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This paper presents a numerical study on the impact of washcoat diffusion on the overall conversion performance of catalytic converters. A comprehensive transient 1D pore diffusion reaction model is embedded in state-of-the-art 1D and 3D catalytic converter models. The pore diffusion model is discussed with its model equations and the applied diffusive transport approaches are summarized. The diffusion reaction model is validated with the help of two available analytical solutions. The impact of basic washcoat characteristics such as pore diameters or thickness on overall conversion performance is investigated by selected 1D+1D calculations. This model is also used to highlight the impact of boundary layer transfer, pore diffusion and reaction on the overall converter conversion performance. The interaction of pore diffusion and flow non-uniformities is demonstrated by 3D+1D CFD simulations.

Vehicle relationship management (vRM) is a means to use data generated from embedded in-vehicle telematics systems to re-define the customer relationship between a vehicle owner and the owner's carmaker and dealer. This ability to tap the vehicle for real-time data offers potential to provide both OEM and dealership with enhanced customer retention and brand loyalty, increased revenue, greater lifetime value of customers, and cost reduction. vRM also involves the return on OEM investment in telematics hardware than currently provided through telematics business models based solely on the sale of annual subscriptions for location-based services.

SIMULTANEOUS RECORDINGS of cylinder pressure, audible sound, and crankshaft motion have shown that rumble is a noise associated with bending vibrations of the crankshaft. The vibrations are caused by abnormally high rates of pressure rise near the top dead center piston position. In this study the high rates of pressure rise were obtained by inducting deposits into the the engine. Thud is a torsional vibration of the crankshaft, similar in sound to rumble but resulting from much earlier occurrence of the maximum rates of pressure rise. Rumble vibrations consisted of a fundamental frequency of 600 cps and higher harmonics in the 11/1 compression ratio V-8 laboratory engine used in the investigation. The audible noise of rumble was predominantly composed of the second harmonic or about 1200 cps.

THE usefulness of planetary gear trains and the engineering techniques necessary for optimum design are discussed in this paper. A simple method for calculating planetary gear ratios is described which can be used to determine quickly the potential usefulness of any planetary configurations. The author lists criteria which help to evaluate the potential of a planetary gear train schematic from the standpoints of gear noise and structural viewpoint. Detailed design of individual members include spacing of the pinions, mounting considerations, thrust direction, lubrication, and stress evaluation.

INVOLUTE SPLINES enjoy three major advantages over their straight-sided counterparts: 1. New design concepts have given a more rational approach to clearances and errors. 2. Manufacturing is cheaper and more accurate. 3. Gaging is simpler. Thus, the involute spline standard of SAE and ASA continue to take precedence over the older straight-sided standards.

THE NEED for greater speed in military aircraft and missiles is, without question, the primary force behind the current quest for lubricants of increased thermal and oxidative stability. Turbojet engines soon to be available will require improved lubricants for trouble-free operation. Once developed, these oils may find use in the engines of future civilian aircraft as well as in a variety of special applications. It is the purpose of this paper to discuss the results of an experimental program in the field of high-temperature lubricants. Problems of relating chemical structure to the physical properties and performance of highly fluorinared ester lubricants will be described. Background information in the field of turbojet engine lubrication will be presented.

mDSF is a novel cylinder deactivation technology developed at Tula Technology, which combines the torque control of Dynamic Skip Fire (DSF) with Miller cycle engines to optimize fuel efficiency at minimal cost. mDSF employs a valvetrain with variable valve lift plus deactivation and novel control algorithms founded on Tula’s proven DSF technology. This allows cylinders to dynamically alternate among 3 potential states: high-charge fire, low-charge fire, and skip (deactivation). The low-charge fire state is achieved through an aggressive Miller cycle with Early Intake Valve Closing (EIVC). The three operating states in mDSF can be used to simultaneously optimize engine efficiency and driveline vibrations. Acceleration performance is retained using the all-cylinder, high-charge firing mode.

