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Ducted Fuel Injection (DFI) engines have emerged as a promising technology in the pursuit of a clean and efficient combustion process. This article aims at elucidating the effect of piston geometry on the engine performance and emissions of a metal DFI engine. Three different types of pistons were investigated and the main piston design features including the piston bowl diameter, piston bowl slope angle, duct angle and the injection nozzle position were examined. To achieve the target, computational fluid dynamics (CFD) simulations were conducted coupled to a reduced chemical kinetics mechanism. Extensive validations were performed against the measured data from a conventional diesel engine. To calibrate the soot model, genetic algorithm and machine learning methods were utilized. The simulation results highlight the pivotal role played by piston bowl diameter and fuel injection angle in controlling soot emissions of a DFI engine.

A special spot weld element (SWE) is presented for simplified representation of spot joints in complex structures for structural durability evaluation using the mesh-insensitive structural stress method. The SWE is formulated using rigorous linear four-node Mindlin shell elements with consideration of weld region kinematic constraints and force/moments equilibrium conditions. The SWEs are capable of capturing all major deformation modes around weld region such that rather coarse finite element mesh can be used in durability modeling of complex vehicle structures without losing any accuracy. With the SWEs, all relevant traction structural stress components around a spot weld nugget can be fully captured in a mesh-insensitive manner for evaluation of multiaxial fatigue failure.

Level 2 (L2) partial driving automation systems are rapidly emerging in the marketplace. L2 systems provide sustained automatic longitudinal and lateral vehicle motion control, reducing the need for drivers to continuously brake, accelerate and steer. Drivers, however, remain critically responsible for safely detecting and responding to objects and events. This paper summarizes variations of L2 systems (hands-on and/or hands-free) and considers human drivers’ roles when using L2 systems and for designing Human-Machine Interfaces (HMIs), including Driver Monitoring Systems (DMSs). In addition, approaches for examining potential unintended consequences of L2 usage and evaluating L2 HMIs, including field safety effect examination, are reviewed. The aim of this paper is to guide L2 system HMI development and L2 system evaluations, especially in the field, to support safe L2 deployment, promote L2 system improvements, and ensure well-informed L2 policy decision-making.

The transition from combustion engines to electric propulsion is accelerating in every coordinate of the globe. The engineers had strived hard to augment the engine performance for more than eight decades, and a similar challenge had emerged again for electric vehicles. To analyze the performance of the engine, the vector engine operating point (EOP) is defined, which is common industry practice, and the performance vector electric vehicle motor operating point (EVMOP) is not explored in the existing literature. In an analogous sense, electric vehicles are embedded with three primary components, e.g., Battery, Inverter, Motor, and in this article, the EVMOP is defined using the parameters [motor torque, motor speed, motor current]. As a second aspect of this research, deep learning models are developed to predict the EVMOP by mapping the parameters representing the dynamic state of the system in real-time.

Often, when assessing the distraction or ease of use of an in-vehicle task (such as entering a destination using the street address method), the first question is “How long does the task take on average?” Engineers routinely resolve this question using computational models. For in-vehicle tasks, “how long” is estimated by summing times for the included task elements (e.g., decide what to do, press a button) from SAE Recommended Practice J2365 or now using new static (while parked) data presented here. Times for the occlusion conditions in J2365 and the NHTSA Distraction Guidelines can be determined using static data and Pettitt’s Method or Purucker’s Method. These first approximations are reasonable and can be determined quickly. The next question usually is “How likely is it that the task will exceed some limit?”

Methanol emerges as a compelling renewable fuel for decarbonizing engine applications due to a mature industry with high production capacity, existing distribution infrastructure, low carbon intensity and favorable cost. Methanol’s high flame speed and high autoignition resistance render it particularly well-suited for spark-ignition (SI) engines. Previous research showed a distinct phenomenon, known deflagration-based knock in methanol combustion, whereby knocking combustion was observed albeit without end-gas autoignition. This work studies the implications of deflagration-based knock on noise emissions by investigating the knock intensity and combustion noise at knock-limited operation of methanol in a single-cylinder direct-injection SI engine operated at both stoichiometric and lean (λ = 2.0) conditions. Results are compared against observations from a premium-grade gasoline.

Optimizing fuel injection spray is essential to comply with stringent future emission regulations for hybrid vehicles and internal combustion engine vehicles, and the spray characteristics and geometry must be robust for various engine operating conditions. This study presents experimental and numerical assessments of spray for lateral-mounted gasoline direct injection (GDI) sprays with different plume arrangements to analyze collapse characteristics, which can significantly deteriorate the geometry and characteristics of fuel sprays. Novel spray characterization methods are applied to analyze complex spray collapse behaviors using LED-based diffusive back-illuminated extinction imaging (DBIEI) and 3D computed tomographic (CT) image reconstruction. High-fidelity computational fluid dynamics (CFD) simulations are performed to analyze the detailed spray characteristics besides experimental characterization.

