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Internal combustion engine gets heated up due to continuous combustion of fuel. To keep engine working efficiently and prevent components damage due to very high temperature, the engine needs to be cooled down. Based on power output requirement and provision for cooling system, every engine has it’s unique cooling system. Liquid based cooling systems are majorly implemented in automobile. It’s important to keep in mind that during design phase that, cooling the engine will lower the power to fuel consumption ratio. Therefore, during lower ambient conditions, the cooling system should be able to uniformly increase the temperature of the engine components, engine oil and transmission oil. This is achieved by circulating the coolant through cooling jacket, engine oil heater and transmission oil heater, which will be heated by the combustion heat.

A CAE-based optimization method is developed for Lube Oil Consumption (LOC) analysis of the piston-ring system. With accurate thermodynamic boundary conditions from 1D engine combustion simulation, piston motion, dynamics of piston ring, and characteristics of oil consumption are simulated using AVL Piston&Ring. The model is validated by comparing with available test data. Good match is achieved. The model is then applied to a diesel engine. The root cause of excessive LOC of the engine has been identified through CAE. The improved understanding has been applied to optimize the piston and piston ring. Engine dyno test, 1200-hour engine durability test, and 45000-kilometer vehicle test have been conducted to validate the optimized design. The experiment results are in good agreement with CAE predictions, and the oil consumption has been improved over the original design.

Structural durability of automotive components is one of the key requirements in design and development of today’s automobiles. Virtual simulations are used to estimate component durability to save the cost and time required to build the components and testing. The objective of this work is to find the service life of automotive HVAC pipe assembly by calculating cumulative fatigue life for operation under actual powertrain load conditions. Modal transient response analysis is performed with the measured powertrain load time history. Strain based fatigue life analysis is carried out using modal superposition method (MSM). The estimated fatigue life was compared with the physical test results. This paper also explains the root cause of low fatigue life on pipe assembly and provide the solution.

Experimental studies of soot particles showed that the intensity ratio of amorphous and graphite layers measured by Raman spectroscopy correlates to soot oxidation reactivities, which is very important for regeneration of the diesel particulate filters and gasoline particulate filters. This physical mechanism is absent in all soot models. In the present paper, a novel two-layer soot model was proposed that considers the amorphous and graphite layers in the soot particles. The soot model considers soot inception, soot surface growth, soot oxidation by O2 and OH, and soot coagulation. It is assumed that amorphous-type soot forms from fullerene. No soot coagulation is considered in the model between the amorphous- and graphitic-types of soot. Benzene is taken as the soot precursor, which is formed from acetylene. The model was implemented into a commercial CFD software CONVERGE using user defined functions. A diesel engine case was simulated.

Automotive fuel and emission regulations are becoming stringent decade over decade. These regulations are expected to be even more strict in future to control global warming, associated health issues and conserve energy. Automobile industries find it difficult to meet these regulations during the homologation cycle i.e. NEDC (New European Drive Cycle). Experiments and research indicated that engine structural parts achieve steady-state near end of the homologation cycle; which lead to account cold start effects as well during testing. Also, studies have proved that thermal efficiency of an IC engine is severely affected in cold start condition due to higher friction losses, incomplete combustion and their allied effects. Oil and coolant temperature helps in diminishing mechanical losses and achieving complete combustion. Hence, an effective distribution of combustion and friction heat during a cold start period is of utmost importance.

Increase in the atmospheric temperature across the globe during summer, increases the heat load in the vehicle cabin, creating a huge thermal discomfort for the passengers. There are two scenarios where these adverse conditions can be a problem during the summer. Firstly, while driving the vehicle in traffic conditions and secondly, when the vehicle is parked under the sun. When the vehicle is exposed to the radiation from the sun for a period, the cabin temperature can reach alarming levels, which may have serious discomfort and health effects on the people entering the vehicle. Although there are options of remote switching on of air conditioners, they are restricted to vehicles having an automatic transmission and availability of the mobile network. So, it is important to explore the possible options which can be used for restricting the external heat load to the cabin.

Nowadays development of automotive HVAC is a challenging task wherein thermal comfort and safety are very critical factors to be met. HVAC system is responsible for the demisting and defrosting of the vehicle’s windshield and for creating/maintaining a pleasing environment inside the cabin by controlling airflow, velocity, temperature and purity of air. Fog or ice which forms on the windshield is the main reason for invisibility and leads to major safety issues to the customers while driving. It has been shown that proper clear visibility for the windshield could be obtained with a better flow pattern and uniform flow distribution in the defrost mode of the HVAC system and defrost duct. Defroster performance has received significant attention from OEMs to meet the specific global performance standards of FMVSS103 and SAE J902. Therefore, defroster performance is seriously taken into consideration during the design of HVAC system and defroster duct.

