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Induction machines (IM) are considered work horse for industrial applications due to their rugged, reliable and inexpensive nature; however, their low power density restricts their use in volume and weight limited environments such as an aerospace, traction and propulsion applications. Given recent advancements in additive manufacturing technologies, this paper presents opportunity to improve power density of induction machines by taking advantage of higher slot fill factor (SFF) (defined as ratio of bare copper area to slot area) is explored. Increase in SFF is achieved by deposition of copper in much more compact way than conventional manufacturing methods of winding in electrical machines. Thus a design tradeoff study for an induction motor with improved SFF is essential to identify and highlight the potentials of IM for high power density applications and is elaborated in this paper.

In this paper we present a time-domain dynamic analysis of a helical gear box with different housing models using a unique finite element-contact mechanics solver. The analysis includes detail contact modeling between gear pairs along with the dynamics of gear bodies, shafts, bearings, etc. Inclusion of the housing in the dynamic analysis not only increases the fidelity of the model but also helps estimate important NVH metrics, such as dynamic load and vibration transmission to the base, sound radiation by the gearbox, etc. Two different housing models are considered. In the first, the housing is represented by a full FE mesh, and in the second, the housing is replaced by a reduced model of condensed stiffness and mass matrices. Component Mode Synthesis (CMS) methods are employed to obtain the reduced housing model. Results from both the models are successfully compared to justify the use of reduced housing model for further studies.

A new method for detecting the low power conditions on electronically-controlled diesel engines used in on-road vehicles has been developed. The advantage of this method is that it uses readily available diagnostic tools and engine installed sensors with no necessity for a dynamometer test. Without removing the engine, it gives an estimate of the real engine power which is accurate to 5%.

Design and development of the Cummins Signature 600, a new high horsepower dual overhead cam truck diesel engine, has been completed. The Signature 600 product system includes an all-new engine, controls, fuel system, and business information systems. During product definition, particular emphasis was placed on target markets, customer input to design, engineering and manufacturing processes, concurrent engineering and extensive mechanical and thermal analyses. Cummins Signature 600 fulfills the needs of Owner-Operator and Premium Fleet linehaul trucking businesses.

The damping effect that is observed when a fibrous acoustical treatment is applied to a thin metal panel typical of automotive structures has been modeled by using three independent techniques. In the first two methods the fibrous treatment was modeled by using the limp frame formulation proposed by Bolton et al., while the third method makes use of a general poro-elastic model based on the Biot theory. All three methods have been found to provide consistent predictions that are in excellent agreement with one another. An examination of the numerical results shows that the structural damping effect results primarily from the suppression of the nearfield acoustical motion within the fibrous treatment, that motion being closely coupled with the vibration of the base panel. The observed damping effect is similar in magnitude to that provided by constrained layer dampers having the same mass per unit area as the fibrous layer.

Energy storage options for a hybrid electric commercial single aisle aircraft were investigated. The propulsion system features twin Geared Turbofan™ engines in which each low speed spool is assisted by a 2,500 HP electric motor during takeoff and climb. During cruise, the aircraft is powered solely by the turbine engines which are sized for efficient operation during this mission phase. A survey of state of the art energy storage options was conducted. Battery, super-capacitor, and flywheel metrics were collected from the literature including Specific Energy (Wh/kg), Volumetric Energy Density (Wh/L), Specific Power (W/kg), Cost ($/kWh), and Number of Cycles. Energy storage in fuels was also considered along with various converters sized to produce a targeted quantity of electric power. The fuel and converters include fuel cells (both proton exchange membrane and solid oxide operating on hydrogen or on jet fuel) and a turbogenerator (jet fuel or LNG).

Induction machines (IM) are considered work horse for industrial applications due to their rugged, reliable and inexpensive nature; however, their low power density restricts their use in volume and weight limited environments such as an aerospace, traction and propulsion applications. Given recent advancements in additive manufacturing technologies, this paper presents opportunity to improve power density of induction machines by taking advantage of higher slot fill factor (SFF) (defined as ratio of bare copper area to slot area) is explored. Increase in SFF is achieved by deposition of copper in much more compact way than conventional manufacturing methods of winding in electrical machines. Thus a design tradeoff study for an induction motor with improved SFF is essential to identify and highlight the potentials of IM for high power density applications and is elaborated in this paper.

