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The modern luxurious electric vehicle (EV) demands high torque and high-speed requirements with increased range. Fulfilling these requirements gives rise to the need for increased efficiency and power density of the motors in the Electric Drive Unit (EDU). Internal Permanent Magnet (IPM) motor is one of the best suited options in such scenarios because of its primary advantages of higher efficiency and precise control over torque and speed. In the IPM motor, permanent magnets are mounted within the rotor body to produce a resultant rotating magnetic field with the 3-phase AC current supply in the stator. IPM configuration provides structural integrity and high dynamic performance as the magnets are inserted within the rotor body. Adhesive glue is used to install the magnets within the laminated stack of rotor.

The rotor and stator of electric motors consist of multiple materials, of which steel forms the majority of mass and volume. Steel in electric motors is commonly in the form of thin sheets (laminations), stacked along the axis of the rotor. The structural integrity of such a stack can be ensured using bolting, welding or bonding of the laminations. Predictive mechanical finite element simulations of these laminated stacks can become computationally intense because the steel sheets are thin, and the motor often contains hundreds of them. If the laminations are modelled individually, the size of the elements is very small compared to the overall dimensions and the interface between the laminations need to be modelled as well. In this paper, we present an alternate method of modelling this laminated stack as a single solid body using homogeneous and orthotropic material property, instead of representing each lamination.

Many incidents associated with filter plugging have extensively been reported in microbially contaminated diesel and biodiesel fuel systems, especially under long term storage conditions. In this study a quantitative assessment of the undesirable insoluble solids produced in contaminated biodiesel fuels was carried out in order to evaluate their evolution rate during biodeterioration. For this purpose, a series of contaminated biodiesel fuel microcosms were prepared and stored for six months under stable conditions. The quantity of the particulate contaminants was monitored during storage by a multiple filtration technique which was followed at the end by a comparison with the active bioburden per ATP bioluminescence protocol. Additionally, identical microcosms were treated with a commercially available biocide in order to examine the latter’s activity both on solids formation and the microbial proliferation.

Predicting Exterior Water Management is important for developing vehicles that meet customer expectations in adverse weather. Fluid film methods, with Lagrangian tracking, can provide spray and surface water simulations for complex vehicle geometries in on-road conditions. To cope with this complexity and provide practical engineering simulations, such methods rely on empirical sub-models to predict phenomena such as the film stripping from the surface. Experimental data to develop and validate such models is difficult to obtain therefore here a high-fidelity Coupled Level-set Volume of Fluid (CLSVOF) simulation is carried out. CLSVOF resolves the interface of the liquid in three dimensions; allowing direct simulation of film behaviour and interaction with the surrounding air. This is used to simulate a simplified wing-mirror, with air flow, on which water is introduced.

Additives that enhance properties, such as cetane number or cold flow, are introduced in diesel-biodiesel blends in order to upgrade its performance as well as to aid its handling and distribution. Furthermore, in order to protect the engine and fuel operating system equipment, diesel fuel may be treated with corrosion inhibitors and detergents. However, additives could also have an impact on other parameters beyond those that they are intended to boost. In the present study the effect of diesel fuel improvers on fuel’s microbial stability is examined. An additive-free ultra low sulfur diesel (ULSD) was blended with Soybean Fatty Acid Methyl Esters (FAME) and the resulting blend was treated separately with a series of commercially available diesel fuel additives.

A prototype multi-hole diesel injector operating with n-heptane fuel from a high-pressure common rail system is used in a high-pressure and high-temperature test rig capable of reaching 1100 Kelvin and 150 bar under different oxygen concentrations. A novel optical set-up capable of visualizing the soot cloud evolution in the fuel jet from 30 to 85 millimeters from the nozzle exit with the high-speed color diffused back illumination technique is used as a result of the insertion of a high-pressure window in the injector holder opposite to the frontal window of the vessel. The experiments performed in this work used one wavelength provide information about physical of the soot properties, experimental results variating the operational conditions show the reduction of soot formation with an increase in injection pressure, a reduction in ambient temperature, a reduction in oxygen concentration or a reduction in ambient density.

FAME is the most common renewable component of conventional automotive diesel. Despite the advantages, biodiesel is more susceptible to oxidative deterioration and due to its chemical composition as well as its higher affinity to water, is considered to be a favorable substrate for microorganisms. On the other hand, apart from biodiesel, alcohols are considered to be promising substitutes to conventional diesel fuel because they can offer higher oxygen concentration leading to better combustion characteristics and lower exhaust emissions. More specifically, n-butanol is a renewable alcohol demonstrating better blending capabilities and properties when it is added to diesel fuel, as its composition is closer to conventional fuel, when compared ethanol to for example. Taking into consideration the alleged disinfectant properties of alcohols, it would be interesting to examine also the microbial stability of blends containing n-butanol in various concentrations.

