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SAE 2011 High Efficiency IC Engines Symposium - Session 3 - Advanced Diesel Engine Technologies Presenter Andrew Brown, Delphi Corp.

Several technological advancements have enabled hybrid technology to become a viable option in the commercial truck market. Although hybrid trucks are becoming more mainstream, they are not the right alternative fuel solution for every application. When matched with the right duty cycle, hybrid technology can provide a significant cost savings. Due to these advancements and anticipated benefits, hybrid commercial trucks are forecasted to become a significant part of the commercial truck market. Presenter Glenn Ellis, Hino Motors Sales USA Inc.

These advanced checks have resulted in development of many new diagnostic monitors, of varying types, and a whole new internal software infrastructure to handle tracking, reporting, and self-verification of OBD related items. Due to this amplified complexity and the consequences surrounding a shortfall in meeting regulatory requirements, efficient and thorough validation of the OBD system in the powertrain control software is critical. Hardware-in-the-Loop (HIL) simulation provides the environment in which the needed efficiency and thoroughness for validating the OBD system can be achieved. A HIL simulation environment consisting of engine, aftertreatment, and basic vehicle models can be employed, providing the ability for software developers, calibration engineers, OBD experts, and test engineers to examine and validate both facets of OBD software: diagnostic monitors and diagnostic infrastructure (i.e., fault memory management).

In “Using Turbocharging in New Engine Design” (9:23), engineers from Schaeffler Group USA and McLaren Performance Tech explain what turbocharging is, and what it can do to improve both the power output of an engine and its fuel efficiency. Another engineer from the General Motors Powertrain group talks about how turbocharging was used in the new engine design for the Cadillac CT6. This episode highlights: The lessons learned from when turbocharging was first used to help heavy-duty trucks go uphill The experience acquired from car racing using turbo-charged engines The advantages of using turbo charging to decrease the size of engines without losing power output Also Available in DVD Format To subscribe to a full-season of Spotlight on Design, please contact SAE Corporate Sales: CustomerSales@sae.org or 1-888-875-3976.

Racing Green Endurance: An EV Record will focus on what a small team of ambitious and talented engineers can do when they have a dream! Back in 2009, a team of graduates from Imperial College London came together to do something radical to change the public perception of electric vehicles forever. They came up with the idea to design and build the world's longest range electric car, and then drive it down the longest and toughest road in the world; the 26,000km Pan-American Highway! Racing Green Endurance: An EV Record will share the story from start to finish, and will also focus on the technology used to achieve such a feat, with particular mention of the electric motors. Presenter Alexander Schey, Imperial College London

The copper-rotor induction-motor made its debut in automotive electric traction in 1990 in GM's Impact EV. Since then, this motor architecture has covered millions of miles on other vehicle platforms which will soon include Toyota's RAV4-EV. With the industry's attention focused on cost-effective alternatives to permanent-magnet traction motors, the induction motor has returned to the spotlight. This talk will overview where the copper-rotor induction-motor is today, how the technology has evolved since the days of the GM Impact, the state-of-play in its mass-manufacturing processes and today's major supply-chain players. Presenter Malcolm Burwell, International Copper Association Inc.

The traction motor is key to the �synergy of the electric powertrain�, the overall functionality of the battery, e-motor, power control electronics, and charging system. Therefore some automakers have decided to design, develop, and produce their traction motors in house while some others are working with suppliers for their electric power train motors. Off-the-shelf motors, no matter how extensively they are adapted for a specific application, can compromise the efficiencies of the propulsion system. Presenter Marc Winterhoff, Roland Berger Strategy Consultants

The CAN protocol has served the automotive and related industries well for over twenty-five (25) years now; with the original CAN protocol officially released in 1986 followed by the release of CAN 2.0 in 1991. Since then many variants and improvements in CAN combined with the proliferation of automotive onboard microprocessor based sensors and controllers have resulted in CAN establishing itself as the dominant network architecture for automotive onboard communication in layers one (1) and two (2). Going forward however, the almost exponential growth of automotive onboard computing and the associated devices necessary for supporting said growth will unfortunately necessitate an equivalent growth in the already crowded wired physical infrastructure unless a suitable wireless alternative can be provided. While a wireless implementation of CAN has been produced, it has never obtained real traction within the automotive world.

