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With well over 25 years of experience, Sven Beiker is widely regarded as the mobility expert in Silicon Valley specializing in future trends for the automotive and mobility industries including autonomous driving, connectivity, electrification, and shared mobility. In The Mobility Diaries: Connecting the Milestones of Innovation Leading to ACES, he opens up his personal diary regarding his take on 50 years of mobility innovation and history interwoven with his experiences from 1978 to 2018. From the Foreword by Reilly P. Brennan: “Understanding how transportation itself evolved requires a unique prism. The core components of vehicles today have stories and engineering journeys worth their own telling, and that is what is so exciting about the way we can learn about them in this text. Dr. Beiker’s curriculum vitae, from BMW to Stanford University to McKinsey, are a compendium of experiences that created this unique historical and biographical book.”

This SAE EDGE™ Research Report identifies key unsettled issues of interest to the automotive industry regarding the new generation of sensors designed for vehicles capable of automated driving. Four main issues are outlined that merit immediate interest: First, specifying a standardized terminology and taxonomy to be used for discussing the sensors required by automated vehicles. Second, generating standardized tests and procedures for verifying, simulating, and calibrating automated driving sensors. Third, creating a standardized set of tools and methods to ensure the security, robustness, and integrity of data collected by such sensors. The fourth issue, regarding the ownership and privacy of data collected by automated vehicle sensors, is considered only briefly here since its scope far exceeds the technical issues that are the primary focus of the present report. SAE EDGE™ Research Reports are preliminary investigations of new technologies.

We propose a composite thermal model of the vehicle passenger compartment that can be used to predict and analyze thermal comfort of the occupants of a vehicle. Physical model is developed using heat flow in and out of the passenger compartment space, comprised of glasses, roof, seats, dashboard, etc. Use of a model under a wide variety of test conditions have shown high sensitivity of compartment air temperature to changes in the outside air temperature, solar heat load, temperature and mass flow of duct outlet air from the climate control system of a vehicle. Use of this model has subsequently reduced empiricism and extensive experimental tests for design and tuning of the automatic climate control system. Simulation of the model allowed several changes to the designs well before the prototype hardware is available.

The use of neat alcohols, namely methanol and ethanol, in direct-injection, compression-ignited engines is difficult, most notably due to their poor ignitability. By employing a high-temperature combustion strategy, this challenge may be overcome, thus creating the opportunity for using these oxygenated and inherently low-sooting fuels for heavy-load applications. Experimental data are provided from a single-cylinder research engine that shows particulate matter (PM) emissions for Diesel-style combustion of both methanol and ethanol that are below the current US Government regulation limit. The level of particulates remained low up to stoichiometric ratios of fuel and air. A complete emissions analysis indicates a high combustion efficiency of ∼ 96% at stoichiometric conditions. In order to achieve reliable combustion, some form of intake-air preheating was required.

There is significant motivation to extend the operating range of naturally aspirated HCCI combustion to high load (8-12 bar IMEP) to attain a combustion strategy with the efficiency benefits of HCCI but without the lost power density of a lean or highly diluted charge. Currently, the high-load limit of HCCI combustion is imposed by a phenomenon commonly known as ringing. Ringing results when the kinetically-driven autoignited combustion process proceeds in such a way as to form strong pressure waves which reverberate in the engine. Inhomogeneities and gradients in mixture reactivity lead certain regions to react ahead of others, and as a result, coupling can occur between a pressure wave and the reaction front. This paper seeks first to sort several related but distinct issues that impose the high load limit: ringing, engine damage, peak in-cylinder pressure, peak rate of pressure rise, and engine noise.

The optimum driving dynamics can be achieved only when the tire forces on all four wheels and in all three coordinate directions are monitored and controlled precisely. This advanced level of control is possible only when a vehicle is equipped with several active chassis control systems that are networked together in an integrated fashion. To investigate such capabilities, an electric vehicle model has been developed with four direct-drive in-wheel motors and an active steering system. Using this vehicle model, an advanced slip control system, an advanced torque vectoring controller, and a genetic fuzzy active steering controller have been developed previously. This paper investigates whether the integration of these stability control systems enhances the performance of the vehicle in terms of handling, stability, path-following, and longitudinal dynamics.

