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The combustion processes of three injection strategies in a light-duty (LD) diesel engine at a medium load point are captured with a high speed video camera. A double-pilot/main/single-post injection strategy representative of a LD Euro 6 calibration is considered as the reference. There is a modest temporal spacing (dwell) after the first pilot (P1) and second pilot (P2). A second strategy, “A,” adds a third pilot (P3). The dwell after both P2 and P3 are several times shorter than in the reference strategy. A third strategy, “B,” further reduces all dwells. Each injection has its own associated local peak in the heat release rate (HRR) following some ignition delay. Between these peaks lie local minima, or dips. In all three cases, the fuel from P1 combusts as a propagating premixed flame. For all strategies, the ignition of P2 primarily occurs at its interface with the existing combustion regions.

Look ahead information can be used to improve the powertrain’s fuel consumption while efficiently controlling exhaust emissions. A passenger car propelled by a Euro 6d capable diesel engine is studied. In the conventional approach, the diesel powertrain subsystem control is rule based. It uses no information of future load requests but is operated with the objective of low engine out exhaust emission species until the Exhaust After-Treatment System (EATS) light off has occurred, even if fuel economy is compromised greatly. Upon EATS light off, the engine is operated more fuel efficiently since the EATS system is able to treat emissions effectively. This paper presents a supervisory control structure with the intended purpose to operate the complete powertrain using a minimum of fuel while improving the robustness of exhaust emissions.

The compression ratio is an important engine design parameter. It determines to a large extend engine properties like the achievable efficiency, the heat losses from the combustion chamber and the exhaust losses. The same properties are affected by insulation of the combustion chamber. It is therefore especially important to know the compression ratio when doing experiments with thermal barrier coatings (TBC). In case of porous TBCs, the standard methods to measure the compression ratio can give wrong results. When measuring the compression ratio by volume, using a liquid, it is uncertain if the liquid fills the total porous volume of the coating. And for a thermodynamic compression ratio estimation, a model for the heat losses is needed, which is not available when doing experiments with insulation. The subject of this paper is the evaluation of an alternative method to assess the compression ratio.

In the quest for a highly efficient, low emission and affordable source of passenger car propulsion system, meeting future demands for sustainable mobility, the concept of homogeneous lean combustion (HLC) in a spark ignited (SI) multi-cylinder engine has been investigated. An attempt has been made to utilize the concept of HLC in a downsized multi-cylinder production engine producing up to 22 bar BMEP in load. The focus was to cover as much as possible of the real driving operational region, to improve fuel consumption and tailpipe emissions. A standard Volvo two litre four-cylinder gasoline direct injected engine operating on commercial 95 RON gasoline fuel was equipped with an advanced two stage turbo charger system, consisting of a variable nozzle turbine turbo high-pressure stage and a wastegate turbo low-pressure stage. The turbo system was specifically designed to meet the high demands on air mass flow when running lean on higher load and speeds.

The foremost aim of the work presented in this paper is to improve fuel economy and decrease CO2 emissions by reducing the aerodynamic drag of passenger vehicles. In vehicle development, computer aided engineering (CAE) methods have become a development driver tool rather than a design assessment tool. Exploring and developing the capabilities of current CAE tools is therefore of great importance. An efficient method for vehicle shape optimization has been developed using recent years' advancements in neural networks and evolutionary optimization. The proposed method requires the definition of design variables as the only manual work. The optimization is performed on a solver approximation instead of the real solver, which considerably reduces computation time. A database is generated from simulations of sampled configurations within the pre-defined design space. The database is used to train an artificial neural network which acts as an approximation to the simulations.

This paper presents measurements on Vehicle to Vehicle (V2V) communication between participants in a platooning application. Platooning, according to the SARTRE concept, implies several vehicles travelling together in tight formation, with a manually driven heavy lead vehicle. The platoon being studied consists of five vehicles; two trucks in the lead and three passenger cars. The V2V-communication node in each vehicle contains an 802.11p radio at 5,9 GHz. It is used to send messages between vehicles to coordinate movements and maintain safety in the platoon. Another cooperative application that relies on V2V-communication is multiple UAVs flying in formation; as investigated in KARYON. This project also investigates cooperative autonomous vehicles. In both applications, V2V-communication is an enabling technology. Two metrics are studied to quantify the V2V-communication quality: system packet error rate and consecutive packet loss.

