Search Results

Automobile manufacturers are reducing the weight of their vehicles in order to meet strict fuel economy legislation. To achieve this goal, a combination of different materials such as steel, aluminum and carbon fiber composites are being considered for use in vehicle bodies. The ability to join these different materials is an ongoing challenge and an area of research for automobile manufacturers. Multiridged fasteners are a viable option for this type of multi-material joining. Commercial systems exist and are being used in the industry, however, new ridged nail designs offer the potential for improvement in several areas. The goal of this paper is to prototype and test a safer flat-end fastener whilst not compromising on strength characteristics, to prevent injury to factory workers. The nails were prototyped using existing RIVTAC® nails.

Electrification of vehicles is an important step towards making mobility more sustainable and carbon-free. Hybrid electric vehicles use an electric machine with an on-board energy storage system, in some form to provide additional torque and reduce the power requirement from the internal combustion engine. It is important to control and optimize this power source split between the engine and electric machine to make the best use of the system. This paper showcases an implementation of the Adaptive Equivalent Consumption Minimization Strategy (A-ECMS) with minimization in real-time in the dSPACE MicroAutobox II as the Hybrid Supervisory Controller (HSC). While the concept of A-ECMS has been well established for many years, there are no published papers that present results obtained in a production vehicle suitably modified from conventional to hybrid electric propulsion including real world testing as well as testing on regulatory cycles.

A machine has been developed to measure the complete inertia matrix; mass, center of gravity (CG) location, and all moments and products of inertia. Among other things these quantities are useful in studying engine vibrations, calculation of the torque roll axis, and in the placement of engine mounts. While the machine was developed primarily for engines it can be used for other objects of similar size and weight, and even smaller objects such as tires and wheels/rims. A key feature of the device is that the object, once placed on the test table, is never reoriented during the test cycle. This reduces the testing time to an hour or less, with the setup time being a few minutes to a few hours depending on the complexity of the shape of the object. Other inertia test methods can require up to five reorientations, separate CG measurement, and up to several days for a complete test.

Hybrid electric vehicles (HEV) are essential for reducing fuel consumption and emissions. However, when analyzing different segments of the transportation industry, for example, public transportation or different sizes of delivery trucks and how the HEV are used, it is clear that one powertrain may not be optimal in all situations. Choosing a hybrid powertrain architecture and proper component sizes for different applications is an important task to find the optimal trade-off between fuel economy, drivability, and vehicle cost. However, exploring and evaluating all possible architectures and component sizes is a time-consuming task. A search algorithm, using Gaussian Processes, is proposed that simultaneously explores multiple architecture options, to identify the Pareto-optimal solutions.

An appropriate fault diagnosis and Isolation (FDI) strategy is very useful to prevent system failure. In this paper, a model-based fault diagnosis strategy is developed for an internal combustion engine (ICE) under speed control. Engine throttle fault and the manifold pressure sensor fault are detected and isolated. A nonlinear observer based residual generation approach is proposed. Manifold pressure and throttle are observed. Fault codes are designed with redundancy to prevent bit error. Performance of fault diagnosis strategy has been evaluated with simulations.

In the last few years, the application of downsizing and turbocharging to internal combustion engines has considerably increased due to the proven potential of this technology to increase engine efficiency. Variable geometry turbines have been largely adopted to optimize the exhaust energy recovery over a large operating range. Two-stage turbocharger systems have also been studied as a solution to improve engine low-end torque and efficiency, with the first units currently available on the market. However, the compressor technology is today still based on fixed geometry machines, which are sized to efficiently operate at the maximum air flow and therefore lead to poor efficiency values at low air flow conditions. Furthermore, the surge limits prevents the full capabilities of VGT systems to increase the boosting at low engine speed.

Simulation-based design of connected and automated hybrid-electric vehicles is a challenging problem. The design space is large, the systems are complex, and the influence of connected and autonomous technology on the process is a new area of research. The Ohio State University EcoCAR Mobility Challenge team developed a comprehensive design and simulation approach as a solution. This paper covers the detailed simulation work conducted after initial design space reduction was performed to arrive at a P0-P4 hybrid vehicle with a gasoline engine. Two simulation environments were deployed in this strategy, each with unique advantages. The first was Autonomie, which is a commercial software tool that is well-validated through peer-reviewed studies. This allowed the team to evaluate a wide range of components in a robust simulation framework.

