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Zero-dimensional, one-dimensional, and quasi-dimensional models for simulation of SI and CI engines with respect to: engine breathing and boosting; SI combustion and emissions; CI combustion and emissions; fundamentals of engine thermodynamics; thermal management; mechanical and lubrication systems; system level models for controls; system level models for vehicle fuel economy and emissions predictions. Presenter Fabio Bozza, Universita di Napoli

In order to extend the CAI operation range in 4-stroke mode and maximize the benefit of low fuel consumption and emissions in CAI mode, 2-stroke CAI combustion is revived operating in a GDI engine with poppet valves, where the conventional crankcase scavenging is replaced by boosted scavenging. The CAI combustion is achieved through the inherence of the 2-Stroke operation, which is retaining residual gas. A set of flexible hydraulic valve train was installed on the engine to vary the residual gas fraction under the boosting condition. The effects of spark timing, intake pressure and short-circuiting on 2-stroke CAI combustion and its emissions are investigated and discussed in this paper. Results show the engine could be controlled to achieve CAI operation over a wide range of engine speed and load in the 2-stroke mode because of the flexibility of the electro-hydraulic valvetrain system. Presenter Yan Zhang, Brunel University

Turbulent Jet Ignition is an advanced spark initiated pre-chamber combustion system for otherwise standard spark ignition engines. Combustion in the main chamber is initiated by jets of partially combusted (reacting) pre-chamber products which provide a high energy ignition source. The resultant widely distributed ignition sites allow relatively small flame travel distances enabling short combustion durations and high burn rates. This presentation outlines development of this combustion concept in a modern normally aspirated PFI production engine. Experimental results have highlighted high thermal efficiency (42.8%), significant fuel economy improvement (>20%), low engine out NOx (<10 ppm), knock limit extension, high load capability (>13 bar IMEPn) and high speed operation (5500 rev/min). Presenter William P Attard, MAHLE Powertrain LLC

Future fuel economy targets represent a significant challenge to the automotive industry. While a range of technologies are in research and development to address this challenge, they all bring additional cost and complexity to future products. The most cost effective solutions are likely to be combinations of technologies that in isolation might have limited advantages but in a systems approach can offer complementary benefits. This presentation describes work carried out at Ricardo to explore Intelligent Electrification and the use of Stratified Charge Lean Combustion in a spark ignition engine. This includes a next generation Spray Guided Direct Injection SI engine combustion system operating robustly with highly stratified dilute mixtures and capable of close to 40% thermal efficiency with very low engine-out NOx emissions.

Moir� method is useful to measure the shape and the whole-field distributions of displacement and strain of structures. There are many kinds of moir� methods such as geometric moir� method, sampling moir� method, Fourier transform moir� method, moir� interferometry, shadow moir� method and moir� topography. Grating method analyzing directly deformation of a grating without any moir� fringe pattern is considered as an extended technique of moire method. Phase analysis of the moire fringe patterns and the grating patterns provides accurate measurements of shapes or displacement and strain distributions. Some applications of these moir� methods and grating methods to dynamic shape and strain distribution measurements of a rotating tire, sub-millimeter displacement measurements from long distance for landslide prediction, real-time shape measurements with micro-meter order accuracy, etc. are shown. Presenter Yoshiharu Morimoto, Moire Institute Inc.

Powertrain Systems development is facing unprecedented challenges driven by the convergence of many factors: increasing government regulations for tailpipe emissions, diagnostics and fuel economy, increased competition, shorter development cycles, and tighter program budgets. Using telematics and information technology to automate the evaluation of a system�s robustness enables engineers to focus their time on problem areas during their normal development process and launch with quality. This presentation will use real world examples to detail how this methodology was jointly applied by Control-Tec and Ford Motor Company to identify and improve the system performance of Ford�s Air-Fuel Imbalance Monitor before production. Presenter Bill Leisenring, Control-Tec LLC

This study undertakes an investigation of the effect of battery charge balance in hybrid electric vehicles (HEVs) on EPA fuel economy label values. EPA's updated method was fully implemented in 2011 and uses equations which weight the contributions of fuel consumption results from multiple dynamometer tests to synthesize city and highway estimates that reflect average U.S. driving patterns. For the US06 and UDDS cycles, the test results used in the computation come from individual phases within the overall certification driving cycles. This methodology causes additional complexities for hybrid vehicles, because although they are required to be charge-balanced over the course of a full drive cycle, they may have net charge or discharge within the individual phases. As a result, the fuel consumption value used in the label value calculation can be skewed.

The number of electronically controlled systems in commercial vehicles is increasing rapidly. Much of this electrical content is controlled using ECUs (Electronic Control Units) which share information using some type of networking technology, such as a CAN bus running the SAE J1939 protocol. Presenter Jeffrey Craig, Vector CANtech Inc.

Research in plug in vehicles (PHEV and BEV) has of course been ongoing for decades, however now that these vehicles are finally being produced for a mass market an intense focus over the last few years has been given to proper evaluation techniques and standard information to effectively convey efficiency information to potential consumers. The first challenge is the development of suitable test procedures. Thanks to many contributions from SAE members, these test procedures have been developed for PHEVs (SAE J1711 now available) and are under development for BEVs (SAE J1634 available later this year). A bigger challenge, however, is taking the outputs of these test results and dealing with the issue of off-board electrical energy consumption in the context of decades-long consumer understanding of MPG as the chief figure of merit for vehicle efficiency.

