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Fuel consumption in internal combustion engines and their associated CO2 emissions have become one of the major issues facing car manufacturers everyday for various reasons: the Kyoto protocol, the upcoming European regulation concerning CO2 emissions requiring emissions of less than 130g CO2/km before 2012, and customer demand. One of the most efficient solutions to reduce fuel consumption is to downsize the engine and increase its specific power and torque by using turbochargers. The engine and the turbocharger have to be chosen carefully and be finely tuned. It is essential to understand and characterise the turbocharger's behaviour precisely and on its whole operating range, especially at low engine speeds. The characteristics at low speed are not provided by manufacturers of turbochargers because compressor maps cannot be achieve on usual test bench.

As on-highway heavy-duty diesel engine designs have evolved to meet tighter emission regulations, the crankcase environment for heavy-duty engine lubricants has become more challenging. The introduction of Exhaust Gas Recirculation (EGR) has allowed for significant reductions of exhaust emissions, but has led to increased oxidation and acid build-up in the lubricant. Engine lubricant quality is important to help ensure engine durability, engine performance, and reduce maintenance downtime. Increased acidity and oxidation accelerate the rate at which the lubricant quality is degraded and hence shorten its' useful life. This paper explores the use of a lube filter with a controlled additive release to maintain lubricant quality.

Various government agencies such as EPA and CARB have established evaporative emission standards for light duty vehicles. To help the OEM's meet these emission standards for volatile organic compounds (VOC's), Honeywell has developed a hydrocarbon adsorber (HCA) approach to reduce hot soak emissions that escape through the air induction system. The HCA has a small footprint and is incorporated in the air filter housing while having a minimal impact on the air flow to the engine during normal operation. As required through EPA regulations it is permanently mounted to provide life of the vehicle durability. In this paper, the process for selecting the VOC adsorbent that functions within the parameters of the hot soak cycle and is regenerated under standard engine operation is discussed. An important part of this technology has been the development of a laboratory test that would simulate engine conditions and permit evaluation of various HCA prototypes.

The molecular filtration of sulfur components in ultra low sulfur diesel (ULSD) fuel is described. A comprehensive screening of potential sulfur removal chemistries has yielded a sorbent which has the capability to efficiently remove organo-sulfur components in ULSD fuel. This sorbent has been used to treat ULSD fuel on a heavy duty engine equipped with NOx adsorber after-treatment technology and has been shown to lengthen the time between desulfation steps for the NOx adsorber. The fuel properties, cetane number and aromatics content, etc., have not been changed by the removal of the sulfur in the fuel with the exception of the lubricity which is reduced.

The Indirect Boundary Element Analysis is employed for developing a computational pass-by noise simulation capability. An inverse analysis algorithm is developed in order to generate the definition of the main noise sources in the numerical model. The individual source models are combined for developing a system model for pass-by noise simulation. The developed numerical techniques are validated through comparison between numerical results and test data for component level and system level analyses. Specifically, the source definition capability is validated by comparing the actual and the computationally reconstructed acoustic field for an engine intake manifold. The overall pass-by noise simulation capability is validated by computing the maximum overall sound pressure level for a vehicle under two separate driving conditions.

A detailed study was conducted on nitrification using a bench top bioprocessor system proposed for water recycling of a urine-soap wastewater expected to be generated by crewmembers on International Space Station (ISS) or similar long-term space missions. The bioprocessor system consisted of two packed bed biofilm reactors; one anoxic reactor used for denitrification and one aerobic reactor used for nitrification. lnfluent wastewater was a mixture of dilute NASA whole body soap (2,300 mg/L) and urea (500 mg/L as organic nitrogen). During two months of steady-state operation, average chemical oxygen demand (COD) removal was greater than 95%, and average total nitrogen removal was 70%. We observed that high levels of nitrite consistently accumulated in the aerobic (nitrifying) reactor effluent, indicating incomplete nitrification as the typical end product of the reaction would be nitrate.

The bleed air contamination monitor was developed at Honeywell to ensure that our products provide the highest quality bleed air to aircraft environmental control systems. The bleed air contamination monitor is currently for ground based applications only. It is being developed into an on board system for future applications. Current Aircraft Cabin Air Quality measurement techniques are very labor intensive and require days or even weeks of laboratory analysis to provide results. This is unacceptable from a manufacturing and service perspective. Development of a real time analyzer began in the early 1990s and has progressed to a point where a product is ready for introduction that not only provides real time information regarding engine air contamination, but is also easy for operators to use with a minimum amount of training.

Increased nickel concentrations in the IATCS coolant prompted a study of the corrosion rates of nickel-brazed heat exchangers in the system. The testing has shown that corrosion is occurring in a silicon-rich intermetallic phase in the braze filler of coldplates and heat exchangers as the result of a decrease in the coolant pH brought about by cabin carbon dioxide permeation through polymeric flexhoses. Similar corrosion is occurring in the EMU de-ionized water loop. Certain heat exchangers and coldplates have more silicon-rich phase because of their manufacturing method, and those units produce more nickel corrosion product. Silver biocide additions did not induce pitting corrosion at silver precipitate sites.

Due to the wide and ever increasing application of thermoplastic parts in the automotive industry, the measurement and interpretation of their properties must be thoroughly understood before anyone can hope to correctly utilize the results in material selection, product design, and performance analysis while all these can be greatly influenced by the end-use conditions. Tensile properties of thermoplastics, such as stress and strain at yield, ultimate tensile strength, and Young's modulus, are among the most widely measured and cited mechanical properties for material evaluation, quality control, structure design, modeling, and failure analysis. This paper deals with several major challenges that an engineer may face when attempting to obtain accurate tensile property data for thermoplastics. One such challenge is the trend of automotive industry today to convert from ASTM to ISO procedures for thermoplastics evaluation and product certification.

Honeywell is developing a 50-kW, high efficiency PEM fuel cell stack system (FCSS) for use in light-duty vehicle transportation under sponsorship from the Department of Energy (DOE) and the South Coast Air Quality Management District. The performance goals of the FCSS include weight, volume, cost, efficiency, and transient performance. The project includes design, testing, and delivery of the FCSS to DOE. A conceptual system design is presented including trade study results and the technology gaps that must be bridged to meet the DOE goals.

Simulated spacecraft water recovery wastewater feed streams were purified with a three-stage vacuum rotary distillation processor (TVRD) during a series of tests conducted to evaluate the operation of this technology. The TVRD was developed to efficiently reclaim potable water from urine in microgravity by NIICHIMMASH (Moscow, Russia). A prototype was evaluated at the Honeywell Space Water Reclamation test lab, where a special test setup was assembled to evaluate the performance of the TVRD. This paper discusses the TVRD technology, test description, test results, and performance analysis. Tests were conducted using four streams of wastewater: pretreated human urine, bioprocessor effluent, reverse osmosis brine ersatz, and deionized water. The testing demonstrated that greater than 90 percent water recovery can be reached with production rates of 2.2 to 2.9 kg/hr (4.84 to 6.30 lb/hr).

The Biological Wastewater Processor Experiment Definition team is performing the preparatory ground research required to define and design a mature space flight experiment. One of the major outcomes from this work will be a unit-gravity prototype design of the infrastructure required to support scientific investigations related to microgravity wastewater bioprocessing. It is envisioned that this infrastructure will accommodate the testing of multiple bioprocessor design concepts in parallel as supplied by NASA, small business innovative research (SBIR), academia, and industry. In addition, a systematic design process to identify how and what to include in the space flight experiment was used.