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The automotive industry uses supercharging in combination with various EGR strategies to meet the increasing demand for Diesel engines with high efficiency and low engine emissions. The charge air is heated by the EGR and the compression in the turbocharger to such an extent that high NOx emissions and a reduction in engine performance occurs. For this reason, the charge air cooler cools down the charge air before it enters the air intake manifold. In case of low pressure EGR, the charge air possesses a high moisture content and under certain operating conditions an accumulation of condensate takes place within the charge air cooler. During demanding engine loads, the condensate is entrained from the charge air cooler into the combustion chamber, resulting in misfiring or severe engine damage.

This paper investigates the pressure drop with and without condensation inside a charge air cooler. The background to this investigation is the fact that the stored condensate in charge air coolers can be torn into the combustion chamber during different driving states. This may result in misfiring or in the worst-case lead to an engine failure. In order to prevent or reduce the accumulated condensate inside charge air coolers, a better understanding of the detailed physics of this process is required. To this end, one single channel of the charge air side is investigated in detail by using an experimental setup that was built to reproduce the operating conditions leading to condensation. First, measurements of the pressure drop without condensation are conducted and a good agreement with experimental data of a comparable heat exchanger reported in Kays and London [1] is shown.

The reliability of electronic components is of increasing importance for further progress towards automated driving. Thermal aging processes such as electromigration is one factor that can negatively affect the reliability of electronics. The resulting failures depend on the thermal load of the components within the vehicle lifetime - called temperature collective - which is described by the temperature frequency distribution of the components. At present, endurance testing data are used to examine the temperature collective for electronic components in the late development stage. The use of numerical simulation tools within Vehicle Thermal Management (VTM) enables lifetime thermal prediction in the early development stage, but also represents challenges for the current VTM processes [1, 2]. Due to the changing focus from the underhood to numerous electronic compartments in vehicles, the number of simulation models has steadily increased.

A powerful and efficient turbocharger turbine benefits the engine in many aspects, such as better transient response, lower NOx emissions and better fuel economy. The turbine performance can be further improved by employing secondary flow injection through an injector over the shroud section. A secondary flow injection system can be integrated with a conventional turbine without affecting its original design parameters, including the rotor, volute, and back disk. In this study, a secondary flow injection system has been developed to fit for an asymmetric twin-scroll turbocharger turbine, which was designed for a 6-cylinder heavy-duty diesel engine, aiming at improving the vehicle’s performance at 1100 rpm under full-loading conditions. The shape of the flow injector is similar to a single-entry volute but can produce the flow angle in both circumferential and meridional directions when the flow leaves the injector and enters the shroud cavity.

Future CO2 emission legislation requires the internal combustion engine to become more efficient than ever. Of great importance is the boosting system enabling down-sizing and down-speeding. However, the thermodynamic coupling of a reciprocating internal combustion engine and a turbocharger poses a great challenge to the turbine as pulsating admission conditions are imposed onto the turbocharger turbine. This paper presents a novel approach to a turbocharger turbine development process and outlines this process using the example of an asymmetric twin scroll turbocharger applied to a heavy duty truck engine application. In a first step, relevant operating points are defined taking into account fuel consumption on reference routes for the target application. These operation points are transferred into transient boundary conditions imposed on the turbine.

The oil transport phenomena in the chamfer beneath the oil control ring of a piston in a motored engine were investigated with a combined experimental-numerical approach. High-speed laser-induced fluorescence was used to visualize the oil distribution crank-angle-resolved on both thrust side and anti-thrust side of an optically accessible single cylinder engine. Corresponding three-dimensional volume-of-fluid CFD simulations were calibrated with the experiment and then utilized to analyze the cross sectional flows in the chamfer. Phenomena triggered by inertial forces and the lateral piston motion, e.g. oil transport from the piston to the liner (bridging) and the formation of a circular flow in the chamfer, are described in detail.

Downsizing and direct injection in modern DISI engines can lead to fuel impinging on the cylinder walls. The interaction of liquid fuel and engine oil due to fuel impinging on the cylinder wall causes problems in both lubrication and combustion. To analyze this issue with temporal and spatial resolution, we developed a laser-induced fluorescence (LIF) system for simultaneous kHz-rate imaging of fuel and oil films on the cylinder wall. Engine oil was doped with traces of the laser dye pyrromethene 567, which fluoresces red after excitation by 532 nm laser radiation. Simultaneously, the liquid fuel was visualized by UV fluorescence of an aromatic “tracer” in a non-fluorescent surrogate fuel excited at 266 nm. Two combinations of fuel and tracer were investigated, iso-octane and toluene as well as a multi-component surrogate and anisole. The fluorescence from oil and fuel was spectrally separated and detected by two cameras.

