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Conventional silencers have extensively been used to attenuate airborne pressure pulsations in the breathing system of internal combustion engines, typically at low frequencies as dictated by the crankshaft speed. With the introduction of turbocharger compressors, however, particularly those with the ported shroud recirculating casing treatment, high-frequency tones on the order of 10 kHz have become a significant contributor to noise in the induction system. The elevated frequencies promote multi-dimensional wave propagation, rendering traditional silencing design methods invalid, as well as the standard techniques to assess silencer performance. The present study features a novel high-frequency silencer designed to target blade-pass frequency (BPF) noise at the inlet of turbocharger compressors. The concept uses an acoustic straightener to promote planar wave propagation across arrays of quarter-wave resonators, achieving a broadband attenuation.

The power loss of bearings is a significant factor in the overall efficiency in a drive unit system. Such bearings are subject to combined radial and axial loading needed to support the gear mesh forces. An experimental methodology has been developed to perform sets of power loss measurements on TRB, 4PCBB and DGBB. These measurements were performed under a variety of speed, load, temperature, and lubrication conditions. The loss behaviors of these types of the bearings are discussed, along with the tradeoff of different bearing arrangements for the fuel economy cycles. Several power loss models are employed to assess the accuracy of the estimations as compared to the experimental measurements. At low speed some models showed good correlations for TRB and DGBB, while at higher speed, they start deviating from the testing results. A higher fidelity model for estimating the losses at high speed, especially speed around 20krpm and beyond, needs to be developed.

Dynamic programming (DP) has been used for optimal control of hybrid powertrain and vehicle speed optimization particularly in design phase for over a couple of decades. With the advent of autonomous and connected vehicle technologies, automotive industry is getting closer to implementing predictive optimal control strategies in real time applications. The biggest challenge in implementation of optimal controls is the limitation on hardware which includes processor speed, IO speed, and random access memory. Due to the use of autonomous features, modern vehicles are equipped with better onboard computational resources. In this paper we present a comparison between multiple hardware options for dynamic programming. The optimal control problem considered, is the optimization of travel time and fuel economy by tuning the torque split ratio and vehicle speed while maintaining charge sustaining operation.

Centrifugal compressors for automotive turbochargers must operate over wide speed and flow ranges to provide the required air pressure and mass flow rate to the intake manifold of the internal combustion engines. At a fixed rotational speed, the flow field near the inducer of the impeller becomes increasingly unstable with decreasing flow rate, as the incidence angle grows between the air flow approaching the impeller, relative to the tangent of the main impeller blades at the leading edge. Flow field measurements conducted earlier have revealed that once the incidence angle exceeds a critical value (nearly independent of rotational speed) of approximately 15°, reversed flow near the periphery (blade tips) starts penetrating upstream of the impeller, with a high tangential velocity in the direction of impeller rotation.

Downsizing and boosting is currently the principal solution to reduce fuel consumption in automotive engines without penalizing the power output. A key challenge for controlling the boost pressure during highly transient operations lies in avoiding to operate the turbocharger compressor in its instability region, also known as surge. While this phenomenon is well known by control engineers, it is still difficult to accurately predict during transient operations. For this reason, the scientific community has directed considerable efforts to understand the phenomena leading to the onset of unstable behavior, principally through experimental investigations or high-fidelity CFD simulations. On the other hand, less emphasis has been placed on creating control-oriented models that adopt a physics-based (rather than data-driven) approach to predict the onset of instability phenomena.

Automobile manufacturers are reducing the weight of their vehicles in order to meet strict fuel economy legislation. To achieve this goal, a combination of different materials such as steel, aluminum and carbon fiber composites are being considered for use in vehicle bodies. The ability to join these different materials is an ongoing challenge and an area of research for automobile manufacturers. Multiridged fasteners are a viable option for this type of multi-material joining. Commercial systems exist and are being used in the industry, however, new ridged nail designs offer the potential for improvement in several areas. The goal of this paper is to prototype and test a safer flat-end fastener whilst not compromising on strength characteristics, to prevent injury to factory workers. The nails were prototyped using existing RIVTAC® nails.

The current work demonstrates effective suppression of compression system surge instabilities by installing a variable cross-sectional flow area restriction within the inlet duct of a turbocharger centrifugal compressor operating on a bench-top facility. This restriction couples with the compressor, similar to stages in a multi-stage turbomachine, where the effective pressure ratio is the product of those for the restriction and compressor. During experiments at constant compressor rotational speed, the compressor is stable over the negatively sloped portion of the pressure ratio vs. flow rate characteristics, so the restriction is eliminated within this operating region to preserve compressor performance. At low flow rates, the slope of the compressor alone characteristics reaches a positive value, and the unrestricted compression system enters mild surge. Further reduction of flow rate with the unrestricted compressor inlet results in a sudden transition to deep surge instabilities.

