This Information Report provides recommendations for alphanumeric messages that are supplied to the vehicle by external (e.g., RDS, satellite radio) or internal (e.g., infotainment system) sources while the vehicle is in-motion. Information/design recommendations contained in this report apply to OEM (embedded) and aftermarket systems. Ergonomic issues with regard to display characteristics (e.g., viewing angle, brightness, contrast, font design, etc.) should review ISO 15008.

Driver Vehicle Interface (DVI) Committee

The Isochoric Engine

2020-01-079604/14/2020

For the gasoline engine, the isochoric process is the ideal limit of the ideal processes. During the project, a combustion engine with real isochoric boundary conditions is built. A “resting time” of the piston for several degrees crank angle in the top dead center (TDC) can be realized with a special crank drive. This crank drive consists of two crankshafts with different strokes, which are combined. The two crankshafts rotate with a ratio of two to one in opposite directions. The total stroke corresponds to the amount of the first crankshaft, so it is possible to investigate different strokes of the second crankshaft in the same crankcase. Different “resting times” can be achieved by different strokes of the second crankshaft. A specific combination of both crankshafts make a stroke possible which corresponds to that of a conventional combustion engine. In addition to the standard cylinder pressure sensor, a quick surface temperature probe is also used as supplementary measurement

Burger, Benjamin, Bargende, Michael

Optimum Positioning of FIP Drive System for Type-II BSVI Engine Based on Coupled 1D “Valve-Train - Chain Drive Dynamic Analysis

2020-01-102004/14/2020

The automotive industry is gearing up to meet the accelerated emission compliance changes posed by the government. This transition to eco-friendly system would also necessitate an automotive engineer to retain the engine packaging as compact and simple as possible. The packaging layout considered should not be at the expense of deteriorating engine performance. The work started with concept level layout development, with the aim of having simplified system with minimum number of components. The engine on which the work was carried out was 4cylinder 3Liter with OHC configuration A number of layouts were developed which included gear type, belt drive and integrated shaft arrangement for driving FIP. Each of these concepts were brainstormed with its advantages and disadvantages, based on which two concepts were initially proposed for driving FIP system (i) Front Driven FIP (ii) Rear Driven FIP. The difference between the two layouts was that in the latter case the FIP system was directly

Kaundabalaraman, Kaarthic, Rathi, Hemantkumar, Bisht, Jasvir Singh

Brake Power Availability Led Optimisation of P0 versus P2 48V Hybrid Powertrain Architectures

2020-01-043904/14/2020

Through improving the 48V hybrid vehicle archetype, governmental emission targets could be more easily met without incurring the high costs associated with increasing levels of electrification. The braking energy recovery function of hybrid vehicles is recognised as an effective solution to reduce emissions and fuel consumption in the short to medium term. The aim of this study was to evaluate methods to maximise the braking energy recovery capability of the 48V hybrid electric vehicle over pre-selected drive cycles using appropriately sized electrified components. The strategy adopted was based upon optimising the battery chemistry type via specific power capability, so that overall brake power is equal to the maximum battery charging power in a typical medium-sized passenger car under typical driving. This will maximise the regenerative braking energy whilst providing a larger torque assistance for a lower battery capacity. Dynamic simulation models were developed using GT-DRIVE

Alnamasi, Khaled, Terry, Simon, La Rocca, Antonino, Cairns, Alasdair

A Holistic Approach to Develop a Modern High Power Density Diesel Engine to Meet Best-in-class NVH levels.

2020-01-040604/14/2020

The ever-increasing customer expectations put a lot of pressure on car manufacturers to constantly reduce the noise, vibration and harshness (NVH) levels. This papers presents the holistic approach used to achieve best-in-class NVH levels in a modern high-power density 1.5 lit 4 cylinder diesel engine. The base engine architecture was designed with NVH reduction features such as crank-offset, cast iron crankcase, stiffened ladder frame, structural oil pan and front cover. Piston skirt profile was optimized to reduce the slapping noise by carefully studying the secondary motion and skirt contact pressure. The plastic parts such as cylinder head cover and intake manifold were designed with closely spaced ribs and high wall thickness. Natural frequency targets for different parts were set for the entire engine at component level and system level and confirmed through simulations. High frequency acoustic simulation was carried out to identify and improve the areas of high surface velocity

Vellandi, Vikraman, Namani, Prasad, Bhagate, Rajkumar, Chalumuru, Madhu

Performance Engine Building Recommended Practices

J2379_201910 (Current)10/03/2019

Motor Vehicle Council

SAE 17.6 Cubic Inch Spark Plug Rating Engine

J2203_201906 (Current)06/11/2019

This SAE Standard defines the standard engine to be used in determining spark plug preignition ratings. The engine is known as the SAE 17.6 Cubic Inch Spark Plug Rating Engine.