The use of twin-scroll turbocharger turbines has gained popularity in recent years. The main reason is its capability of isolating and preserving pulsating exhaust flow from engine cylinders of adjacent firing order, hence enabling more efficient pulse turbocharging. Asymmetrical twin-scroll turbines have been used to realize high pressure exhaust gas recirculation (EGR) using only one scroll while designing the other scroll for optimal scavenging. This research is based on a production asymmetrical turbocharger turbine designed for a heavy duty truck engine of Daimler AG. Even though there are number of studies on symmetrical twin entry scroll performance, a comprehensive modeling tool for asymmetrical twin-scroll turbines is yet to be found. This is particularly true for a meanline model, which is often used during the turbine preliminary design stage.

Large-bore natural gas engines may use pre-chamber ignition. Despite extensive research in engine environments, the exact nature of the jet, as it exits the pre-chamber orifice, is not thoroughly understood and this leads to uncertainty in the design of such systems. In this work, a specially-designed rig comprising a quartz pre-chamber fit with an orifice and a turbulent flowing mixture outside the pre-chamber was used to study the pre-chamber flame, the jet, and the subsequent premixed flame initiation mechanism by OH* and CH* chemiluminescence. Ethylene and methane were used. The experimental results are supplemented by LES and 0D modelling, providing insights into the mass flow rate evolution at the orifice and into the nature of the fluid there. Both LES and experiment suggest that for large orifice diameters, the flow that exits the orifice is composed of a column of hot products surrounded by an annulus of unburnt pre-chamber fluid.

The real cycle simulation is an important tool to predict the engine efficiency. To evaluate Extended Expansion SI-engines with a multi-link cranktrain, the challenge is to consider all concept specific effects as best as possible by using appropriate submodels. Due to the multi-link cranktrain, the choice of a suitable heat transfer model is of great importance since the cranktrain kinematics is changed. Therefore, the usage of the mean piston speed to calculate a heat-transfer-related velocity for heat transfer equations is not sufficient. The heat transfer equation according to Bargende combines for its calculation the actual piston speed with a simplified k-ε model. In this paper it is assessed, whether the Bargende model is valid for Extended Expansion engines. Therefore a single-cylinder engine is equipped with fast-response surface-thermocouples in the cylinder head. The surface heat flux is calculated by solving the unsteady heat conduction equation.

Engines with reduced emissions and improved efficiency are of high interest for road transport. However, achieving these two goals is challenging and various concepts such as PFI/DI/HCCI/PCCI are explored by engine manufacturers. The computational fluid dynamics is becoming an integral part of modern engine development programme because this method provides access to in-cylinder flow and thermo-chemical processes to develop a closer understanding to tailor tumble and swirling motions to construct green engines. The combustion modelling, its accuracy and robustness play a vital role in this. Out of many modelling methods proposed in the past flamelet based methods are quite attractive for SI engine application. In this study, FlaRe (Flamelets revised for physical consistencies) approach is used to simulate premixed combustion inside a gasoline PFI single-cylinder, four-stroke SI engine. This approach includes a parameter representing the effects of flame curvature on the burning rate.

A simulation approach to predict the amount of snow which is penetrating into the air filter of the vehicle’s engine is important for the automotive industry. The objective of our work was to predict the snow ingress based on an Eulerian/Lagrangian approach within a commercial CFD-software and to compare the simulation results to measurements in order to confirm our simulation approach. An additional objective was to use the simulation approach to improve the air intake system of an automobile. The measurements were performed on two test sites. On the one hand we made measurements on a natural test area in Sweden to reproduce real driving scenarios and thereby confirm our simulation approach. On the other hand the simulation results of the improved air intake system were compared to measurements, which were carried out in a climatic wind tunnel in Stuttgart.

There is a growing need for life-cycle data – so-called collectives – when developing components like elastomer engine mounts. Current standardized extreme load cases are not sufficient for establishing such collectives. Supplementing the use of endurance testing data, a prediction methodology for component temperature collectives utilizing existing 3D CFD simulation models is presented. The method uses support points to approximate the full collective. Each support point is defined by a component temperature and a position on the time axis of the collective. Since it is the only currently available source for component temperature data, endurance testing data is used to develop the new method. The component temperature range in this data set is divided in temperature bands. Groups of driving states are determined which are each representative of an individual band. Each of the resulting four driving state spaces is condensed into a substitute load case.