It is desired to reduce stator end winding length and mass to reduce associated resistive losses, increase efficiency and power density of an induction motor. With recent advancements in additive manufacturing technology, it is possible to deposit copper conductive paths and insulation layers in a selective controlled manner. This enables more compact end winding designs. The objective of this paper is to present a topology optimization based approach for design of stator end winding to minimize its overall length, volume and mass. Design approach and parametric study results for a representative stator design are presented in this paper. By reducing length of end winding, efficiency and power density of the induction motor can be increased enabling benefit realization for weight critical aerospace applications, incorporation in electric vehicle market and potentially reducing rare-earth dependency.

Auto transformer rectifier units (ATRUs) are commonly used in aircraft applications such as electric actuation for harmonic mitigation due to their high reliability and relative low cost. However, those components and the magnetic filter components associated to it are the major contributors to the overall size and weight of the system. Optimization of the magnetic components is essential in order to minimize weight and size, which are major market drivers in aerospace industry today. This requires knowledge of the harmonic content of the current. This can be obtained by simulation, but the process is slow. In order to enable fast and efficient design space exploration of optimal solutions, an algebraic calculation process is proposed in this paper for multi-pulse ATRUs (e.g. 12-pulse and 18-pulse rectifiers), starting from existing solution proposed for 6 pulse rectifier in the literature.

Testing procedures to evaluate new coolant pump seal face materials and new coolant pump seal designs were evaluated. Rig testing of materials and seals followed by engine dynamometer testing enabled changes in the seal materials or design to be validated prior to field testing and limited production. These procedures were used to test and implement a coolant pump seal face material change to silicon carbide versus carbon. The change resulted in higher reliability for the coolant pump seal and reduced warranty cost for the engine.

Previous work on the cooling jackets of the Cummins L10 engine revealed flow separation, and low coolant velocities in several critical regions of the cylinder head. The current study involved the use of detailed cooling jacket temperature measurements, and finite element heat transfer analysis to attempt the identification of regions of pure convection, nucleate boiling, and film boiling. Although difficult to detect with certainty, both the measurements and analysis pointed strongly to the presence of nucleate boiling in several regions. Little or no evidence of film boiling was seen, even under very high operating loads. It was thus concluded that the regions of seemingly inadequate coolant flow remained quite effective in controlling cylinder head temperatures. The Cummins L10 upon which this study has focused is an in-line six cylinder, four-stroke direct injection diesel engine, with a displacement of 10 liters.

The paper presents the latest research results on the piston ring free shape. A new free shape measurement method with optical gauging was developed. Three numerical models to compute the contact force distribution of piston ring were developed using finite element analysis (FEA). These numerical methods have been compared each other, and validated with the experimental results of ring deformation in a ring gage. The contact force distribution of a piston ring at working condition was also studied. It consists of the ring thermal boundary conditions (RTBC) validation, 3-D FEA thermal analysis and thermal contact force computation based on validated wire-cable element model. The RTBC for heavy duty diesel engine has been validated for the first time using a CUMMINS L10 engine test. Three different free shapes have been tested. The wear band measurements of tested rings all show tremendous improvements over the standard top ring.

A new telemetry system has been developed for temperature or strain measurements on a spherical joint piston. The system includes a piston mounted signal multiplexer and transmitter. A patented, piston mounted power generator operates in conjunction witii a modified cylinder liner. The telemetry system is robust, having high inertia load capability and high environmental temperature operating capability. The telemetry system was installed and operated on an engine motoring test rig. Temperature signals were transmitted at engine speeds from 400 rpm to 2100 rpm. Over 100 hours of high engine speed testing with oil sump temperatures up to 122°C were completed.

