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Although it has long been recognized that tight air to fuel ratio control under all engine operating conditions should improve engine fuel economy and simplify emissions control, economical, precision and packageable devices for measuring these parameters have not been available for engine control application. Fuel and air input systems, consequently, have continued to rely on other alternate methods of controlling the air to fuel mix. In recent years, advancements in both sensor and electronic technology have begun to make available to the engine control systems engineer compact,high accuracy/reliability devices that offer possibilities of even tighter fundamental controls. At Ford Motor Company, one such car engineering concept that has been under development for several years is a precision engine air input measuring meter.

With the use of a simulated exhaust system, the sulfuric acid and sulfur dioxide emission from a monolith noble-metal oxidation catalyst (Engelhard IIB) is measured. It was found that the storage rate of sulfur onto an initially sulfur-free catalyst decreases to a few percent of the sulfur rejection rate within 3-4 h. The amount of sulfur on the catalyst when the catalyst is in equilibrium with 20 ppm sulfur in the gas phase varies between 0.3 weight percent of the catalyst at about 400°C to 0.1 weight percent at 600°C. The sulfur can readily desorb from the catalyst if the gas phase sulfur content is lowered or if the catalyst temperature is increased. It was found that the conversion of sulfur dioxide to sulfuric acid reaches thermodynamic equilibrium at temperatures of 400-500°C and space velocities of 30,000 h-1. These conditions correspond approximately to a small V8 engine at 20 mph cruise.

A method has been developed for the acquisition and analysis of electrical signals, called combustion signals, from the cylinders of spark ignition engines based on using the spark plugs as ionization probes. A correlation has been established between the simultaneously recorded combustion and cylinder pressure signals based on which combustion signals could be used to identify three types of burns. These burn types were called good burns, slow burns, and misfires. The statistical occurrence of these burn types was also correlated with the hydrocarbon exhaust emission levels for engines operating under dynamometer simulated decelerations and for engines operating with various amounts of exhaust gas recirculation (EGR). Both production and experimental engines have been investigated. It was found that during both decelerations and operation with EGR, the degradation from good burns followed the same pattern irrespective of engine type.

This paper discusses in detail three applications of photoelasticity to engine component design and failure analysis. This stress analysis technique provides whole field stress distribution and can also be used to optimize a design by obtaining even stress distribution. The applications discussed cover several aspects of photoelasticity such as two and three dimensional model analysis, stress freezing, thermal and mechanical loading simulation. These are some of the many investigations conducted by the authors and can be used as a guide to many other applications. The results of the analysis have been verified during endurance testing, but are not discussed in this paper.

A cycle counting algorithm that will reduce a complex history into a series of discrete cycles is presented. The cycles determined by this technique are defined as closed stress-strain hysteresis loops of the type obtained from constant amplitude tests. Using the computer cycle counting algorithm, life predictions were made and compared with experimental results. These predictions were found to be typically within a ±3 factor of error. Also, the computer counting method was found to yield more accurate life predictions when compared to the histogram and range counting methods.

This paper identifies and analyzes steady-state and transient tire properties affecting vehicle directional response characteristics. The study is limited to the relationship between lateral force and slip angle. It shows fundamental differences between steady-state and transient properties. Tire transient properties are described by a force-slip angle loop with cornering stiffness and dynamic lateral force offset as parameters. Cornering stiffness is presented as a variable that changes with speed and steer rate. An interrelationship between cornering stiffness and dynamic lateral force offset resulting from the time lag between lateral force and slip angle is shown. Ramp steer techniques for measuring transient tire properties on a road trailer and on an external drum machine are described. A need for transient tire data for computer simulations of vehicle transient steer maneuvers is shown.

The objective of this paper is to illustrate an interactive computer graphics program developed to simplify the creation of finite element data which will be used for computerized structural analysis. Three-dimensional, part definition data in the form of basic design lines is input to the program and displayed on a cathode ray tube, and then a structural engineer creates the finite element definition using various computer graphics techniques. The procedures involved are discussed in detail, as well as the advantages over the traditional manual approach to element generation. Actual experience has demonstrated that this interactive computer graphic approach, in addition to being both accurate and reliable, is approximately fifteen times faster than the tedious manual method.

