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The purchase of a new automobile is unquestionably a significant investment for most customers, and with this recognition, comes a correspondingly significant expectation for quality and reliability. Amongst automotive systems -when it comes to considerations of reliability - the brakes (perhaps along with the tires) occupy a rarified position of being located in a harsh environment, subjected to continuous wear throughout their use, and are critical to the safe performance of the vehicle. Maintenance of the brake system is therefore a fact of life for most drivers - something that almost everyone must do, yet given the potentially considerable expense, it is something that of great benefit to minimize.

This study emphasizes the fact that there lies value and potential savings in harmonizing some of the inherent differences between the USA, EU, and China regulations with respect to the role of vehicle mass and lightweighting within Fuel Economy (FE) and Green House Gas (GHG) regulations. The definition and intricacies of FE and mass regulations for the three regions (USA, EU, and China) have been discussed and compared. In particular, the nuances of footprint-based, curb-mass-based, and stepped-mass-based regulations that lead to the differences have been discussed. Lightweighting is a customer benefit for fuel consumption, but in this work, we highlight cases where lightweighting, as a CO2 enabler, has incentives that do not align with rational customer values. A typical vehicle’s FE performance sensitivity to a change in mass on the standard regional certification drive cycles is simulated and compared across the three regions.

The market for electric vehicles and hybrid electric vehicles is expected to grow in the coming years, which is increasing interest in design optimization of electric motors for automotive applications. Under demanding duty cycles, the moving part within a motor, the rotor, may experience varying stresses induced by centrifugal force, a necessary condition for fatigue. Rotors contain hundreds of electrical steel laminations produced by stamping, which creates a characteristic edge structure comprising rollover, shear and tear zones, plus a burr. Fatigue properties are commonly reported with specimens having polished edges. Since surface condition is known to affect fatigue strength, an experiment was conducted to evaluate the effect of sample preparation on tensile and fatigue behavior of stamped specimens. Tensile properties were unaffected by polishing. In contrast, polishing was shown to increase fatigue strength by approximately 10-20% in the range of 105-107 cycles to failure.

The diesel particulate filters (DPF) are considered the most robust technologies for particle emission reduction both in terms of mass and number. On the other hand, the increase of the backpressure in the exhaust system due to the accumulation of the particles in the filter walls leads to an increase of the engine fuel consumption and engine power reduction. To limit the filter loading, and the backpressure, a periodical regeneration is needed. Because of the growing interest about particle emission both in terms of mass, number and size, it appears important to monitor the evolution of the particle mass and number concentrations and size distribution during the regeneration of the DPFs. For this matter, in the presented work the regeneration of a catalyzed filter was fully analyzed. Particular attention was dedicated to the dynamic evolution both of the thermodynamic parameters and particle emissions.

As the automotive industry quickly moves towards hybridized and electrified vehicles, the optimal integration of power electronics in these vehicles will have a significant impact not only on the cost, performance, reliability, and durability; but ultimately on customer acceptance and market success of these technologies. If properly executed with the right cost, performance, reliability and durability, then both the industry and the consumer will benefit. It is because of these interdependencies that the pace and scale of success, will hinge on effective collaboration. This collaboration will be built around the convergence of automotive and industrial technology. Where real time embedded controls mixes with high power and voltage levels. The industry has already seen several successful collaborations adapting power electronics to the automotive space in target vehicles.

Variable valve actuation is a focus to improve fuel efficiency for passenger car engines. Various means to implement early and late intake valve closing (E/LIVC) at lower load operating conditions is investigated. The study uses GT Power to simulate on E/LIVC on a 2.5 L gasoline engine, in-line four cylinder, four valve per cylinder engine to evaluate different ways to achieve Atkinson cycle performance. EIVC and LIVC are proven methods to reduce the compression-to-expansion ratio of the engine at part load and medium load operation. Among the LIVC strategies, two non-traditional intake valve lift profiles are investigated to understand their impact on reduction of fuel consumption at low engine loads. Both the non-traditional lift profiles retain the same maximum lift as a normal intake valve profile (Otto-cycle) unlike a traditional LIVC profile (Atkinson cycle) which needs higher maximum lift.

This paper describes the design of a multivariable, constrained Model Predictive Control (MPC) system for torque tracking in turbocharged gasoline engines scheduled for production by General Motors starting in calendar year 2018. The control system has been conceived and co-developed by General Motors and ODYS. The control approach consists of a set of linear MPC controllers scheduled in real time based on engine operating conditions. For each MPC controller, a linear model is obtained by system identification with data collected from engines. The control system coordinates throttle, wastegate, intake and exhaust cams in real time to track a desired engine torque profile, based on measurements and estimates of engine torque and intake manifold pressure.

