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SAE 2011 High Efficiency IC Engines Symposium - Opening Session Presenter John Gary Smyth, General Motors Company

Leading during normal times is plenty challenging. Leading in crazy times requires extra understanding and skill. This presentation explores how you and your team can be your best, regardless of what craziness may be going on around your organization, your team members, and you. Presenter Theresa Rich, General Motors Company

OBD system requirements were first developed by the California Air Resources Board, the U.S. Environmental Protection Agency, and the European Commission. New OBD requirements should be as consistent as possible with existing requirements to maximize reliability and to minimize system complexity, proliferation of configurations, and consumer cost. New OBD requirements from around the world are briefly reviewed and most are consistent with the original U.S. and European requirements. Worldwide OBD requirements are being further harmonized under the United Nations, Economic Commission for Europe, World Forum for Harmonization of Vehicle Regulations (WP29). Presenter David H. Ferris, General Motors Company

Plug-In Hybrid and Extended Range Electric Vehicle's have quickly become the focus of many OEM's and suppliers. Existing regulations and test procedures did not anticipate this rapid adoption of this new technology, resulting in many product development challenges. The lack of clear requirements is further complicated by CARBs consideration of CO2 inclusion in their next light duty OBD regulation. This presentation provides an overview of the regulatory requirements for OBD systems on hybrid vehicles that intend to certify in California. Near term challenges for EREV?s and PHEV?s are discussed, including concerns with the existing denominator and warm-up cycle calculations. Some proposals are made to address these concerns. Presenter Andrew Zettel, General Motors Company

A combination of laboratory reactor measurements and vehicle FTP testing has been combined to demonstrate a method for diagnosing the formation of NO2 from a diesel oxidation catalyst (DOC). Using small cores from a production DOC and simulated diesel exhaust, the laboratory reactor experiments are used to support a model for DOC chemical reaction kinetics. The model we propose shows that the ability to produce NO2 is chemically linked to the ability of the catalyst to oxidize hydrocarbon (HC). For thermally damaged DOCs, loss of the HC oxidation function is simultaneous with loss of the NO2 production function. Since HC oxidation is the source of heat generated in the DOC under regeneration conditions, we conclude that a diagnostic of the DOC exotherm is able to detect the failure of the DOC to produce NO2. Vehicle emissions data from a 6.6 L Duramax HD pick-up with DOC of various levels of thermal degradation is provided to support the diagnostic concept.

Exhaust Emission Control: DPF Systems. Presenter Shingo Iwasaki, NGK Insulators, Ltd.

Turbulent Jet Ignition is an advanced spark initiated pre-chamber combustion system for otherwise standard spark ignition engines. Combustion in the main chamber is initiated by jets of partially combusted (reacting) pre-chamber products which provide a high energy ignition source. The resultant widely distributed ignition sites allow relatively small flame travel distances enabling short combustion durations and high burn rates. This presentation outlines development of this combustion concept in a modern normally aspirated PFI production engine. Experimental results have highlighted high thermal efficiency (42.8%), significant fuel economy improvement (>20%), low engine out NOx (<10 ppm), knock limit extension, high load capability (>13 bar IMEPn) and high speed operation (5500 rev/min). Presenter William P Attard, MAHLE Powertrain LLC

The future deployment of safety-oriented Dedicated Short Range Communications (DSRC) technology may be hindered due to the so-called “Market Penetration” problem: as a wireless network built from scratch, there is lack of value to consumers who are early adopters. In this paper, we explore potential applications that can be supported during the initial phase of vehicular ad-hoc network (VANET) deployment, i.e., sparsely populated VANETs. We show that delay-insensitive information sharing applications are promising since they only require opportunistic network connections (in contrast to safety applications that require “always on” connectivity). This is done via “gossip spread” information distribution protocols by which DSRC vehicles cache and then exchange the information while in range of other DSRC vehicles or road side units. This approach is especially attractive since the number of communicating vehicles will be very small during early deployment years.

