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As CO2 legislation tightens, the next generation of turbocharged gasoline engines must meet stricter emissions targets combined with increased fuel efficiency standards. Recent studies have shown that the following technologies offer significant improvements to the efficiency of turbocharged GDI engines: Miller Cycle via late intake valve closing (LIVC), low pressure loop cooled EGR (LPL EGR), port water injection (PWI), and cylinder deactivation (CDA). While these efficiency-improving technologies are individually well-understood, in this study we directly compare these technologies to each other on the same engine at a range of operating conditions and over a range of compression ratios (CR). The technologies tested are applied to a boosted and direct injected (DI) gasoline engine and evaluated both individually and combined.

Direct Coating is a new processing technique which applies a single-layer polyurethane coating directly to a plastic part within a 2-shot molding cycle. The advantages of Direct Coating over traditional paint are improved surface quality, scratch resistance, and cost-effective processing. This concept has been previously showcased in high-gloss piano black with the simple geometry of the exterior door garnish. In this paper, the capabilities of Direct Coating are expanded to include metallic pigments and complex geometries for interior trim. For this development project, the Hyundai Sonata center fascia was selected as the target application due to the complex flow geometry around the bezel, and the high occurrence of customer contact, necessitating scratch and chemical resistance. Results of plaque-level testing showed that the coating material passed all requirements, including interior chemical resistance and scratch resistance.

The sliding door’s movement is 3-dimensional unlike the conventional door. So the electric power and signal are exchanged via the long ‘Power Cable’. It has a quite complex structure in order to be suitable to connect the vehicle’s body and the sliding door even during it’s moving. As the result, it is more expensive than conventional door’s one and the quality could not be guaranteed easily. In this paper, I have developed new technology which could transfer electric power by ‘wireless transfer’ in order to resolve the problem from using ‘Power cable’. I would propose the proper structure to transfer the electric power at any position of the sliding door without any physical connection. To transfer the electric power which drives the window regulator and the actuators in door, I have applied the ‘inductive coupling’ system.

The large luxury sedan seat has a 22-way Movement. It offers a wide range of adjustments to enhance passenger comfort performance while it has many constraints on movement in constrained indoor space. In addition, the power seat is operated by a motor, which makes it difficult for the user to determine the amount of adjustment, unlike determining the amount of adjustment by the power and feel of a person, such as manual seat adjustment. IMS, one-touch mode, is also constrained by parameters such as indoor space package, user's lifestyle, etc. during function playback. This paper aims to design the seat control logic to achieve the best seat comfort while satisfying each constraint. The results of this study are as follows. Increase robustness of power seat control logic. Provide optimal adjustments and comfort at each location. Offer differentiated custom control and seating modes for each seat. Improve customer satisfaction and quality by upgrading software.

Numerical investigation of engine performance and emissions of a six-stroke gasoline compression ignition (GCI) engine combustion at low load conditions is presented. In order to identify the effects of additional two strokes of the six-stroke engine cycle on the thermal and chemical conditions of charge mixtures, an in-house multi-dimensional CFD code coupled with high fidelity physical sub-models along with the Chemkin library was employed. The combustion and emissions were calculated using a reduced chemical kinetics mechanism for a 14-component gasoline surrogate fuel. Two power strokes per cycle were achieved using multiple injections during compression strokes. Parametric variations of injection strategy viz., individual injection timing for both the power strokes and the split ratio that enable the control of combustion phasing of both the power strokes were explored.

Although subjective measurements are critical for qualifying seat comfort in terms of good or bad, objective measurements are the basis for quantifying these differences and ultimately controlling seat comfort performance through engineering design specs, targets, and/or guidelines. Many objective automotive seat comfort tools and techniques used today are based on methods derived in the past. This paper examines the engineering problems and solutions that make these historical influences relevant today. Particular focus is given to design considerations for the A-surface, B-surface, and the compressed surface of the seating system.

