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The development of PM and NOx reduction system with the combination of DOC included DPF and SCR catalyst in addition to the AOC sub-assembly for NH3 slip protection is described. DPF regeneration strategy and manual regeneration functionality are introduced with using ITH, HCI device on the EUI based EGR, VGT 12.3L diesel engine at the CVS full dilution tunnel test bench. With this system, PM and NOx emission regulation for JPNL was satisfied and DPF regeneration process under steady state condition and transient condition (JE05 mode) were successfully fulfilled. Manual regeneration process was also confirmed and HCI control strategy was validated against the heat loss during transient regeneration mode. Presenter Seung-il Moon

Plug-in hybrid electric vehicles (PHVs) consume both fossil fuel and grid electricity, which imposes emission testing challenges on the current constant volume sampler (CVS) test method. One reason is that in the charge-depleting cycle, PHVs having all-electric range operate the engine for a small portion of the traction energy need, causing the CVS to overdilute the exhaust gas. The other reason is that the dilution factor (DF) in the EPA calculation has an error caused by ignoring the CO₂ concentration in ambient air. This paper evaluates these challenges by testing a Toyota PHV on the industry standard CVS system combined with additional continuous sampling methodology for continuous diluents, smooth approach orifice (SAO) measurement for ambient air flow, and fuel flow meter (FFM) measurement for fuel consumption. The current EPA DF can produce an error resulting in higher mass calculation.

It is estimated that operating continuously on a B20 fuel containing the current allowable ASTM specification limits for metal impurities in biodiesel could result in a doubling of ash exposure relative to lube-oil-derived ash. The purpose of this study was to determine if a fuel containing metals at the ASTM limits could cause adverse impacts on the performance and durability of diesel emission control systems. An accelerated durability test method was developed to determine the potential impact of these biodiesel impurities. The test program included engine testing with multiple DPF substrate types as well as DOC and SCR catalysts. The results showed no significant degradation in the thermo-mechanical properties of cordierite, aluminum titanate, or silicon carbide DPFs after exposure to 150,000 mile equivalent biodiesel ash and thermal aging. However, exposure of a cordierite DPF to 435,000 mile equivalent aging resulted in a 69% decrease in the thermal shock resistance parameter.

Biofuels, such as ethanol and butanol, have been the subject of significant political and scientific attention, owing to concerns about climate change, global energy security, and the decline of world oil resources that is aggravated by the continuous increase in the demand for fossil fuels. This study evaluated the potential emissions impacts of different alcohol blends on a fleet of modern gasoline vehicles. Testing was conducted on a fleet of nine vehicles with different combinations of ten fuel blends over the Federal Test Procedure and Unified Cycle. The vehicles ranged in model year from 2007-2014 and included four vehicles with port fuel injection (PFI) fueling and five vehicles with direct injection (DI) fueling. The ten fuel blends included ethanol blends at concentrations of 10%, 15%, 20%, 51%, and 83% by volume and iso-butanol blends at concentrations of 16%, 24%, 32%, and 55% by volume, and an alcohol mixture giving 10% ethanol and 8% iso-butanol in the final blend.

The objective of this study was to identify and gain an understanding of the origins of noise in a commercial excavator cab. This paper presents the results of two different tests that were used to characterize the vibration and acoustic characteristics of the excavator cab. The first test was done in an effort to characterize the vibration properties of the cab panels and their associated contribution to the noise level inside the cab. The second set, of tests, was designed to address the contribution of the external airborne noise produced by the engine and hydraulic pump to the overall interior noise. This paper describes the test procedures used to obtain the data for the signature analysis, operational deflection shapes (ODS), and sound diagnosis analysis. It also contains a discussion of the analysis results and an inside look into the possible contributors of key frequencies to the interior noise in the excavator cab.

Technical groups worldwide have been actively developing specifications and requirements for biodegradable hydraulic fluids for mobile applications. These groups have recognized that an industry-wide specification is necessary due to the increase in environmental awareness in the agriculture, construction, forestry, and mining industries, and to the increasing number of local regulations primarily throughout Europe. Caterpillar has responded to this need by publishing a requirement, Caterpillar BF-1, that may be used by Caterpillar dealers, customers, and industry to help select high-performance biodegradable hydraulic fluids. This requirement was written with the input of several organizations that are known to be involved with the development of similar types of specifications and requirements.

