effective processes to shorten the development phase and to provide better fuel efficiencies. In this work ETAS ASCMO Online DoE with Constraint Modelling (ODCM) to execute smart online DoE on a new common rail diesel engine with EGR, whose exact bounds of operation was not available. A Global test plan with ASCMO Static was created without much focus on detailed constraints of engine operation, other than the full load curve. The parameters which were selected were Speed, Torque, Rail Pressure, Main Timing, EGR Valve Position, Pilot Separation and Quantity and Post Quantity and Separation. For these parameters, the safe operating bounds were not available. This ASCMO Static test plan is automated and executed on engine test cell with ETAS INCAFlow. ODCM at each step
Paulraj, Lemuel Srinivasan, Varsha, Anuroopa, Karadi, Subramanya, KUMAR, DEVENDRA
Data driven decisions to calculate CO2 emission for materials derived from estimated vehicle weight2024-26-015901/16/2024
Change in the gross weight of the car due to change in Special Accessories (SA)/parts/different materials can drastically alter the overall CO2 emission readings. Each carline has multiple variants offered to the customers. Each variant additionally has different code rules associated with them further increasing the customizability. This requires a system to predict the estimated gross weight of the cars to calculate the CO2 emission accurately. Carlines, which are already in production phase, have certified weights associated with them. For each variant of the car, there is a specific weight threshold, which governs the emission certification of it. However, carlines, which are in development phase, have yet to certify for CO2 emission. This makes it very difficult to identify customizability options for development variants. Any change in the part/accessory can make the variant exceed the weight threshold, thus, making it difficult to offer alternatives. The idea is to help the
Majumder, Kuntal, Pundir, Manish, Pathak, Arindam, Kumar, Rahul
Energy Conservation And Protecting Global Health By Automated Corporate Transport Services Application/System.2024-26-023801/16/2024
Energy Conservation And Protecting Global Health By Automated Corporate Transport Services Application/System. Now a days the huge problem our globe is facing is global warming and energy conservation. All world engineering is happening around this topic particularly, that’s why we have introduce clean fuels, EV’s, solar systems, stopping all conventional energy sources ex; thermal power plants, limited use of coal and conventional fuel etc. world is putting all investment, technology in making world a better place to live and sustain healthy environment. That’s the corporates also up to, saving paper by limited use of it, no carbon footprint awareness program, saving electricity using more day light many more. Still, corporates are missing on crucial point known to all, i.e. To daily commute from office to home employees are using their own vehicle hatchback, sedan, SUV etc. As India a country with hot climate it is understandable that to retain work energy, we need comfortable
Thakare, Ashish
Thermal system simulation and modelling for Alternative Fuels in a Heavy Duty Truck2024-26-029601/16/2024
In the current scenario, demand for Alternate energy source is increasing to reduce dependency on presently available fuels. Internal Combustion engines working on multiple fuels developed in which LNG/CNG is a close contender. Cooling system is one of the critical components of an automobile that influences the engine performance and efficiency. Higher heat demands efficient Cooling system. In this paper an approach is defined to arrive at a Cooling system architecture for CNG/LNG fuel. The aim is to finalise a Cooling system package which is simple and Energy efficient. Modelling is done in Thermal simulation software KULI. Detailed study is done on simulation results of air flow and temperatures and correlated with test results.
M S, Vignesh, KIRAN, NALAVADATH, M, VIGNESH
High Speed Driveline Power Loss & Influencing Factors2024-26-033701/16/2024
Energy savings in automotive applications has always remain an important aspect of research. In addition, today's highspeed requirements in electric vehicles require high-efficiency drivelines to match overall vehicle mileage or range. This paper presents the validation of the overall efficiency & drag losses of the highspeed Driveline for an ATV with 4 Wheel Drive System. The efficiency & drag losses were measured in the powertrain testbed where the test units were placed between two Transient Dynamometers. The main aim of the test was to validate the overall efficiency as a function of input speed and torque. All these measured values of the gearbox efficiency are included in various graphs. The tests were performed for complete functional range of UUT at max. operating oil temperatures for Transmission and Front Differential testing. Drive shafts tests were performed at its complete range and various inclination angle up to max. failure point. The Wheel Hub was tested at various
Jain, Sankalp, Singh, Parminder
Drive GPT – An AI based generative driver model2024-26-002501/16/2024
Studies have shown that good driving alone can improve the energy efficiency of the vehicle by 30-40%, reduce accidents by 20% and reduce maintenance costs by 25%. Thus, providing feedback about driving behavior can help drivers optimize their driving habits enabling them to reduce the total cost of vehicle ownership while also increasing their safety. To solve this, we have built Drive GPT, an AI-based generative pre-trained transformer model, trained using 90 million data points from 100 vehicles driven across 8 cities within India over 6 months. The model has learned to generate good driving behavior under various road, traffic, weather, and vehicle conditions. Its architecture is based on a transformer network, which allows it to efficiently process sequences of driving steps. To make this a generic model and reduce bias, drives from across the cities and fleets have been oversampled and balanced to generate a representative driving behavior database on which the model is trained
Kumar, Vedant, Jain, Siddhant, Soni, Nimish, Saran, Amitabh
