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Sequel is the third vehicle in GM's Reinvention of the Automobile and is the first zero emissions passenger vehicle to drive more than 300 miles on public roads without refueling or recharging. It is purpose-built around the hydrogen storage and fuel cell systems and uses the skateboard principle introduced in the Autonomy vision concept and the Hy-wire proof-of-concept vehicles. Sequel's aluminum structure, Flexray controlled chassis-by-wire systems and AWD system comprising a single front electric motor and two rear wheel motors make it, perhaps, the most technically advanced automobile ever built. The paper describes the vehicle's design and performance characteristics.

A fully flexible valve actuation (FFVA) system was developed for a single cylinder research engine to investigate high efficiency clean combustion (HECC) in a diesel engine. The main objectives of the study were to examine the emissions, performance, and combustion characteristics of the engine using late intake valve closing (LIVC) to determine the benefits and limitations of this strategy to meet Tier 2 Bin 5 NOx requirements without after-treatment. The most significant benefit of LIVC is a reduction in particulates due to the longer ignition delay time and a subsequent reduction in local fuel rich combustion zones. More than a 95% reduction in particulates was observed at some operating conditions. Combustion noise was also reduced at low and medium loads due to slower heat release. Although it is difficult to assess the fuel economy benefits of LIVC using a single cylinder engine, LIVC shows the potential to improve the fuel economy through several approaches.

With increasingly stringent emissions regulations and concurrent requirements for enhanced engine thermal efficiency, a comprehensive characterization of the automotive gasoline fuel spray has become essential. The acquisition of accurate and repeatable spray data is even more critical when a combustion strategy such as gasoline direct injection is to be utilized. Without industry-wide standardization of testing procedures, large variablilities have been experienced in attempts to verify the claimed spray performance values for the Sauter mean diameter, Dv90, tip penetration and cone angle of many types of fuel sprays. A new SAE Recommended Practice document, J2715, has been developed by the SAE Gasoline Fuel Injection Standards Committee (GFISC) and is now available for the measurement and characterization of the fuel sprays from both gasoline direct injection and port fuel injection injectors.

General Motors' 3.6L DOHC 4V V6 engine has been upgraded to provide substantial improvements in performance, fuel economy, and emissions for the 2008 model year Cadillac CTS and STS. The fundamental change was a switch from traditional manifold-port fuel injection (MPFI) to spark ignition direct injection (SIDI). Additional modifications include enhanced cylinder head and intake manifold air flow capacities, optimized camshaft profiles, and increased compression ratio. The SIDI fuel system presented the greatest opportunities for system development and optimization in order to maximize improvements in performance, fuel economy, and emissions. In particular, the injector flow rate, orifice geometry, and spray pattern were selected to provide the optimum balance of high power and torque, low fuel consumption, stable combustion, low smoke emissions, and robust tolerance to injector plugging.

In developing a direct injection gasoline engine, the in-cylinder fuel air mixing is key to good performance and emissions. High speed visualization in an optically accessible single cylinder engine for direct injection gasoline engine applications is an effective tool to reveal the fuel spray pattern effect on mixture formation The fuel injectors in this study employ the unique multi-hole turbulence nozzles in a PFI-like (Port Fuel Injection) fuel system architecture specifically developed as a Low Pressure Direct Injection (LPDI) fuel injection system. In this study, three injector sprays with a narrow 40° spray angle, a 60°spray angle with 5°offset angle, and a wide 80° spray angle with 10° offset angle were evaluated. Image processing algorithms were developed to analyze the nature of in-cylinder fuel-air mixing and the extent of fuel spray impingement on the cylinder wall.

Homogeneous Charge Compression Ignition (HCCI) combustion shows a high potential of reducing both fuel consumption and exhaust gas emissions. Many works have been devoted to extend the HCCI operation range in order to maximize its fuel economy benefit. Among them, fuel injection strategies that use fuel reforming to increase the cylinder charge temperature to facilitate HCCI combustion at low engine loads have been proposed. However, to estimate and control an optimal amount of fuel reforming in the cylinder of an HCCI engine proves to be challenging because the fuel reforming process depends on many engine variables. It is conceivable that the amount of fuel reforming can be estimated since it correlates with the combustion phasing which in turn can be measured using a cylinder pressure sensor.

This paper presents an unambiguous and intuitive method for identification of steering column resonant (SCR) mode of vibration. One simple but overlooked technique to determine the SCR mode in-vehicle is to provide local stiffnesses of the body locations where the Instrument Panel (IP) attaches, to the IP suppliers to be used in their design and development. This paper describes how this technique is useful in predicting the first few important in-vehicle steering column modes for different classes of vehicles, with examples presented in each class. The results obtained from such analyses are compared against those from direct in-buck simulations. This technique is not limited to its application in developing IP systems, but can easily be extended to include other systems such as seats, fuel tanks, etc. Also it is shown that a design optimization analysis may be performed using these attachment stiffnesses as design variables resulting in a system level solution.