Magnesium and aluminum alloys offer lightweighting opportunities in automotive applications. Joining of dissimilar materials, however, generally requires methods that do not involve fusion. This paper explores the use of self-pierce riveting (SPR) to join magnesium to aluminum alloys for structural and closure applications. The preliminary results indicate that SPR is a viable option for joining aluminum extrusions to magnesium die castings, as well as stamped sheet aluminum to quick-plastic-formed (QPF) sheet magnesium.

With the introduction of plug-in electric vehicles (PEVs), the conventional mindset of “fill-up time” will be challenged as customers top off their battery packs. For example, using a standard 120VAC outlet, it may take over 10hrs to achieve 40-50 miles of EV range-making range anxiety a daunting reality for EV owners. As customers adapt to this new mindset of charge time, it is critical that automotive OEMs supply the consumer with accurate charge time estimates. Charge time accuracy relies on a variety of parameters: battery pack size, power source, electric vehicle supply equipment (EVSE), on-board charging equipment, ancillary controller loads, battery temperature, and ambient temperature. Furthermore, as the charging events may take hours, the initial conditions may vary throughout a plug-in charge (PIC). The goal of this paper is to characterize charging system sensitivities and promote best practices for charge time estimations.

As mass reduction becomes an increasingly important enabler for fuel economy improvement, having a robust structural development process that can comprehend Vehicle Dynamics-specific requirements is correspondingly important. There is a correlation between the stiffness of the body structure and the performance of the vehicle when evaluated for ride and handling. However, an unconstrained approach to body stiffening will result in an overly-massive body structure. In this paper, the authors employ loads generated from simulation of quasi-static and dynamic vehicle events in ADAMS, and exercise structural finite element models to recover displacements and deflected shapes. In doing so, a quantitative basis for considering structural vehicle dynamics requirements can be established early in the design/development process.

Experimental decklids for the Cadillac STS sedan were made with Al AA5083 sheet outer panels and Mg AZ31B sheet inner panels using regular-production forming processes and hardware. Joining and coating processes were developed to accommodate the unique properties of Mg. Assembled decklids were evaluated for dimensional accuracy, slam durability, and impact response. The assemblies performed very well in these tests. Explicit and implicit finite element simulations of decklids were conducted, and showed that the Al/Mg decklids have good stiffness and strength characteristics. These results suggest the feasibility of using Mg sheet closure panels from a structural perspective.

Organic acid degradation products and other anions in engine oil were speciated by capillary electrophoresis (CE) and liquid chromatography-mass spectrometry (LCMS) with electrospray ionization. The sample preparation procedure involved selectively extracting the acids and other water soluble salts into 0.05M aqueous potassium hydroxide. Samples of engine-aged mineral oil and synthetic engine oil contained formic acid, acetic acid, and complex mixtures of fatty acid degradation products. CE analysis of formic acid, acetic acid and selected fatty acids is proposed as a new chemical analysis method for evaluating the condition of engine oil and for studying the effects of high temperature-high load (HTHL) oxidation. Because the overall pattern of CE peaks in the electropherogram changes with oil age or condition, CE-fingerprint (i.e., pattern recognition) techniques may also be useful for evaluating an aged oil's condition or remaining service life.

This paper details the design and operating attributes of a triple input clutch, layshaft automatic transmission (TCT) with a torque converter in a rear wheel drive passenger vehicle. The objectives of the TCT design are to reduce fuel consumption while increasing acceleration performance through the design of the gearing arrangement, shift actuation system and selection of gear ratios and progression. A systematic comparison of an 8-speed TCT design is made against a hypothetical 8-speed planetary automatic transmission (AT) with torque converter using an energy analysis model based upon empirical data and first principles of vehicle-powertrain systems. It was found that the 8-speed TCT design has the potential to provide an approximate 3% reduction in fuel consumption, a 3% decrease in 0-100 kph time and 30% reduction in energy loss relative to a comparable 8-speed planetary AT with an idealized logarithmic ratio progression.