Development of Fuel efficiency Enhancement Module for tractors2024-26-006401/16/2024
In farm tractors, the available drawbar power and Power Take-Off (PTO) power are generally lower than the engine power due to parasitic losses. These losses are caused by engine-driven auxiliary loads such as cooling fans, hydraulic pumps for power steering, alternators, etc. Minimizing these parasitic losses can increase the available drawbar power and PTO power, resulting in direct fuel savings by reducing fuel consumption. The continuous increase in fuel costs and the environmental impact of emitted gases from burned fuel into the atmosphere have necessitated the replacement of hydraulic power steering and mechanical fans with electric power steering (EPS) and electric fans, respectively, to improve efficiency. The existing battery has been replaced with a higher capacity battery to provide power to the electric fan, electric power steering, and other electrical components. Additionally, the existing alternator has been replaced with a higher capacity alternator to meet the
Arjun, P., Natarajan, Saravanan, Chinnathambi, Manikandan, a, Radhakrishnan, nabar, Omkar
A computational process to predict and mitigate liftgate gap noise2025-01-002805/05/2023
Noise comfort significantly influences vehicle purchasing decisions. With wind noise being a primary contributor to the overall cabin experience vehicle manufacturers must focus on optimizing the exterior shape of their models to minimize wind noise while balancing fuel efficiency and aesthetic appeal. High-speed airflow over gaps in the vehicle’s exterior can generate considerable noise, which often enters the cabin through seals. A good sealing strategy could be very helpful to address these gap noise issues. However, doing this with traditional experimental processes can be challenging, since early stage prototypes may lack detailed gap information. Modifying the seal design after the tooling stage to address these noise issues can be costly for manufacturers, as suppliers often incur expenses related to tool modifications and redesigns. Overdesigning by incorporating multiple layers of seals for all the gaps can inflate part and manufacturing costs, ultimately impacting profit
Moron, Philippe, Jantzen, Andreas, Kim, Minsuk, Senthooran, Sivapalan
Assessment of Future Scope of Waste Heat Recovery System for IC Engine Powertrain Vehicles of Highway and Off-Highway Applications2022-28-044411/09/2022
In this article we summarize the major types of waste heat recovery ( WHR) systems developed and tested. The primary use of WHR system is to increase the fuel economy by minimum 3% from the energy recovery from the exhaust system ( 300-400 deg C ) instead of released to environment, which has heat energy about 18 ~ 25% of total fuel energy. There are 3 types of energy recovery system is discussed in detail, namely (1) thermoelectric devices (TED) to generate electrical energy directly, (2) Turbo-compound system and (3) Rankine cycle-based systems used to generate mechanical energy and that is transferred to crankshaft. Depend on these different technical approaches, there is a potential for up to 5% improvement in fuel economy and CO2 reduction , which can be achieved by generating mechanical or electrical power from exhaust energy using WHR system. However, the payback period for introduction of this WHR system to be taken into consideration while developing new system for the highway
Muthu, Selvaraji, N, SEKARAPANDIAN, KANNAIYAN, ASHOK
Faster Cool-Down of a Reefer Unit by Optimizing the System Losses through Experimental Investigation2022-28-044211/09/2022
Refrigerated shipping containers are one of the four segments of the cold chain; cooling and storage; refrigerated transport; distribution centre and refrigerated display in super markets. The term reefer has become an established term to refer refrigerated shipping containers. It is one of the emerging areas in transport segments. With the onset of ongoing pandemic this area has further drawn global attention recently and due focus is being given to the development and improvement of reefer unit Hence with the growing demand in this field the energy consumption is also leapfrogging day by day. Primary energy sources (fossil fuel) are depleting and their environmental impact is raising anxiety around the world. In order to minimize unnecessary energy waste in refrigerated shipping container system, it needs to be designed to be energy efficient and provide high cooling capacity to ensure rapid pull down to carriage temperature and to maintain product quality at idle. Improper operation
Sen, Somnath
Evaluation of Fixed Displacement Compressors for Control Logic Formulation of External Variable Displacement Compressors2022-28-042111/09/2022
The aim of this paper is to analyze the test performance data of fixed displacement compressors in vehicle level tests and identify the functioning regimes wherein the climate control unit forces the compressor to stop intermittently owing to low icing temperatures being reached at evaporator. The exercise provides a deeper insight to compressors operation as well as overall performance that assists in formulation of control strategy and various operating inputs necessary for variable displacement compressors to function as a replacement to fixed displacement compressors. The test data is used to arrive at variable duty cycle for EVDC that ensures smooth operation while yielding benefits of silent operation, lower power consumption and better cabin comfort inside vehicle. The test data used as benchmark was further used to arrive at startup and shutdown strategies for EVDC’s and same was incorporated in control logic developed for hardware controller that supervises the operation of
Yadav, Aditya Pratap, SHUKLA, ANKIT, Sharma, Kamal, Goel, Arun Kumar
Mobile Air Conditioner Off the Grid Cooling Solution2022-28-045411/09/2022