Ignition Standards Committee

Noise Problem Resolution and Sound Quality Improvement of Valve Timing Belt in 4 Cylinders PFI Gasoline Engine

2019-01-078304/02/2019

IC Engine Timing belt is a major noise prone area and it takes time during development to achieve acceptable NVH characteristics. In an existing engine under series production noise problem observed due to excitation of timing belt span by crank timing sprocket tooth. From vehicle perspective noise was heard in vehicle cabin at around idling RPM and a second peak observed around twice the initial RPM. This paper includes a methodology for use of computer based analytical simulation methods to predict timing belt dynamic behavior and NVH characteristics. Along with development of computer based multi body dynamic model for timing belt, validation of simulation model with actual testing was done and after correlation of testing and simulated results countermeasure were finalized based on iterations in multi body simulation model. Multi body dynamics model of timing drive indicated resonance in one belt span when belt transverse vibration amplitude was converted from time domain to

Poonia, Sanjay, Singh, Amandeep, Singh, Jaspreet, Sharma, Shailender, Kumar, Narinder

Dynamic Modeling of CNC Drive Systems: Comparison of Two Models

2019-01-080304/02/2019

Accurate positioning and precision of CNC machines are directly affected by performance of their mechanical drive system and control unit (CNC feeddrive system). This is more important in contouring operations where axes motion is synchronized by interpolators and errors are accumulative. This research work is focused on study of dynamics of the feeddrive unit. In this regard, a detailed dynamic model is developed in state-space format that is used to study its response properties. A parametric study of the system is carried out by studying shifts in eigenvalue loci when a parameter is changed. The results are used in further simplifying this model to a reduced order system which is simpler in structure and more appropriate for control applications. A comparison is made between these models and the merits of each individual model are presented.

Mehrabi, Mostafa

Analysis of Rotational Vibration Mechanism of Camshaft at High Engine Speed in Engines with In-Line Four-Cylinder DOHC Configuration

2018-32-007210/30/2018

In engines having an inline four cylinder DOHC configuration, the rotational vibrations of camshaft increase at high engine speeds above 10000 rpm, causing an increase of tension in the cam chain. It is therefore difficult to realize an optimum designing of a cam chain system when the durability has to be taken into considerations. Using the simulation we analyzed in this research how the rotational vibrations and tension increase at high engine speeds in an inline four cylinder DOHC engine. As its consequent, it is understood that the increases of rotational vibrations and tension caused by the resonance of the spring mass vibration system in which the cam chain serves as springs and the camshafts as the equivalent masses. Also it is found out that the vibration system is of a unique non-linear type in which the resonance of the fourth order frequency is also excited by the crankshaft torque fluctuations of the second order frequency. Furthermore, it is uncovered that the natural

Hatakeyama, Ryoh, Niino, Tadashi

Single-Axis Motion Control Systems: Multi-Sourced vs. Single-Sourced

TBMG-3307810/01/2018

In today’s fast-paced industrial settings, speed and efficiency are key. Reducing time spent on sourcing, installing, and testing motion control systems can play a big role in cost containment and design cycle efficiency. Machine designers face a variety of challenges and ever-changing requirements. They customize and configure their designs to address global markets as well as customer-specific applications. Also, industry trends are moving to smart products, connectivity, total cost of ownership, efficiency, flexibility, and complete, integrated motion control systems. These factors change how components are researched, designed, purchased, tested, and implemented to optimize system performance.

