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SAE 2011 High Efficiency IC Engines Symposium - Session 2 - Frontiers in Light-Duty Engine R&D Presenter Ulrich Spicher, Karlsruhe Inst. of Technology

SAE 2011 High Efficiency IC Engines Symposium - Session 4 - Novel Engine Components and Systems. Presenter Neville Jackson, Ricardo plc

The presentation describes the aerodynamic development and optimization process of the three different new models of the Audi A6/A7 family. The body types of these three models represent the three classic aerodynamic body types squareback, notchback and fastback. A short introduction of the flow structures of these different body types is given and their effect on the vehicle aerodynamic is described. In order to achieve good aerodynamic performance, the integration into the development process of the knowledge about these flow phenomena and the breakdown of the aerodynamic resistance into its components friction- and pressure drag as well as the induced drag is very important. The presentation illustrates how this is realized within the aerodynamic development process at Audi. It describes how the results of CFD simulations are combined with wind tunnel measurements and how the information about the different flow phenomena were used to achieve an aerodynamic improvement.

Moir� method is useful to measure the shape and the whole-field distributions of displacement and strain of structures. There are many kinds of moir� methods such as geometric moir� method, sampling moir� method, Fourier transform moir� method, moir� interferometry, shadow moir� method and moir� topography. Grating method analyzing directly deformation of a grating without any moir� fringe pattern is considered as an extended technique of moire method. Phase analysis of the moire fringe patterns and the grating patterns provides accurate measurements of shapes or displacement and strain distributions. Some applications of these moir� methods and grating methods to dynamic shape and strain distribution measurements of a rotating tire, sub-millimeter displacement measurements from long distance for landslide prediction, real-time shape measurements with micro-meter order accuracy, etc. are shown. Presenter Yoshiharu Morimoto, Moire Institute Inc.

FutureSteelVehicle's (FSV) objective is to develop detailed design concepts for a radically different steel body structure for a compact Battery Electric Vehicle (BEV). It also will identify structure changes to accommodate larger Plug-In Hybrid (PHEV) and Fuel Cell (FCEV) vehicle variants. The presentation will demonstrate seven optimized structural sub-systems that contribute to the program's 35 percent mass reduction goals and meet its safety and life cycle emissions targets. It will explain the advanced design optimization process used and the resulting aggressive steel concepts. Presenter Jody R. Shaw, US Steel

Advanced vehicular thermal management system can improve engine performance, minimize fuel consumption, and reduce emissions by harmoniously operating computer-controlled servomotor components. In this paper, a neural network-based optimal control strategy is proposed to regulate the engine temperature through the advanced cooling system. Presenter Asma Al Tamimi, Hashemite University

Battery Electric Vehicles and Extended Range Electric Vehicles, like the Chevrolet Volt, can use electrical energy from the Grid to meet the majority of a driver�s transportation needs. This has the positive societal effects of displace petroleum consumption and associated pollutants from combustion on a well to wheels basis, as well as reduced energy costs for the driver. CO2 may also be lower, but this depends upon the nature of the grid energy generation. There is a mix of sources � coal-fired, gas -fired, nuclear or renewables, like hydro, solar, wind or biomass for grid electrical energy. This mix changes by region, and also on the weather and time of day. By monitoring the grid mix and communicating it to drivers (or to their vehicles) in real-time, electrically driven vehicles may be recharged to take advantage of the lowest CO2, and potentially lower cost charging opportunities.

EGR coolers are used in combustion engines to reduce NOx emissions. However, heat transfer in these coolers also results in thermophoresis-temperature-gradient driven motion of suspended particles towards cooler regions-which leads to significant soot deposition. Presenter Meisam Mehravaran

From 2009 until present Toyota has had a demonstration program of Prius PHV which is comprised of 600 vehicles throughout Japan, Europe and in the US. The vehicles were given to government agencies, corporations, utility companies and private individuals to use. With these demo units Toyota wanted to understand the market reaction and real world impact of plug-in technology on gasoline displacement with increased use of electricity as a fuel. This presentation shows that approximately 50% of fuel was saved using the PHVs in the US. An experiment in Toyota City shows that if public infrastructure is optimized to be convenient and located where people normally park, there is a potential to achieve an ideal fuel savings of 61%. The demonstration program shows that plug-in technology in fact saves fuel and that the proper infrastructure can optimize the fuel savings of plug-in hybrids. Presenter Avernethy Francisco, Toyota

The number of electronically controlled systems in commercial vehicles is increasing rapidly. Much of this electrical content is controlled using ECUs (Electronic Control Units) which share information using some type of networking technology, such as a CAN bus running the SAE J1939 protocol. Presenter Jeffrey Craig, Vector CANtech Inc.