MOBILE AIRCONDITIONER OFF THE GRID COOLING SOLUTION ABSTRACT Rooftop air conditioners are great to use at camp sites with power supply, and swamp coolers only work effectively in dry areas. Rooftop Air Conditioners have excellent cooling capacity. It cools down an entire van space but consumes huge amount of energy! Unable to take on the go. Swamp Cooler consumes less power. Ideal to use in dry climates. But once the humidity gets high, the swamp cooler will struggle to have any effect. And one will have to fill the unit with water manually. Window Air Conditioner is an inexpensive solution with good cooling effect, but it’s bulky, difficult to move, install and power. It blocks windows and damages easily on bumpy roads if fitted in vehicle. Solution for these problems and to bring endless possibilities to outdoor cooling is state of the art device called mobile Airconditioner that provides cooling on the go and off the grid. Concept design is made with special features like small size
SINGHAL, SUNNY
"Operation Strategies of Heat Pump Systems in High-Performance Electric Vehicles"1329909/15/2022
"The energy consumption of a thermal management system cannot be neglected and is a significant contributor compared to the total energy consumption of a battery electric vehicle. Using a heat pump as part of the thermal management system, can heat and reduce energy consumption at low ambient temperatures. A state-of-the-art heat pump system consists of numerous actuators such as fans, pumps, electrical heater, compressor, and valves. An existing challenge remains to develop efficient operational strategies for these components with the corresponding interactions in dynamic boundary conditions. A physical model of the system can be used to optimize the control method and consequently, helps to save energy. The objective of this investigation is to obtain an operating strategy, which efficiently distributes the electric power between the heat pump compressor and the electric heater. In this context, the influence of an optimized, model-based control of the compressor speed on the
Hug, Thimo
The influence of the selection of engine point in operation based on the working condition identification on the overall fuel consumption2022-01-112608/13/2022
abstract：Response to the government's higher requirements for car fuel consumption and emissions the research, design and manufacturing of advanced hybrid engine has become a current hot topic。This paper starts with a comparative analysis of several hybrid powertrain and transmission mechanism technical schemes that have been applied or are still under study.Then, a mathematical model is established to optimize the parameters of the MAP diagram of hybrid engine to get the impact of different engine points in operation of hybrid engines on the overall fuel consumption under different Driving cycles, and model the best engine points in operation to achieve the goal of improving fuel economy.Through building the mathematical models and comparing the data arrival at the conclusion that:(1)Through the data analysis of the energy conversion efficiency and the cooperation relationship between the engine and the motor, the Mixed type power systems（SPHEV） can have more working mode and higher
GAO, XINWEN
Quantifying System Level Impact of Connected and Automated Vehicles in an Urban Corridor2022-01-017303/29/2022
Numerous studies have demonstrated significant energy reduction for an ego vehicle by up to 20% leveraging Vehicle-to-Everything (V2X) technologies [1, 2, 3, 4]. Some studies have also analyzed the impact of such vehicles on the energy consumption of other vehicles in a suburban or a highway corridor [5, 6]. Southwest Research Institute (SwRI), in collaboration with Continental and Hyundai, is currently working on a Department of Energy funded project that is focused on quantifying the impact of multiple ego vehicles (smart vehicles) on the total energy consumption of the corridor under various traffic conditions, vehicle electrification level, vehicle-to-vehicle (V2V) technology penetration, and the number of smart (ego) vehicles in an urban setting. A six-kilometer-long urban corridor from Columbus, Ohio was modeled and calibrated via real-world data in PTV Vissim traffic microsimulation software. Five forward-looking powertrain models, consisting of two battery electric vehicles
Bhagdikar, Piyush, Gankov, Stanislav, Rengarajan, Sankar, Sarlashkar, Jayant, Hotz, Scott, Bakshi, Kaivalya
Rule-based Power Management Strategy of Electric-Hydraulic Hybrid Vehicles: Case Study of A Class 8 Heavy-Duty Truck2022-01-090103/29/2022
Mobility in the automotive and transportation sector has been experiencing a period of unprecedented evolution. A growing need for efficient, clean and safe mobility has made a strong momentum toward sustainable technologies in this sector. Toward this end, battery electric vehicles have drawn keen interest and the market share is expected to grow significantly in the coming years, especially in light-duty applications such as passenger cars. Although battery electric vehicles feature high performance and zero emissions characteristics, economic and technical issues such as high battery cost, a short driving range, and limited infrastructure should be tackled. In particular, the low power density of battery electric vehicles limits their broad adoption in heavy-duty applications such as class 8 long haul trucks due to a size and weight of battery. In this work, motivated by the high power density and potential for improving energy efficiency through regenerative braking of a hydraulic
Yoon, Yongsoon, Romero, Giovanni, Nkemdilim-Dantzler, Emil, DelVescovo, Dan, Guessous, Laila
Ultra Flow, High Stiffness Polypropylene Material For Light Weight Exterior Trim Panels2022-01-039403/29/2022
Light weighting is an effective strategy in increasing energy efficiency in the automotive industry. In this paper, mass reduction with cost benefit was targeted in an exterior trim panel. Modified polypropylene copolymer (PPCP) material was developed for an exterior trim large panel (1400 X 700mm) with integrated grill mesh. The part had challenging requirements in terms of slow speed impact, structural durability, dimensional stability, aesthetics, thermal ageing resistance, cold impact resistance, scratch resistance and weathering resistance. The compounded PPCP material met these requirements by having ultra-flow behaviour, optimum tensile strength, modulus, impact strength and thermal properties. The combination of material, optimized part and tool design led to weight savings and considerable cost reduction.