Gasoline Direct Injection (GDI) has become the preferred technology for spark-ignition engines resulting in greater specific power output and lower fuel consumption, and consequently reduction in CO2 emission. However, GDI engines face a substantial challenge in meeting new and future emission limits, especially the stringent particle number (PN) emissions recently introduced in Europe and China. Studies have shown that the fuel used by a vehicle has a significant impact on engine out emissions. In this study, nine fuels with varying chemical composition and physical properties were tested on a modern turbo-charged side-mounted GDI engine with design changes to reduce particulate emissions. The fuels tested included four fuels meeting US certification requirements; two fuels meeting European certification requirements; and one fuel meeting China 6 certification requirements being proposed at the time of this work.

In an earlier paper, the authors described how Model-Based System Engineering could be utilized to provide a virtual Hardware-in-the-Loop simulation capability, which creates a framework for the development of virtual ECU software by providing a platform upon which embedded control algorithms may be developed, tested, updated, and validated. The development of virtual ECU software is increasingly valuable in automotive control system engineering because vehicle systems are becoming more complex and tightly integrated, which requires that interactions between subsystems be evaluated during the design process. Variational analysis and robustness studies are also important and become more difficult to perform with real hardware as system complexity increases. The methodology described in this paper permits algorithm development to be performed prior to the availability of vehicle and control system hardware by providing what is essentially a virtual integration vehicle.

Hybrid electric vehicles and battery electric vehicles (BEV) use power electronics (PE) devices to convert between high voltage DC power of the battery and other formats of power. These PE components requires operation within certain temperature range, otherwise, overheating causes component as well as vehicle performance degradation. Therefore, a thermal management system is required for PE components. This paper focuses on the design and development of such a PE components thermal control system. The proposed control system is a distributed thermal control system in which all the PE components are placed in series within one cooling loop. The advantage of the proposed control system is its reduced system complexity, energy efficiency and flexibility to add future PE components. In addition, electric control unit (ECU) are utilized so that complex control algorithms can be implemented.

As the automotive industry vies to meet progressively more stringent global CO2 regulations in a cost-effective manner, electrified drive system cost and losses must be reduced. To this end, a parametric Drive Unit (DU) mechanical-loss model was developed to aid in the design and development of electrified propulsion systems, where the total propulsion system cost and DU losses can be directly linked (e.g., Hybrid Electric Vehicle (HEV) motor/inverter/engine content, or Battery Electric Vehicle (BEV) battery size). Many DUs for electrified propulsion systems are relatively “simple” drive systems, consisting of gears, bearings, shafts, lip seals, and an electric motor(s), but without clutches, high-pressure lube systems, or chains/belts as found in conventional automatic transmissions. The DU loss model described in this paper studies these simple DUs, with the mechanical losses dissected into 10 loss components.

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio, and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. A high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the first to two papers describing the development of a combustion system combining lean-stratified combustion with Miller cycle for downsized boosted applications. The work was completed under a multi-year US DOE project. The goal was to define a light-duty engine package capable of achieving a 35% fuel economy improvement at US Tier 3 emission standards over a naturally aspirated stoichiometric baseline vehicle.

Automotive manufacturers relentlessly explore engine technology combinations to achieve reduced fuel consumption under continued regulatory, societal and economic pressures. For example, technologies enabling advanced combustion modes, increased expansion to effective compression ratio and reduced parasitics continue to be developed and integrated within conventional and hybrid propulsion strategies across the industry. A high-efficiency gasoline engine capable for use in conventional or hybrid electric vehicle platforms is highly desirable. This paper is the second of two papers describing the multi-cylinder integration of a technology package combining lean-stratified combustion with Miller cycle for downsized boosted applications. The first paper describes the design, analysis and single-cylinder testing conducted to down-select the combustion system deployed to the multi-cylinder engine.

Methanol is currently being evaluated as a promising alternative fuel for internal combustion engines, due to being attainable by carbon neutral or negative pathways (renewable energy and carbon capture technology). The low ignitability of methanol has made it attractive mostly as a fuel for spark ignition engines, however the low sooting properties of the fuel could potentially reduce the NOx-soot tradeoff present in compression ignition engines. In this work, using a 4-cylinder engine with compression ratio modified from 16:1 to 19:1, methanol combustion is evaluated under five operating conditions in terms of fuel consumption, criteria pollutants, CO2 emissions and engine efficiency in addition to the qualitative assessment of the combustion stability. It was found that combustion is stable at medium to high loads, with medium load NOx emissions levels at least 30% lower than the original diesel engine and comparable emissions at maximum load conditions.