A novel semi-analytical solution has been developed for the calculation of the static and dynamic response of an off road tire interacting with a deformable terrain, which utilizes soil parameters independent of the size of the contact patch (size-independent). The models involved in the solution presented, can be categorized in rigid and/or pneumatic tires, with or without tread pattern. After a concise literature review of related methods, a detailed presentation of the semi-analytical solution is presented, along with assumptions and limitations. A flowchart is provided, showing the main steps of the numerical implementation, and various test cases have been examined, characterized in terms of vertical load, tire dimensions, soil properties, deformability of the tire, and tread pattern. It has been found that the proposed model can qualitatively capture the response of a rolling wheel on deformable terrain.

One of the concerns for biolubricants is the improvement of their oxidation resistance. In this paper the oxidative behavior of seven different types of biobased lubricants basestocks is examined. The aim was to study their relative oxidation stability and also to investigate their response to various antioxidants. The renewable lubricants were treated with four antioxidant additives at a concentration of 0.5% wt. and a comparative assessments of the latters' effectiveness in suppressing the oxidation rate was carried out. Alterations in the acid value were examined as well as relative changes of the oxidized samples by FTIR spectroscopy. The oxidation stability was assessed by employing a Rapid Small Scale Oxidation Test (RSSOT) apparatus according to the accelerated oxidation stability standard method ASTM D7545/EN16091. RSSOT is a relatively new method and thus the behaviour of biobased lubricants and antioxidant agents in this accelerated method has not been thoroughly examined.

To meet corporate CO2 emission targets polymer composites are being explored for light-weighting vehicle applications. Operational requirements may demand that such materials function above glass transition temperatures or heat deflection points. Intumescent coatings are traditionally used in construction to protect steelwork during fire. This paper presents a novel experimental investigation of two intumescent technologies to thermally protect a reinforced polyamide, for use as a semi-structural vehicle component. Coatings were assessed against the thermal requirement to withstand 500°C for 10 minutes. The differences in performance observed between water and epoxy based coatings as well as when an insulation layer was introduced are reported. Ultimate Tensile Stress (UTS) and modulus values were obtained at −40°C, ambient, and 85°C for uncoated specimens before and after thermal cycling.

The advent of 3D displays offers Human-Machine Interface (HMI) designers and engineers new opportunities to shape the user's experience of information within the vehicle. However, the application of 3D displays to the in-vehicle environment introduces a number of new parameters that must be carefully considered in order to optimise the user experience. In addition, there is potential for 3D displays to increase driver inattention, either through diverting the driver's attention away from the road or by increasing the time taken to assimilate information. Manufacturers must therefore take great care in establishing the ‘do’s and ‘don’t's of 3D interface design for the automotive context, providing a sound basis upon which HMI designers can innovate. This paper describes the approach and findings of a three-part investigation into the use of 3D displays in the instrument cluster of a road car, the overall aim of which was to define the boundaries of the 3D HMI design space.

Mathematical modelling has become an essential tool in the design of modern catalytic systems. Emissions legislation is becoming increasingly stringent, and so mathematical models of aftertreatment systems must become more accurate in order to provide confidence that a catalyst will convert pollutants over the required range of conditions. Automotive catalytic converter models contain several sub-models that represent processes such as mass and heat transfer, and the rates at which the reactions proceed on the surface of the precious metal. Of these sub-models, the prediction of the surface reaction rates is by far the most challenging due to the complexity of the reaction system and the large number of gas species involved.

For many years Rancimat was the only standardized method for measuring the oxidation stability of FAME and FAME/diesel blends. However this method is not applicable to pure conventional petroleum products and so the effect of FAME on diesel fuel stability could not be evaluated directly. Recently a Rapid Small Scale Oxidation Test (RSSOT) that covers the determination of the stability of biofuels and petroleum products was developed and standardized. In this study the oxidation stability of seven different types of FAMEs was assessed, either neat or blended with three types of ULSD fuel, by employing both the Rancimat and the RSSOT accelerated oxidation methods. The determinations from either test were analyzed and a comparative assessment of these two method was carried out.

