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Spotlight on Design: Automotive Charging Infrastructure: Vehicle and Grid Integration

2016-01-30
“Spotlight on Design” features video interviews and case studies, focusing on technology breakthroughs, hands-on testimonials, and the importance of fundamentals. Viewers are virtually taken to industry labs and research centers to learn how design engineers solve real-life problems. These challenges include enhancing product performance, reducing cost, improving quality and safety, while decreasing environmental impact, and achieving regulatory compliance. In the episode “Automotive Charging Infrastructure: Vehicle and Grid Integration” (21:00), engineers from NextEnergy and an infrastructure expert from General Motors explain how technologies are rapidly converging to power electric vehicles and support the overall electric grid. This episode highlights: How the fast expansion of charging infrastructure is changing the way electric and hybrid-electric vehicles are gaining the confidence of consumers.
Video

Spotlight on Design: 3D Printing in the Automotive Industry

2015-12-22
“Spotlight on Design” features video interviews and case studies, focusing on technology breakthroughs, hands-on testimonials, and the importance of fundamentals. Viewers are virtually taken to industry labs and research centers to learn how design engineers solve real-life problems. These challenges include enhancing product performance, reducing costs, improving quality and safety, while decreasing environmental impact, and achieving regulatory compliance. In the episode “Additive Manufacturing: 3D Printing in the Automotive Industry” (20:00), engineers from Fiat Chrysler Corporation (FCA) explain the importance of using 3D printing to test multiple design scenarios and develop solutions that can be quickly evaluated on test tracks. And Local Motors shows how it builds a vehicle from the ground up with a 3D printer, and without a traditional assembly line.
Video

Spotlight on Design Insight: Fuel Efficiency: Fuel Economy Testing

2015-05-07
“Spotlight on Design: Insight” features an in-depth look at the latest technology breakthroughs impacting mobility. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. As global concerns about the negative consequences of greenhouse gases on the environment increase, regulatory agencies around the world are taking serious steps to address the issue of tailpipe emissions In the episode “Fuel Efficiency: Fuel Economy Testing” (12:05), engineers at the EPA’s National Vehicle and Fuel Emissions Laboratory demonstrate how different vehicles are tested for emissions, and AVL’s technical team shows how accurate tailpipe emissions can be measured and reported.
Video

Spotlight on Design Insight: Sensors: Fluid Measurements and Avionics

2015-05-07
“Spotlight on Design: Insight” features an in-depth look at the latest technology breakthroughs impacting mobility. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. The quality of fluids used in aviation, such as oil or fuel, is an extremely important safety issue. One way to reliably monitor fluids is through the use of special measurement sensors. In the episode “Fluid Measurements and Avionics” (9:13), an engineer at Meggitt demonstrates the capabilities of time-domain reflectometry sensors, explaining how they are assembled and used. The business case for monitoring oil and fuel degradation, and how to proactively take advantage of preventative maintenance is also explained.
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Spotlight on Design Insight: Diagnostics and Prognostics: Telematics Deep Dive

2015-05-04
“Spotlight on Design: Insight” features an in-depth look at the latest technology breakthroughs impacting mobility. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. When automotive and aerospace manufacturers look for a material with superior lightweight and strength characteristics, they often look no further than composite materials. In the episode “Composite Materials: New Trends in Automotive Design” (10:20), an engineer from Molded Fiber Glass Research Company demonstrates how they develop and test the properties of composite materials, and an engineer at MirTEQ Incorporated discusses designing molds for an aftermarket composite part.
Video