Combustion engines are typically only 20-30% efficient at part-load operating conditions, resulting in poor fuel economy on average. To address this, LiquidPiston has developed an improved thermodynamics cycle, called the High-Efficiency Hybrid Cycle (HEHC), which optimizes each process (stroke) of the engine operation, with the aim of maximizing fuel efficiency. The cycle consists of: 1) a high compression ratio; 2) constant-volume combustion, and 3) over-expansion. At a modest compression ratio of 18:1, this cycle offers an ideal thermodynamic efficiency of 74%. To embody the HEHC cycle, LiquidPiston has developed two very different rotary engine architectures ? called the ?M? and ?X? engines. These rotary engine architectures offer flexibility in executing the thermodynamics cycle, and also result in a very compact package. In this talk, I will present recent results in the development of the LiquidPiston engines. The company is currently testing 20 and 40 HP versions of the ?M?

Abstract Investigation of vehicle resistant forces and power losses is of crucial importance owing to current state of energy consumption in transport sector. Meanwhile, considerable portion of resistant forces in a ground vehicle is traced back to tires. Pneumatic tires are known to be a source of energy dissipation as a consequence of their viscoelastic nature. The current study aims to provide a modification to tire resistance by considering the power loss in a tire due to longitudinal slip. The modified tire resistance is comprised of rolling resistance and a newly introduced resistance caused by tire slip, called slip resistance. The physical model is chosen for parameters sensitivity study since the tractive force is described in this model via tangible physical parameters, e.g. tire tangential stiffness, coefficient of friction, and contact patch length.

Abstract The non-pneumatic tire (NPT) has been widely used due to its advantages of no run-flat, no need for air maintenance, low rolling resistance, and improvement of passenger comfort due to its better shock absorption. It has a variety of applications in military vehicles, earthmovers, the lunar rover, stair-climbing vehicles, etc. Recently, the Unique Puncture-Proof Tire System (UPTIS) NPT has been introduced for passenger vehicles. In this study, three different design configurations, viz., Tweel, Honeycomb, and newly developed UPTIS, have been compared. The effect of polyurethane (PU) material nonlinearity has also been introduced by applying five different nonlinear PU material properties in the spokes. The combined analysis of the PU material nonlinearity and spoke design configuration on the overall tire stiffness and spoke damage prediction is done using three-dimensional (3D) finite element modelling (FEM) simulations performed in ANSYS 16.0.

Abstract In this article performance of the innovative Crank-Lever Electromagnetic Damper (CLEMD) for an off-road vehicle suspension system is analyzed. To determine the characteristic behavior of the CLEMD, the damping force it provides on the suspension system is varied by changing the values of the damping coefficient in the simulations. Various parameters considered in the analyses include power regenerated, voltage, current, comfort, road-holding, etc. The behavior of all the parameters of the CLEMD is observed for an off-road vehicle by carrying out simulations on country roads since the off-road vehicles are subjected to higher road irregularities and hence provide an opportunity to regenerate a higher amount of power. A two-dimensional (2-D) model of a vehicle developed in SimMechanics is interfaced with a Simulink model of CLEMDs for the analyses.

Abstract This article applies a new method for the evaluation and estimation of real-life energy consumption of two different thermal management systems based on driving behavior in the course of the day. Recent attempts to find energy-efficient thermal management systems for electric and plug-in hybrid electric vehicles have led to using secondary loop systems as an alternative approach for meeting dynamic heating and cooling demands and reducing refrigerant charge. However, the additional layer of thermal resistance, which influences the system’s transient behavior as well as passenger compartment comfort during cool-down or heat-up, makes it difficult to estimate the annual energy consumption. In this article, the overall energy consumption of a conventional and a secondary loop system is compared using a new method for describing actual customers’ driving behavior in the course of the day.

Abstract The dynamic characteristics of tires are critical in the overall vibrations of vehicles because the tire-road interface is the only medium of energy transfer between the vehicle and the road surface. Obtaining the natural frequencies and mode shapes of the tire helps in improving the comfort of the passengers. The vibrational characteristics of structures are usually obtained by performing conventional impact hammer modal testing, in which the structure is excited with an impact hammer and the response of the structure under excitation is captured using accelerometers. However, this approach only provides the response of the structure at a few discrete locations, and it is challenging to use this procedure for rotating structures. Digital Image Correlation (DIC) helps in overcoming these challenges by providing the full-field response of the structure.