There are a number of numerical and experimental studies of the aerodynamic performance of wheels that have been published. They show that wheels and wheel-housing flows are responsible for a substantial part of the total aerodynamic drag on passenger vehicles. Previous investigations have also shown that aerodynamic resistance moment acting on rotating wheels, sometimes referred to as ventilation resistance or ventilation torque is a significant contributor to the total aerodynamic resistance of the vehicle; therefore it should not be neglected when designing the wheel-housing area. This work presents a numerical study of the wheel ventilation resistance moment and factors that affect it, using computational fluid dynamics (CFD). It is demonstrated how pressure and shear forces acting on different rotating parts of the wheel affect the ventilation torque. It is also shown how a simple change of rim design can lead to a significant decrease in power consumption of the vehicle.

Heat transfer losses are one of the largest loss contributions in a modern internal combustion engine. The aim of this study is to evaluate the contribution of the piston bowl type and swirl ratio to heat losses and performance. A commercial CFD tool is used to carry out simulations of four different piston bowl geometries, at three engine loads with two different swirl ratios at each load point. One of the geometries is used as a reference point, where CFD results are validated with engine test data. All other bowl geometries are scaled to the same compression ratio and make use of the same fuel injection, with a variation in the spray target between cases. The results show that the baseline case, which is of a conventional diesel bowl shape, provides the best emission performance, while a more open, tapered, lip-less combustion bowl is the most thermodynamically efficient.

The effect of various fuel-cut agings, on a Volvo Cars 4-cylinder gasoline engine, with bimetallic three-way catalysts (TWCs) was examined. Deactivation during retardation fuel-cut (low load) and acceleration fuel-cut (high load, e.g. gearshift or traction control) was compared to aging at λ=1. Three-way catalysts were aged on an engine bench comparing two fuel-cut strategies and their impact on of the life and performance of the catalysts. In greater detail, the catalytic activity, stability and selectivity were studied. Furthermore, the catalysts were thoroughly analyzed using light-off and oxygen storage capacity measurements. The emission conversion as a function of various lambda values and loads was also determined. Fresh and 40-hour aged samples showed that the acceleration fuel-cut was the strategy that had the highest contribution towards the total deactivation of the catalyst system.

Under a global impulse for less man-made emissions, the automotive manufacturers search for innovative methods to reduce the fuel consumption and hence the CO2-emissions. Aerodynamics has great potential to aid the emission reduction since aerodynamic drag is an important parameter in the overall driving resistance force. As vehicles are considered bluff bodies, the main drag source is pressure drag, caused by the difference between front and rear pressure. Therefore increasing the base pressure is a key parameter to reduce the aerodynamic drag. From previous research on small-scale and full-scale vehicles, rear-end extensions are known to have a positive effect on the base pressure, enhancing pressure recovery and reducing the wake area. This paper investigates the effect of several parameters of these extensions on the forces, on the surface pressures of an SUV in the Volvo Cars Aerodynamic Wind Tunnel and compares them with numerical results.

In the early stages of an aerodynamic development programme of a road vehicle it is common to use wind tunnel scale models. The obvious reasons for using scale models are that they are less costly to build and model scale wind tunnels are relatively inexpensive to operate. It is therefore desirable for model scale testing to be utilized even more than it is today. This however, requires that the scale models are highly detailed and that the results correlate with those of the full size vehicle. This paper presents a correlation study that was carried out in the Chalmers and Volvo Car Aerodynamic Wind Tunnels. The aim of the study was to investigate how successfully a correlation of the cooling air flow between a detailed scale model and a real full size vehicle could be achieved. Results show limited correlation on absolute global aerodynamic loads, but relative good correlation in drag and lift increments.

Automotive wind tunnel testing is a key element in the development of the aerodynamics of road vehicles. Continuous advancements are made in order to decrease the differences between actual on-road conditions and wind tunnel test properties and the importance of ground simulation with relative motion of the ground and rotating wheels has been the topic of several studies. This work presents a study on the effect of active ground simulation, using moving ground and rotating wheels, on the aerodynamic coefficients on a passenger car in yawed conditions. Most of the published studies on the effects of ground simulation cover only zero yaw conditions and only a few earlier investigations covering ground simulation during yaw were found in the existing literature and all considered simplified models. To further investigate this, a study on a full size sedan type vehicle of production status was performed in the Volvo Aerodynamic Wind Tunnel.

A primary goal within the industry is to shorten the lead time to get shorter time to market and lower cost. System verification can set the limits for how short the lead time can be. Traditionally verification of automotive communication systems like Remote Keyless Entry, RKE, is performed in a complete vehicle late in the product development process. To fulfill the quality demands during the shorter project time Volvo Cars, VCC, has experienced that it is necessary to develop new requirements and verification methods. Six Sigma contains a complete toolbox to do this in a structured and time efficient way. VCC has together with other Ford Motor Company, FMC, brands and the supplier Continental developed methods and requirements so that the RKE system can be verified before vehicles are built. Only a last validation has to be performed in a complete vehicle.