The Dual Phase Twin Synchronous Belt Drive

2017-01-177306/05/2017

The dual phase twin synchronous drive has been developed for belt noise reduction. Two identical synchronous belts are arranged parallel side by side with one tooth staggered against other by the half pitch offset. The noise cancellation effect is achieved as one belt tooth engagement coincides with the other belt tooth dis-engagement. A center flange is used as a divider to prevent the belts contacting each other along the axial direction during their entrance and exit of the sprocket. An overall 20 [dBA] noise reduction has been achieved with the dual phase twin belt drive compared to an equal width single belt counterpart. The vibration amplitude of the hub load is also reduced which is directly correlated to the structural borne noise. Comparing to the related dual phase helical tooth belt, the dual phase twin belt is superior in torque carrying capability; and is on par with noise mitigation. The dual phase twin belt has been demonstrated with the automotive transfer case

Yuan, Jing

Thermal Protection of Rear Mounted Engine and Its Components Using a Ventilation Fan with Unique Monitoring and Fault Diagnosis Technique

2017-01-062003/28/2017

The engine compartment of passenger car application contains various source which radiates the produced heat and raises the temperature level of the compartment. The rise in compartment temperature increases the body temperature of individual component. The rise in body temperature of critical components can endanger the durability or functionality of the specific component or a system in which it operates. The aim of this paper is to strategize thermal protection of the rear mounted engine and its components of a vehicle having radiator and cooling fan mounted in front. An additional ventilation fan with speed sensor is fitted alongside rear mounted engine and a unique monitoring technique framed in the EMS ECU to protect critical components like HT cables, alternators, ECUs, wiring harness etc. from thermal damage. The EMS continuously monitors the engine speed, vehicle speed and the PWM signal of ventilation fan to ensure the intended operation of the ventilation fan. With the

Parmar, Chandrakant, Tyagarajan, Sethuramalingam, Tiwari, Sashikant, Thonge, Ravindra, Paul, S Arun

Physically Motivated Model for Efficient Dynamic Simulation of Chain Tensioners with Labyrinth Seals

2017-01-107303/28/2017

The object of this study is a new chain tensioner with two labyrinth seals. For the simulation of chain tensioners within the framework of multi-body dynamics, a physically orientated model to describe the fluid dynamics of the labyrinth seals is derived. The easiest way to describe labyrinth seals is to use maps obtained from measurements. As this is very time-consuming, methods of 1D and 2D fluid-mechanics are used in this work to model the labyrinth seals. The seals are characterized by physically motivated parameters e.g. coefficients of resistance or friction. As these parameters can be derived from geometric data, a very good forecast feasibility without experimental investigations is provided. For high accuracy simulations model parameters can be refined by experimental data. As many and highly complex parameters have to be identified, this refinement is very time-consuming and requires lots of experiments. Therefore, a third approach for modeling a labyrinth sealing is derived

Huber, Robert, Clauberg, Jan

Gear Whine Noise Due to Deformation- A Case Study

2017-01-112203/28/2017

Vehicle noise has reduced over the years due to the customer demand for quieter vehicles. As the background noises such as combustion noise, pumping noise, etc. have reduced, mechanical noises such as gear noise have become prominent and a major cause of customer complaints. Engine timing gear train uses gears for transferring torque to cam and accessory gears. As engines have become quieter by efforts to reduce the combustion noise, as well as, by moving away from mechanical fuel pumps to common rail fuel pumps, the gear train noise has come under increased scrutiny. Gear whine could be a result of multiple factors. Gear profile distortion is one of the factors. Gear torque variation also has a significant effect on gear whine. Operation of the accessory drives such as hydraulic pumps under variable loads and speeds, is one of the major challenges for resolving a gear whine issue in the engine gear train. ISO 10064 provides guidance on the distortion due to temperature effects, but

Joshi, Yashodhan V.

Advanced Lubrication - Enabling and Protecting Turbocharged, Direct Injection Gasoline Engines for Optimum Efficiency

2016-01-227510/17/2016

There has been a global technology convergence by engine manufacturers as they strive to meet or exceed the ever-increasing fuel economy mandates that are intended to mitigate the trend in global warming associated with CO2 emissions. While turbocharging and direct-injection gasoline technologies are not new, when combined they create the opportunity for substantial increase in power output at lower engine speeds. Higher output at lower engine speeds is inherently more efficient, and this leads engine designers in the direction of overall smaller engines. Lubricants optimized for older engines may not have the expected level of durability with more operating time being spent at higher specific output levels. Additionally, a phenomenon that is called low-speed pre-ignition has become more prevalent with these engines. While more pre-ignition may be expected with highly-boosted engines, an especially destructive version of this has been found to be related to some of the essential

Yang, Kongsheng, Fletcher, Kristin A., Styer, Jeremy P., Lam, William Y., Guinther, Gregory H.

