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SAE 2011 High Efficiency IC Engines Symposium - Session 2 - Frontiers in Light-Duty Engine R&D Presenter Ulrich Spicher, Karlsruhe Inst. of Technology

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

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.

Advanced vehicular thermal management system can improve engine performance, minimize fuel consumption, and reduce emissions by harmoniously operating computer-controlled servomotor components. In this paper, a neural network-based optimal control strategy is proposed to regulate the engine temperature through the advanced cooling system. Presenter Asma Al Tamimi, Hashemite University

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.

EGR coolers are used in combustion engines to reduce NOx emissions. However, heat transfer in these coolers also results in thermophoresis-temperature-gradient driven motion of suspended particles towards cooler regions-which leads to significant soot deposition. Presenter Meisam Mehravaran

Diesel Dual Fuel, DDF, is a concept which promises the possibility to utilize CNG/biogas in a compression ignition engine maintaining a high compression ratio, made possible by the high knock resistance of methane, and the resulting benefits in thermal efficiency associated with Diesel combustion. Presenter Fredrik K�nigsson, AVL Sweden

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.

JLR is on track to develop stop-start, parallel hybrid and plug-in parallel hybrid vehicles in the next few years. Plug-in hybridization is arguably the most suitable technology for large, premium luxury vehicles for the foreseeable future. Range_e is a UK based demonstrator for a plug-in hybrid system and has brought into sharp focus the attribute issues and wider challenges that need to be taken into consideration when moving towards production. Presenter Paul Bostock, Jaguar Land Rover

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

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

Who are the people who know the most about the buses in your fleet? They are most likely the operators and the servicing technicians. They are also the key people whose knowledge, level of training and attitude can determine the success or failure of new powertrain technologies. Training and recruitment of both need to be held to a higher standard than we have seen in the past. I will argue that even the culture of those involved in fleet operations needs to be changed. The bar for technical competence and product knowledge needs to be raised for operators and technicians. In return managers should find ways to include them as stakeholders, investing them with both additional responsibility and accountability. This will require greater access to training and recognition of achievement. Where are the busses stored and serviced? Most likely in an all-purpose state/county/municipal service facility servicing a variety of equipment.

A review of the processes that lead to the conclusion that CNG was the best solution for the fleet, including the efforts to gain public support for alternative fuels for school buses. MISD is now home for 42 CNG powered school buses (of 200). The presentation will include training and design tips for safety and smooth operations along with maintenance considerations for using CNG. Alternative fuels, the dilemma of which comes first - refueling station or operational buses ? has an impact on grant approval and funding, bearing discussion of the option of a public/private model. Unlike other alternative fuels, CNG has a national security impact Presenter Charles Stone, Mansfield Indep School Dist

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

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.

Downsizing and downspeeding are two efficient strategies to reduce vehicles CO2 emission, provided that high BMEP can be achieved at any engine speed under clean, safe, stable and efficient combustion. With a 6:1 minimum compression ratio, the MCE-5 VCRi achieves 40 bar peak BMEP at 1200 rpm with no irregular combustion. If peak BMEP is maintained below 35 bar, fuel enrichment is no longer necessary. When running at part loads, the engine operates at high compression ratios (up to 15:1) to minimize BSFC and maximize the sweet spot area on the map. Next generation MCE-5 VCRi engines will combine VCR and stoichiometric charges, highly diluted with external cooled EGR, in order to improve part loads efficiency by means of both the reduction in heat and pumping losses, and the optimization of compression-expansion ratio. This strategy, added to downsizing-donwspeeding, requires high-energy ignition systems to promote repeatable, stable, rapid and complete combustion.

Ford's EcoBoost GTDI engine technology (Gasoline Direct Injection, Turbo-charging and Downsizing) is being successfully implemented in the market place with the EcoBoost option accounting for significant volumes in vehicle lines as diverse as the F150 pickup truck, Edge CUV and the Lincoln MKS luxury sedan. A logical question would be what comes after GTDI? This presentation will review some of the technologies that will be required for further improvements in CO2, efficiency and performance building on the EcoBoost foundation as well as some of the challenges inherent in the new technologies and approaches. Presenter Eric W. Curtis, Ford Motor Co.

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

The 13 papers in this technical paper collection discuss variable valve actuation mechanisms, devices, and systems; and the impact and control of such systems on thermodynamics, combustion, fuel economy, emissions, and performance.

Providing thermal comfort to the occupants and thermal management of components in an energy efficient way has challenged the automotive industry to search for new and innovative approaches to thermal management. Hence, management of heat flow, coolant flow, oil flow, and airflow is extremely important as it directly affects the system performance under full range of vehicle operating conditions. The 31 papers in this technical paper collection describe methods or concepts to increase efficiency, improve occupant comfort, improve test methodology and minimize the environmental impact of the climate control system; and thermal management components addressing design and/or application topics.