This SAE Aerospace Information Report (AIR) contains a description of the design approach, the calculations, some comparisons to alternate SAE Aerospace Recommended Practice (ARP) documents, and the background information used to generate the standard face seal gland dimensions specified in AS6235. NOTE: This AIR should be read in conjunction with AS6235. In some instances, the information contained within AS6235 is repeated for clarity.

A-6C2 Seals Committee

Calculations and Background Information Used to Specify the Dimensions in AS6235

AIR7358-TEST-REC (Historical)11/09/2021

A-6C2 Seals Committee

O-Ring Groove Design for Metric O-Ring Seals Used in Static Radial Compression Applications Specifically for Engine and Engine Control Systems

MAP3440A (Current)

11/09/2021

This SAE Recommended Practice provides the design criteria for static elastomeric O-ring seals used specifically in engine and engine control systems. It provides radial compression groove dimensions for aerospace metric O-ring sizes specified in MA2010. The conditions considered to formulate the design criteria are also described, e.g., seal stretch, cross-section reduction, seal squeeze, and swell.

A-6C2 Seals Committee

O-Ring Groove Design for Metric O-Ring Seals Used in Static Radial Compression Applications Specifically for Engine and Engine Control Systems

MAP3440A-TEST-REC (Historical)11/09/2021

A-6C2 Seals Committee

testing author buckets: pending, published, rejected

SAE-PP-0048710/27/2021

test

MobrxivNonAdmin, Lindsay, SintzUSER, Jeneane, SintzADMIN, JenEANE

eFMI (FMI for embedded systems) in AUTOSAR for Next Generation Automotive Software Development

2021-26-004809/22/2021

Nowadays automobiles are getting smart and there is a growing need for the physical behavior to become part of its software. This behavior can be described in a compact form by differential equations obtained from modeling and simulation tools. In the offline simulation domain the Functional Mockup Interface (FMI), a popular standard today supported by most of the tools, allows to integrate a model with solver (Co-Simulation FMU) into another simulation environment. These models cannot be directly integrated with embedded automotive software due to special restrictions with respect to hard real-time constraints and MISRA compliance. Another architectural restriction is organizing software components according to the AUTOSAR standard which is typically not supported by the physical modeling tools. On the other hand AUTOSAR generating tools do not have the required advanced symbolic and numerical features to process differential equations. In order to bridge the gap to the embedded world

Armugham, Siva Sankar, Lenord, Oliver, Werther, Kai, Bertsch, Christian, Ramachandran, Karthikeyan

Fuel economy improvement of the two wheeler through system simulation

2021-26-042809/22/2021

Fuel economy has become a key challenge for Automotive engineers due to the increasing fuel prices and efficiency standards. System level simulation is vital in assessing the vehicle performance and fuel economy at an early stage of product development life cycle. A workflow for powertrain simulation is established and the relation between calibrations and fuel economy is analysed. A map-based engine is modelled using the engine performance data obtained from engine dynamometer test bench setup. Design of experiments (DOE) is carried out on the measured data with an objective of minimizing fuel consumption or maximizing brake power to arrive at an optimized set of data. Exhaust temperature and knock limit are set as constraints for the DOE study. A full vehicle model is developed with the optimized map-based engine along with transmission, chassis and driver model. Desired drive cycle (WMTC) is used as target velocity profile to the driver model along with a neutral gear selection

Thekke Kolayath, Nabeel, Krishnamurthy, G.S., Giles, Rod

Application of Electric Cam Phaser System (ECP) for Smooth Engine Starting Behavior in Hybrid Vehicles

2021-26-005709/22/2021

In the current situation and upcoming government regulations, hybrid vehicles are very promising in terms of meeting fuel economy and stringent requirements of emission norms. Herein, hybridization will be mostly done with gasoline and CNG vehicles. As a normal practice, engine is switch off at the signal and again restart with engine start-stop technology. So, instances of engine start/stop are increases in hybrid vehicle in comparison with standard IC engine vehicle. In order to achieve smooth engine start, engine starting torque can be optimized by adjusting engine valve timing. As electric cam phaser (ECP) meets valve timing target even before first engine combustion start, this is one of the critical technologies in reducing engine starting torque and time reaching to idle speed. This engine starting strategy also gives benefits in terms of reducing engine start emissions and improving fuel economy. This paper describes selection of electric cam phaser for hybrid vehicle depending

