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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

Since transient vehicle HVAC computational fluids (CFD) simulations take too long to solve in a production environment, the goal of this project is to automatically create a lumped-parameter flow network from a steady-state CFD that solves nearly instantaneously. The data mining algorithm k-means is implemented to automatically discover flow features and form the network (a reduced order model). The lumped-parameter network is implemented in the commercial thermal solver MuSES to then run as a fully transient simulation. Using this network a “localized heat transfer coefficient” is shown to be an improvement over existing techniques. Also, it was found that the use of the clustering created a new flow visualization technique. Finally, fixing clusters near equipment newly demonstrates a capability to track localized temperatures near specific objects (such as equipment in vehicles).

Cost reduction in the automotive industry becomes a widely-adopted operational strategy not only for Original Equipment Manufacturers (OEMs) that take cost leader generic corporation strategy, but also for many OEMs that take differentiation generic corporation strategy. Since differentiation generic strategy requires an organization to provide a product or service above the industry average level, a premium is typically included in the tag price for those products or services. Cost reduction measures could increase risks for the organizations that pursue differentiation strategy. Although manufacturers in the automotive industry dramatically improved production efficiency in past ten years, they are still facing the pressure of cost control. The big challenge in cost control for automakers and suppliers is increasing prices of raw materials, energy and labor costs. These costs create constraints for the traditional economic expansion model.

An experimental investigation of non-intrusive combustion sensing was performed using a tri-axial accelerometer mounted to the engine block of a small-bore high-speed 4-cylinder compression-ignition direct-injection (CIDI) engine. This study investigates potential techniques to extract combustion features from accelerometer signals to be used for cycle-to-cycle engine control. Selection of accelerometer location and vibration axis were performed by analyzing vibration signals for three different locations along the block for all three of the accelerometer axes. A magnitude squared coherence (MSC) statistical analysis was used to select the best location and axis. Based on previous work from the literature, the vibration signal filtering was optimized, and the filtered vibration signals were analyzed. It was found that the vibration signals correlate well with the second derivative of pressure during the initial stages of combustion.

Structure-borne inputs to hybrid FEA/SEA models could have significant effects on the model prediction accuracy. The purpose of this work was to obtain the structure-borne noise (SBN) inputs using a simplified transfer path analysis (TPA) and identify the significance of the structure-borne and airborne contributions to the spectator sound power of an engine with enclosure for future modeling references. Force inputs to the enclosure from the engine were obtained and used as inputs to a hybrid engine enclosure model for sound prediction.

In this paper, residual stress distributions in rectangular bars due to rolling or burnishing at very high rolling or burnishing loads are investigated by roll burnishing experiments and three-dimensional finite element analyses using ABAQUS. First, roll burnishing experiments on rectangular bars at two roller burnishing loads are presented. The results indicate the higher burnishing load induces lower residual stresses and the higher burnishing load does not improve fatigue lives. Next, in the corresponding finite element analyses, the roller is modeled as rigid and the roller rolls on the flat surface of the bar with a low coefficient of friction. The bar material is modeled as an elastic-plastic strain hardening material with a nonlinear kinematic hardening rule for loading and unloading.

In-cylinder ion sensing is a subject of interest due to its application in spark-ignited (SI) engines for feedback control and diagnostics including: combustion knock detection, rate and phasing of combustion, and mis-fire On Board Diagnostics (OBD). Further advancement and application is likely to continue as the result of the availability of ignition coils with integrated ion sensing circuitry making ion sensing more versatile and cost effective. In SI engines, combustion knock is controlled through closed loop feedback from sensor metrics to maintain knock near the borderline, below engine damage and NVH thresholds. Combustion knock is one of the critical applications for ion sensing in SI engines and improvement in knock detection offers the potential for increased thermal efficiency. This work analyzes and characterizes the ionization signal in reference to the cylinder pressure signal under knocking and non-knocking conditions.