Currently, high-pressure fuel systems and swirl injectors dominate direct injection spark ignition (DISI) engine applications worldwide. Besides its advantage of good atomization due to the high pressure, this technology also has many inherent drawbacks, such as, high system cost, complicated system configuration, excessive wall wetting, lack of spray tailoring flexibility, etc., which limit the benefits available from the DISI concept. To overcome these drawbacks, a low-pressure direct injection (LPDI) fuel injector was developed which utilizes a novel high-turbulence nozzle to produce a soft spray, with droplet size comparable to the high-pressure swirl injector sprays, but much reduced penetration. This unique nozzle design provides a degree of independent control of injector flow, spray droplet size, spray angle, penetration, and spray distribution pattern.

It is well-known that in-cylinder ionization signals can be used for detecting combustion characteristics of IC (Internal Combustion) engines. For example, engine misfire, incomplete combustion (or partial-burn), knock, MBT (Minimum spark advance for Best Torque) timing and combustion stability can be detected using in-cylinder ionization signals. In addition, closed loop combustion spark timing control strategies have been developed to control engine MBT timing and to manage spark timing advance (knock) and retard (incomplete combustion) limits. In-cylinder ionization signals can also be used for closed loop control of maximum equivalence ratio (lean limit) at a desired combustion stability level. Up to now, most of the ionization applications have been for PFI (Port Fuel Injection) engines. This paper presents ionization detection for gasoline Direct Injection (DI) engines.

A low-pressure direct injection fuel system for spark ignition direct injection engines has been developed, in which a high-turbulence nozzle technology was employed to achieve fine fuel droplet size at a low injection pressure around 2 MPa. It is particularly important to study spray characteristics in the near-nozzle region due to the immediate liquid breakup at the nozzle exit. By using an ultrafast x-ray area detector and intense synchrotron x-ray beams, the interior structure and dynamics of the direct injection gasoline sprays from a multi-orifice turbulence-assisted nozzle were elucidated for the first time in a highly quantitative manner with μs-temporal resolution. Revealed by a newly developed, ultrafast computed x-microtomography technique, many detailed features associated with the transient liquid flows are readily observable in the reconstructed spray.

In today's search for a better fuel economy and lower emissions, it is essential to precisely control the injected fuel quantity, as demanded by the engine load, into each of the engine cylinders. In fuel injection systems, the pressure pulsations due to the rapid opening and closing of the injectors can cause uneven injected fuel amounts between cylinders. In order to develop effective techniques to reduce these pressure pulsations, it is crucial to have a good understanding of the dynamic characteristics of such fuel injection systems. This paper presents the benefits of using simulation as a tool to analyze the dynamic behaviors of a V8 gasoline injection system. The fuel system modeling, based on a one-dimensional (1D) lumped parameter approach, has been developed in the AMESim® environment. The comparison between the simulation results and the experimental data shows good agreement in fluid transient characteristics for both time and frequency domains.

A rapid prototyping controller (RPC) based, full-authority, diesel control system is developed, implemented, tested and validated on FTP cycle. As rapid prototyping controller, dSPACE Autobox is coupled with a fast processor based slave for lower level I/O control and a collection of in-house designed interface cards for signal conditioning. The base software set implemented mimics the current production code for a production diesel engine. This is done to facilitate realistic and accurate comparison of production algorithms with new control algorithms to be added on future products. The engine is equipped with all the state-of-the art subsystems found in a modern diesel engine (common rail fuel injection, EGR, Turbocharger etc.).

Engine position synchronous control of fuel injection and spark ignition at engine start can reduce regulated emissions, and improve start quality. Synchronous fuel and ignition control requires full 720° engine position information. Emissions and start quality benefits are gained if engine position is available at key-on before initial engine rotation. Typical engine position sensor sets require substantial engine rotation before engine position is initialized. Tracking engine stop position, for use on the next start, eliminates the initial engine angular travel required for synchronization. The previous stop position of the engine is stored in non-volatile memory, giving engine position immediately at start. This approach is applicable for systems in which the engine controller remains powered for some time after key-off. As the engine stops, direction reversals are common.

The Experimental Safety Vehicle powertrain and fuel system developed by General Motors in compliance with Contract DOT-OS-00095 with the U.S. Department of Transportation include several special features: a low engine accessory package to meet the front visibility down angle of 8 degrees, engine and transmission mounting for retention at high decelerations, a light aluminum engine, an over-the-rear-axle fuel tank, and a unique evaporative emission fuel pipe routing. A comprehensive test program was planned and final testing to validate contract specifications was conducted.