Sheikh, Shabbir, Thoelke, Andreas, Deshmukh, Uday, Rathore, Krishna Kumar

A Real-Time Chemical Equilibrium Mechanism for Control-Oriented Combustion Models

2021-26-032709/22/2021

To enable closed loop combustion control, in-cylinder pressure needs to be sensed and analyzed in real time on engine control units (ECU). Therefore, computationally light weight models are necessary. One way to reduce computational effort is to adapt the way how the composition of dissociating flue gas is calculated. The widely used chemical equilibrium mechanism developed by Olikara and Borman describes the gas phase products of burnt hydrocarbon fuels and is used as a reference throughout this work. The reaction scheme considers eleven species and seven elementary reactions. Different approaches to reduce computational effort while maintaining enough accuracy have been explored. As first approach, complete combustion approach is used. Secondly, mass fractions at various in-cylinder conditions are calculated using the reference mechanism and stored in tabulated form. Subsequently, linear interpolation is used to estimate mass fractions at any input condition. Thirdly, the mechanism

Patel, Akash, Eichmeier PhD, Johannes, Schwarte, Joachim, Mane, Archana

“Connected Vehicles – A Testing Approach and Methodology”

2021-26-045009/22/2021

With the introduction of Connected vehicles, it is possible to extend the limited horizon of vehicles on the road by collective perceptions, where vehicles periodically share their information with others vehicles / servers using cloud. Nevertheless, by the time the connected vehicle spread expands, it is critical to understand the validation techniques which can be used to ensure a flawless transfer of data and connectivity. Usually the connected vehicle validation is limited to Application layer only in most of the OEMs. However in this work, we focus on validation of all the 4 layers involved namely, Physical hardware layer, Communication layer, Cloud platform and Application layer. For physical and communication layer, we simulated the in-vehicle environment using standalone vehicle electronic control units (ECUs) which communicate with the telematics control unit (TCU) available in the vehicle and a localized load box for replicating the actual load cases. By applying various use

PATHAK, ISHA, Shinde, Vivek

Development of a piston fuel flow meter based on a microcontroller and its use for vehicle diagnostics

2021-01-115009/21/2021

During operation, it is advisable to periodically monitor the actual fuel consumption of the vehicle. Fuel consumption can be used to assess the driving conditions and technical condition of the vehicle, which affects the intensity of environmental pollution. The engine control system calculates fuel delivery based on driving conditions and vehicle load based on information from sensors. When diagnosing on fuel economy, it is convenient to directly measure the consumption in the fuel line of the delivery system. The advantages and disadvantages of the main types of different flow sensors were analyzed. It is proposed to measure the amount of fuel per unit of time with a piston volumetric flow meter. The design of a software and hardware system for measuring fuel consumption has been developed, which consists of control systems for the actuators of the flow meter and a system for recording and processing information in a microcontroller. Organized data transfer from the flow meter to an

Krivoshapov, Sergy

Development of a Novel Dynamically Loaded Journal Bearing Test Rig

2021-01-121809/21/2021

In this work, a dynamically loaded hydrodynamic journal bearing test rig is developed and introduced. The rig is a novel design, using a hydraulic actuator with fast acting spool valves to apply load to a connecting rod. This force is transmitted through the connecting rod to the large end bearing which is mounted on a spinning shaft, simulating a crankshaft journal. The hydraulic actuator allows for fully variable load control and can be used to apply either static load in compression and tension or dynamic loading to simulate engine operation. A variable speed electric motor controls shaft speed and is synchronized to the hydraulic actuator motion to accurately simulate loading from each stroke in a four-stroke cycle. In addition to these dynamically loaded cycles, the journal bearing rig is also capable of controlled static loading. This static loading is used to simulate stop/start engine operation. A high precision torque meter enables direct measurements of journal bearing