Govindaraj, Karthik, Vimalathithan, Murukesan, YANAMANDRA, BHARADWAJA, D, VENKATESAN
Design and Validation of Energy-optimal Adaptive Cruise Control (EACC)2022-01-050303/29/2022
The energy consumption of electric vehicles (EVs) is not only influenced by the efficiency of the powertrain components (battery, electric machines, inverters, etc.), but also to a large extend by the driving profile. Therefore, the new function of energy-optimal adaptive cruise control (EACC) is proposed as a new feature in this paper. This function exploits a large potential for energy consumption reduction by optimizing the EVs’ speed trajectory using model predictive control (MPC). EACC optimizes the speed profile of EVs by considering various connected driving information (speed limits, road gradients, predicted future behavior of the vehicle ahead, etc.). To validate the performance of EACC, a prototype system was implemented in an EV. The EV controlled by EACC was driven as the ego-vehicle on a test track. In the test cycles, which represent realistic urban driving scenarios, EACC reduces the energy consumption of the ego-vehicle by up to 13% in comparison to an ego-vehicle
Jia, Yanzhao, Abdelkarim, Anas, Klingbeil, Xiaonan, Görges, Daniel
Engine Thermodynamic Design, Optimization, Test & Analysis of Daimler SuperTruck2 Program Towards 55% BTE Target2022-01-050403/29/2022
Daimler's effort toward demonstration of 55% brake thermal efficiency for the US Department of Energy SuperTruck2 program relied on a holistic approach to optimization of the Daimler heavy-duty 12.8L diesel engine. Core technical approaches used in this effort include efficient two-stage turbocharging with intercooling, valve timing optimization, improved combustion system design, friction and parasitics reduction through optimized lubrication system, and in-cylinder heat transfer reduction. These measures in combination provided an anticipated engine efficiency of over 50% BTE before application of an additional waste heat recovery system. Utilization of high-fidelity simulations from 1D physical model simulation studies and CFD/FEA framework allowed for optimization of the engine pumping loop and heat transfer reduction efforts. Test bench data provides high-level overview of combustion improvement, friction & parasitics reduction, improvement in in-cylinder heat transfer reduction
Bashir, Murad
Development of Vehicle Thermal Management Model for Improving the Energy Efficiency of Electric Vehicle2022-01-022603/29/2022
Recently, automobile manufacturers are interested in the development of battery electric vehicle (BEV) having a longer mileage to satisfy customer needs. The BEV with high efficiency depends on the temperature of the electric components. Hence it is important to study the effect of the cooling system in electric vehicle in order to optimize efficiency and performance. In this study, we present a 1-D vehicle thermal management (VTM) simulation model. The individual vehicle subsystems were modeled including cooling, power electric (PE), mechanical, and control components. Each component was integrated into a single VTM model and it would be used to calculate energy transfer among electrical, thermal, and mechanical energy. As a result, this simulation model predicts a plenty of information including the state of each component such as temperature, energy consumption, and operating point about electric vehicle depending on driving cycles and environmental conditions. The characteristic of
Hong, Seokbin, Kyoung, Song, Sung, Wonjune, Lee, Dongkyu, Choi, Kyungwook, Park, Minjung, Seo, Heung Seok, Park, Sunghoon, Jung, Young Ho
Dynamics hybrid vehicle driven with electric motor driving wheels from batteries2022-01-081003/29/2022
The use of electric energy to drive the drive wheels allows you to improve not only the environment, but also the performance indicators of cars. A hybrid car uses both thermal energy from an internal combustion engine (ICE) and electrical energy from generators or batteries. The authors of the paper have conducted a study on the dynamics of a hybrid car, in which ICE energy is used to charge rechargeable batteries, and the latter provide the driveline. By reducing the amplitude of the traction force oscillations, the energy costs for the forward movement of the car are reduced. The purpose of the study is to determine the energy savings for accelerating a car with a combined power plant with electric engines on wheels using battery power. As a result of the study, a mathematical model of the car acceleration process with a combined power plant and powered electric engines of the driving wheels from the batteries has been obtained. The obtained analytical dependencies allow us to
Kholodov, Mykhailo
Parts Consolidation of Automotive Front Subframe: From Two-Piece CFRP Design to One-Piece Design2022-01-041003/29/2022
As demand for fuel efficiency rises, an increasing number of automotive companies are replacing their existing metal designs with carbon-fiber-reinforced polymer (CFRP) redesigns. Due to the handling and manufacturing processes associated with CFRP materials, engineers have more design freedom to create complex, light-weight designs, which would be infeasible to manufacture using metal. Additionally, it is likely that by redesigning with CFRP, many steel assemblies can be consolidated to significantly fewer parts, simplifying or potentially eliminating the assembly process. When designing a subframe using CFRP materials, designers often aim for a two-piece design (top and bottom), while utilizing reinforcement material where needed. The joining of these two pieces is typically accomplished with many mechanical fasteners and adhesives, significantly increasing the part count and the manufacturing complexity. The objective of this research project is to redesign a CFRP front subframe
Krsikapa, Daniel, Jalayer, Shayan, Dossett, Wesley, Lee, Young Min, Ko, Kwang Un, Huh, Mong Young, Choi, Byeung Hyeun, Ku, Ja Won, Lee, Keon Chul, Kim, Il Yong
High performance unfilled polypropylene material for light weight interior trims2022-01-039303/29/2022
Light weighting is important to improve energy efficiency in the automotive industry. In this paper, high performance unfilled polypropylene copolymer (PPCP) material was selected and developed to reduce weight and cost without compromising on functional requirements for interior trims such as door trims, lower pillar trims, scuff trims and rear quarter trims (RQT). Interior trims are loaded with challenging requirements such as stiffness, dimensional stability, haptic feel, scratch resistance, cleanability, thermal stability, toughness, low emission and weathering resistance. Reactor polymerised PPCP material compound met these requirements by having ultra-flow behaviour, optimum tensile strength, balanced modulus - impact strength, scratch resistant, low emission and improved thermal properties. The combination of material, optimized part and tool design led to weight savings and considerable cost reduction.