Downsizing and turbocharging are today considered an effective way to reduce CO2 emissions in automotive gasoline engines, especially for the European and US markets. In the broad field of research and development for engine boosting systems, the instability phenomenon of surge has gathered considerable interest in recent years, as the main limiting factor to high performance boosting and boost pressure control. To this extent, developing an in-depth knowledge of the surge dynamics and on the phenomena governing the transition from stable to unstable operation can provide very valuable information for the design of the intake system and boost pressure control algorithms, allowing optimal boost pressure without compromising the transient response.

Ported shroud compressor covers recirculate low momentum air near the inducer blade tips, and the use of these devices has traditionally been confined to extending the low-flow operating region at elevated rotational speeds for compressors on compression-ignition (CI) engines. Implementation of ported shrouds on compressors for spark-ignition (SI) engines has been generally avoided due to operation at pressure ratios below the region where ported shrouds improve low-flow range, the slight efficiency penalty, and the perception of increased noise. The present study provides an experimental investigation of performance and acoustics for a SI engine turbocharger compressor both with a ported shroud and without (baseline). The objective of implementing the ported shroud was to reduce mid-flow range broadband whoosh noise of the baseline compressor over 4-12 kHz.

The die wear up to 80,800 hits on a prog-die setup for bare DP1180 steel was investigated in real production condition. In total, 31 die inserts with the combination of 11 die materials and 9 coatings were evaluated. The analytical results of die service life for each insert were provided by examining the evolution of surface wear on inserts and formed parts. The moments of appearance of die defects, propagation of die defects, and catastrophic failure were determined. Moreover, the surface roughness of the formed parts for each die insert was characterized using Wyko NT110 machine. The objectives of the current study are to evaluate the die durability of various tooling materials and coatings for flange operations on bare DP 1180 steel and update OEM tooling standards based on the experimental results. The current study provides the guidance for the die material and coating selections in large volume production for next generation AHSSs.

To improve torque management algorithms for drivability, the powertrain controller must be able to compensate for the nonlinear dynamics of the driveline. In particular, the presence of backlash in the transmission and drive shafts excites sharp torque fluctuations during tip-in or tip-out transients, leading to a deterioration of the vehicle drivability and NVH. This paper proposes a model-based estimator that predicts the wheel torque in an automotive drivetrain, accounting for the effects of backlash and drive shaft flexibility. The starting point of this work is a control-oriented model of the transmission and vehicle drivetrain dynamics that predicts the wheel torque during tip-in and tip-out transients at fixed gear. The estimator is based upon a switching structure that combines a Kalman Filter and an open-loop prediction based on the developed model.

This study examines clutch-damper subsystem dynamics under transient excitation and validates predictions using a new laboratory experiment (which is the subject of a companion paper). The proposed models include multi-staged stiffness and hysteresis elements as well as spline nonlinearities. Several example cases such as two high (or low) hysteresis clutches in series with a pre-damper are considered. First, detailed multi-degree of freedom nonlinear models are constructed, and their time domain predictions are validated by analogous measurements. Second, key damping sources that affect transient events are identified and appropriate models or parameters are selected or justified. Finally, torque impulses are evaluated using metrics, and their effects on driveline dynamics are quantified. Dynamic interactions between clutch-damper and spline backlash nonlinearities are briefly discussed.

The effect of aerodynamically induced pre-swirl on the acoustic and performance characteristics of an automotive centrifugal compressor is studied experimentally on a steady-flow turbocharger facility. Accompanying flow separation, broadband noise is generated as the flow rate of the compressor is reduced and the incidence angle of the flow relative to the leading edge of the inducer blades increases. By incorporating an air jet upstream of the inducer, a tangential (swirl) component of velocity is added to the incoming flow, which improves the incidence angle particularly at low to mid-flow rates. Experimental data for a configuration with a swirl jet is then compared to a baseline with no swirl. The induced jet is shown to improve the surge line over the baseline configuration at all rotational speeds examined, while restricting the maximum flow rate. At high flow rates, the swirl jet increases the compressor inlet noise levels over a wide frequency range.