Fillet and plug weld are commonly used in structural applications in commercial heavy vehicles. This paper is primarily concerned with an investigation of the full field deformations fields in fillet and plug welds using three dimensional digital image correlation (3D-DIC). Two identical vehicle parts are constructed using a fillet weld for one specimen, and a plug weld for the other. The specimens are loaded under quasi-static conditions with simultaneous measurement of load, displacements and strain gage measurements. Strain gage locations are selected based on the results of a finite element analysis model. 3D-DIC measurements are constructed using a two camera setup. Thus, 3D-DIC measurements are compared to strain gage measurements and finite element predictions. The effectiveness of the non-contact full field method is evaluated for application to studying the weld details considered and potential for fatigue damage and durability.

Comfort is a main factor in customer's decision when buying a car. The seat plays a very important role, as it is the interface between occupant and vehicle. Pressure distribution is today's most common approach to characterize seat comfort, but it shows limitations. Analysis of human inter-tissue stress tends to be relevant for an objective comfort assessment. This paper presents the construction and validation of a CAE human model, based on Magnetic Resonance Imaging scans and in-vivo tests data. Correlation between objective criteria and subjective evaluation will be investigated, comfort performance of a real seat will be predicted.

The work was concerned with visualisation of the charge homogeneity and cyclic variations within the planar fuel field near the spark plug in an optical spark ignition engine fitted with an outwardly opening central direct fuel injector. Specifically, the project examined the effects of fuel type and injection settings, with the overall view to understanding some of the key mechanisms previously identified as leading to particulate formation in such engines. The three fuels studied included a baseline iso-octane, which was directly compared to two gasoline fuels containing 10% and 85% volume of ethanol respectively. The engine was a bespoke single cylinder with Bowditch style optical access through a flat piston crown. Charge stratification was studied over a wide spectrum of injection timings using the Planar Laser Induced Fluorescence (PLIF) technique, with additional variation in charge temperature due to injection also estimated when viable using a two-line PLIF approach.

A pilot-main injection strategy is investigated for a part-load operating point in a single cylinder optical Diesel engine. As the energizing dwell between the pilot and main injections decreases below 200 μs, combustion noise reaches a minimum and a reduction of 3 dB is possible. This decrease in combustion noise is achieved without increased pollutant emissions. Injection schedules employed in the engine are analyzed with an injection analyzer to provide injection rates for each dwell tested. Two distinct injection events are observed even at the shortest dwell tested; rate shaping of the main injection occurs as the dwell is adjusted. High-speed elastic scattering imaging of liquid fuel is performed in the engine to examine initial liquid penetration rates.

Over the past decade, there have been many efforts to generate engine sound inside the cabin either in reducing way or in enhancing way. To reduce the engine noise, the passive way, such as sound absorption or sound insulation, was widely used but it has a limitation on its reduction performance. In recent days, with the development of signal processing technology, ANC (Active Noise Control) is been used to reduce the engine noise inside the cabin. On the other hand, technologies such as ASD (Active Sound Design) and ESG (Engine Sound Generator) have been used to generate the engine sound inside the vehicle. In the last ISNVH, Hyundai Motor Company newly introduced ESEV (Engine Sound by Engine Vibration) technology. This paper describes the ESEV Plus Minus that uses engine vibration to not only enhance the certain engine order components but reduce the other components at the same time. Consequently, this technology would produce a much more diverse engine sound.

Unpredictable faults oriented from ambiguous reasons could occur in an engine of a vehicle. However, there are some symptoms from which an engine is working abnormally before the engine is stalled by faults. In this paper, methods for diagnosis of engine faults by using vibrations are proposed. Through bench tests, to extract features for fault diagnosis, various samples with normal and abnormal conditions are prepared and vibration signals from the block of an engine are measured and analyzed. To consider cost and performance of a sensor, vibrations from a knock sensor signal as well as accelerometers are analyzed. Measured vibration signals are synchronized with signal of the crank position sensor and analyzed to detect which event is involved. Modulation analysis and Hilbert transform are applied to extract features representing the symptoms of engine faults and to indicate when the abnormal event happens, respectively.