Safety-critical embedded software has to satisfy stringent quality requirements. All contemporary safety standards require evidence that no data races and no critical run-time errors occur, such as invalid pointer accesses, buffer overflows, or arithmetic overflows. Such errors can cause software crashes, invalidate separation mechanisms in mixed-criticality software, and are a frequent cause of errors in concurrent and multi-core applications. The static analyzer Astrée has been extended to soundly and automatically analyze concurrent software. This novel extension employs a scalable abstraction which covers all possible thread interleavings, and reports all potential run-time errors, data races, deadlocks, and lock/unlock problems. When the analyzer does not report any alarm, the program is proven free from those classes of errors. Dedicated support for ARINC 653 and OSEK/AUTOSAR enables a fully automatic OS-aware analysis.

In order to offer a wide range of driving experiences to their customers, original equipment manufacturers implement different driving programs. The driver is capable of manually switching between these programs which alter drivability parameters in the engine control unit. As a result, acceleration forces and gradients are modified, changing the perceived driving experience. Nowadays, drivability is calibrated iteratively through road testing. Hence, the resulting set of parameters incorporated within the engine control unit is strongly dependent on the individual sentiments and decisions of the test engineers. It is shown, that implementing a set of objective criteria offers a way to reduce the influences of personal preferences and sentiments in the drivability calibration process. In combination with the expertise of the test engineers, the desired vehicle behavior can be formalized into a transient set point sequence to give final shape to the acceleration behavior.

This paper makes a contribution toward a more efficient chassis durability process for the development of passenger cars, in which the simulation of relevant load data is a time-consuming part. This is especially due to the full vehicle model complexity which is usually determined by the demands of rough road simulations. However, for the load calculation on a racetrack, time saving model approaches that are more simplified might be sufficient. Our investigation comprises two levels of vehicle model complexity: one with all chassis parts modeled in a multibody system environment and one characteristic curve based model in an internal simulation environment. Both approaches consider an original chassis control system as a Software-in-the-Loop model. By the evaluation of real-world experiments the main influence factors in terms of durability are demonstrated. With the help of those highly sensitive durability criteria the measurement and simulation results are then compared.

The underbody of a truck is responsible for an appreciable portion of the vehicle’s aerodynamic drag, and thus its fuel consumption. This paper investigates experimentally the flow around side-skirts, a common underbody aerodynamic device which is known to be effective at reducing vehicle drag. A full, 1/10 scale European truck model is used. The chassis of the model is designed to represent one that would be found on a typical trailer, and is fully reconfigurable. Testing is carried out in a water towing tank, which allows the correct establishment of the ground flow and rotating wheels. Optical access into the underbody is possible through the clear working section of the facility. Stereoscopic and planar Particle Image Velocimetry (PIV) set-ups are used to provide both qualitative images of and quantitative information on the flow field.

The future emission regulation (BS V) in India is expected to create new challenges to meet the particulate matter (PM) limit for diesel cars. The upcoming emission norms will bring down the limit of PM by 80 % when compared to BS IV emission norms. The diesel particulate filter (DPF) is one of the promising technologies to achieve this emission target. The implementation of DPF system into Indian market poses challenges against fuel quality, driving cycles and warranty. Hence, it is necessary to do a detailed on-road evaluation of the DPF system with commercially available fuel under country specific drive cycles. Therefore, we conducted full vehicle durability testing with DPF system which is available in the European market to evaluate its robustness and reliability with BS III fuel (≤350ppm sulfur) & BS IV (≤50ppm sulfur) fuel under real Indian driving conditions.

This work presents turbulent premixed combustion modeling in spark ignition engines using G-equation based turbulent combustion model. In present study, a turbulent flame speed expression proposed and validated in recent years by two co-authors of this paper is applied to the combustion simulation of spark ignition engines. This turbulent flame speed expression has no adjustable parameters and its constants are closely tied to the physics of scalar mixing at small scales. Based on this flame speed expression, a minor modification is introduced in this paper considering the fact that the turbulent flame speed changes to laminar flame speed if there is no turbulence. This modified turbulent flame speed expression is implemented into Ford in-house CFD code MESIM (multi-dimensional engine simulation), and is validated extensively.

Three-dimensional Computational Fluid Dynamics (CFD) has become an integral part in analysing engine in-cylinder processes since it provides detailed information on the flow and combustion, which helps to find design improvements during the development of modern engine concepts. The predictive capability of simulation tools depends largely on the accuracy, fidelity and robustness of the various models used, in particular concerning turbulence and combustion. In this study, a flamelet model with a physics based closure for the progress variable dissipation rate is applied for the first time to a spark ignited IC engine. The predictive capabilities of the proposed approach are studied for one operating condition of a gasoline port fuel injected single-cylinder, four-stroke spark ignited full-metal engine running at 3,500 RPM close to full load (10 bar BMEP) at stoichiometric conditions.