Spotlight on Design: Composite Materials: Advanced Materials and Lightweighting

2015-04-15
“Spotlight on Design” features video interviews and case study segments, focusing on the latest technology breakthroughs. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. In the episode “Composite Materials: Advanced Materials and Lightweighting” (30:20), Molded Fiber Glass Companies, known for its deep involvement in the creative development of the molded fiberglass process for the Corvette, demonstrates the manufacturing of sheet molded composite for fiberglass parts. Tanom Motors introduces the Tanom Invader, a blend between an automobile and a motorcycle made exclusively with composite materials. Finally, Euro-Composites demonstrates the manufacturing of honeycomb core material made out of aramid paper and phenolic resin used in aircraft structures.
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Catalyzed Particulate Filter Passive Oxidation Study with ULSD and Biodiesel Blended Fuel

2012-06-18
The development of PM and NOx reduction system with the combination of DOC included DPF and SCR catalyst in addition to the AOC sub-assembly for NH3 slip protection is described. DPF regeneration strategy and manual regeneration functionality are introduced with using ITH, HCI device on the EUI based EGR, VGT 12.3L diesel engine at the CVS full dilution tunnel test bench. With this system, PM and NOx emission regulation for JPNL was satisfied and DPF regeneration process under steady state condition and transient condition (JE05 mode) were successfully fulfilled. Manual regeneration process was also confirmed and HCI control strategy was validated against the heat loss during transient regeneration mode. Presenter Seung-il Moon
Video

Battery Charge Balance and Correction Issues in Hybrid Electric Vehicles for Individual Phases of Certification Dynamometer Driving Cycles as Used in EPA Fuel Economy Label Calculations

2012-05-23
This study undertakes an investigation of the effect of battery charge balance in hybrid electric vehicles (HEVs) on EPA fuel economy label values. EPA's updated method was fully implemented in 2011 and uses equations which weight the contributions of fuel consumption results from multiple dynamometer tests to synthesize city and highway estimates that reflect average U.S. driving patterns. For the US06 and UDDS cycles, the test results used in the computation come from individual phases within the overall certification driving cycles. This methodology causes additional complexities for hybrid vehicles, because although they are required to be charge-balanced over the course of a full drive cycle, they may have net charge or discharge within the individual phases. As a result, the fuel consumption value used in the label value calculation can be skewed.
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Modeling and Optimization of Plug-In Hybrid Electric Vehicle Fuel Economy

2012-05-23
One promising solution for increasing vehicle fuel economy, while still maintaining long-range driving capability, is the plug-in hybrid electric vehicle (PHEV). A PHEV is a hybrid electric vehicle (HEV) whose rechargeable energy source can be recharged from an external power source, making it a combination of an electric vehicle and a traditional hybrid vehicle. A PHEV is capable of operating as an electric vehicle until the battery is almost depleted, at which point the on-board internal combustion engine turns on, and generates power to meet the vehicle demands. When the vehicle is not in use, the battery can be recharged from an external energy source, once again allowing electric driving. A series of models is presented which simulate various powertrain architectures of PHEVs. To objectively evaluate the effect of powertrain architecture on fuel economy, the models were run according to the latest test procedures and all fuel economy values were utility factor weighted.
Video

5000 Hours Aging of THERBAN® (HNBR) Elastomers in an Aggressive Biodiesel Blend

2012-05-23
The need for light-weighting of automotive structures has spurred on a tremendous amount of interest in and development of low cost carbon fiber composite materials and manufacturing. This presentation provides a description of the commercial carbon fiber concept compared to traditional aerospace and specialty carbon fiber products. A specific update is presented on the development and commercialization of new low cost carbon fiber based on lignin / PAN precursor technology. The second focus of the presentation is on carbon fiber composite manufacturing processes, including carbon SMC, RTM, prepregs, and thermoplastic processes. Advantages and disadvantages of these processes are discussed, especially related to low cost manufacturing. Presenter George Husman, Zoltek Companies Inc.
Video

Biodiesel Permeability in Polyethylene

2012-05-22
This paper reports solubility, diffusivity and permeability data for soy and rapeseed methyl esters in polyethylene together with comparisons with methyl oleate and linoleate. These data were used to discuss the reliability of predictive models for diffusion and solubility of additive type molecules into semi-crystalline thermoplastic polymers. Presenter Emmanuel Richaud
Video