Surrogate fuels that reproduce the characteristics of full-boiling range fuels are key tools to enable numerical simulations of fuel-related processes and ensure reproducibility of experiments by eliminating batch-to-batch variability. Within the PACE initiative, a surrogate fuel for regular-grade E10 (10%vol ethanol) gasoline representative of a U.S. market gasoline, termed PACE-20, was developed and adopted as baseline fuel for the consortium. Although extensive testing demonstrated that PACE-20 replicates the properties and combustion behavior of the full-boiling range gasoline, several concerns arose regarding the purity level required for the species that compose PACE-20. This is particularly important for cyclo-pentane, since commercial-grade cyclo-pentane typically shows 60%–85% purity. In the present work, the effects of the purity level of cyclo-pentane on the properties and combustion characteristics of PACE-20 were studied.

For 2D surface temperature monitoring applications, a variant of Electrical Impedance Tomography (EIT) was evaluated computationally in this study. Literature examples of poor sensor performance in the center of the 2D domains away from the side electrodes motivated these efforts which seek to overcome some of the previously noted shortcomings. In particular, the use of ‘sensing skins’ with novel tailored baseline conductivities was examined using the EIDORS package for EIT. It was found that the best approach for detecting a temperature hot spot depends on several factors such as the current injection (stimulation) patterns, the measurement patterns, and the reconstruction algorithms. For well-performing combinations of these factors, customized baseline conductivities were assessed and compared to the baseline uniform conductivity.

Knock in spark-ignition (SI) engines has been a subject of many research efforts and its relationship with high efficiency operating conditions keeps it a contemporary issue as engine technologies push classical limits. Despite this long history of research, literature is lacking coherent and generalized descriptions of how knock is affected by changes in the full cylinder temperature field, residence time (engine speed), and air/fuel ratio. In this work, two dimensionless numbers are applied to fully 3D SI conditions. First, the characteristic time of autoignition (ignition delay) is compared against the characteristic time of end-gas deflagration, which was used to predict knocking propensity. Second, the temperature gradient of the end-gas is compared against a critical detonation-based temperature gradient, which predicts the knock intensity.

A novel advanced combustion strategy that employs the kinetically controlled compression ignition of gasoline whose autoignition is sensitive to fuel concentration is termed Low Temperature Gasoline Combustion. The LTGC method can achieve high thermal efficiency with a commercially available fuel while generating ultra-low soot and NOx emissions relative to the conventional combustion modes. At high loads, a double direct injection (D-DI) strategy is used where the first injection generates a background premixed charge while a second compression stroke injection controls the level of fuel stratification on a cycle-to-cycle basis to manage the heat release rates. With lower loads, this combustion performance of this D-DI strategy decreases as the background charge becomes increasingly lean. Instead, a single direct injection (S-DI) is used at lower loads to maintain an adequate combustion efficiency.

Finite element (FE) analyses of macroscopic stress-strain relations and failure modes for tensile tests of additively manufactured (AM) AlSi10Mg in different loading directions with respect to the building direction are conducted with consideration of melt pool (MP) microstructures and pores. The material constitutive relations in different orientations of AM AlSi10Mg are first obtained from fitting the experimental tensile engineering stress-strain curves by conducting axisymmetric FE analyses of round bar tensile specimens. Four representative volume elements (RVEs) with MP microstructures with and without pores are identified and selected based on the micrographs of the longitudinal cross-sections of the vertical and horizontal tensile specimens. Two-dimensional plane stress elastic-plastic FE analyses of the RVEs subjected to uniaxial tension are then conducted.

Connected autonomy brings with it the means of significantly increasing vehicle Energy Economy (EE) through optimal Eco-Driving control. Much research has been conducted in the area of autonomous Eco-Driving control via various methods. Generally, proposed algorithms fall into the broad categories of rules-based controls, optimal controls, and meta-heuristics. Proposed algorithms also vary in cost function type with the 2-norm of acceleration being common. In a previous study the authors classified and implemented commonly represented methods from the literature using real-world data. Results from the study showed a tradeoff between EE improvement and run-time and that the best overall performers were meta-heuristics. Results also showed that cost functions sensitive to the 1-norm of acceleration led to better performance than those which directly minimize the 2-norm.