Michlberger, Alexander, Bachu, Pruthvi, Bitsis, Daniel Christopher

Virtual Platform Development for New Control Logic Concept Test and Validation

2021-01-114309/21/2021

As computer-aided engineering software tools advance, more simulation-based processes are utilized to reduce development time and cost. Traditionally, during the development of a new control algorithm dyno or on-road testing is necessary to validate a new function, however, physical testing is both costly and time consuming. This study introduces a co-simulation platform and discusses its use as an improved method of powertrain control logic development. The simulation platform consists of a dynamic vehicle model, virtual road network and simulated traffic objects. Engineers can utilize Matlab/Simulink along with other programs such as PTV Vissim, Tass Prescan, and AVL Cruise to create an integrated platform capable of testing and validating new control strategies. The structure and configuration of this virtual platform is explained in this paper, and an example use case is demonstrated. A driver model was developed to simulate realistic vehicle inputs. Validation of this new driver

Fan, Shihong, Lee, Jason, Sun, Yong, Ha, Jinho, Harber, John

Avoidance Algorithm Development to Control Unrealistic Operating Conditions of Diesel Engine Systems under Transient Conditions

2021-24-002509/05/2021

Emission regulations are becoming tighter, and Real Driving Emissions (RDE) is proposed as a testing cycle for evaluating modern engine emissions under a wide operation range. For this reason, engine manufacturers have been developing a method to effectively assess engine performances and emissions under a wide range of transient conditions. Transient engine performances can be evaluated efficiently by applying time-series data created by chirp signals. However, when the time-series data produced by the chirp signal are used directly, the engine hardware may damage, and emission performances deteriorate drastically. It is therefore essential to develop a method to avoid these undesirable operating conditions. This work aims to develop an algorithm to avoid such unrealistic operation conditions for engine performance evaluation. A virtual diesel engine (VDE) model is developed based on a four-cylinder engine using GT-POWER software. The manipulated variables are fuel injection

Asakawa, Rio, Tanabe, Iku, Yamaguchi, Kyohei, Sok, Ratnak, Kusaka, Jin, Ogawa, Masatoshi, Degawa, Takuma, Kurita, Shigeaki, Jeyamoorthy, Arravind, Beini, Zhou

Towards a Complete Engine Calibration Methodology, Dynamic Design of Experiments (DDoE), Application to Catalyst warm-up phase

2021-24-002809/05/2021

In recent years, engine calibration became a very hard task because of the increasing complexity of systems and the severity of the depollution norms regarding Real Driving Emissions (RDE). In particular, optimal engine control during dynamic phases became crucial for reducing pollutant emissions. Beyond the classical engine calibration method based on steady state experiments, methods that integrate the dynamical response of the system constitute therefore a promising approach. This work proposes a global approach of engine dynamical model-based calibration (DMBC) and optimization based on a dynamic Design of Experiments (DDoE). After a description of the general architecture of the calibration process, the paper focuses on the methodology for the design of DDoE. The proposed DDoE is based on an extraction of highly dynamical legal norm cycles (from the analysis of existing RDE cycles), together with variations of control parameters which are intern variables of the control strategy

HAMBAREK, Djamel Eddine, PETIOT, Jean-François, Chesse, Pascal, WATEL, Eric

confirmation test

SAE-PP-0041708/31/2021

confirmation test

SintzADMIN, Jeneane, SintzUSER, Jeneane, Mutagaana, Festo, Anthony, Lindsay, Mutagaana, Festo, SintzUSER, Jeneane

Engine High-Level Nonlinear Model Predictive Torque Control

03-15-02-001308/31/2021

In this article, a new nonlinear optimal methodology regarding transient torque control of spark-ignition (SI) engines is presented. The internal combustion engine is a highly nonlinear system, and transients are of great importance especially for hybrid vehicles as the engine is frequently started and loaded up to demanded torques. To address bandwidth requirements, purely feedback controllers are avoided, and a semi-feed-forward controller is incorporated into the high-level layer of the hierarchical structure. The controller is derived based on offline nonlinear model predictive control (MPC), minimizing the fuel consumption for optimal transition to demanded torques. The methodology can be extended to the whole desired engine torques.