The role of a brake disc is to convert the kinetic energy of automobiles into thermal energy caused by friction between the brake pads and disc surfaces. The braking performance of an overheated disc is decreased due to hot judder and fade. Hence, the cooling technology of a brake disc is one of the most important issues related to automobile safety. In the present study, the fluid flow and heat transfer analysis of a ventilated brake disc are conducted numerically. Some geometries of automotive parts such as bearings, hubs and wheels are considered in this study. The commercial code ANSYS CFX is used to simulate the fluid flow and the conjugate heat transfer which includes conduction and convection. To evaluate the cooling performance in each case, the results, including the flow patterns of cooling air inside the wheel and the heat transfer coefficient distribution at the disc surfaces, were investigated and compared for various disc-hub combinations.

Voice Recognition (VR) systems have become an integral part of the infotainment systems in the current automotive industry. However, its recognition rate is impacted by external factors such as vehicle cabin noise, road noise, and internal factors which are a function of the voice engine in the system itself. This paper analyzes the VR performance under the effect of two external factors, vehicle cabin noise and the speakers’ speech patterns based on gender. It also compares performance of mid-level sedans from different manufacturers.

Polylactide (PLA), which is one of the most important biocompatible polyesters that are derived from annually renewable biomass such as corn and sugar beets, has attracted much attention for automotive parts application. The manufacturing method of PLA is the ring-opening polymerization of the dimeric cyclic ester of lactic acid, lactide. For the PLA composites including stereocomplexed with L- and D-PLA, we developed the unit processes such as fermentation, separation, lactide conversion, and polymerization. We investigated D-lactic acid fermentation with a view to obtaining the strains capable of producing D-lactic acid, and through catalyst screening test for polycondensation and depolymerization reactions, we got a new method which shortens the whole reaction time of lactide synthesis step. Poly(d-lactide) is obtained from the ring-opening polymerization of d-lactide. Also we investigated several catalysts and polymerization conditions.

Owing to the enhanced performance of engines these days, more heat should be dissipated in the braking system. Failure of doing this properly causes temperature rise in the brake disc which result in the brake fade, disc distortion, brake judder, etc. A cooling-air-duct was proposed as a solution to prevent these from happening. In this paper, we present our work based on experiments optimized parameters such as direction, location, shapes and the size of the duct for the cooling-air-duct installation in real cars. We installed the duct extended from a front bumper to a rear wheel guard. Experimental parameters were compared with theoretical analysis using the impinging jet analysis. The heat transfer coefficients were determined by using the finite elements method (FEM). We found that our experimental data is supportive of theoretical analysis. We believe that our results should serve an useful guideline for designing the cooling-air-duct for braking system.

Numerical durability analysis is the only approach that can be used to assess the durability of vehicles in early stages of development. In these stages, where there are no physical prototypes available, the road wheel forces (or spindle forces) for durability testing on Belgian PG (Proving Ground) must be predicted by VPG (Virtual Proving Ground) or derived from the measured forces of predecessor vehicles. In addition, the tuning parts and geometry are not fixed at these stages. This results in the variation of spindle forces during the development stages. Therefore, it is not reasonable to choose the forces predicted at a specific tuning condition as standard forces. It is more reasonable to determine the standard forces stochastically using the DB of the measured forces of predecessor vehicles. The spindle forces measured or predicted on Belgian PG are typically stationary random.

The main contribution of this paper is to employ a sound and vibration theory in order to develop a light and cost effective plastic intercooler pipe. The intercooler pipe was composed of two rubber hoses and one aluminum pipe mounted between an ACV (Air Control Valve) and an intercooler outlet. The engineering design concept is to incorporate low-vibration type bellows and an impedance-mismatched center pipe, which replaces the rubber hoses and aluminum pipe respectively. The bellows were designed to adapt powertrain movement for high vibration transmission loss to the intercooler outlet. Also, the impedance-mismatched center pipe was implemented to increase reflected wave by using relatively higher modulus than bellows part and applying a SeCo (Sequential Coextrusion) processing method.

Hyundai Motor Group launched a Continuously Variable Valve Lift (CVVL) engine in 2012. The engine is equipped with HMG's unique CVVL mechanism and is characterized by low fuel consumption, high performance and its responsiveness. The CVVL mechanism is based on a six-linkage mechanism and has advantages of compactness and durability. The engine is a 4 cylinder In-Line, 2.0L gasoline engine and is designed for a mid-sized passenger car. The engine increases fuel efficiency by 7.7% and the peak engine power by 4.2%. One of the most challenging issues in producing a CVVL engine is the valve lift deviations throughout the engine cylinders. The valve cap shim and set screw were designed to adjust the valve lift deviations. Cap shim thickness is chosen by measuring the valve top height, and shoe lift of the cam carrier assembly. The set screw is an auxiliary device to adjust the valve lift deviation.