Measurements have been made to determine the effect of piston crown surface properties on combustion. Back-to-back engine tests were conducted to compare surface modified pistons to a production piston. Each modified piston was found to prolong combustion duration. Porous coatings and a non porous, roughened piston were observed to increase fuel consumption. Increase in fuel consumption was determined to be the result of increased heat release duration. The data show surface roughness alone affects the duration of heat release. The shift in magnitude of the centroid of heat release was similar to the shift observed in insulated engine experiments.

Data have been gathered to compare the performance of steel crown pistons coated with yttria stabilized zirconia or mullite to an uncoated piston. The effect of coated pistons on in-cylinder heat transfer was determined from curves of ISFC versus centroid of heat release. Error analysis of the measurements showed uncertainty of ± 3% in ISFC and ± 2 crank angle degrees in the centroid of heat release could be expected for the data. Particulate emissions increased at advanced injection timings with the mullite coated piston while the zirconia coated piston showed an increase in particulate and NOx at advanced timings.

Recent engine design trends towards increasing power, reducing weight, advancing of injection timing and increasing of injection rate and pressure could result in increased incidence of liner pitting. Liner pitting due to coolant cavitation is a complex function of many engine design parameters and operating conditions as described in reference [1]*. Traditionally, liner cavitation problems were not detected early in the development cycle. Traditional liner vibration and coolant pressure measurements in conjunction with a numerous amount of expensive engine endurance tests were then needed to resolve cavitation problems. A method newly developed by the author and described in reference [2] for cavitation intensity measurements was successfully utilized to map out engine operating condition and develop limit curves. This method could also be applied in a non intrusive fashion.

Cavitation corrosion is a very complex phenomenon that is governed by a formidable amount of factors and parameters. The phenomenon is a multi-disciplinary one which involves several aspects of physical sciences and engineering. This process is a slow progressive phenomenon with its detrimental effects being felt after severe damage has already occurred. A real time detection method for the severity of fluid cavitation and bubble collapse is described. The results are correlated to dynamic instantaneous pressure fluctuation measurements. The method is fast, reliable, and less restrictive of the sensing location. It has been tested and verified through a specially designed cavitation test rig and instrumentation setup. The method can be used for cavitation studies on ultrasonic bench rig tests and for cavitation measurements on running engines. The method was used to shed some light on characteristic cavitation differences between water and glycol which is used in engine coolants.

The increased use of on-board and off-board electronic systems with medium duty and heavy duty trucks and buses presents challenges with compatibility and proper integration. The vehicle architecture is taking shape to establish three areas of computer control-the powertrain, the cab instrument panel, and the cab operations center. The critical element of pursuing proper integration of these systems requires established and clear standards and test methods. Clear roles and responsibilities, a defined system architecture and common test methods are required between subsystem electronic product suppliers and vehicle manufacturers. The electronics integration challenges are presented in the context of the U.S. medium duty and heavy duty automotive industry but have broad applicability to other heavy vehicles and markets worldwide. SAE and ISO forums are needed to address these issues.

A dynamic simulation of a school bus powertrain has been constructed for the purpose of assisting in the development of engine control strategies. With some extensions, this model can also be used as a first approximation to support the development of transmission shift control strategies, predict vehicle performance and drivability as well as estimate transient loads on the powertrain components. The simulation was constructed using the Matlab* computing environment along with the Simulink* toolbox, a package for the graphical development of dynamic simulation models. The vehicle model was validated against test data measured in the target vehicle powered by a natural gas engine to ensure that the simulation model yielded sensible predictions of the dynamic powertrain behavior. Equipped with a validated model, the control engineer can now use the simulation tool to assist in algorithm development. Sample applications are illustrated.

A novel approach to vehicle airborne contaminant removal based on UV illumination of the photoactive semiconductor TiO2 (titania) at room temperature is described. This paper describes fundamental surface chemistry measurements, prototype development, and theoretical models needed for practical application of the technology. The process of incorporating this information into the design of effective air-purifiers for cabin air applications is described.