The analysis presented in this paper indicates that while 1700 lbf (7560 N) is a realistic femur fracture load for 30-50 ms duration impacts, the human femur can withstand higher loads for shorter-duration impacts. Experimental femur fracture data from cadaver and bone specimen tests are reviewed. These data are used to develop femur load fracture tolerance as a function of impact duration. On the basis of a measured 10% amplification of 1-2 ms input forces by the dummy, the cadaver fracture tolerance is proportionately adjusted to arrive at equivalent load levels for forces measured on current dummy test devices. Experimental dummy test device data are included and compared to the theoretical response of a mathematical model of the human upper leg. This comparison demonstrates that even neglecting the 10% amplification, there are still significant differences in the response of dummy and human upper leg structures for impact durations less than 3 ms.

Crash sensor interfacing with the automobile must be approached from the occupant protection standpoint. Generation of the crash pulse, which determines occupant response, is affected by complex vehicle variables that often preclude discrimination from noncrash signals. Synthesis of the design solution is approached on a systems basis to match sensor capability to vehicle variables. Reliability is provided for with appropriate design of experiments and statistical analysis.

This paper discusses the development of adequate criteria and evaluation methods for seat belt restraint design. These criteria should include the effect of seat belts in abdominal injury as well as head injury. It is concluded that belt load limiters and energy-absorbing devices should limit head-to-vehicle contact, ensure that the lap belt maintains proper contact with the bony pelvic girdle, and limit the belt loads. Studies are made of pulse shape and belt fabrics. Currently available mathematical models are used for the studies included in the paper.

Thermal reactor systems have been designed to assist in the development of a low emission concept vehicle to meet exhaust emission goals of 0.82 gm/mile hydrocarbon, 7.1 gm/mile carbon monoxide, and 0.68 gm/mile nitrogen oxides established by the Inter-Industry Emission Control (IIEC) Program. The reactor includes design features required for acceptable life characteristics, together with the quick warm-up necessary to achieve the emission targets. Exhaust gas recirculation and enrichened carburetion are used to reduce the oxides of nitrogen. Associated problems defined during development of several thermal reactor systems are described. The primary problem was achieving durability at the typically high operating exhaust gas temperatures (1600-1800 F) necessary for concurrent HC, CO, and NOx control.

The results of recent dynamic load measurements on human skull and patella bone, conducted with less-than-1-sq-in. penetrators, are discussed in relation to previously reported skull impact data from larger contact areas. These medical data are compared to the dynamic response of a large variety of natural and synthetic plastic materials, for use in trauma-indicating headform and kneeform design. Several bodyform designs are proposed as research tools.

The presentation here of a computer program simulating an engine cycle emphasizes mechanical factors under the control of the engine designer rather than scientific aspects of combustion. Data secured by measuring valves, manifolds, and other parts on a flow bench are used to calculate instantaneous flow in and out of the cylinder for the firing engine. Heat transfer, finite time of combustion, and variable specific heat of the gas are also calculated. The program is particularly well adapted to indicating the direction and relative magnitude of the effect of changing one variable, such as valve size, at a time.

RUMBLE is a low-frequency noise heard in high compression engines and accompanied by high rates of pressure rise. Thus, rumble indicates a rapid combustion process. This paper describes a method of studying this problem: by detection of flame fronts by ionization gaps. Results of experiments show that rumble is caused by deposit ignition in the end-gas region. These multiple ignitions occur after the normal flame front has progressed partially across the chamber. The authors conclude that this type of deposit ignition is generally a self-sustaining process, lasting until the deposits are burned out at a particular engine performance level. When the level is increased, the process repeats itself.

THIS paper describes the development and utilization of a new Ford free-piston power-plant, the model 519. Mr. Noren traces the development of the engine from the initial idea to the point where commercial utilization could be considered. Mr. Erwin describes one commercial use: in the Typhoon tractor. The ratio of size and weight to horsepower is favorable for farm tractors, being smaller and lighter than equivalent diesel engines. The performance of the tractor has been satisfactory thus far, operating smoothly and being practically vibration-free, with little noise. The advantages of the free-piston gasifier, as reported by the authors, are: flexibility, fuel economy, no need for auxiliary starting engine, economical manufacture of a wide range of engine sizes, adaptability to a wide range of fuels, and good torque characteristics.