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SAE 2011 High Efficiency IC Engines Symposium - Session 3 - Advanced Diesel Engine Technologies Presenter Andrew Brown, Delphi Corp.

The pace of replacement of petroleum-based fuels as the primary fuel supply for transportation may still be a point of debate. However, the need to find a viable replacement fuel or group of fuels is no longer a major point of debate. The panel will outline what has changed on the journey during the past few years and what the future holds. Viewpoints from government, the military, fuel suppliers and academia will be presented.

Nissan has released our original HEV system in Japan on November 2010, and will release it in US market on March 2011. The 1 motor 2 clutch parallel type using conventional 7 speed automatic transmission has been employed without torque converter and with a manganese cathode and laminated type Li-ion Battery. This system is well recognized its higher efficiency but lower weight and cost, however, has never realized due to technical difficulties of smoothness. At this session, performance achievements and hinged breakthrough technologies will be presented. Presenter Tetsuya Takahashi, Nissan Motor Co., Ltd.

Several technological advancements have enabled hybrid technology to become a viable option in the commercial truck market. Although hybrid trucks are becoming more mainstream, they are not the right alternative fuel solution for every application. When matched with the right duty cycle, hybrid technology can provide a significant cost savings. Due to these advancements and anticipated benefits, hybrid commercial trucks are forecasted to become a significant part of the commercial truck market. Presenter Glenn Ellis, Hino Motors Sales USA Inc.

These advanced checks have resulted in development of many new diagnostic monitors, of varying types, and a whole new internal software infrastructure to handle tracking, reporting, and self-verification of OBD related items. Due to this amplified complexity and the consequences surrounding a shortfall in meeting regulatory requirements, efficient and thorough validation of the OBD system in the powertrain control software is critical. Hardware-in-the-Loop (HIL) simulation provides the environment in which the needed efficiency and thoroughness for validating the OBD system can be achieved. A HIL simulation environment consisting of engine, aftertreatment, and basic vehicle models can be employed, providing the ability for software developers, calibration engineers, OBD experts, and test engineers to examine and validate both facets of OBD software: diagnostic monitors and diagnostic infrastructure (i.e., fault memory management).

Toyota is researching and developing several advanced vehicle powertrain technologies that increase fuel efficiency and decrease the environmental impact of consumer transportation. This presentation will describe the Toyota Plug-In Hybrid (PHV) architecture, its major components, the Toyota PHV Demonstration program, and the benefits of the Toyota approach to Plug-In hybrids. The current Toyota PHV features all electric driving for approximately 13 miles, while maintaining the fuel economy of Prius even when the vehicle is in hybrid mode. The vehicle that will be available in 2012 will also be affordable, allowing many customers to enjoy the benefits of electric drive. Presenter Avernethy Francisco, Toyota Motor Engineering & Manufacturing

In “Using Turbocharging in New Engine Design” (9:23), engineers from Schaeffler Group USA and McLaren Performance Tech explain what turbocharging is, and what it can do to improve both the power output of an engine and its fuel efficiency. Another engineer from the General Motors Powertrain group talks about how turbocharging was used in the new engine design for the Cadillac CT6. This episode highlights: The lessons learned from when turbocharging was first used to help heavy-duty trucks go uphill The experience acquired from car racing using turbo-charged engines The advantages of using turbo charging to decrease the size of engines without losing power output Also Available in DVD Format To subscribe to a full-season of Spotlight on Design, please contact SAE Corporate Sales: CustomerSales@sae.org or 1-888-875-3976.

“Spotlight on Design” features video interviews and case study segments, focusing on the latest technology breakthroughs. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. Fuel efficiency, or simply put, how to get more mileage out of the same amount of fuel has become one of the main goals to be achieved by new automotive technologies in the future, thanks in part to new government regulations. In the episode “Fuel Efficiency: Racing toward CAFE 2025” (21:24) AVL engineers show simulation and testing being used to design more fuel efficient vehicles, including the equipment that actually analyzes fuel economy.

This presentation will cover an overview of challenges and key discussion points for advanced electric motor and drive testing . Voiko will visit some examples of how D&V approaches these issues and also some suggestions for how the industry can view these intriguing problems as opportunities. The presentation will also delve into current testing developments that involve resolver, load bank and power measurement devices by highlighting solutions in the market today. There will also be a cursory look into the future of electric motor testing and what we can expect in the near term. Presenter Voiko Loukanov, D&V Electronics Limited

In Oct. 2011, Nissan announced its new six-year environmental plan, Nissan Green Program 2016 (NGP 2016), that includes initiatives to lead fuel efficiency: 35% fuel economy improvement compared with 2005 on a corporate average for all Nissan vehicles sold in Japan, China, Europe and the United States. To achieve this target, we`re planning to launch products delivering class-leading fuel efficiency such as an all-new FWD hybrid model, Introducing a next-generation continuously variable transmission (CVT). In this session, Nissan`s apploach for fuel erfficiency is presented with internal-conbustion powered technology evolution and hybridization, referring to new FWD hybrid system. Presenter Taiichi Onoyama, Nissan Motor Company, Ltd.