Shamekhi, Amir-Mohammad, Shamekhi, Amir H.

2 jms 8/27

SAE-PP-0041508/27/2021

2 jms 8/27 jeneane was here

SintzUSER, Jeneane, SintzADMIN, Jeneane

Static Axial O-Ring Seal Applications Without Anti-Extrusion Devices for Engine and Engine Control Systems

ARP1234D-TEST-REC (Historical)08/26/2021

This document establishes standard gland design criteria and dimensions for static axial O-ring seal applications without anti-extrusion devices specifically for engines and engine control systems operating at a maximum pressure of 1500 psi (10345 kPa). NOTE: The criteria herein are similar, but not identical, to those in AS4716 and the legacy standard MIL-G-5514.

A-6C2 Seals Committee

Static Axial O-Ring Seal Applications Without Anti-Extrusion Devices for Engine and Engine Control Systems

ARP1234D (Historical)

08/26/2021

A-6C2 Seals Committee

Regulated Intake Air Boosting and Engine Downspeeding as a Viable Solution for Performance Improvement and Emission Reduction of a Single-Cylinder Diesel Engine

03-15-02-0009

08/16/2021

The present work proposes a viable approach to develop single-cylinder diesel engines for the future by implementing regulated intake air boosting (RIAB) and engine downspeeding (ED) along with the well-established low compression ratio (LCR) approach. The investigations were conducted in a mass-production light-duty single-cylinder diesel engine initially equipped with a naturally aspirated (NA) intake system. By lowering the compression ratio (CR) and implementing the intake air boosting (IAB) using a belt-driven supercharger, the maximum brake mean effective pressure (BMEP) of the engine could be increased by 50%. More importantly, the improved performance could be achieved without violating the peak firing pressure (PFP) limits. However, a significant penalty was observed in the brake-specific fuel consumption (BSFC) at low-load operating points due to the additional power consumption of the IAB system. Hence, RIAB was implemented to optimize the boost pressure with respect to

Vikraman, V., Krishnasamy, Anand, Ramesh, A.

Engine Intake Air Water Separation Test Procedure

J2554_202104 (Current)

04/22/2021

This water separation technical report has been established to cover heavy-duty engine intake filter systems. It may also be applicable to some automotive and industrial air inlet systems where water separation is an issue.

Air Cleaner Test Code Standards Committee

Engine Intake Air Water Separation Test Procedure

J2554_202104-TEST-REC (Historical)04/22/2021

Air Cleaner Test Code Standards Committee

Gland Design Criteria and Dimensions for Dynamic Radial O-Ring Seal Applications Specifically for Engine and Engine Control Systems Operating at 1500 psi Max

ARP1233B (Current)

04/14/2021

This document recommends standard gland design criteria and dimensions for dynamic radial O-ring seal applications specifically for engine and engine control systems operating at pressures up to a maximum of 1500 psi (10342.14 kPa) and provides recommendations for modifying these glands in special applications. There are no provisions in this document for anti-extrusion devices. NOTE: The criteria set forth here are similar to but not identical with those in MIL-G-5514 and AS4716. This document is not intended to replace MIL-G-5514 or AS4716 for hydraulic applications.

A-6C2 Seals Committee

Gland Design Criteria and Dimensions for Dynamic Radial O-Ring Seal Applications Specifically for Engine and Engine Control Systems Operating at 1500 psi Max

ARP1233B-TEST-REC (Historical)04/14/2021

A-6C2 Seals Committee

Power and Torque Determination for UAS Engines Having Maximum Power Ratings at or Below 22.4 kW

ARP6971 (Current)

04/07/2021

This recommended practice is applicable to reciprocating engines powering unmanned aerial vehicles (UAV) having rated power values less than 22.4 kW, and which are not to be used for human transport.

E-39 Unmanned Aircraft Propulsion Committee