Search Results

The target of dynamic simulation is to investigate complex engine dynamic behavior in the whole speed range under different loading conditions in the most effective way during Engine Development Process (EDP). AVL has developed a method for transient run-up analysis by using the simulation tool AVL EXCITE. The main objective of this new method is the controlled speed increase by defining a speed ramp. Transient run-up analysis is of interest for different kind of analysis during the EDP, such as crankshaft dynamics and strength, low frequency vibration analysis, bracket strength and durability analysis, acoustic analysis, etc. By using this method the time required for simulations and thus the whole project duration is significantly reduced. Conventionally the speed range is divided in single speed steps and for each speed a separate transient simulation has to be performed. The number of these simulations depends on the required speed resolution.

The paper describes a zero-dimensional crank angle resolved combustion model which was developed for the analysis and prediction of combustion in compression ignition (CI) engines. The model relies on the multi zone combustion model (MZCM) approach of Hiroyasu. The main sub-models were taken from literature and extended with additional features described in this paper. A special procedure described in a previous paper is used to identify the mechanisms of the combustion process on the basis of the measured cylinder pressure trace. Based on the identified mechanisms the present work concentrates on the analysis of the causal effects that predominantly control the combustion process and the formation of NOx and Soot. The focus lies on the changes of the thermodynamic states and the composition of the reaction zones caused by different emission control strategies.

In the automotive industry, various simulation-based analysis methods have been suggested and applied to reduce the time and cost required to develop the engine structure to improve the NVH performance of powertrain. This simulation is helpful to set the engine design concept in the initial phase of the powertrain development schedules. However, when using the conventional simulation method with a uniformed force, the simulation results sometimes show different results than the test results. Therefore, in this paper, we propose a method for predicting the radiated noise level of a diesel engine using actual combustion excitation force. Based on the analytical radiated noise development target, we identify the major components of the engine that are beyond this development target by in the frequency range. The components of the problem found in this way are reflected in the engine design of the early development stage to shorten the development time.

In recent years, the slip lock-up mechanism has been adopted widely, because of its fuel efficiency and its ability to improve NVH. This necessitates that the automatic transmission fluid (ATF) used in automatic transmissions with slip lock-up clutches requires anti-shudder performance characteristics. The test methods used to evaluate the anti-shudder performance of an ATF can be classified roughly into two types. One is specified to measure whether a μ-V slope of the ATF is positive or negative, the other is the evaluation of the shudder occurrence in the practical vehicle. The former are μ-V property tests from MERCON® V, ATF+4®, and JASO M349-98, the latter is the vehicle test from DEXRON®-III. Additionally, in the evaluation of the μ-V property, there are two tests using the modified SAE No.2 friction machine and the modified low velocity friction apparatus (LVFA).

When pickup trucks are driven on concrete paved freeways, freeway hop shake is a major complaint. Freeway hop shake occurs when the vehicle passes over the concrete joints of the freeway which impose in-phase harmonic road inputs. These road inputs excite vehicle modes that degrade ride comfort. The worst shake level occurs when the vehicle speed is such that the road input excites the vehicle 1st bending mode and/or the rear wheel hop mode. The hop and bending mode are very close in frequency. This phenomenon is called freeway hop shake. Automotive manufacturers are searching for ways to mitigate freeway hop shake. There are several ways to reduce the shake amplitude. This paper documents a new approach using hydraulic body mounts to reduce the shake. A full vehicle analytical model was used to determine the root cause of the freeway hop shake.

Model-based design is a collection of practices in which a system model is at the center of the development process, from requirements definition and system design to implementation and testing. This approach provides a number of benefits such as reducing development time and cost, improving product quality, and generating a more reliable final product through the use of computer models for system verification and testing. Model-based design is particularly useful in automotive control applications where ease of calibration and reliability are critical parameters. A novel application of the model-based design approach is demonstrated by The Ohio State University (OSU) student team as part of the Challenge X advanced vehicle development competition. In 2008, the team participated in the final year of the competition with a highly refined hybrid-electric vehicle (HEV) that uses a through-the-road parallel architecture.