Govindaraj, Karthik, Deoli, Manish, Gregory, Koch
Path planning strategy of Distributed-driven articulated vehicle considering steering energy consumption2022-01-034903/29/2022
The over-actuated characteristic of distributed driving vehicle can be used to generate the yaw moment by the reasonable allocation of each wheel driving force, which can reduce the energy consumption in the process of vehicle handling. The dynamic model of articulated vehicle with the electric-hydraulic hybrid steering is established by integrating the differential steering of vehicle. In this paper, the dynamic programming method is used to study the energy consumption of articulated vehicle with electro-hydraulic hybrid steering, and the energy-saving effects under different operating conditions are compared and analyzed. And on this basis, the rule-based control steering strategy for the articulated vehicle is built which can be used on-line. The model of articulated vehicle is established based on ROS platform, and tentacle algorithm is used for path planning of articulated vehicles. The stability and handling energy consumption of the vehicle are calculated for each tentacle
Niu, Tianwei, Shen, Yanhua, Bin, Xu
Model-based thermal control strategy for electrified vehicles2022-01-022903/29/2022
Stringent requirements for high fuel economy and energy efficiency mandate using increasingly complex vehicle thermal systems in most types of electrified vehicles (xEVs). Enabling the maximum benefits of such complex thermal systems under the full envelope of their operating modes demands designing complex thermal control systems. This is becoming one of the most challenging problems for electrified vehicles. Typically, the thermal systems of such vehicles have several modes of operation, constituting nonlinear multiple-input/multiple-output (MIMO) dynamic systems that cannot be efficiently controlled using classical or rule based strategies. This paper covers the different steps towards the design of a model-based control (MBC) strategy that can improve the overall performance of xEV thermal control systems. To achieve the above objective, the latter MBC strategy is applied to control cooling of the cabin and high voltage battery. First, a plant model representative of a real vehicle
Hosseini, Mehrdad, Nahid, Mohammad, Talaei, Behzad, Shojaei, Sina, Ali, Syed Ashraf, Weslati, Feisel, Bouyoucef, Kamal
Development of a Generalized Model to Predict Efficiency of Electrified Power Transmission Considering Optimal Driving Efficiency2022-01-077603/29/2022
The expansion of electrified powertrain over the past decade due to strict fuel efficiency regulations has led to the development of various powertrain systems. While operating the engine at high efficiency using a multi-speed gearbox is a feature of existing powertrain system development, recent trends are being developed to improve system operation efficiency based on a multi-power source configured by mixing an engine and a motor in a simple gearbox. This situation makes it necessary to analyze the overall system efficiency to compare the competitiveness of each system from the early stages of powertrain system development. The prediction of powertrain system efficiency is a process to understand how the system is composed and what strategy can be used for the system in driving cycle. The driving efficiency in a vehicle is determined not only by the efficiency of each power source, but also by loss on the path through which the power flows and how to use each power source to drive
KIM, DONGWOO, WON, Kwang Hyun, Son, Woo Churl, Park, Kijong
Spark Discharge Characteristics for varying Spark Plug Geometries and Gas Compositions2022-01-052703/29/2022
Spark discharge properties were studied and characterized for varying gas compositions and spark plug geometries using a spark calorimeter and constant volume optical vessel. Two different 18mm natural gas engine spark plugs were used in the experiments. All measurements were recorded under quiescent conditions and with a spark gap of 0.30mm. The spark plug calorimeter was used for measuring thermal energy deposition to the gas for gas compositions of nitrogen, a stoichiometric mixture of nitrogen and methane, a stoichiometric mixture of nitrogen and methane, diluted with 30% carbon dioxide by volume, and for air. Other measurements of interest included breakdown voltage, electrical energy delivered to the spark gap, electrical-to-thermal energy conversion efficiency, and spark duration, for pressures up to 28 bar at 300K. The optical vessel was used for the combusting mixture of stoichiometric air and methane at pressures up to 28 bar. For these experiments, thermal energy deposition
Tambasco, Corey, Hall, Matthew, Matthews, Ron
The ICON Digital Wind-Tunnel Validation2022-01-108803/29/2022
The discipline of aerodynamics engineering is a cornerstone in the rapid transition of the automotive industry to emission-free technologies. The endless pursuit of maximum energy efficiency, comfort, and safety requires designers to achieve unprecedented aerodynamic characteristics for the cars of tomorrow, which would be impossible to attain using traditional development processes. In recent years, computational testing has reached a maturity level close to that of physical wind-tunnel testing with all of its’ sophistications. Complementing the data from physical testing, well-calibrated computational simulations provide opportunities to interrogate and analyze salient flow phenomena in even greater depth, and explore the design space with more flexibility. Enabling designers to easily and efficiently exploit the increasing power and range of computational simulation to achieve the emission-free objectives of the automotive industry represents a significant challenge. This talk will