In order to increase the efficiency of automotive turbochargers at low speed without compromising the performance at maximum boost conditions, variable geometry compressor (VGC) systems, based on either variable inlet guide vanes or variable geometry diffusers, have been recently considered as a future design option for automotive turbochargers. This work presents a modeling, analysis and optimization study for a Diesel engine equipped with a variable geometry compressor that help understand the potentials of such technology and develop control algorithms for the VGC systems,. A cycle-averaged engine system model, validated on experimental data, is used to predict the most important variables characterizing the intake and exhaust systems (i.e., mass flow rates, pressures, temperatures) and engine performance (i.e., torque, BMEP, volumetric efficiency), in steady-state and transient conditions.

Connectivity in ground vehicles allows vehicles to share crucial vehicle data, such as vehicle acceleration and speed, with each other. Using sensors such as radars and lidars, on the other hand, the intravehicular distance between a leader vehicle and a host vehicle can be detected. Cooperative Adaptive Cruise Control (CACC) builds upon ground vehicle connectivity and sensor information to form convoys with automated car following. CACC can also be used to improve fuel economy and mobility performance of vehicles in the said convoy. In this paper, a CACC system is presented, where the acceleration of the lead vehicle is used in the calculation of desired vehicle speed. In addition to the smooth car following abilities, the proposed CACC also has the capability to calculate a speed profile for the ego vehicle that is fuel efficient, making it an Ecological CACC (Eco-CACC) model.

The definition of the energy management strategy for a hybrid electric vehicle is a key element to ensure maximum energy efficiency. The ability to optimally manage the on-board energy sources, i.e., fuel and electricity, greatly affects the final energy consumption of hybrid powertrains. In the case of plug-in series-hybrid architectures, such as Range-Extender Electric Vehicles (REEVs), fuel efficiency optimization alone can result in a stressful operation of the range-extender engine with an excessively high number of start/stops. Nonetheless, reducing the number of start/stops can lead to long periods in which the engine is off, resulting in the after-treatment system temperature to drop and higher emissions to be produced at the next engine start.

In the face of growing concerns about environmental sustainability and urban congestion, the integration of eco-driving strategies has emerged as a pivotal solution in the field of the urban transportation sector. This study explores the potential benefits of a CAV functioning as a virtual eco-driving controller in an urban traffic scenario with a group of following human-driven vehicles. A computationally inexpensive and realistic powertrain model and energy management system of the Chrysler Pacifica PHEV are developed with the field experiment data and integrated into a forward-looking vehicle simulator to implement and validate an eco-driving speed planning and energy management strategy assuming longitudinal automation. The eco-driving algorithm determines the optimal vehicle speed profile and energy management strategy.

In recent years, the trend in the automotive industry has been favoring the reduction of fuel consumption in vehicles with the help of new and emerging technologies, such as Vehicle to Infrastructure (V2I), Vehicle to Vehicle (V2V) and Vehicle to Everything (V2X) communication and automated driving capability. As the world of transportation gets more and more connected through these technologies, the need to implement algorithms with V2I capability is amplified. In this paper, an algorithm called Pass at Green, utilizing V2I and vehicle longitudinal automation to modify the speed profile of a mid-size generic vehicle to decrease fuel consumption has been studied. Pass at Green (PaG) uses Signal Phase and Timing (SPaT) information acquired from upcoming traffic lights, which are the current phase of the upcoming traffic light and remaining time that the phase stays active.

The EcoCAR 2: Plugging into the Future team at The Ohio State University is designing a Parallel-Series Plug-in Hybrid Electric Vehicle capable of 44 miles of all-electric range. The vehicle features an 18.9-kWh lithium-ion battery pack with range extending operation in both series and parallel modes. This is made possible by a 1.8-L ethanol (E85) engine and 6-speed automated manual transmission. This vehicle is designed to drastically reduce fuel consumption, with a utility factor weighted fuel economy of 50 miles per gallon gasoline equivalent (mpgge), while meeting Tier II Bin 5 emissions standards. This paper details three years of modeling and simulation development for the OSU EcoCAR 2 vehicle. Included in this paper are the processes for developing simulation platform and model requirements, plant model and soft ECU development, test development and validation, automated regression testing, and controls and calibration optimization.