The internal combustion engine contains several actuators to control engine performance and emissions. These are controlled within the engine ECU and follow a specific operating strategy to achieve objectives such as NOx reduction and fuel economy. However, these two goals are conflicting and a compromise is required. The operating state depends on system constraints such as engine speed, load, temperature levels, and aftertreatment system efficiency. This results in constantly changing target values to stay within the defined limits, especially the legal emission limits. The conventional approach is to use multiple operating modes. Each mode represents a specific compromise and is activated accordingly. Multiple modes are required to meet emissions regulations under all required conditions, which increases the calibration effort. This new control approach uses an artificial neural network to replace the conventional multiple mode approach.

The paper describes a universally structured simulation platform which is used for the analysis and prediction of combustion in compression ignition (CI) engines. The models are on a zero-dimensional crank angle resolved basis as commonly used for engine cycle simulations. This platform represents a kind of thermodynamic framework which can be linked to single and multi zone combustion models. It is mainly used as work environment for the development and testing of new models which thereafter are implemented to other codes. One recent development task focused on a multi zone combustion model which corresponds to the approach of Hiroyasu. This model was taken from literature, extended with additional features described in this paper, and implemented into the thermodynamic simulation platform.

Today, OEMs are challenged with an increasing number of powertrain variants and complexity of controls software. They are facing internal pressure to provide mature and refined calibrations earlier in the development process. Until now, it was difficult to respond to these requests as the drivability's calibration tasks are mostly done in vehicles. This paper describes a new methodology designed to answer these challenges by performing automated shift quality calibration prior to the availability of vehicles. This procedure is using a powertrain dynamometer coupled with a real-time vehicle dynamics model. By using a Power Train Test Bed (PTTB), a physical vehicle is not required. As soon as the vehicle dynamics model and its parameters have been defined, it can be simulated on the PTTB and drivability calibrations can be developed. A complete powertrain is coupled with low inertia and highly dynamic dynamometers.

Due to increasing complexity of engine electronic systems, there is a demand to handle the often more than 10,000 calibration data automatically. Establishing optimized start of injection and EGR tables of a TC DI Diesel engine by conventional methods takes about two weeks of intensive calibration work. By automatic map calibration, this task can be handled in less than 20 hours automatically, with no staff required during optimization. The benefits of automatic calibration therefore are reduced costs and faster response to any changes in parameters, even with complex multidimensional engine calibration problems. The paper describes the optimization method as well as the experimental work on the test stand that produces the results.

During a new engine development program, or the adaptation of an existing engine to new platform architectures, testing is performed to determine the durability characteristics of the basic engine structure. Such testing helps to uncover High Cycle durability-related issues that can occur at the bulkhead walls as well as cap bolt thread areas in an aluminum cylinder block. When this class of issues occurs, an Elastohydrodynamic (EHD) bearing simulation capability is required. In this study, analytical methods and processes are established to calculate the localized distributed load on the bulkhead. The complexity in performing a system analysis is due to the nonlinear coupling between the bearing hydrodynamic pressure distribution and the crankshaft and block deformation. A system approach for studying the crankshaft-block interaction requires a crankshaft flexible body dynamics model, an engine block assembly flexible body dynamics model and a main bearing lubrication model.

CFD method for the calculation of flow rate and air re-circulation at vehicle idle conditions is described. A small velocity is added to the ambient airflow in order to improve the numerical stability. The flow rate passing through the heat exchangers is insensitive to the ambient velocity, since the flow rate is largely determined by the fan operation. The air re-circulation, however, is quite sensitive to the ambient air velocity. The ambient velocity of U=-1m/s was found to be the more critical case, and is recommended for the air re-circulation analysis. The CFD analysis can also lead to design modifications improving the air re-circulation.

Development and integration of the cooling system for an automotive vehicle requires a balancing act between several performance and styling objectives. The cooling system needs to provide sufficient air for heat rejection with minimal impact on the aerodynamic drag, styling requirements and other criteria. An optimization of various design parameters is needed to develop a design to meet these objectives in a short amount of time. Increase in the accuracy of the numerical predictions and reduction in the turn-around time has made it possible for Computational Fluid Dynamics (CFD) to be used early in the design phase of the vehicle development. This study shows application of the CFD for robust design of the engine cooling system.