In cold weather conditions, cabin heating performance is critical for retaining the thermal comfort. Heat is absorbed from the engine by circulating coolant through the engine water jacket and same will be rejected by the heater core. A variable speed blower is used to transfer heat from the heater core to the passenger compartment through floor ducts. The time taken to achieve comfortable cabin temperature determines the performance and capacity of heating ventilating and air conditioning (HVAC) system. In current automotive field, the engine options are provided to customers to meet their needs on the same vehicle platforms. Hence few engine variants cannot warm the cabin up to customer satisfaction. To improve the existing warm up performance of system, Positive thermal coefficient heater (PTC), electric coolant PTC heater, auxiliary pump etc. can be used which increases the overall cost of the vehicle. During warmup, HVAC system operates in 100% fresh mode.

Acoustic comfort of automotive cabins has progressively become one of the key attributes of passenger comfort within vehicle design. Wind noise and the heating, ventilation, and air conditioning (HVAC) system noise are two of the key contributors to noise levels heard inside the car. The increasing prevalence of hybrid technologies and electrification has an associated reduction in powertrain noise levels. As such, the industry has seen an increasing focus on understanding and minimizing HVAC noise, as it is a main source of noise in the cabin particularly when the vehicle is stationary. The complex turbulent flow path through the ducts, combined with acoustic resonances can potentially lead to significant noise generation, both broadband and tonal.

In current scenario, there is an increasing need to have faster product development and achieve the optimum design quickly. In an automobile air conditioning system, the main function of HVAC third row floor duct is to get the sufficient airflow from the rear heating ventilating and air-conditioning (HVAC) system and to provide the sufficient airflow within the leg locations of passenger. Apart from airflow and temperature, fatigue strength of the duct is one of the important factors that need to be considered while designing and optimizing the duct. The challenging task is to package the duct below the carpet within the constrained space and the duct should withstand the load applied by the passenger leg and the luggage. Finite element analysis (FEA) has been used extensively to validate the stress and deformation of the duct under different loading conditions applied over the duct system.

A valid human biodynamic model is very useful for studying the human body's response to whole body vibration. Whole body vibration is one of the important factors in the study of vehicle ride comfort. The environmental vibrations are transferred to the human body through floor and seat. Seated posture is the most commonly used position in automobiles. Therefore, studying the human body response in a seated position has attracted a lot of attention. Because the human body is in direct contact with the seat, its design plays a very important role in vibration transmission. In seat design, two important components are seat suspension and cushion. The mechanical properties of these components are stiffness, damping and mass. These properties can be changed by adjusting cushion material and seat suspension linkages. In this paper, three types of seat models are used. The first one is a hard seat.

In the vehicle development process, the door slam durability assessment is of significant importance in the estimation of fatigue life for body closure system. So far, various exertions have been taken into consideration to better represent the door slam simulation for door durability performance. Nowadays, with computer aided engineering (CAE) being extensively implemented, simulation procedures are constantly being investigated in order to get precise outcomes as physical testing. In a real world scenario, the customer closes the door frequently against the sealed cabin which offers the cabin pressure to close. The cabin pressure acts in the opposite direction of door closing providing the damping effect and minimizes the overall damage to the structure. Currently, simulations are focused on determining the total energy required for closing the door by summing up the energy lost in the weather seal and latch.

Powertrain wiring cable is a backbone of the electrical architecture in any vehicle electrical system design. The weight of a wiring cable is increasing year by year because of the recent development on high-voltage wiring systems, hybrid electric vehicles (HEVs) and electric vehicles (EVs). Clip failure, loosening clip and terminal breakage under engine roll condition is a common issue in powertrain electric cable (or body harness routing) development cycle in automotive industry. Usage of more number of clips in cable routing results in the powertrain design being more complex and it increases manufacturing cost. The standard procedure practiced to develop any dynamic envelope is by using CAD software tools and performing rigid body movements with the help of the motion file.