Hrncir PhD, Zbynek
G Index: a novel knock detection method that is simpler and calibration-free2022-01-057703/29/2022
Ever restrictive emissions legislations and fuel efficiency targets have been posing challenges for engine development. Knocking is aloways a limiting factor for spark-ignited engines and has to be tighly controlled during the development phase. There are several methods that address how to detect and measure its occurense. They often require complex calculations with high computational costs that limit them only to laboratorial operation. Moreover, they are often calibrated with subjective factors, for each engine. Thus, this paper offers a novel process that is simpler and does not require previous calibration, called G Index. It is based on the angular position of the peak of maximum pressure rise rate and its relation to the 50% mass fraction burn angular possition. The results showed that there is a locus of knock-free operation with GI between -10 and 0. Higher values lead to a sudden jump towards a locus of knocking operation with GI between 6-10, where the thermodynamic state
Martins, Mario Eduardosantos
Vehicle surge reduction technology during towing in parallel HEV pickup trucks2022-01-073303/29/2022
In order to ensure the comfort of the parallel HEV pickup truck, this report proposes a vehicle surge reduction technology during towing that utilizes a motor and shifting. Hybridization is one of the approaches to reduce fuel consumption toward the realization of carbon neutrality. The parallel HEV is more advantageous to high-load operation such as towing and loading, which are often used in pickup trucks than the series parallel HEV represented by the Toyota Hybrid System. Since the parallel HEV has an engine, motor, torque converter, and transmission connected in series, a vehicle surge may occur when engaging the lockup clutch due to fuel efficiency and drivability needs, as with conventional powertrains. Vehicle surge is a low-frequency vibration phenomenon. In general, the applied force is the torque fluctuation caused by the engine and tires, and the amplification is the driveline torsional first-order resonance, suspension resonance, and cabin resonance. The vibration is more
Okaya, Shingo, Kokaji, Jun, Quinteros, Luis, Hasegawa, Yoshio, Masunaga, Seiji
New Metrics for Quantifying the Energy Efficiency of Platoons in the Presence of Disturbances2022-01-064503/29/2022
Due to aerodynamic drag reduction, vehicles have shown significant fuel savings while platooning in close succession. However, when circumstances force active deceleration to maintain the platoon, such as vehicle cut-ins or grade changes, the aerodynamic efficiency benefits may be undermined. In this work, the influence of active deceleration on platooning dynamics is investigated using over 400 hours of experimental data from PID-controlled and NMPC-controlled vehicle platoons. The test vehicles are Class 8 line-haul tractors with dry vans and various powertrain configurations. Using J1939 CAN data and GPS-estimated grade profiles, off-throttle data is isolated and longitudinal acceleration is estimated as a function of grade using Kalman filtering. Efficiency losses are analyzed as a function of active deceleration and analyzed to describe the effects of grade and cut-ins on platooning fuel economy. Finally, new metrics are proposed to analyze the efficiency of platoons that
Stegner, Evan, Snitzer, Philip, Bevly, David M., Hoffman, Mark
Using GPU to Accelerate Backward Induction for Vehicle Speed Optimal Control2022-01-009103/29/2022
This paper proposes a method to adapt backward induction, which is used to solve the vehicle speed optimal control problem for energy efficiency, to a computer with GPU to accelerate the computation. A common application of this type of problem is to control a vehicle on a given route with surrounding vehicles, road grades, traffic signals, stop signs, speed limits, and other conditions. Several indicators can be used to determine the performance of the controller, such as the driving speed smoothness, time consumption to a given target, or the energy consumption of the trip. Solving this optimization problem globally by backward induction is time-consuming, due to its’ large searching space of the vehicle’s distance, velocity, and acceleration. The proposed method converts the single thread implementation to a parallel process that runs on a consumer-level GPU. This is done by choosing the problem scale, separate independent sub-processes, and prune the data to accommodate the GPU
Ma, Zhaoyuan, Zeng, Xiangrui
A Study of Combustion Inefficiencies in SI Engines Powered by Alcohol and Ether Fuels Using Detailed Emission Speciation2022-01-061703/29/2022
Advanced combustion engines, as power sources, dominate all aspects of the transportation sector. Stringent emission and fuel efficiency standards have promoted the research interest in advanced combustion strategies and alternative fuels. Owing to the comparable energy density to the existing fossil fuels and renewable production, alcohol and ether fuels may be a suitable replacement, or an additive to the gasoline/diesel fuels to meet the future emission standards with minimal modification to current engine geometry. Furthermore, lean and diluted combustion are well-researched pathways for efficiency improvement and reduction of engine-out emissions of modern engines. However, lean-burn or EGR dilution can introduce combustion inefficiencies in the form of excessive hydrocarbon, carbon monoxide, and hydrogen emissions. In this study, the total energy loss to the exhaust in the form of emission species due to incomplete/inefficient combustion of alcohol (butanol and ethanol) and ether