A computational, three-dimensional approach to investigate the behavior of diesel soot particles in the micro-channels of wall-flow Diesel Particulate Filters is presented. The KIVA3V CFD code, already extended to solve the 2D conservation equations for porous media materials [1], has been enhanced to solve in 2-D and 3-D the governing equations for reacting and compressible flows through porous media in non axes-symmetric geometries. With respect to previous work [1], a different mathematical approach has been followed in the implementation of the numerical solver for porous media, in order to achieve a faster convergency as source terms were added to the governing equations. The Darcy pressure drop has been included in the Navier-Stokes equations and the energy equation has been extended to account for the thermal exchange between the gas flow and the porous wall.

Exhaust emissions were characterized from a Cummins LTA10 heavy-duty diesel engine operated at two EPA steady-state modes with and without an uncatalyzed Corning ceramic particulate trap. The regulated emissions of nitrogen oxides (NOx), hydrocarbons (HC), and total particulate matter (TPM) and its components as well as the unregulated emissions of PAH, nitro-PAH, mutagenic activity and particle size distributions were measured. The consistently significant effects of the trap on regulated emissions included reductions of TPM and TPM-associated components. There were no changes in NOx and HC were reduced only at one operating condition. Particle size distribution measurements showed that nuclei-mode particles were formed downstream of the trap, which effectively removed accumulation-mode particles. All of the mutagenicity was direct-acting and the mutagenic activity of the XOC was approximately equivalent to that of the SOF without the trap.

Lubricating oil affects the performance of friction materials in transmission, steering and brake systems. The TO-2 Test measured friction retention characteristics of lubricating oils used with sintered bronze friction discs. This paper introduces a new friction performance test for drive train lubricants that will be used to support Caterpillar's new transmission and drive train fluid requirements, TO-4, which measures static and dynamic friction, wear, and energy capacity for six friction materials, and replaces the TO-2 test. The new test device to be introduced is an oil cooled, single-faced clutch in the Link Engineering Co. M1158 Oil/Friction Test Machine.

Homogeneous low temperature combustion is believed to be a promising approach to resolve the conflict of goals between high efficiency and low exhaust emissions. Disadvantageously for this kind of combustion, the whole process depends on chemical kinetics and thus is hard to control. Reactivity controlled combustion can help to overcome this difficulty. In the so-called RCCI (reactivity controlled compression ignition) combustion concept a small amount of pilot diesel that is injected directly into the combustion chamber ignites a highly diluted gasoline-air mixture. As the gasoline does not ignite without the diesel, the pilot injection timing and the ratio between diesel and gasoline can be used to control the combustion process. A phenomenological multi-zone model to predict RCCI combustion has been developed and validated against experimental and 3D-CFD data. The model captures the main physics governing ignition and combustion.

Sensory jury testing was utilized to characterize vibration levels perceived by the operator, with respect to levels measured using instrumentation, in order to develop a tool for the evaluation of vibration at the operator interfaces. Details of the jury testing and jury data processing method are highlighted as well as the refinement of vibration characterization for a specific application. The vibration at user interface locations of both snowmobiles and ATVs was measured along with subjective feedback from a panel of jurists. Statistical analysis was performed on the jury data to provide both a qualitative and quantitative number to represent the opinion of the jury. Correlations were developed between the measured levels of vibration and the opinions of the jury. Finally, a set of correlation functions suitable for design predictions was developed.

Rear Window Buffeting (RWB) is the low-frequency, high amplitude, sound that occurs in many 4-door vehicles when driven 30-70 mph with one rear window lowered. The goal of this paper is to demonstrate that the mechanisms of RWB are similar to that of sun roof buffeting and to describe the results of several actions suspected in contributing to the severity of RWB. Finally, the results of several experiments are discussed that may lend insight into ways to reduce the severity of this event. A detailed examination of the side airflow patterns of a small Sport Utility Vehicle (SUV) shows these criteria exist on a small SUV, and experiments to modify the SUV airflow pattern to reduce RWB are performed with varying degrees of success. Based on the results of these experiments, design actions are recommended that may result in the reduction of RWB.