Light weight alloys are widely used in the automotive industry in order to meet environmental requirements. Cast magnesium alloys are candidate materials due to their high strength to weight ratio, high stiffness and excellent castability. However, some previously reported anomalous cyclic stress-strain behaviours of magnesium alloys have not been fully investigated especially in LCF characterisation. The main objective of this work was to investigate the cyclic loading-unloading behaviour of high pressure die cast (HPDC) AM60B and AE44 magnesium alloys under uniaxial tension or/and compression and its effect on LCF behaviour. It was found that classical linear stress-strain behaviour, for both AM60B and AE44 alloys, applied only to a very small range of stress beyond which significant pseudo-elastic behaviour was discovered. This affected LCF characterisation and subsequent fatigue analysis processes.

Complexity of electronics and embedded software systems in automobiles has been increasing over the years. This necessitates the need for an effective and exhaustive development and validation process in order to deliver fault free vehicles at reduced time to market. Model-based Product Engineering (MBPE) is a new process for development and validation of embedded control software. The process is generic and defines the engineering activities to plan and assess the progress and quality of the software developed for automotive applications. The MBPE process is comprised of six levels (one design level and five verification and validation levels) ranging from the vehicle requirements phase to the start of production. The process describes the work products to be delivered during the course of product development and also aligns the delivery plan to overall vehicle development milestones.

The ability of a catalyst to enhance the performance of synthesized biobased lubricant basestock was investigated in this study. Pomace olive oil, cottonseed oil, used frying oil and methyl oleate were utilized as starting materials for the production of the biobased lubricants and a two stages transesterification methodology was followed. Initially the oils were converted to their corresponding fatty acid methyl esters via methanolysis. The resulting methylesters were subsequently transesterified with TMP producing the desired oleochemical ester. These syntheses were carried out in the presence of either sodium methoxide or Ca/TEA alkoxide as catalysts. Following the purification phase, the synthesized esters were evaluated as potential biolubricants regarding their physicochemical properties such as viscosity index, pour point and acid value.

Water accumulating on a vehicle's wind screen, driven over the A-pillar by a combination of aerodynamic forces and the action of the windscreen wipers, can be a significant impediment to driver vision. Surface water film, or streams, persisting in key vision areas of the side glass can impair the drivers' ability to see clearly through to the door mirror, and laterally onto junctions. Common countermeasures include: water management channels and hydrophobic glass coatings. Water management channels have both design and wind noise implications. Hydrophobic coatings entail significant cost. In order to manage this design optimisation issue a water film and wiper effect model has been developed in collaboration with Jaguar Land Rover, extending the capabilities of the PowerFLOW CFD software. This is complimented by a wind-tunnel based test method for development and validation. The paper presents the progress made to date.

The increased application of lightweight materials, such as aluminium has initiated many investigations into new joining techniques for aluminium alloys. As a result, Self-piercing riveting (SPR) was introduced into the automotive industry as the major production process to join aluminium sheet body structures. Although both hydraulic and servo types of SPR equipment are used by the industry, the servo type is most commonly used in a volume production environment. This type uses stored rotational inertia to set the rivet. The initial rotational velocity of the mass dictates the setting force and hence the tool is described as velocity-controlled. A study was therefore conducted to examine the effect of setting velocity on the process including tooling and joint performance. It was found that the setting velocity would have a significant effect on tooling life. Over 80kN force could be introduced into the tooling depending on selection of the setting velocity.

To reduce the fuel related logistic burden, NATO Armed Forces are advancing the use of a single fuel for both aircraft and ground equipment. To this end, F-34 is replacing distillate diesel fuel in many applications. Yet, unacceptable wear due to poor lubricity was illustrated by tests conducted with kerosene on High Frequency Reciprocating Rig. Therefore, HFRR tests were performed with fatty acid methyl esters of sunflower, palm, cotton-seed, tobacco-seed, olive, rape-seed and used frying oils, at volume concentrations from 0.05% to 0.6%. This study showed that the biodiesels used, produced a significant decrease in the wear scar diameter at concentrations of 0.2% to 0.4 %. Biodiesels derived from non-polyunsaturated oils, such as palm and olive gave better lubrication at certain concentrations.

The introduction to the European market of higher levels of biodiesel blends focuses the research interest on the compatibility problems of the diesel fuel distribution system. The influence of metals in the oxidation stability and lubricity of two different types of commercially available FAMEs (without antioxidant additive) was investigated. Zinc (Zn), Copper (Cu) and Tin (Sn), were added in the form of solid metals (heterogeneous catalysis in liquid phase oxidation) and examined for their impact on the oxidation stability of biodiesel fuel. Oxidation stability was determined by Rancimat accelerated oxidation method, according to European Standard EN14214. Additionally, in order to examine the effect of the above mentioned metals in the presence of antioxidant additive, BHT was added in both biodiesel samples and oxidation stability determinations were carried out, as well.