Sandhu, Navjot Singh, Yu, Xiao, Leblanc, Simon
Analysis of energy and exergy distribution for improving fuel economy of marine low-speed two-stroke diesel engine2022-01-046303/29/2022
Increasingly strict emission regulations and unfavorable economic climate bring severe challenges to energy conservation of marine low-speed engine. Besides traditional methods, the energy and exergy analysis could acknowledge the losses of fuel energy from a global perspective to further improve the engine economy. Therefore, in this study, a thermodynamic model is built based on experimental data to conduct the energy and exergy analysis for marine low-speed engine. Results of energy analysis shows that the exhaust gas accounts for the highest proportion of energy losses, and it rises with the increment of engine load. The proportion from heat transfer is just after the exhaust gas. But, it is negatively correlated to engine load. The energy analysis results indicate that reducing the proportions of exhaust gas and heat transfer is the best way to improve the fuel economy of engine. However, the exergy analysis demonstrates that there is still another more effective approach to
Zhang, Heng, Deng PhD, Kangyao, Wang, Dawei, LONG, Wuqiang, Qian, Yuehua
A Study on the Robust Crash Performance Structure of Continuous Fiber Thermoplastic Composite Cowl Crossbar2022-01-105603/29/2022
Since the 1990s, an increasing amount of research has been done in the automotive industry, not only to improve vehicle production efficiency and performance but also for environmental preservation and enhanced recycling. For this reason, recently, keen interest has been focused on the reduction of fuel consumption through the development of eco-friendly and weight-effective vehicles. This is due in part to the strengthening of regulatory standards for fuel efficiency in each country. This study will focus on the high crash safety performance and the optimization of the IP module, in particular, the cowl crossbar, which in most vehicles, can account for more than 33% of the total weight. In fact, the cowl crossbar is the main part of the vehicle that must support the duct system, steering column module as well as the entire IP module. Therefore, it requires a high stiffness to meet the performance requirements for NVH, durability, and crash protection. For example, during a frontal
Kim, Heeseok, KIM, IL SANG, JAE HYUN, AN, IN SOO, HAN, CHOI, IKKEUN, Park, Sanghyeon
Development of a Light-duty Commercial Vehicle Demonstrator Featuring a Low-cost PCB Fuel Cell 2022-01-084103/29/2022
Today the light-duty commercial market is dominated by internal combustion engine powered vehicles, primarily diesel-powered delivery vans, which contribute to urban air quality issues. Furthermore, global concerns regarding climate change have prompted zero emission vehicles to be mandatory in many markets as soon as 2035. For the light-duty commercial vehicle sector there is significant interest in pure electric vehicles. However, for some markets or usage cases electric vehicles may not be the best solution, due to the limitation of practical battery energy storage capacity or recharging times. For such applications there is growing interest in hydrogen fuel cells as a zero emissions alternative. Bramble Energy’s patented printed circuit board (PCB) fuel cell technology – the PCBFC™ - enables the use of cost-effective production methods and materials from the PCB industry to reduce the cost and complexity of manufacturing hydrogen fuel cell stacks. This paper will describe the
Mason PhD, Tom, Bharath, Vidal, Hall, Jonathan, Borman, Stephen, Bassett, Michael
Hybrid Drivetrain Design Using a Power Curve Heuristic Method2022-01-079403/29/2022
Emerging electrified powertrains benefit from efficient conversion and regenerative braking by storing energy in batteries rather than liquid or gaseous fuels. The downside of batteries, however, is that they're heavy and expensive compared to Diesel or Hydrogen fuel. A hybrid drivetrain, compared to a purely electric vehicle, can provide many of the same benefits with a much smaller battery. A heuristic is proposed to design hybrid vehicle architectures which achieve high energy efficiency while minimizing the mass and cost of onboard components. The heuristic uses vehicle power-energy curves to size motor, battery, engine, fuel cell, and hydrogen storage components to meet the required peak power and total energy storage requirements for various commercial vehicles configured as parallel, series, or powersplit hybrids. Commercial vehicles have distinct duty cycles to which a hybrid system must be closely tailored. The heuristic design method is verified using a vehicle drivetrain
Miller, Eric
Numerical simulation of multicomponent diesel fuel spray surrogates using real-fluid thermodynamic modelling 2022-01-059103/29/2022