Electric motor whine is one of the main noise sources of hybrid and electric vehicles. This paper describes a comprehensive analytical and experimental investigation of permanent magnetic electric motor NVH designs focusing on the contribution from torque ripple (TR) and radial forces (RF). A design-of-experiment method is adopted to design and build candidate motors with (i) high TR and high RF; (ii) high TR and low RF; (iii) low TR and high RF and (iv) low TR and low RF. Four prototype motors are built and tested on motor fixtures to measure dynamic stator forces in radial, tangential and axial directions, track dominant motor orders, and estimate motor Operational Deflection Shapes (ODS). Finite-element based electromagnetic and NVH analyses are performed and correlated to test data. Both tests and analyses confirm reducing TR and RF improves motor NVH performance at dominant pole pass orders.

Electric motor whine is one of the main noise sources of hybrid and electric vehicles. Motor air gap eccentricity due to propulsion system deflection, part tolerances and manufacturing variation is typically ignored in motor NVH design and analysis. Such eccentricity can be a dominant noise source by amplifying critical motor whine orders up to 10 dB, leading to poor NVH robustness. However, this problem cannot be explained by conventional method based on symmetric 2D approach. New 3D electromagnetic (EM) and NVH analyses are developed and validated to accurately predict air gap induced motor noise to enhance NVH robustness: First, a true 3D full 360-degree electric motor model is developed to model asymmetric air gap distribution along motor stack length. Predicted 3D EM forces are mapped to mechanical finite-element mesh over the cylindrical stator surface.

De-fossilization is an increasingly important trend in the energy sector. In the transport sector the de-fossilization efforts have been centered in promoting the electrification of vehicles, nonetheless other pathways, like the use of carbon neutral or carbon-offsetting fuels under current vehicle fleets, are also worth considering. Low-carbon fuels (LCF) can be synthetized from sources that can take advantage of the carbon already present in the atmosphere (either by technologies like direct carbon capture or biological processes like photosynthesis in biofuels) and use energy from renewable sources for the necessary industrial processes. Although, LCFs can be compared to fossil fuels as energy sources for internal combustion engines, their composition is not the same and their properties can modify the engine combustion and emissions.

Regenerative braking without question greatly impacts brake pad service life in the field, in most cases extending it significantly. Estimating its impact precisely has not been an overriding concern - yet - due in part to the extensive sharing of brake components between regen-intensive battery-electric and hybrid vehicles, and their more friction-brake intensive internal combustion engine powered sibling. However, a multitude of factors are elevating the need for a more accurate estimation, including the emerging of dedicated electric vehicle architectures with opportunities for optimizing the friction brake design, a sharp focus on brake particulate emissions and the role of regenerative braking, a need to make design decisions for features such as corrosion protection for brake pad and pad slide components, and the emergence of driver-facing features such as Brake Pad Life Monitoring.

The paper presents a robust adaptive control technique for precise regulation of a port fuel injection + direct injection (PFI+DI) system, a dual fuel injection configuration adopted in modern gasoline engines to boost performance, fuel efficiency, and emission reduction. Addressing parametric uncertainties on the actuators, inherent in complex fuel injection systems, the proposed approach utilizes an indirect model reference adaptive control scheme. To accommodate the increased control complexity in PFI+DI and the presence of additional uncertainties, a nonlinear plant model is employed, incorporating dynamics of the exhaust burned gas fraction. The primary objective is to optimize engine performance while minimizing fuel consumption and emissions in the presence of uncertainties. Stability and tracking performance of the adaptive controller are evaluated to ensure safe and reliable system operation under various conditions.

A linear parameter-varying model predictive control (LPVMPC) is proposed to enhance the longitudinal vehicle speed control of a gas-engine vehicle, with potential application in autonomous vehicles. To achieve this objective, an advanced vehicle dynamic model and a sophisticated fuel consumption model are derived, forming a control-oriented model for the proposed control system. The vehicle dynamic model accurately captures the motions of the tires and the vehicle body. The fuel consumption model incorporates new powertrain modes such as automatic engine stop/start, active fuel management, and deceleration fuel cut-off, etc. The performance of the proposed LPV-MPC is evaluated by comparing it to a PID controller. Both simulation tests and vehicle-in-the-loop tests demonstrate the superior performance of the proposed controller. The results indicate that the LPV-MPC provides improved longitudinal vehicle speed control and reduced fuel consumption.