Test Method for Seat Wrinkling and Bagginess

2012-05-22
This study evaluates utilizing an accelerated test method that correlates customer interaction with a vehicle seat where bagginess and wrinkling is produced. The evaluation includes correlation from warranty returns as well as test vehicle results for test verification. Consumer metrics will be discussed within this paper with respect to potential application of this test method, including but not limited to JD Power ratings. The intent of the test method is to aid in establishing appropriate design parameters of the seat trim covers and to incorporate appropriate design measures such as tie downs and lamination. This test procedure was utilized in a Design for Six Sigma (DFSS) project as an aid in optimizing seat parameters influencing trim cover performance using a Design of Experiment approach. Presenter Lisa Fallon, General Motors LLC
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Overview of Southwest Research Institute Activities in Engine Technology R&D

2012-05-10
This presentation will cover an overview of challenges and key discussion points for advanced electric motor and drive testing . Voiko will visit some examples of how D&V approaches these issues and also some suggestions for how the industry can view these intriguing problems as opportunities. The presentation will also delve into current testing developments that involve resolver, load bank and power measurement devices by highlighting solutions in the market today. There will also be a cursory look into the future of electric motor testing and what we can expect in the near term. Presenter Voiko Loukanov, D&V Electronics Limited
Video

Blue Bird Propane Powered Vision School Bus

2012-04-10
Propane autogas, the world?s third most-used engine fuel, powers vehicles, transit buses, and now school buses. Blue Bird has recently launched the Next Generation Vision type C school bus, powered by a ROUSH CleanTech liquid propane autogas fuel system and a Ford 6.8L V10 engine. The bus reduces operating costs by up to 40%, greenhouse gas emissions by up to 24%, and maintains the factory horsepower, torque, and towing capacity ratings. Learn about how school districts are saving over $.30 / mile using this clean, domestically-produced fuel. Presenter Brian Carney, Roush CleanTech.
Video

Propane Autogas: The Clear Choice

2012-04-10
The presentation by Tucker Perkins, President of CleanFUEL USA, provides important information to those wanting to learn about alternative fuels, specifically propane autogas. CleanFUEL USA provides liquid propane injection engine system for the 6L engine in the GM G4500 cutaway chassis used in many Type A busses. They are also developing an 8L engine in partnership with Freightliner/ThomasBuilt Bus for the Type C bus. This presentation discussed many of the advantages of propane autogas use, such as better economics, lower emissions, and inexpensive infrastructure for the fueling network. Presenter Tucker Perkins, CleanFUEL USA
Video

Powertrain Innovation Requires Infrastructure Innovation!

2012-04-10
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.
Video

Funding Opportunities for Clean Vehicle Initiatives

2012-04-10
Understanding the different types of alternative fuel and advanced vehicle technologies that are available, and deciding which would be the best fit for your fleet, is only half the battle. Limited budgets, now more than ever, create a need to find funding assistance to pursue these new technologies. This presentation will provide insight into making sure you know what assistance is available by providing information not only on the funding programs themselves, but also who to know and where to go to make sure you always have access to the best available information. Presenter Lori Clark, North Central Texas Council of Gov
Video

Natural Gas for School Buses: A Case for Using the Only Domestically Produced Alternative Fuel

2012-04-10
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
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Preparing for Alternative Fuels and Advanced Technologies: Guidance for School Bus Fleet Managers

2012-04-10
With so many options for alternative fuels, advanced vehicles, and emission reduction technologies, how can fleet managers make the best decisions for their fleet?s performance, compliance, and sustainability goals? Even more important, where is the funding that is often critical for implementing these decisions? This presentation will provide guidance on how to assess the options, how to prepare for writing grants and where to find funding opportunities. Presenter Laura Palombi, Clean Energy Coalition
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