Improvements in highway fuel economy require clever design and novel methods to reduce the drag coefficient. The integration of active flow control devices into vehicle design shows promise for greater reductions in drag coefficient. This paper examines the use of fluidic oscillators for separation control at the rear of an Ahmed vehicle model. A fluidic oscillator is a simple device that generates a sweeping jet output, similar to some windshield wiper spray nozzles, and is increasingly recognized as an efficient means to control separation. In this study, fluidic oscillators were used to blow unsteady air jets and control flow separation on rear boat-tail flaps, achieving drag reductions greater than 70 counts. The method appears to scale favorably to a larger model, and realistic effects such as a rolling road appear to have a small impact on the oscillator's control authority.

In a conventional passenger vehicle, the AC system is the largest ancillary load. This paper proposes a novel control strategy to reduce the energy consumption of the air conditioning system of a conventional passenger car. The problem of reducing the parasitic load of the AC system is first approached as a multi-objective optimization problem. Starting from a validated control-oriented model of an automotive AC system, an optimization problem is formalized to achieve the best possible fuel economy over a regulatory driving cycle, while guaranteeing the passenger comfort in terms of cabin temperature and reduce the wear of the components. To complete the formulation of the problem, a set of constraints on the pressure in the heat exchanger are defined to guarantee the safe operation of the system. The Dynamic Programming (DP), a numerical optimization technique, is then used to obtain the optimal solution in form of a control sequence over a prescribed driving cycle.

This paper presents the implementation of an off-line optimized torque vectoring controller on an electric-drive vehicle with four in-wheel motors for driver assistance and handling performance enhancement. The controller takes vehicle longitudinal, lateral, and yaw acceleration signals as feedback using the concept of state-derivative feedback control. The objective of the controller is to optimally control the vehicle motion according to the driver commands. Reference signals are first calculated using a driver command interpreter to accurately interpret what the driver intends for the vehicle motion. The controller then adjusts the braking/throttle outputs based on discrepancy between the vehicle response and the interpreter command.

To investigate the effect of aeration on fluid-elastomer compatibility, 4 types of elastomers were aged in three gear lubes. The four types of elastomers include a production fluorinated rubber (FKM) and production hydrogenated nitrile rubber (HNBR) mixed by the part fabricator, a standard low temperature flexible fluorinated rubber (FKM, ES-4) and a standard ethylene-acrylic copolymer (AEM, ES-7) mixed by SAE J2643 approved rubber mixer. The three gear lubes are Fluid a, Fluid b and Fluid c, where Fluid b is a modified Fluid with additional friction modifier, and Fluid c is friction modified chemistry from a different additive supplier. The aeration effect tests were performed at 125°C for 504 hours. The aerated fluid aging test was performed by introducing air into fluid aging tubes as described in General Motors Company Materials Specification GMW16445, Appendix B, side-by-side with a standard ASTM D471 test.

Corrosion inhibitors (CIs) have been used for years to protect the supply and distribution hardware used for transportation of fuel from refineries and to buffer the potential organic acids present in an ethanol blended fuel to enhance storage stability. The impact of these inhibitors on spark-ignition engine fuel systems, specifically intake valve deposits, is known and presented in open literature. However, the relationship of the corrosion inhibitors to the powertrain intake valve deposit performance is not understood. This paper has two purposes: to present and discuss a second market place survey of corrosion inhibitors and how they vary in concentration in the final blended fuel, specifically E85 (Ethanol Fuel Blends); and, to show how the variation in the concentrations of the components of the CIs impacts the operation and performance of vehicles, specifically, the effects on intake valve deposit formation.

ASIL decomposition is a method described in the ISO 26262 standard for the assignment of ASILs to redundant requirements. Although ASIL decomposition appears to have similar intent to the hardware fault tolerance concept of IEC 61508-2, ASIL decomposition is not intended to reduce ASIL assignments to hardware elements for random hardware failures, but instead focuses on functions and requirements in the context of systematic failures. Based on our participation in the development of the standard, the method has been applied in different ways in practice, not all of which are fully consistent with the intent of the standard. Two potential reasons that may result in the use of “modified” ASIL algebra include the need of OEMs to partition a system and specify subsystem requirements to suppliers and the need for designers to construct systems bottom up.

An iterative learning control (ILC) algorithm has been developed for a test cell electro-hydraulic, fully flexible valve actuation system to track valve lift profile under steady-state and transient operation. A dynamic model of the plant was obtained from experimental data to design and verify the ILC algorithm. The ILC is implemented in a prototype controller. The learned control input for two different lift profiles can be used for engine transient tests. Simulation and bench test are conducted to verify the effectiveness and robustness of this approach. The simple structure of the ILC in implementation and low cost in computation are other crucial factors to recommend the ILC. It does not totally depend on the system model during the design procedure. Therefore, it has relatively higher robustness to perturbation and modeling errors than other control methods for repetitive tasks.