Abstract Future SAE Level 4 and Level 5 autonomous vehicles (AV) will require novel applications of localization, perception, control, and artificial intelligence technology in order to offer innovative and disruptive solutions to current mobility problems. This article concentrates on low-speed autonomous shuttles that are transitioning from being tested in limited traffic, dedicated routes to being deployed as SAE Level 4 automated driving vehicles in urban environments like college campuses and outdoor shopping centers within smart cities. The Ohio State University has designated a small segment in an underserved area of the campus as an initial AV pilot test route for the deployment of low-speed autonomous shuttles. This article presents initial results of ongoing work on developing solutions to the localization and perception challenges of this planned pilot deployment.

Abstract The ability of senior citizens as well as other members of the general population to engage in an effective manner with technology is of increasing importance as new and innovative technologies become available. While recognizing the challenges that technologies can have on different populations, the ability to interact successfully with new technologies will, for seniors, have important consequences that can affect their quality of life and those of their families in numerous and important ways. This study, building upon previous research, examines the major dimensions of decision-making regarding attitudes toward autonomous vehicle technologies (ATVs) and their use. The study utilized data from a study of senior citizens in the Dallas-Fort Worth (DFW) area and compared the results with a sample of graduate students from a local university.

How can car designers evaluate device’s position inside a car today? Today only subjective tests or “reachability” tests are made to assess if a generic user is able to reach devices, but it’s no longer enough. The aim of this study is to identify an instrument (index) that is able to provide a numerical information about the discomfort level connected with a posture that is kept inside a car to reach a device, by this instrument it should be possible not only judge a posture, but also compare different solutions and get rapid and accurate evaluations. In the state of the art there are many indexes developed to evaluate postural comfort (like RULA, REBA and LUBA [3, 4, 5]) but none of them has been realized to evaluate postures’ conditions that can be detected inside a car, so their evaluations cannot be acceptable.

In order to detect degradation of engine oil lubricant, bench testing along with a number of diesel-powered Ford trucks were instruments and tested. The purpose of the bench testing was primarily to determine performance aspects such as repeatability, hysteresis effects and so on. Vehicle testing was conducted by designing and installing a separate oil reservoir along with a circulation system which was mounted in the vicinity of the oil pan. An innovative oil sensor was directly installed on the reservoir which can measure five (5) independent oil parameters (viscosity, density, permittivity, conductance, temperature). In addition, the concept is capable of detecting the oil level continuously during normal engine operation. The sensing system consists of an ultrasonic transducer for the oil level detection as well as a Tuning Fork mechanical resonator for the oil condition measurement.

This recommended practice defines methods for the measurement of periodic, random and transient whole-body vibration. It indicates the principal factors that combine to determine the degree to which a vibration exposure will cause discomfort. Informative appendices indicate the current state of knowledge and provide guidance on the possible effects of motion and vibration on discomfort. The frequency range considered is 0.5 Hz to 80 Hz. This recommended practice also defines the principles of preferred methods of mounting transducers for determining human exposure. This recommended practice is applicable to light passenger vehicles (e.g., passenger cars and light trucks). This recommended practice is applicable to motions transmitted to the human body as a whole through the buttocks, back and feet of a seated occupant, as well as through the hands of a driver.

This recommended practice defines methods for the measurement of periodic, random and transient whole-body vibration. It indicates the principal factors that combine to determine the degree to which a vibration exposure will cause discomfort. Informative appendices indicate the current state of knowledge and provide guidance on the possible effects of motion and vibration on discomfort. The frequency range considered is 0.5 Hz to 80 Hz. This recommended practice also defines the principles of preferred methods of mounting transducers for determining human exposure. This recommended practice is applicable to light passenger vehicles (e.g., passenger cars and light trucks). This recommended practice is applicable to motions transmitted to the human body as a whole through the buttocks, back and feet of a seated occupant, as well as through the hands of a driver.