The concept of condenser, fan, and radiator power train cooling module (CFRM) was further evaluated via three-dimensional computational fluid dynamics (CFD) studies in the present paper for vehicle at idle conditions. The analysis shows that the CFRM configuration was more prone to the problem of front-end air re-circulation as compared with the conventional condenser, radiator, and fan power train cooling module (CRFM). The enhanced front-end air re-circulation leads to a higher air temperature passing through the condenser. The higher air temperature, left unimproved, could render the vehicle air conditioning (AC) unit ineffective. The analysis also shows that the front-end air re-circulation can be reduced with an added sealing between the CFRM package and the front of the vehicle, making the CFRM package acceptable at the vehicle idle conditions.

Condenser, fan, radiator power train cooling module (CFRM) proposed by Delphi Automobile Systems was evaluated in the context of vehicle thermal system analysis. The results from the CFRM configuration were compared with those from the conventional condenser, radiator, and fan power train cooling module (CRFM). The analysis shows that for a typical passenger vehicle, the underhood temperature for the CFRM configuration is more than 10°C lower than its CRFM counterpart when the fan is operating at the same speed of 2500 rpm. This is due mainly to the higher mass flow rate impelled by the fan in the CFRM configuration. At the equal mass flow condition, both the CFRM and the CRFM configurations give similar underhood temperatures; but the fan in the CFRM configuration uses 19% less power, due mainly to the reduction in the fan speed needed to impel the same amount of mass flow rate.

The need for significant reduction of fuel consumption and CO₂ emissions has become the major driver for development of new vehicle powertrains today. For the medium term, the majority of new vehicles will retain an internal combustion engine (ICE) in some form. The ICE may be the sole prime mover, part of a hybrid powertrain or even a range extender; in every case potential still exists for improvement in mechanical efficiency of the engine itself, through reduction of friction and of parasitic losses for auxiliary components. A comprehensive approach to mechanical efficiency starts with an analysis of the main contributions to engine friction, based on a measurement database of a wide range of production engines. Thus the areas with the highest potential for improvement are identified. For each area, different measures for friction reduction may be applicable with differing benefits.

Calibrating a vehicle’s powertrain for dynamic operation needs to focus on efforts to mitigate the risks of thermal overload which may arise in the stator or rotor components of an e-motor. Risks also may arise for expected NVH or durability targets, with torque and torque “oscillations” acting as primary sources for the vehicles’ NVH behavior. Both topics, temperature measurement of stator and rotor as well as dynamic torque measurements of the powertrain’s drive shaft are addressed with examples demonstrating the sensors applications in normal test bed and vehicle configurations.

For a broad acceptance of electric vehicles, the trade-off between all electric range and battery cost respectively weight represents the most important challenge. The all electric range obtained under real world conditions most often deviates significantly from the nominal value which is measured under idealized conditions. Under extreme conditions - slow traffic and demanding requirements for cabin heating or cooling - the electrical range might become less a question of spatial distance but even more of total operation time. Whereas with conventional powertrain, high flexibility of the total driving range can be obtained without sacrificing cost, with a pure battery vehicle this results in extreme high cost and weight of the energy storage. Therefore the difference between the typical daily driving range (e.g. in Germany 80-90% is below 50 km) and the minimum total range requested by most customers for acceptance of battery vehicles (200- 250 km), becomes essential.

Sequel is the third vehicle in GM's Reinvention of the Automobile and is the first zero emissions passenger vehicle to drive more than 300 miles on public roads without refueling or recharging. It is purpose-built around the hydrogen storage and fuel cell systems and uses the skateboard principle introduced in the Autonomy vision concept and the Hy-wire proof-of-concept vehicles. Sequel's aluminum structure, Flexray controlled chassis-by-wire systems and AWD system comprising a single front electric motor and two rear wheel motors make it, perhaps, the most technically advanced automobile ever built. The paper describes the vehicle's design and performance characteristics.

This paper presents the development of a transmission closed loop pressure control system. The objective of this system is to improve transmission pressure control accuracy by employing closed-loop technology. The control system design includes both feed forward and feedback control. The feed forward control algorithm continuously learns solenoid P-I characteristics. The closed loop feedback control has a conventional PID control with multi-level gain selections for each control channel, as well as different operating points. To further improve the system performance, Robust Optimization is carried out to determine the optimal set of control parameters and controller hardware design factors. The optimized design is verified via an L18 experiment on spin dynamometer. The design is also tested on vehicle.