Tracer-based PLIF temperature diagnostics have been used to study the distribution and evolution of naturally occurring thermal stratification (TS) in an HCCI engine under fired and motored operation. PLIF measurements, performed with two excitation wavelengths (277, 308 nm) and 3-pentanone as a tracer, allowed investigation of TS development under relevant fired conditions. Two-line PLIF measurements of temperature and composition were first performed to track the mixing of the fresh charge and hot residuals during intake and early compression strokes. Results showed that mixing occurs rapidly with no measureable mixture stratification remaining by early compression (220°CA aTDC), confirming that the residual mixing is not a leading cause of thermal stratification for low-residual (4-6%) engines with conventional valve timing.

Simultaneous crank-angle-resolved measurements of gasoline concentration and gas temperature were made with two-color mid-infrared (mid-IR) laser absorption in a production spark-ignition engine (Nissan MR20DE, 2.0L, 4 cyl, MPI with premium gasoline). The mid-IR light was coupled into and out of the cylinder using fiber optics incorporated into a modified spark plug. The absorption line-of-sight was a 5.3 mm optical path located closely adjacent to the ignition spark providing spatially resolved absorption. Two sensor wavelengths were selected in the strong bands associated with the carbon-hydrogen (C-H) stretching vibration near 3.4 μm, which have an absorption ratio that is strongly temperature dependent. Fuel concentration and temperature were determined simultaneously from the absorption at these two wavelengths.

Multiple fuel-injections during a single engine cycle can reduce combustion noise and improve pollutant emissions tradeoffs. Various hypotheses have been proposed in the literature regarding the in-cylinder processes responsible for the pollutant emissions improvements. This paper provides a brief overview of these hypotheses along with an investigation exploring which of these mechanisms are important for post injections under low-temperature combustion (LTC) conditions in a heavy-duty diesel engine. In-cylinder soot and exhaust smoke are measured by 2-color soot thermometry and filter paper blackening, respectively. The evolution and interaction of soot regions from each of the injections is visualized using high-speed imaging of soot luminosity, both in the piston bowl and in the squish regions.

Homogenous Charge Compression Ignition (HCCI) combustion offers significant efficiency improvements compared to conventional gasoline engines. However, due to the nature of HCCI combustion, traditional HCCI engines show some degree of sensitivity to in-cylinder thermal conditions; thus higher cylinder-to-cylinder variation was observed especially at low load and high load operating conditions due to different injector characteristics, different amount of reforming as well as non-uniform EGR distribution. To address these issues, a cylinder balancing control strategy was developed for a multi-cylinder engine. In particular, the cylinder balancing control strategy balances CA50 and AF ratio at high load and low load conditions, respectively. Combustion noise was significantly reduced at high load while combustion stability was improved at low load with the cylinder balancing control.

Magnesium alloy extrusions offer potentially more mass saving compared to magnesium castings. One of the tasks in the United States Automotive Materials Partnership (USAMP) ?Magnesium Front End Research and Development? (MFERD) project is to evaluate magnesium extrusion alloys AM30, AZ31 and AZ61 for automotive body applications. Solid and hollow sections were made by lowcost direct extrusion process. Mechanical properties in tension and compression were tested in extrusion, transverse and 45 degree directions. The tensile properties of the extrusion alloys in the extrusion direction are generally higher than those of conventional die cast alloys. However, significant tension-compression asymmetry and plastic anisotropy need to be understood and captured in the component design.

Magnesium alloys are the lightest structural metal and recently attention has been focused on using them for structural automotive components. Fatigue and durability studies are essential in the design of these load-bearing components. In 2006, a large multinational research effort, Magnesium Front End Research & Development (MFERD), was launched involving researchers from Canada, China and the US. The MFERD project is intended to investigate the applicability of Mg alloys as lightweight materials for automotive body structures. The participating institutions in fatigue and durability studies were the University of Waterloo and Ryerson University from Canada, Institute of Metal Research (IMR) from China, and Mississippi State University, Westmorland, General Motors Corporation, Ford Motor Company and Chrysler Group LLC from the United States.

Fully Flexible Valve Actuation (FFVA) systems provide maximum flexibility to adjust lift profiles of engine intake and exhaust valves. A research grade electro-hydraulic servo valve based FFVA system was designed to be used with an engine in a test cell to precisely follow desired lift profiles. Repetitive control was chosen as the control strategy. Crank angle instead of time is used to trigger execution to ensure repeatability. A single control is used for different engine speeds even though the period for one revolution changes with engine speeds. The paper also discusses lift profile extension, instantaneous lift profile switching capability and built-in safety features.