Engineering new technology and products challenges managers to balance design innovation and program risk. To do this, managers need methods to judge future results to avoid program and product disasters. Besides the traditional prediction tools of schedule, simulations and “iron tests”, process control standards (with measurements) can also be applied to the development programs to mitigate risks. This paper briefly discusses the theory and case history behind some new process control methods and standards currently in place at Caterpillar's Electrical & Electronics department. Process standards reviewed in this paper include process mapping, ISO9001, process controls, and process improvement models (e.g. SEI's CMMs.)

This paper presents the damping effectiveness of free-layer damping materials through standard Oberst bar testing, solid plate excitation (RTC3) testing, and prediction through numerical schemes. The main objective is to compare damping results from various industry test methods to performance in an automotive body structure. Existing literature on laboratory and vehicle testing of free-layer viscoelastic damping materials has received significant attention in recent history. This has created considerable confusion regarding the appropriateness of different test methods to measure material properties for damping materials/treatments used in vehicles. The ability to use the material properties calculated in these tests in vehicle CAE models has not been extensively examined. Existing literature regarding theory and testing for different industry standard damping measurement techniques is discussed.

This paper deals with the dynamic characterization of an automotive shock absorber, a continuation of an earlier work [1]. The objective of this on-going research is to develop a testing and analysis methodology for obtaining dynamic properties of automotive shock absorbers for use in CAE-NVH low-to-mid frequency chassis models. First, the effects of temperature and nominal length on the stiffness and damping of the shock absorber are studied and their importance in the development of a standard test method discussed. The effects of different types of input excitation on the dynamic properties of the shock absorber are then examined. Stepped sine sweep excitation is currently used in industry to obtain shock absorber parameters along with their frequency and amplitude dependence. Sine-on-sine testing, which involves excitation using two different sine waves has been done in this study to understand the effects of the presence of multiple sine waves on the estimated dynamic properties.

Most of the history of systems engineering has been focused on processes for engineering a single complex system. However, most large enterprises design, manufacture, operate, sell, or support not one product but multiple product lines of related but varying systems. They seek to optimize time to market, costs of development and production, leverage of intellectual assets, best use of talented human resources, overall competitiveness, overall profitability and productivity. Optimizing globally across multiple product lines does not follow from treating each system family member as an independently engineered system or product. Traditional systems engineering principles can be generalized to apply to families. This article includes a multi-year case study of the actual use of a generic model-based systems engineering methodology for families, Systematica™, across the embedded electronic systems products of one of the world's largest manufacturers of heavy equipment.

Considerations follow [1] on the development of the carbon/epoxy body of the Lamborghini Murcièlago. Laminate lay-up and material selection for stiffness criteria are reviewed. Engineering solutions for tooling operations in order to achieve class A surface certification are analyzed. Design for environmental aging is also discussed and accelerated degradation testing methods are described. Finally, the program that lead to the adoption of hybrid adhesive bonding as sole method of joining the composite body components to the tubular steel frame is reviewed.

The traditional method of dynamic characterization of elastomers used in industry has largely been based on sinusoidal input excitation. Discrete frequency sine wave signals at specified amplitudes are used to excite the elastomer in a step-sine sweep fashion. This paper will examine new methods of characterization using various broadband input excitations. These different inputs include continuous sine sweep (chirp), shaped random, and acquired road profile data. Use of these broadband data types is expected to provide a more accurate representation of conditions seen in the field, while helping to eliminate much of the interpolation that is inherent with the classic discrete step-sine technique. Results of the various input types are compared in this paper with those found using the classic discrete step-sine input.

The history and state of the art use of pigments known as transparent titanium dioxides in automotive coatings is described. This pigment, also known as microfine TiO2, produces a unique and patented color effect in combination with Al flake pigments via Rayleigh light scattering. The potential for styling new “effect colors” has been investigated extensivley at BASF Corporation. Early feasibility and durability problems have been resolved with a better understanding of the mechanisms responsible for color effect and film degradation in sun light. Florida exposure data in both solventborne and waterborne coatings systems has shown this pigment to be very durable when used within certain formulating guide lines. Critical is the choice of pigment particle size and encapsulation chemistry. First used in 1989 in a color styled for the Ford Motor Company, production colors have expanded to other US and Japanese car manufacturers.