The automotive industry widely accepted the launch of electric vehicles in the global market, resulting in the emergence of many new areas, including battery health, inverter design, and motor dynamics. Maintaining the desired thermal stress is required to achieve augmented performance along with the optimal design of these components. The HVAC system controls the coolant and refrigerant fluid pressures to maintain the temperatures of [Battery, Inverter, Motor] in a definite range. However, identifying the prominent factors affecting the thermal stress of electric vehicle components and their effect on temperature variation was not investigated in real-time. Therefore, this article defines the vector electric vehicle thermal operating point (EVTHOP) as the first step with three elements [instantaneous battery temperature, instantaneous inverter temperature, instantaneous stator temperature].

Engaging in visual-manual tasks such as selecting a radio station, adjusting the interior temperature, or setting an automation function can be distracting to drivers. Additionally, if setting the automation fails, driver takeover can be delayed. Traditionally, assessing the usability of driver interfaces and determining if they are unacceptably distracting (per the NHTSA driver distraction guidelines and SAE J2364) involves human subject testing, which is expensive and time-consuming. However, most vehicle engineering decisions are based on computational analyses, such as the task time predictions in SAE J2365. Unfortunately, J2365 was developed before touch screens were common in motor vehicles.

End-gas temperature stratification has long been studied with respect to its effect on stoichiometric spark-ignition (SI) engine knock. The role of temperature stratification for homogeneous-charge compression ignition (HCCI) engine operation is also reasonably well understood. However, the role of temperature stratification in ultra-lean SI engines has had less coverage. Literature is lacking well-controlled studies of how knock is affected by changes in the full cylinder temperature fields, especially since cycle-to-cycle variability can impede a determination of cause and effect. In this work, the knocking propensity of specific cylinder conditions is investigated via 3D computational fluid dynamics (CFD) simulations utilizing a large eddy simulation (LES) framework.

Nitric Oxide (NO) can significantly influence the autoignition reactivity and this can affect knock limits in conventional stoichiometric SI engines. Previous studies also revealed that the role of NO changes with fuel type. Fuels with high RON (Research Octane Number) and high Octane Sensitivity (S = RON - MON (Motor Octane Number)) exhibited monotonically retarding knock-limited combustion phasing (KL-CA50) with increasing NO. In contrast, for a high-RON, low-S fuel, the addition of NO initially resulted in a strongly retarded KL-CA50 but beyond the certain amount of NO, KL-CA50 advanced again. The current study focuses on same high-RON, low-S Alkylate fuel to better understand the mechanisms responsible for the reversal in the effect of NO on KL-CA50 beyond a certain amount of NO.

With the evolution of telemetry technology in vehicles, Advanced Automatic Collision Notification (AACN), which detects occupants at risk of serious injury in the event of a crash and triages them to the trauma center quickly, may greatly improve their treatment. An Injury Severity Prediction (ISP) algorithm for AACN was developed using a logistic regression model to predict the probability of sustaining an Injury Severity Score (ISS) 15+ injury. National Automotive Sampling System Crashworthiness Data System (NASS-CDS: 1999-2015) and model year 2000 or later were filtered for new case selection criteria, based on vehicle body type, to match Subaru vehicle category. This new proposed algorithm uses crash direction, change in velocity, multiple impacts, seat belt use, vehicle type, presence of any older occupant, and presence of any female occupant.

Spray-wall interactions in diesel engines have a strong influence on turbulent flow evolution and mixing, which influences the engine’s thermal efficiency and pollutant-emissions behavior. Previous optical experiments and numerical investigations of a stepped-lip diesel piston bowl focused on how spray-wall interactions influence the formation of squish-region vortices and their sensitivity to injection timing. Such vortices are stronger and longer-lived at retarded injection timings and are correlated with faster late-cycle heat release and soot reductions, but are weaker and shorter-lived as injection timing is advanced. Computational fluid dynamics (CFD) simulations predict that piston bowls with more space in the squish region can enhance the strength of these vortices at near-TDC injection timings, which is hypothesized to further improve peak thermal efficiency and reduce emissions. The dimpled stepped-lip (DSL) piston is such a design.

Pre-chamber ignition has demonstrated capability to increase internal combustion engine in-cylinder burn rates and enable the use of low engine-out pollutant emission combustion strategies. In the present study, newly designed passive pre-chambers with different nozzle-hole patterns - that featured combinations of radial and axial nozzles - were experimentally investigated in an optically accessible, single-cylinder research engine. The pre-chambers analyzed had a narrow throat geometry to increase the velocity of the ejected jets. In addition to a conventional inductive spark igniter, a nanosecond spark ignition system that promotes faster early burn rates was also investigated. Time-resolved visualization of ignition and combustion processes was accomplished through high-speed hydroxyl radical (OH*) chemiluminescence imaging. Pressure was measured during the engine cycle in both the main chamber and pre-chamber to monitor respective combustion progress.