Hybrid vehicles in the modern era were developed with a strong primary goal to increase fuel efficiency in the North American market. Over the last 15 years, this market has expanded from zero sales to as high as 3% of total US sales. Most recently, the portfolio of competitive offerings with HEV propulsion systems has grown even more to about 30 models on sale today. Some interesting features and attributes have evolved thru this wider array of products giving the customer much more choice of which characteristics to select to match their needs. Ford�s 3rd generation HEV system will be offered for sale this fall. With it, we have continued our focus on the Fuel Efficiency as the driving force for our efforts. The overall process for the system engineering and some of the relevant subsystem and component contributors to the Fuel Efficiency improvement reflected in the 2013 Model Year Fusion and CMAX Hybrids will be presented. Presenter Charles Gray, Ford Motor Co.

In support of the U.S Department of Energy's Vehicle Technologies Program, numerous vehicle technology combinations have been simulated using Autonomie. Argonne National Laboratory (Argonne) designed and wrote the Autonomie modeling software to serve as a single tool that could be used to meet the requirements of automotive engineering throughout the development process, from modeling to control, offering the ability to quickly compare the performance and fuel efficiency of numerous powertrain configurations. For this study, a multitude of vehicle technology combinations were simulated for many different vehicles classes and configurations, which included conventional, power split hybrid electric vehicle (HEV), power split plug-in hybrid electric vehicle (PHEV), extended-range EV (E-REV)-capability PHEV, series fuel cell, and battery electric vehicle.

Historically, the opposed-piston, two-stroke (OP2S) diesel engine set combined records for fuel efficiency and power density that have yet to be met by any other engine type. However, with modern emissions standards, wide-spread development of this engine for on-highway use stopped. At Achates Power, state-of-the-art analytical tools and engineering methods have produced an OP2S engine that, when compared to a leading medium-duty engine, has demonstrated a 21% fuel efficiency gain and engine-out emissions levels meeting U.S. EPA10 with conventional after-treatment. Among the presentation topics covered are thermodynamic efficiency, demonstrated engine results, cost and weight advantages, and overcoming two-stroke engine challenges. Presenter David Johnson, Achates Power Inc.

Combustion engines are typically only 20-30% efficient at part-load operating conditions, resulting in poor fuel economy on average. To address this, LiquidPiston has developed an improved thermodynamics cycle, called the High-Efficiency Hybrid Cycle (HEHC), which optimizes each process (stroke) of the engine operation, with the aim of maximizing fuel efficiency. The cycle consists of: 1) a high compression ratio; 2) constant-volume combustion, and 3) over-expansion. At a modest compression ratio of 18:1, this cycle offers an ideal thermodynamic efficiency of 74%. To embody the HEHC cycle, LiquidPiston has developed two very different rotary engine architectures ? called the ?M? and ?X? engines. These rotary engine architectures offer flexibility in executing the thermodynamics cycle, and also result in a very compact package. In this talk, I will present recent results in the development of the LiquidPiston engines. The company is currently testing 20 and 40 HP versions of the ?M?

In this presentation, we will explain how the traditional Miller Cycle - which has its limitations in the traditional four-stroke, Otto Cycle engine provides new opportunities for greater fuel efficiency gains and engine downsizing when incorporated in a split-cycle combustion process. Results will also be shared from studies showing how these implementations can provide both significant drops in fuel consumption and increases in power when incorporated into some of today's most economic vehicles. Presenter Stephen Scuderi, Scuderi Group LLC

Gasoline engines continue to suffer from significant pumping losses despite decades of effort focused on reducing throttling. Honeywell Turbo has developed a throttle with an integrated turbine/generator that generates electricity by recovering pumping work. This energy offsets power normally provided by the crank driven alternator, thereby saving fuel. It integrates well with modern electrical systems which employ smart charging and idle stop strategies. The ThrottleCharger provides fuel economy benefits up to 5% over federal test cycles and in real world conditions. Presenter Mike Guidry, Honeywell Int'l (Turbo Technologies)

Proper thermal management can significantly contribute to overall system energy efficiency. This technical paper collection highlights the latest developments in thermal management energy efficiency.

The papers in this collleciton focus on state of the art simulation technologies for modeling thermal systems and their application in the development and optimization of vehicle thermal management and fuel economy. The papers range from empirical, 1D modeling methods to three dimensional CFD models as well as coupled methods.

The papers in this collleciton focus on state of the art simulation technologies for modeling thermal systems and their application in the development and optimization of vehicle thermal management and fuel economy. The papers range from empirical, 1D modeling methods to three dimensional CFD models as well as coupled methods

Proper thermal management can significantly contribute to overall system energy efficiency. The papers in this collection highlight the latest developments in thermal management energy efficiency.