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In ever increasing demand to reduce the product cost and to increase the product durability and reliability, the use of simulation tools for identifying the optimum structural load paths for a given component is crucial. Translating these structural load paths into light weight components that are easy to manufacture is also very important. In this paper, the structural optimization methodology in new product development process was discussed. Application of structural optimization methodology and some strategies to reduce overall product cost and weight were also presented with structural optimization analysis case studies.

This paper describes recent progress in our program to develop an emissions technology allowing diesel engines to meet the upcoming 2007/2010 regulations for NOx. At the heart of this technology is the ArvinMeritor Diesel Fuel Reformer that reforms the fuel, on-demand, on-board a vehicle. The fuel reformer uses plasma to partially oxidize a mixture of diesel fuel and air creating a highly reducing mixture of Hydrogen and Carbon monoxide. In a previous publication, we have demonstrated that using a reformate rich in H2 and CO to regenerate a NOx trap is highly advantageous compared to vaporized diesel fuel used conventionally. In this paper we present results and a strategy for performing desulfation of the traps using the fuel reformer. In contrast to vaporized diesel, which requires very high temperatures that fall outside the normal exhaust operating temperatures for diesel engines, desulfation was achieved at temperatures lower by more than 100 °C using the Plasma Fuel Reformer.

This paper describes recent progress in our program to develop an emissions technology allowing diesel engines to meet the upcoming stringent worldwide regulations for NOx. The Plasma Fuel Reformer (PFR) has the ability to rapidly convert diesel fuel (with air), to a hydrogen rich gas on-board a vehicle, which is then utilized to efficiently regenerate a NOx trap. We have made several advances on the PFR as well as on the NOx reducing system. The Plasma Fuel Reformer operating range has been extended by 120% up to 1.5 g/s fuel flow rate while retaining the high hydrogen and low soot characteristics. The plasma power consumption has been further reduced and the high voltage design has been made more robust. The T90 start-up time during regenerations has been reduced to less than 4 seconds. The NOx reducing system utilizes a novel algorithm for NOx trap regeneration that reduces the fuel penalty by 25% while increasing NOx conversion by 10%.

In recent years, several transit agencies have tested buses equipped with hybrid powertrain systems. It has been reported that hybrid powertrains have significant advantages over conventional diesel engine systems, in the area of emissions and fuel economy performance. Presented in this paper are engineering issues and suggestions from an auto component supplier point of view in the design of such a powertrain system. The particular system being considered consists of a downsized diesel engine, a generator, a battery package, two identical AC induction motors, and gearbox systems for the left and right driven wheels. The assembly is supported by an H-shaped suspension sub-structure uniquely designed to achieve the “ultra-low floor” configuration. Our discussion covers the system performance, as well as the durability issues. In particular, the presentation focuses on the durability and the design layout of the gearbox and suspension substructure.