A 2007 Cummins ISL 8.9L direct-injection common rail diesel engine rated at 272 kW (365 hp) was used to load the filter to 2.2 g/L and passively oxidize particulate matter (PM) within a 2007 OEM aftertreatment system consisting of a diesel oxidation catalyst (DOC) and catalyzed particulate filter (CPF). Having a better understanding of the passive NO₂ oxidation kinetics of PM within the CPF allows for reducing the frequency of active regenerations (hydrocarbon injection) and the associated fuel penalties. Being able to model the passive oxidation of accumulated PM in the CPF is critical to creating accurate state estimation strategies. The MTU 1-D CPF model will be used to simulate data collected from this study to examine differences in the PM oxidation kinetics when soy methyl ester (SME) biodiesel is used as the source of fuel for the engine.

The following paper discusses Elastoflex® TF foam, it's use in headliners and other non-load bearing automotive interior trim. Elastoflex® TF foam's history and present use in Europe are reviewed. Raw materials, such as the thermoformable foam, reinforcements, and adhesives for this sandwich construction, are also discussed, along with processing parameters such as the foam manufacturing, sandwich lamination and thermoforming. The key physical properties and acoustics are shown on the included charts and tables. The total process and weight saving advantages are given.

Evaluations of the liner pitting protection performance provided by engine coolant corrosion inhibitors and supplemental coolant additives have presented many problems. Current practice involves the use of full scale engine tests to show that engine coolant inhibitors provide sufficient liner pitting protection. These are too time-consuming and expensive to use as the basis for industry-wide specifications. Ultrasonic vibratory test rigs have been used for screening purposes in individual labs, but these have suffered from poor reproducibility and insufficient additive differentiation. A new test procedure has been developed that reduces these problems. The new procedure compares candidate formulations against a good and bad reference fluid to reduce the concern for problems with calibration and equipment variability. Cast iron test coupons with well-defined microstructure and processing requirements significantly reduce test variability.

This paper is written to provide information on the fuel efficiency, emissions and energy cost of vehicles ranging from a pure electric (ZEV) to gasoline hybrid vehicles with electric range varying from 30 mi (50km) to 100 mi (160km). The Federal government s PNGV and CARB s ZEV have different goals, this paper explores some possibilities for hybrid-electric vehicle designs to meet both goals with existing technologies and batteries. The SAE/CARB testing procedures for determining energy and emission performance for EV and HEV and CARB s HEV ruling for ZEV credit are also critically evaluated. This paper intends to clarify some confusion over the comparison, discussion and design of electric- hybrid- and conventional- vehicles as well.

A KIVA-based CFD tool has been utilized to simulate the effect of a Common-Rail injection system applied to a large, uniflow-scavenged, two-stroke diesel engine. In particular, predictions for variations of injection pressure and injection duration have been validated with experimental data. The computational models have been evaluated according to their predictive capabilities of the combustion behavior reflected by the pressure and heat release rate history and the effects on nitric oxide formation and wall temperature trends. In general, the predicted trends are in good agreement with the experimental observations, thus demonstrating the potential of CFD as a design tool for the development of large diesel engines equipped with Common-Rail injection. Existing deficiencies are identified and can be explained in terms of model limitations, specifically with respect to the description of turbulence and combustion chemistry.

The potential for improving the efficiency of a heavy duty turbocharged diesel engine by closed loop Air-Fuel Ratio (AFR) management has been evaluated. Testing conducted on a 12 liter diesel engine, and subsequent data evaluation, has established the feasibility of controlling the performance through electronic control of air management hardware. Furthermore, the feasibility of using direct in-cylinder pressure measurement for control feedback has been established. A compact and robust fiber optics sensor for measuring real time in-cylinder pressure has been demonstrated on a test engine. A preferred method for reducing the cylinder pressure data for control feedback has been established for continued development.

The relationship between ethanol and iso-butanol fuel concentrations and vehicle particulate matter emissions was investigated. This study utilized a gasoline direct injection (GDI) flexible fuel vehicle (FFV) with wall-guided fueling system tested with four fuels, including E10, E51, E83, and an iso-butanol blend at a proportion of 55% by volume. Emission measurements were conducted over the Federal Test Procedure (FTP) driving cycle on a chassis dynamometer with an emphasis on the physical and chemical characterization of particulate matter (PM) emissions. The results indicated that the addition of higher ethanol blends and the iso-butanol blend resulted in large reductions in PM mass, soot, and total and solid particle number emissions. PM emissions for the baseline E10 fuel were characterized by a higher fraction of elemental carbon (EC), whereas the PM emissions for the higher ethanol blends were more organic carbon (OC) in nature.