Simplified Machine Design Approach for Optimal Servomotor Control

TBMG-24893

06/01/2016

An often asked question from industrial machine builders or integrators is how they can effectively design or implement the conversion of a machine with servo technology to meet performance expectations. This is a specialized task filled with layers of complexity that can prove difficult to execute, even when the scope of work is fully understood.

Towards the Direct Evaluation of Turbine Isentropic Efficiency in Turbocharger Testing

2016-01-103304/05/2016

Turbocharging is playing today a fundamental role not only to improve automotive engine performance, but also to reduce fuel consumption and exhaust emissions for both Spark Ignition and diesel engines. Dedicated experimental investigations on turbochargers are therefore necessary in order to get a better understanding of its performance. The availability of experimental information on realistic turbine steady flow performance is an essential requirement to optimize engine-turbocharger matching calculations developed in simulation models. This aspect is more noticeable as regards turbine efficiency, since its swallowing capacity can be accurately evaluated through the measurement of mass flow rate, inlet temperature and pressure ratio across the machine. Actually, in the case of a turbocharger turbine, isentropic efficiency directly evaluated starting from measurement of thermodynamic parameters at the inlet and outlet sections can give significant errors. This inaccuracy is mainly

Marelli, Silvia, Marmorato, Giulio, Capobianco, Massimo, Boulanger, Jean-Maxime

Design Methodology and Development of an Economical 3D Printer

2016-01-032504/05/2016

Additive manufacturing has experienced rapid growth over a span of 25 years. Additive manufacturing involves the development of a three-dimensional (3D) object by stacking layer upon layer. Conventional machining techniques involve the removal of material. However, this technique differentiates itself from other techniques by means of addition of the material. The integration of CAD with additive manufacturing has offered the ability to create complex structures. Despite its clear benefits, additive manufacturing suffers from a high initial investment. An average cost of an entry level commercial 3D printer is 600$. A low-cost 3D printer has been designed and built for experimental investigation within a budget of 300$. The paramount process of 3D printing involves a combination of interpreting data from CAD files and controlling the motors using this data. The various design considerations while developing the 3D printer have been discussed. The 3D printer developed, provides the user

Javed, Farhan, Javed, Salman

Study of Optimization of Reciprocating Parts for General-Purpose Engine with Aluminum-Alloy Connecting Rods

2015-32-080511/17/2015

The connecting rods employed in most of general-purpose engines with a power from 1.5 kW to 10 kW are manufactured from aluminum alloy in order to increase productivity and reduce weight, and therefore display lower material strength than steel connecting rods. In terms of operating conditions, general-purpose engines are frequently operated under high load while being held at a comparatively low engine speed, necessitating strength and durability in relation to combustion pressure. Realizing a balance between the rigidity of each part is an important factor in reconciling the achievement of weight reduction in the reciprocating parts while also keeping strength. The research discussed in this paper developed a structure optimization system to examine shape parameters for reciprocating parts targeting 4 kW class engines, and studied shapes that would balance the reduction of weight with the keeping of strength. These realizes design shapes of 4 kW class engines in which the stress

Okubo, Masami, Suzuki, Masato

Evaluation of Drain Life and Filtration of Engine Oil for New Gen-ICV's Operating in Extreme Conditions

2015-01-287609/29/2015

In tropical conditions, twelve numbers of ten ton intermediate commercial vehicles run at regular interval from zero to 60000 kilometer. Vehicle field run data were composed and analyzed with intended duty cycle for engine oil drain life estimation. The intermediate commercial vehicle trucks with sump capacity 0.083- 0.104 liter/HP and SAE 15W40 viscosity of oil meeting API CH-4, API CI-4+ from group-I and group-II base stocks are considered. The engine wear is more a function of silica concentration, load factor and age than the API category of the oil. Oil drain interval is found to be proportional to the sump volume for the same stress on the oil. Iron concentration and kinematic viscosity decide to be useful oil life with respect to the limits fixed by the engine manufacturer. In tropical conditions, field trials are carried out on 10 ton payload vehicles at higher temperature, humidity, dust levels and payload factor. API CI-4+ oil provide higher level of protection against soot

Patil, Shankar, Mahesh, P, Sadagopan, Krishnan, Gokhul, Senniappan Arunachalam

Choosing the Right Drive Technology

TBMG-22931

09/01/2015

Although there are a number of variations of drive technologies for motion applications, there are a few that are used for the majority of systems being built today. These most common drives do take a bit of understanding before applying.