JLR is on track to develop stop-start, parallel hybrid and plug-in parallel hybrid vehicles in the next few years. Plug-in hybridization is arguably the most suitable technology for large, premium luxury vehicles for the foreseeable future. Range_e is a UK based demonstrator for a plug-in hybrid system and has brought into sharp focus the attribute issues and wider challenges that need to be taken into consideration when moving towards production. Presenter Paul Bostock, Jaguar Land Rover

An overview of Daimler?s progression to advance powertrain technology in a growth industry shows many different solutions to improvement in transportation. Daimler continues to make breakthroughs in technology development and application building on 125 years of automotive development. Optimization of current powertrains will enable a significant gain in CO2/mi reductions, that dependent on product mix can be augmented with additional technologies. There is however no bypass to some form of electrification, enabling efficiency gains and alternative forms of power supply. Development of hybrid powertrains continues in an established manner and enhanced development of further electrified powertrains are in development. Organizationally and technically, significant skills and adjustments need to continue to be undertaken enabling OEMs and in particular the supply base to develop optimized solutions efficiently. The outlook is bright for novel component development and innovation.

There are several variables to consider when specifying a hydraulic hybrid system in a commercial vehicle. Parameters which can be controlled include various component sizes and some hybrid system calibration parameters. Presenter Paul Schwark, Bosch Rexroth AG

Silicones have been utilized in multiple industries in the last 50 years and their applications are still expanding as technology grows. Ice phobic coatings, as an example, have been utilized on lock walls, navigation channels, wind turbines, hydropower intakes, and aircraft. Without protection these applications have a high risk of failure in the functions they perform. For example, ice build up on an aircraft?s aerodynamic surfaces increases drag which reduces lift during flight operations. Utilizing a silicone ice phobic coating significantly reduces the adhesion of ice to aerodynamic surfaces. Compared to other polymeric materials, silicones are known for their broad operating temperature range and lend themselves to excellent performance in a variety of harsh environments. Especially in low temperatures where ice adhesion is a concern, silicones retain their elastomeric physical properties and low modulus.

This article characterizes the special features of drilling of CFRP/Titanium and -Aluminium stacks. Simplified theoretic models will show how CFRP/Titanium stacks should be machined without scratches and burn marks contacting carbon. Low axial forces and smart chip removal technology are the main characteristics of the drilling tool technology, optimized to reach H8 quality in one shot operation. Presenter Peter Mueller-Hummel, Cutting Tools Inc.

High Speed Machining of CFRP Parts Investigation of the influence of new geometries, cutting datas and coolant capabilities on the surface finish of CFRP parts. State of the art: Different CFRP grades and machining conditions make geometry adjustments to the tool necessary. Mechanical failures through machining operations can be avoided in most of the cases. New unidirectional CFRP grades and dry machining processes again lead to machining problems. This study investigates new geometries to avoid heat damage with dry maching and air coolant in case of unidirectional CFRP. With help of a thermo camera and the surface investigation with a scanning electron microscope, heat damage can be analysed and therefore new geometries can be developed and tested. Target is to develop a new multi purpose CFRP geometry to meet the requirements of the future. The reduction of different geometries used leads to major cost savings. Presenter Ingo von Puttkamer, Guhring oHG

The presentation provides an overview about the activities of Eurocae Working Group 72 (WG-72) starting with a brief synopsis of the context which suggested why such a committee should be established in 2006. It then goes into further detail about the drivers for the work of the committee, which call for the products to be delivered. It addresses some of the challenges with respect to its users. It points out that one of the lessons the committee learned was importance of the focus on the users, such that the products provide their maximum utility. Hence, the users should better be among the participants to achieve this objective. Other industries have dealt with the subject of Information System (or Cyber-Physical) Security long before this industry was forced to consider it. Consequently there are many industry standards and national or international norms, which may help to develop what is deemed needed for Civil Aviation.

Many manufacturing companies want to apply AFP technology to complex high-curvature part shapes. As new AFP machine technologies are developed to specifically apply material over complex shapes, new and innovative NC programming approaches are needed to successfully, reliably, and accurately apply material with good consolidation, while meeting the fiber direction and coverage requirements. A big issue with AFP is the production rate vs. part complexity. Most complex shapes can be created with a single .125? wide strip (tow) of material. But the production time would be impractically long. So machine builders create 6, 8, 16, even 32 tow AFP heads, and use the widest tow possible for the highest laydown rates. But then wide compaction rollers on these systems have difficulty consolidating material over curved surfaces, and the minimum steering radius of wider tows challenge the software?s ability to meet the layup requirements.

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

As a result of recommendation from the Augustine Panel, the direction for Human Space Flight has been altered from the original plan referred to as Constellation. NASA's Human Exploration Framework Team (HEFT) proposes the use of a Shuttle Derived Heavy Lift Launch Vehicle (SDLV) and an Orion derived spacecraft (salvaged from Constellation) to support a new flexible direction for space exploration. The SDLV must be developed within an environment of a constrained budget and a preferred fast development schedule. Thus, it has been proposed to utilize existing assets from the Shuttle Program to speed development at a lower cost. These existing assets should not only include structures such as external tanks or solid rockets, but also the Flight Software which has traditionally been a ?long pole? in new development efforts. The avionics and software for the Space Shuttle was primarily developed in the 70's and considered state of the art for that time.