ENGINE noise has become an increasing problem with the higher and higher compression ratios of present-day automotive engines. Because fuel octane number cannot be raised indefinitely, the problem is one of engine design and selection of crankcase lubricating oils and gasoline formulations, the authors think. This paper describes investigations into the cause of spark knock, wild ping, rumble, and the added problem of hot-spot surface ignition (which also intensifies as compression ratios increase). The authors have found gasolines with phosphorous additives, used with properly formulated multiviscosity lubricating oils, provide a partial answer to the problem of engine rumble. The authors conclude that very exact tailoring of fuels, lubricants, additives, and engines will be necessary to prevent engine noise if compression ratios continue to rise.

Truck and bus manufacturers have been constantly facing an issue to disassemble the rear axle shaft from the hub when transporting the truck from the factory to the dealership. In addition to that, the dealerships have the very same problem every time they have to replace the brake pads in some truck models, which leads to excessive service time, extra costs and aftermarket complaints. The current problematic fastening system is composed by a lock nut, a flat washer and a coned slotted bushing. The concept of this 30 year old design involves the coned slotted bushing being pressed against a tapered hole on the shaft’s flange. After tightening the lock nut, the bushing clamps towards the stud and it gets stuck in between the shaft and the stud generating the problem described above. This paper shows the R&D process that Tekfor used to come up with the 1-piece fastener named iLokTM nut that replaces the problematic 3-piece fastening system.

e-Thermal is a vehicle level thermal analysis tool developed by General Motors to simulate the transient performance of the entire vehicle HVAC and Powertrain cooling system. It is currently in widespread (global) use across GM. This paper discusses the details of the air-conditioning module of e-Thermal. Most of the literature available on transient modeling of the air conditioning systems is based on finite difference approach that require large simulation times. This has been overcome by appropriately modeling the components using Sinda/Fluint. The basic components of automotive air conditioning system, evaporator, condenser, compressor and expansion valve, are parametrically modeled in Sinda/Fluint. For each component, physical characteristics and performance data is collected in form of component data standards. This performance data is used to curve fit parameters that then reproduce the component performance.

THE NEW DIRECT-INJECTION diesel engines — the naturally aspirated 16000 and the turbocharged 21000 — were developed to power specific crawler and wheel vehicles built by Allis-Chalmers. Thus the original design and performance specifications were defined by the space available in these machines, and by the power and torque characteristics required by them. Also, the engines had to be suitable not only for commercial applications such as generator sets, shovels, and compressors, but also for oil field and marine service. Torque and speed requirements indicated that a 5¼-in. bore and 6½-in. stroke would give the desired performance. To meet the low heat rejection and good starting requirements, an open-chamber combustion system had to be used. The three-valve arrangement — two intake and one exhaust — was chosen because it offered low pumping losses and reasonable cost. This paper describes the design considerations and development work which produced the new diesel engines.*

ALTHOUGH turbocharging of low-speed diesel engines has been used world-wide for a long time, it is only during recent years that it has been applied to high-speed diesels. This is the result of considerable engineering efforts from both the turbocharger and the diesel side that were put into the turbocharger, which appears to be a so utterly simple device. This paper de­scribes some of these engineering efforts. The basic design characteristics are developed with the point of view in mind that the turbo­charger has become much more than just an ad­ditional accessory. It is a vital component of the basic engine itself, contributing actively to the advancement of this prime mover. The basic de­sign characteristics center heavily around aero­dynamical and thermodynamical performance cri­teria which are so important in any advanced high-speed turbomachine.

AFTERCOOLING, coupled with higher pressure turbocharging can increase vehicle engine output. The author thinks that it is possible to anticipate diesel engines being run with compressors supplying air at pressure ratios higher than 2/1. Density ratio is the most important consideration in increasing pressure ratio, since the engine's output is dependent upon weight rather than volume of air supplied. Because the density of the compressed air is dependent upon its temperature at any pressure level, cooling the air after compression results in density increases. This paper describes various methods of after-cooling which increase engine output and fuel economy.