This study focus on the aerodynamic influence of the engine bay packaging, with special emphasis on the density of packaging and its effect on cooling and exterior flow. For the study, numerical and experimental methods where combined to exploit the advantages of each method. The geometry used for the study was a model of Volvo S60 sedan type passenger car, carrying a detailed representation of the cooling package, engine bay and underbody area. In the study it was found that there is an influence on the exterior aerodynamics of the vehicle with respect to the packaging of the engine bay. Furthermore, it is shown that by evacuating a large amount of the cooling air through the wheel houses a reduction in drag can be achieved.

The Inflatable Curtain (IC) has shown great potential to reduce head injuries in side impacts. This study explores and presents enhanced performance in two steps of improved activation algorithms. Crash data analysis, 21 full scale crash tests and component tests in a custom built drop tower rig have been performed. The IC performance in wider crash scenarios, including side impacts outside the occupant compartment (L-type impacts), was evaluated. Both statistical crash data and in-depth studies were used. It was found in the analysis of real life crashes that moderate to fatal head injuries can occur without intrusion in the occupant compartment. In L-type side impacts, the motion of the occupant relative to the vehicle interior may cause a head impact of sufficiently high severity to cause moderate to severe head injuries. A combined analysis of real world crash data and crash test results indicates that a substantial reduction in moderate to fatal head injuries can be achieved.

A structured, semi-automatic method for reducing a high-fidelity engine model to a fast running one has been developed. The principle of this method rests on the fact that, under certain assumptions, the computationally expensive components of the simulation can be substituted with simpler ones. Thus, the computation speed increases substantially while the physical representation of the engine is retained to a large extent. The resulting model is not only suitable for fast running simulations, but also usable and updatable in later stages of the development process. The thrust of the method is that the calibration of the fast running components is achieved by use of automatically selected neural networks. Two illustrative examples demonstrate the methodology. The results show that the methodology achieves substantial increase in computation speed and satisfactory accuracy.

A naturally aspirated in-line six-cylinder 2.9-litre Volvo engine is operated in Homogeneous Charge Compression Ignition (HCCI) mode, using camshafts with low lift and short duration generating negative valve overlap. This implementation requires only minor modifications of the standard SI engine and allows SI operation outside the operating range of HCCI. Standard port fuel injection is used and pistons and cylinder head are unchanged from the automotive application. A heat exchanger is utilized to heat or cool the intake air, not as a means of combustion control but in order to simulate realistic variations in ambient temperature. The combustion is monitored in real time using cylinder pressure sensors. HCCI through negative valve overlap is recognized as one of the possible implementation strategies of HCCI closest to production. However, for a practical application the intake temperature will vary both geographically and from time to time.

In order to achieve ultra low emission levels with three-way catalysts, an early accurate air/fuel ratio control is essential. Positioning the oxygen sensor in the first part of the substrate helps to protect the oxygen sensor from being splashed by water during cold start, so that early heating and activation becomes a less limiting factor. For emission control purpose, a position of a rear sensor in the warm part of the catalyst gives improved possibilities for oxygen buffer control during catalyst warming up conditions. This enhances balancing HC and NOx in an early phase. In addition, for OBD reasons it is possible to locate the sensor in any axial position in the catalyst, which improves design possibilities for cold start detection, even for single brick catalyst systems. The paper describes the construction of the catalyst with an integrated oxygen sensor.

A single cylinder, naturally aspirated, four-stroke and camless (Otto) engine was operated in homogeneous charge compression ignition (HCCI) mode with commercial gasoline. The valve timing could be adjusted during engine operation, which made it possible to optimize the HCCI engine operation for different speed and load points in the part-load regime of a 5-cylinder 2.4 liter engine. Several tests were made with differing combinations of speed and load conditions, while varying the valve timing and the inlet manifold air pressure. Starting with conventional SI combustion, the negative valve overlap was increased until HCCI combustion was obtained. Then the influences of the equivalence ratio and the exhaust valve opening were investigated. With the engine operating on HCCI combustion, unthrottled and without preheating, the exhaust valve opening, the exhaust valve closing and the intake valve closing were optimized next.

This paper reports how numerical simulation can be used as a tool to guide vehicle design with respect to brake cooling demands. Detailed simulations of different brake cooling concepts are compared with experimental results. The paper consists of two parts. The first part places the emphasis on how to model the flow inside and around the brake disc. The boundary layer and the pumping effect is investigated for a ventilated single rotor. The numerical results will be compared to experimental results. In the second part, an engineering approach is applied in order to rank different technical solutions on a Volvo S80 vehicle in terms of brake cooling and aerodynamic drag. The results from the free brake disc simulations indicate that the tangential velocity can be predicted with high accuracy, e.g. standard k-ε model with prism near wall cells typically within 4% of measured data.