Brake caliper and corner behavior in the off-brake condition can lead, at times, to brake system performance issues such as residual drag (and related issues such as pulsation, judder, and loss of fuel economy), and caliper pryback during aggressive driving maneuvers. The dynamics in the brake corner can be strikingly complex, with numerous friction interfaces, rubber component and grease dynamics, deflections of multiple components, and significant dependence on usage conditions. Displacements of moving parts are usually small, and the residual forces in the caliper interfaces involved are also small in comparison with other forces acting on the same components, making direct observation very difficult. The present work attempts to illuminate off-brake behavior in two different conditions - residual drag and pryback - through the use of low-range pressure distribution sensors placed in between the caliper (pistons and fingers) and the brake pad pressure plates.

In response to the TREAD act of 2002, ASTM F09.30 Aged Tire Durability Task Group was formed with the objective of developing a scientifically valid, short duration aged durability test which correlates to field behavior. The target end-of-test condition was belt edge separation (or related damage). One strategy, driven by that objective, has been a steady state design of experiment investigating aging temperature and duration as well as roadwheel speed, pressure and deflection. The rationale behind investigating a steady state test and selecting these parameters and methodology for setting their initial values is reviewed.

In the work leading to the TREAD Act, some members of Congress expressed the need for some type of aging test on light vehicle tires. Since no industry-wide recommended practice existed, the ASTM F09.30 Aged Tire Durability task group was established in 2002 to develop a scientifically valid, short duration, laboratory aged tire durability test which correlates to in-service aging. The target end-of-test condition was belt edge separation (or related tire conditions). One strategy, driven by that objective, has been a Steady State DOE investigating aging temperature and duration, as well as, roadwheel speed, pressure and deflection. Testing was performed on three tire types, including two where relevant field aging data was publicly available from NHTSA studies. A region of interest, within the design space, was identified where target end-of-test conditions were possible and undesirable (non-target or non-representative of those seen in consumer use) were avoided.

Since 1997, General Motors Body Manufacturing Engineering - Die Engineering Services (BME-DES) has been working jointly with our software vendor to develop and implement a parallel version of stamping simulation software for mass production analysis applications. The evolution of this technology and the insight gained through the implementation of DMP/MPP technology as well as performance benchmarks are discussed in this publication.

A spectroscopic diagnostic system was designed to study the effects of different engine parameters on the chemiluminescence characteristic of HCCI combustion. The engine parameters studied in this work were intake temperature, fuel delivery method, fueling rate (load), air-fuel ratio, and the effect of partial fuel reforming due to intake charge preheating. At each data point, a set of time-resolved spectra were obtained along with the cylinder pressure and exhaust emissions data. It was determined that different engine parameters affect the ignition timing of HCCI combustion without altering the reaction pathways of the fuel after the combustion has started. The chemiluminescence spectra of HCCI combustion appear as several distinct peaks corresponding to emission from CHO, HCHO, CH, and OH superimposed on top of a CO-O continuum. A strong correlation was found between the chemiluminescence light intensity and the rate of heat release.

A numerical simulation of the flow structure around an idealized automotive A-pillar rain-gutter and the sound radiated from it is reported. The idealized rain-gutter is an infinitesimally thin backward facing elbow mounted on a flat plate. It is kept in a virtual wind-tunnel with rectangular cross-section. The transient flow structure around the rain-gutter is described and time-averaged pressure distribution along the base plate is provided. Time-varying static pressure was recorded on every grid point on the base-plate as well as the rain-gutter surfaces and used to calculate sound pressure signal at a microphone held above the rain-gutter using the Ffowcs-Williams-Hawkings (FWH) integral method was used for calculating sound propagation. Both the transient flow simulation as well as the FWH sound calculation were performed using the commercial CFD code FLUENT6.1.22.

The ozone forming potential (OFP) and specific reactivity (SR) of tailpipe exhaust are among the factors that determine the environmental impact of a motor vehicle. OFP and SR measurements require a lengthy determination of about 190 non-methane hydrocarbon species. A rapid gas chromatography (GC) instrument has been constructed to separate both the light (C2 - C4) and the midrange (C5 - C12) hydrocarbons in less than 10 minutes. The limit of detection is about 0.002 parts per million carbon (ppmC). Thirty exhaust samples from natural gas vehicles (NGV's) were analyzed to compare the rapid GC method with the standard GC method, which required 40-minute analyses on two different instruments. In general, evaluation of the commercial prototype from Separation Systems, Inc., indicates that a high speed, high resolution gas chromatograph can meet the need for fast, efficient exhaust hydrocarbon speciation.