Software products in the automotive industry are by nature widely distributed and costly to update (recall), so high reliability is clearly of utmost importance. Just as clearly, the increasing reliance on remote access to such systems, for diagnostic and other purposes, has made security an essential requirement, and traditional techniques for software development are proving to be inadequate in dealing with these issues. Correctness by Construction is a software design and development methodology that builds reliability and security into the system from the start. It can be used to demonstrate, with mathematical rigor, a program's correctness properties while reducing the time spent during testing and debugging. This paper will discuss the use of Correctness by Construction, and its accompanying SPARK language technology, to improve automotive systems' security and reliability. (The approach can also account for safely issues, although that is not the focus of this paper.)

Nissan has released our original HEV system in Japan on November 2010, and will release it in US market on March 2011. The 1 motor 2 clutch parallel type using conventional 7 speed automatic transmission has been employed without torque converter and with a manganese cathode and laminated type Li-ion Battery. This system is well recognized its higher efficiency but lower weight and cost, however, has never realized due to technical difficulties of smoothness. At this session, performance achievements and hinged breakthrough technologies will be presented. Presenter Tetsuya Takahashi, Nissan Motor Co., Ltd.

Battery Electric Vehicles and Extended Range Electric Vehicles, like the Chevrolet Volt, can use electrical energy from the Grid to meet the majority of a driver�s transportation needs. This has the positive societal effects of displace petroleum consumption and associated pollutants from combustion on a well to wheels basis, as well as reduced energy costs for the driver. CO2 may also be lower, but this depends upon the nature of the grid energy generation. There is a mix of sources � coal-fired, gas -fired, nuclear or renewables, like hydro, solar, wind or biomass for grid electrical energy. This mix changes by region, and also on the weather and time of day. By monitoring the grid mix and communicating it to drivers (or to their vehicles) in real-time, electrically driven vehicles may be recharged to take advantage of the lowest CO2, and potentially lower cost charging opportunities.

In this presentation, we will explain how the traditional Miller Cycle - which has its limitations in the traditional four-stroke, Otto Cycle engine provides new opportunities for greater fuel efficiency gains and engine downsizing when incorporated in a split-cycle combustion process. Results will also be shared from studies showing how these implementations can provide both significant drops in fuel consumption and increases in power when incorporated into some of today's most economic vehicles. Presenter Stephen Scuderi, Scuderi Group LLC

This paper presents the first results of an experimental study into a hybrid combustion concept for next-generation heavy-duty diesel engines. In this hybrid concept, at low load operating conditions, the engine is run in Pre-mixed Charge Compression Ignition (PCCI) mode, whereas at high load conventional CI combustion is applied. This study was done with standard diesel fuel on a flexible multi-cylinder heavy-duty test platform. This platform is based on a 12.9 liter, 390 kW heavy-duty diesel engine that is equipped with a combination of a supercharger, a two-stage turbocharging system and low-pressure and high-pressure EGR circuitry. Furthermore, Variable Valve Actuation (VVA) hardware is installed to have sufficient control authority. Dedicated pistons, injector nozzles and VVA cam were selected to enable PCCI combustion for a late DI injection strategy, free of wall-wetting problems.

Hybrid vehicles in the modern era were developed with a strong primary goal to increase fuel efficiency in the North American market. Over the last 15 years, this market has expanded from zero sales to as high as 3% of total US sales. Most recently, the portfolio of competitive offerings with HEV propulsion systems has grown even more to about 30 models on sale today. Some interesting features and attributes have evolved thru this wider array of products giving the customer much more choice of which characteristics to select to match their needs. Ford�s 3rd generation HEV system will be offered for sale this fall. With it, we have continued our focus on the Fuel Efficiency as the driving force for our efforts. The overall process for the system engineering and some of the relevant subsystem and component contributors to the Fuel Efficiency improvement reflected in the 2013 Model Year Fusion and CMAX Hybrids will be presented. Presenter Charles Gray, Ford Motor Co.

SAE 2011 High Efficiency IC Engines Symposium - Session 4 - Novel Engine Components and Systems. Presenter Neville Jackson, Ricardo plc

Hybrid systems have been available for several years now, and offer customers a decrease in fuel consumption and CO2 emissions at an incremental price. Hybrids, in some cases, have offered improved other customer benefits such as reduced noise, vibration and harshness or better acceleration and the satisfaction of increased societal benefit. Sometimes the vehicle utility is compromised by the volume dedicated to energy storage systems. Several hybrid architecture arrangements exist in the market, and offer various levels of hybrid feature. But considering acquisition cost and operating expense, most hybrid vehicles have not offered a direct total cost advantage when compared to non-hybrids. GM's new e-Assist system is highly integrated with the engine and transmission functionality, and takes advantage of the highest value fuel economy enablers available with light electrification.

Exhaust Emission Control: DPF Systems. Presenter Shingo Iwasaki, NGK Insulators, Ltd.

High Speed Machining of CFRP Parts Investigation of the influence of new geometries, cutting datas and coolant capabilities on the surface finish of CFRP parts. State of the art: Different CFRP grades and machining conditions make geometry adjustments to the tool necessary. Mechanical failures through machining operations can be avoided in most of the cases. New unidirectional CFRP grades and dry machining processes again lead to machining problems. This study investigates new geometries to avoid heat damage with dry maching and air coolant in case of unidirectional CFRP. With help of a thermo camera and the surface investigation with a scanning electron microscope, heat damage can be analysed and therefore new geometries can be developed and tested. Target is to develop a new multi purpose CFRP geometry to meet the requirements of the future. The reduction of different geometries used leads to major cost savings. Presenter Ingo von Puttkamer, Guhring oHG

The paper describes the approach, addresses integration challenges and discusses capabilities of the Hybrid Powertrain-in-the-Loop (H-PIL) facility for the series/hydrostatic hydraulic hybrid system. We describe the simulation of the open-loop and closed-loop hydraulic hybrid systems in H-PIL and its use for concurrent engineering and development of advanced supervisory strategies. Presenter Fernando Tavares, Univ. of Michigan