Computational models widely employed for predicting the dispersion of fuel sprays in combustion engines suffer from well-known drawbacks associated with the utilization of case-dependent empirical phase-change models, describing the conversion of liquid into vapour during fuel injection. The present work couples the compressible Navier-Stokes and energy conservation equations with a thermodynamic closure approximation covering pressures from 0 to 2000bar and temperatures that expand from compressed liquid, vapor-liquid equilibrium to trans/supercritical mixing, and thus, cover the whole range of P-T values that diesel fuel undergoes during its injection into combustion engines. The model assumes mechanical and thermal equilibrium between the liquid, vapour and surrounding air phases and thus, it avoids utilization of case-dependent empirical phase-change models for predicting in-nozzle cavitation and vaporization of fuels. Model development is based on the recent works reported for one
Justino Vaz, Marilia Gabriela, Geber, Evangelos, Koukouvinis, Foivos, Karathanassis, Ioannis K., Mouokue, Gerard, Gavaises, Manolis
Non-destructive Evaluation of the Magnetic Quality of Electrical Steel Sheets by Magnetic Barkhausen Noise (MBN) Analysis2022-01-026903/29/2022
Soft magnetic lamination core is a major component of all electric motors, and the magnetic quality of the lamination has a significant effect on the energy efficiency of the motor. The magnetic properties of electrical steel sheets, which are important design parameters for the manufacturing of electric motors, are normally measured on cut steel strips by standard Epstein frame method, which is destructive and is not suitable for the evaluation of magnetic anisotropy. This paper presents a relatively new technology, i.e., magnetic Barkhausen noise (MBN) analysis, to evaluate the magnetic quality of electrical steel sheets. This method is featured by non-destructive, simple measurement, short measuring time, and online/offline measurements, etc. In addition, it can be readily used to estimate the magnetic anisotropy of electrical steel sheets. Non-oriented electrical steel sheets at different stages of thermomechanical processing were evaluated by MBN analysis, and the textures of the
He, Youliang
Effectiveness of Cdd-IoHwAb device drivers in Automotive industry2022-01-011203/29/2022
The AUTOSAR Basic Software is composed of Service Layer, ECU Abstraction Layer (EAL), Microcontroller Abstraction Layer (MCAL) and Complex Driver. In these components, an IO Driver Module including I/O Hardware Abstraction (IoHwAb) is one of the most important components in a development of ECU-target applications. However, it is difficult to integrate and emulate it to ECU-targets in coincidence with the AUTOSAR MCAL/EAL architecture. In this paper, I present an implementation process of an AUTOSAR IO Driver module and system integration method. In addition, I apply this development process to the inertial measurement unit (IMU: ISM330DLC): 3D accelerometer and 3D gyroscope with digital output for industrial applications. The ISM330DLC has a full-scale acceleration range of ±2/±4/±8/±16 g and an angular rate range of ±125/±250/±500/±1000/±2000 dps and embedded temperature sensor. The module will supply the acceleration values and the angular rotation in three directions. This driver
Jagtap, Anuja
Development of an electric vehicle battery module laser welding process using SYSWELD and validation by test data2022-01-037603/29/2022
With lightweight design in modern electric vehicles to achieve high energy efficiency, high strength and thin materials are widely adopted. For battery modules, 5000 and 6000 aluminum are typically utilized as a structural material with a thickness range between 1 to 5 mm. Laser welding is one of the most optimum welding tools for joining such a thin material due to its unique advantages, e.g., high welding speed, high accuracy, high energy yet the smallest heat affect zone, etc. This paper aims to develop an FE modeling procedure using SYSWELD to simulate the laser welding process used in electric vehicle battery module manufacturing. A sequentially-coupled thermo-mechanical analysis procedure is developed based on the welding processes for 6063 T6 aluminum alloys and the dissimilar joint between 6063 T6 and 5083 aluminum alloys. Different heat source models for laser welding are studies and compared. The effectiveness of the developed modeling procedure is confirmed by a large number
Song, Shaopin, JIANG, Weiran, Ding, Peiran
Accelerating In-vehicle Network Intrusion Detection System using Binarized Neural Network2022-01-018603/29/2022
Modern vehicles are utilizing more software modules and interfaces while new risks and attacks are emerging and threatening the security of vehicles. Researchers demonstrate that in-vehicle networks have become a target of vehicle attackers. Controller Area Network (CAN), the de facto standard for in-vehicle networks, has insufficient security features and thus is inherently vulnerable to various attacks. Intrusion detection systems (IDSs) based on advanced deep learning methods, such as Convolutional Neural Network (CNN) and Recurrent Neural Network (RNN), have been proposed to protect CAN bus from attacks. However, those models generally introduce high latency and require considerable computing resources. To accelerate intrusion detection and also reduce both latency and model size, we propose a new IDS system based on Binarized Neural Network (BNN). As BNN uses binary values for activations and weights rather than full precision values, it usually results in faster computation and
Zhang, Linxi, Yan, Xuke, Ma, Di
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