It is difficult to reach higher compression ratios of the gasoline engine even though higher compression ratios improve thermal efficiency. One of the barriers is large torque drop led by knocking. Extensive researches to suppress knocking of the gasoline engine have been conducted. It is focused on lowering the temperature of fuel mixture in combustion chamber at compression top dead center (TDC). This paper covers the new valvetrain system to decrease the temperature of exhaust valve bottom (combustion) side. Hollow head and stem sodium filled valve (HHSV) have shown more heat transfer from combustion chamber to valve seat insert and valve guide, and higher thermal conductivity valve seat insert (HVSI) and valve guide (HVG) help to decrease valve temperature lower by higher heat transfer.

In order to improve the fuel consumption ratio of the vehicle, a great deal of research is being carried out to improve air-conditioning efficiency. Increasing the efficiency of the condenser is directly connected to the power consumption of the compressor. This paper describes an experimental method of using an additional water-cooled condenser to reduce power consumption and decrease discharge pressure of the air-conditioning system. First, the principle of a combined cooling (water + air) method was evaluated theoretically. Next, experimental proof was conducted with the additional water-cooled condenser. The shape and structure is similar to the plate type of the transmission oil cooler used in a radiator. Through a number of tests, it was found that it is possible is to reduce power consumption of compressor by decreasing discharge pressure.

This paper outlines an improved methodology to perform calculations to verify the compliance of automotive door latch systems to minimum legal requirements as well as to perform additional due diligence calculations necessary to comprehend special cases such as roll over crashes and locally high inertial loadings. This methodology builds on the calculation method recommended by SAE J839 and provides a robust and clear approach for application of this method to cable release systems, which were not prevalent at the time J839 was originally drafted. This method is useful in and of itself but its utility is further increased by the application of the method to a Computer Aided Design (CAD) template (in this case for Catia V5), that allows some automation of the calculation process for a given latch type. This will result in a savings of time, fewer errors and allows for an iterative concurrent analysis during the design process.

In this project, phenomena in a SCR catalyst, such as heat transfer and catalytic reactions, are modeled numerically. The model is simplified to be integrated on an electronic control unit. The calibration process for this model has been developed, which is performed on gas bench and validated on a vehicle equipped with a Urea-SCR system and a Rapid Prototype Control Unit. With this simplified SCR reaction model, it is possible to estimate NH3 consumption and properly control the urea injection quantity with less calibration efforts.

We developed the hard IP (Instrument Panel) that is integrally over molded with a soft layer (TPO, Thermo Plastic Olefin) for the soft feeling and cost reduction. And also we produced the cost-effective PAB(Passenger-side Airbag) door system that had an in-mold tearseam and avoided competitors' patents simultaneously. The development procedure of this technology is; ① Material for overmolding ② Design optimization ③ Solving tool challenges. The reduction of process through integrally molding with soft material helped to accomplish a soft feeling on the IP and cost reduction at the same time. The deployment, head impact and heat aging tests were conducted and 5 patents were applied such as the optimization of the mold structure and injection condition.

This session covers topics regarding new CI and SI engines and components. This includes analytical, experimental, and computational studies covering hardware development as well as design and analysis techniques. Presenter Sung Hoon Lee, Hyundai Motor Co.

In this paper, an active type variable intake system is proposed, which improves both engine power and NVH performance. The proposed system uses a magnet valve to control the air path to the engine intake manifold. While other types of variable intake system such as vacuum actuator type or DC motor type need an ECU to control the valve, the proposed system only uses force equilibrium between magnetic force and vacuum pressure, resulting in weight and cost reduction. The system is composed of dual duct (duct A, duct B) and a magnet valve. In low RPM region, the magnet valve is closed and only duct A is used to supply air into the engine. In high RPM region the valve opens up and maximizes the amount of the air that goes into the engine intake manifold. The result is that the output power of the engine is maximized in high RPM region, as well as the NVH performance is improved in low RPM region.