Pressure ringing phenomena in internal combustion engine are often observed in cylinder pressure measurement, which may be due to combustion dynamics, pressure oscillation inside the combustion chamber and/or inside a drilled probe hole for cylinder pressure sensor installation. In the present study, combustion process in a production DI diesel engine instrumented with pressure sensors in the cylinder head was analyzed using 3D combustion CFD simulation. Three combustion models (the CTC model with the Shell autoignition model, the Sage model with detailed chemistry, and the ECFM-3Z model) and three reaction mechanisms (the Shell autoignition model, the Chalmers reduced n-heptane mechanism, and the IFP PRF mechanism) were employed to validate their capability in capturing pressure ringing phenomena. Grid size within the drilled hole and speed of sound CFL number were varied to evaluate the effects on pressure ringing prediction.

Hybrid electric vehicle with hydrogen fueled internal combustion engine could be an interim between current vehicles and fuel cell vehicles which are thought to be more of far term reality. This paper introduces the hydrogen engine powered parallel hybrid electric vehicle developed by Texas Tech University Advanced Vehicle Engineering Lab. It presents the innovative use of LabVIEW Real-Time controllers to develop the prototype vehicle powertrain control system. Then it discusses the hydrogen engine control issues and presents the development of the engine control unit by LabVIEW FPGA. Vehicle communication issues among the distribution management system are presented. The vehicle test results are also shown in this paper.

Interest in electric vehicles (EVs) has significantly increased from the last decade, as the whole world is concerned about the reduction of emission of greenhouse gas by reducing the use of fossil fuel in transportation. The primary issue for electric vehicles is to develop an energy storage system i.e battery that can enable high mileage, rapid charging, and high-performance driving. Hence, battery management is required to get maximum, safe, and consistent performance of electric vehicles when running in a variety of conditions. To get the most out of a battery, it's important to keep an eye on its operating conditions, especially temperature, which has been shown to have a direct impact on battery performance and life. So, a battery thermal management system (BTMS) is crucial in the control of the thermal behavior of the battery. A good system simulation tool can minimize the time and cost of designing such a complicated thermal management system.

Machine learning methods, such as decision trees and deep neural networks, are becoming increasingly important and useful for data analysis in various scientific fields including dynamics and control, signal processing, pattern recognition, fluid mechanics, and chemical synthesis, etc. For future engine design and performance optimization, there is an urgent need for a robust predictive model which could capture the major combustion properties such as autoignition and flame propagation of multicomponent fuels under a wide range of engine operating conditions, without massive experimental measurement or computational efforts. It will be shown that these long-held limitations and challenges related to complex fuel combustion and engine research could be readily solved by implementing machine learning methods.

The application of Computational Fluid Dynamics (CFD) for three-dimensional (3D) combustion analysis coupled with detailed chemistry in engine development is hindered by its expensive computational cost. Chemistry computation may occupy as much as 90% of the total computational cost. In the present paper, a new two-step iso-octane combustion model was developed for spark-ignited (SI) engine to maximize computational efficiency while maintaining acceptable accuracy. Starting from the model constants of an existing global combustion model, the new model was developed using an approach based on sensitivity analysis to approximate the results of a reference skeletal mechanism. The present model involves only five species and two reactions and utilizes only one uniform set of model constants. The validation of the new model was performed using shock tube and real SI engine cases.

In recent years, study on the ride comfort of vehicles has attracted wide attention. The vibration caused by the road is transmitted to the human body through the tire, suspension, vehicle body, and the seat. Since the human body is in contact with the seat and the vibration is transmitted directly to the human body through the seat, the seat pan angle plays an important role on the vibration response of the human body. Previous studies have explored the effects of different backrest designs on human vibration response, but ignored the effects of different seat pan angles. Therefore, this paper will use a human biodynamic model combined with a 6-DOF seat model to study the effect of seat pan angles and feet-floor interaction on human vibration response. Three cases are proposed: Case 1 has a seat pan angle 8°, Case 2 has a seat pan angle 13°, and Case 3 has a seat pan angle 17°.

Flame speed data reported in most literature are acquired in conventional apparatus such as the spherical combustion bomb and counterflow burner, and are limited to atmospheric pressure and ambient or slightly elevated unburnt temperatures. As such, these data bear little relevance to internal combustion engines and gas turbines, which operate under typical pressures of 10-50 bar and unburnt temperature up to 900K or higher. These elevated temperatures and pressures not only modify dominant flame chemistry, but more importantly, they inevitably facilitate pre-ignition reactions and hence can change the upstream thermodynamic and chemical conditions of a regular hot flame leading to modified flame properties. This study focuses on how auto-ignition chemistry affects flame propagation, especially in the negative-temperature coefficient (NTC) regime, where dimethyl ether (DME), n-heptane and iso-octane are chosen for study as typical fuels exhibiting low temperature chemistry (LTC).