“Zoning” a catalytic converter involves placing higher concentrations of platinum group metals (PGM) in the inlet portion of the substrate. This is done to optimize the cost-to-performance tradeoff by increasing the reaction rate at lower temperatures while minimizing PGM usage. A potentially useful application of catalyst zoning is to improve performance using a constant PGM mass. A study was performed to assess what the optimum ratio of front to rear palladium zone length is to achieve the highest performance in vehicle emission testing. Varying the zone ratio from 1:1 to 1:9 shows a clear hydrocarbon performance optimum at a 1:5.66 (15%/85%) split. This performance optimum shows as both a minimum in FTP75 non-methane organic gas (NMOG) emissions as well as a minimum in hydrocarbon, carbon monoxide, and nitrogen oxide light-off temperature. Overall, an improvement of 18%, or 11 mg/mi of combined NMOG+NOx emissions was obtained without using additional PGM.

Zinc-manganese alloy electroplated has been developed for automotive body panel applications. The product is manufactured on a conventional electrogalvanizing line using an electrolyte containing zinc sulfate, manganese sulfate and sodium citrate. Electroplated steel with an alloy content of 30-50% manganese exhibits excellent corrosion resistance both as-produced and after painting. Zinc-manganese coatings also show good workability and voidability. Accordingly, this product is suitable for both unexposed parts and the interior surfaces of exposed parts. Finally, zinc-manganese electroplated steel displays good wet adhesion and anti-cratering characteristics so that the product can also be used for exposed applications as automotive body panels.

Energy Development Associates, a division of Gulf+Western Industries, Inc., has undertaken the design and fabrication of a four-passenger electric car incorporating state-of-the art zinc-chloride battery technology. The purpose of the project is to demonstrate the viability of the zinc-chloride energy storage system as a practical alternative to cars powered by internal combustion engines. Significant among the project goals to be achieved is the attainment of a vehicle range three to four times that of current lead-acid battery-powered vehicles on a single battery charge. Progress to date on the project is discussed. It includes the design, specification, and fabrication of the battery, vehicle and its components, motor control system, and battery control microprocessor.

Press-hardening steels get more and more popular for body in white applications as an approach to meet the demands of passenger safety and CO2 reduction. Unlike the larger part of the structure that is typically zinc coated, the majority of the PHS parts is either uncoated or aluminum silicon coated. This paper shall give an overview of press-hardening steels with zinc coatings with detailed results for corrosion resistance, weldability and mechanical properties for strength levels of 490 to 1800 MPa. Furthermore as for zinc coated material maintaining a robust press-hardening process is of even higher importance than for uncoated or AlSi coated material. A range of different processes including indirect and direct process are shown in detail. Especially the topic of micro-cracks, mechanisms and avoidance of micro-cracks in the direct process will be discussed. Results from industrial and semi industrial production are shown.

A zero-dimensional dynamic model was developed in the Matlab/Simulink® environment to predict the behaviour of a variable-displacement lubricating vane pump for internal combustion engine applications. Based on the geometric and kinematic characteristics of the pump, the model allows predictions of the pressure evolution in each chamber of the pump and in the delivery piping, by employing an integrative-derivative approach. Simulation results were compared with experimental data of pressure transducers, which were fitted along the periphery of the pump case and in the delivery channel. The analysis of the experimental data shows that the pressure dynamics, which is experienced by the transducers, is in some cases quite different from the pressure dynamics in the pump chambers and produces pressure peaks which are not actually present in the original signal. The pressure transducers output was then also modelled in order to properly compare simulation results and experimental data.

This study aims at a new concept for a fast catalyst light-off in combining a latent heat storage with a catalyst. The arrangement of a latent heat storage device into the exhaust system offers significant benefits for the catalyst light-off. Different arrangements have been examined. The first arrangement, called the sequential arrangement, comprises a latent heat storage device and a subsequent catalyst. This offers a significantly faster heat up of the catalyst compared to the standard arrangement. By that emissions during the cold start phase can be significantly reduced. The setup of the latent heat storage device is designed for a high heat transfer between storage material and the exhaust gas. A second integrated arrangement of a latent heat storage and a catalyst into one common substrate has also been set up and investigated. The main advantage of this arrangement is that the catalyst itself is kept on its operation temperature during the engine off time.