Numerical models are used in this study to investigate the oil flow and heat transfer in the piston gallery of a diesel engine. An experiment is set up to validate the numerical models. In the experiment a fixed, but adjustable steel plate is instrumented and pre-heated to a certain temperature. The oil is injected vertically upwards from an underneath injector and impinges on the bottom of the plate. The reduction of the plate temperature is recorded by the thermocouples pre-mounted in the plate. The numerical models are used to predict the temperature history at the thermocouple locations and validated with the experimental data. After the rig model validation, the numerical models are applied to evaluate the oil sloshing and heat transfer in the piston gallery. The piston motion is modeled by a dynamic mesh model, and the oil sloshing is modeled by the VOF (volume of fluid) multiphase model.

A 2-D CFD model was developed to describe the heat transfer, and reaction kinetics in a honeycomb structured ceramic diesel particulate trap. This model describes the steady state as well as the transient behavior of the flow and heat transfer during the trap regeneration processes. The trap temperature profile was determined by numerically solving the 2-D unsteady energy equation including the convective, heat conduction and viscous dissipation terms. The convective terms were based on a 2-D analytical flow field solution derived from the conservation of mass and momentum equations (Opris, 1997). The reaction kinetics were described using a discretized first order Arrhenius function. The 2-D term describing the reaction kinetics and particulate matter conservation of mass was added to the energy equation as a source term in order to represent the particulate matter oxidation. The filtration model describes the particulate matter accumulation in the trap.

Since the advent of P/M technology as a near net shape production process, millions of mechanical components of various shapes and sizes have been produced. Although P/M continues to be one of the fast growing shaping processes, it suffers from the inability to produce intricate geometry's such as internal tapers, threads or recesses perpendicular to pressing direction. In such cases application of machining as a secondary forming operation becomes the preferred alternative. However, machining of P/M parts due to their inherent porosity is known to decrease tool life and increase tool chatter and vibration. Consequently, several attempts have been made to improve the machinability of P/M materials by either addition of machinability enhancing elements such as sulfur, calcium, tellurium, selenium, etc., or by resin impregnation of P/M parts.

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.)

Engineering education at the University level is enhanced by competition-based projects. The SAE Clean Snowmobile Challenge is a prime example of how competition-based engineering education benefits the small engines industry and improves the engineering talent pool of the nation in general. For the past several decades, SAE has encouraged young engineers to compete in designing off road vehicles (Baja SAE ®), small race cars (Formula SAE ®), remote control airplanes (Aero Design ®), high mileage vehicles (Supermileage ®) and robots (Walking Robot ®). Now a new competition, the SAE Clean Snowmobile Challenge ™ (CSC), based on designing a cleaner and quieter snowmobile has led to a new path for young engineers to explore the challenges of designing engines that emit less pollution and noise. The paper will summarize the results of the most recent Clean Snowmobile Challenge 2006 and document the successes of the past seven years of the Challenge.

Researchers desire to evaluate system reliability uniquely and efficiently. Despite its strong technical demand, little progress has been made on system reliability analysis in the last two decades. Up to now, bound methods for system reliability prediction have been dominant. For system reliability bounds, the second order bound method gives fairly accurate prediction for system reliability assuming that the probabilities of second-order joint events are accurately obtained. Two primary challenges in system reliability analysis are evaluation of the probabilities of second-order joint events and no unique system reliability for design optimization. Firstly, the greatest technical demand is found in an accurate and efficient method to numerically evaluate the probability of a second-order joint event.

This paper presents an innovative approach for quality engineering using the Eigenvector Dimension Reduction (EDR) Method. Currently industry relies heavily upon the use of the Taguchi method and Signal to Noise (S/N) ratios as quality indices. However, some disadvantages of the Taguchi method exist such as, its reliance upon samples occurring at specified levels, results to be valid at only the current design point, and its expensiveness to maintain a certain level of confidence. Recently, it has been shown that the EDR method can accurately provide an analysis of variance, similar to that of the Taguchi method, but is not hindered by the aforementioned drawbacks of the Taguchi method. This is evident because the EDR method is based upon fundamental statistics, where the statistical information for each design parameter is used to estimate the uncertainty propagation through engineering systems.