The power loss of bearings is a significant factor in the overall efficiency in a drive unit system. Such bearings are subject to combined radial and axial loading needed to support the gear mesh forces. An experimental methodology has been developed to perform sets of power loss measurements on TRB, 4PCBB and DGBB. These measurements were performed under a variety of speed, load, temperature, and lubrication conditions. The loss behaviors of these types of the bearings are discussed, along with the tradeoff of different bearing arrangements for the fuel economy cycles. Several power loss models are employed to assess the accuracy of the estimations as compared to the experimental measurements. At low speed some models showed good correlations for TRB and DGBB, while at higher speed, they start deviating from the testing results. A higher fidelity model for estimating the losses at high speed, especially speed around 20krpm and beyond, needs to be developed.

Centrifugal compressors for automotive turbochargers must operate over wide speed and flow ranges to provide the required air pressure and mass flow rate to the intake manifold of the internal combustion engines. At a fixed rotational speed, the flow field near the inducer of the impeller becomes increasingly unstable with decreasing flow rate, as the incidence angle grows between the air flow approaching the impeller, relative to the tangent of the main impeller blades at the leading edge. Flow field measurements conducted earlier have revealed that once the incidence angle exceeds a critical value (nearly independent of rotational speed) of approximately 15°, reversed flow near the periphery (blade tips) starts penetrating upstream of the impeller, with a high tangential velocity in the direction of impeller rotation.

Global regulatory targets and customer demand are driving the automotive industry to improve vehicle fuel efficiency. Methods for achieving increased efficiency include improvements in the internal combustion engine and an accelerating shift toward electrification. A key enabler to maximizing the benefit from these new powertrain technologies is proper systems integration work - including developing optimized controls for the propulsion system as a whole. The next step in the evolution of improving the propulsion management system is to make use of available information not typically associated with the powertrain. Advanced driver assistance systems, vehicle connectivity systems and cloud applications can provide information to the propulsion management system that allows a shift from instantaneous optimization of fuel consumption, to optimization over a route. In the current paper, we present initial work from a project being done as part of the DOE ARPA-E NEXTCAR program.

Improvements in highway fuel economy require clever design and novel methods to reduce the drag coefficient. The integration of active flow control devices into vehicle design shows promise for greater reductions in drag coefficient. This paper examines the use of fluidic oscillators for separation control at the rear of an Ahmed vehicle model. A fluidic oscillator is a simple device that generates a sweeping jet output, similar to some windshield wiper spray nozzles, and is increasingly recognized as an efficient means to control separation. In this study, fluidic oscillators were used to blow unsteady air jets and control flow separation on rear boat-tail flaps, achieving drag reductions greater than 70 counts. The method appears to scale favorably to a larger model, and realistic effects such as a rolling road appear to have a small impact on the oscillator's control authority.

In practical operation, serpentine belts are subjected to parametric excitation caused by tension and translation speed fluctuations from pulley rotations and crankshaft speed oscillations. Each of these excitation sources has spectral content at multiple frequencies and arbitrary phases. Stability boundaries for primary, secondary, and simultaneous primary/secondary parametric instabilities are determined analytically. The classical result that primary instability occurs when one of the excitation frequencies is close to twice a natural frequency changes as a result of multiple excitation frequencies. Unusual interactions occur for the practically important case of simultaneous primary and secondary instabilities.

The transient vibration phenomenon in a vehicle powertrain system during the start-up (or shut-down) process is studied with focus on the development and experimental validation of the nonlinear powertrain models. First, a new nonlinear four-degree-of-freedom torsional powertrain model for this transient event, under instantaneous flywheel motion input, is developed and then validated with a vehicle start-up experiment. Second, the interactions between the clutch damper and the transmission transients are established via transient metrics. Third, a single-degree-of-freedom nonlinear model, focusing on the multi-staged clutch damper, is developed and its utility is then verified.

Ported shroud compressor covers recirculate low momentum air near the inducer blade tips, and the use of these devices has traditionally been confined to extending the low-flow operating region at elevated rotational speeds for compressors on compression-ignition (CI) engines. Implementation of ported shrouds on compressors for spark-ignition (SI) engines has been generally avoided due to operation at pressure ratios below the region where ported shrouds improve low-flow range, the slight efficiency penalty, and the perception of increased noise. The present study provides an experimental investigation of performance and acoustics for a SI engine turbocharger compressor both with a ported shroud and without (baseline). The objective of implementing the ported shroud was to reduce mid-flow range broadband whoosh noise of the baseline compressor over 4-12 kHz.