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A project was conducted by Southwest Research Institute on behalf of the California Air Resources Board and the South Coast Air Quality Management District to demonstrate the technical feasibility of utilizing closed-loop three-way catalyst technology in off-road equipment applications. Five representative engines were selected, and baseline emission-tested using both gasoline and LPG. Emission reduction systems, employing three-way catalyst technology with electronic fuel control, were designed and installed on two of the engines. The engines were then installed in a fork lift and a pump system, and limited durability testing was performed. Results showed that low emission levels, easily meeting CARB's newly adopted large spark-ignited engine emission standards, could be achieved.

A new approach to reclaiming the spoil areas produced by area-type mining operations has been developed. This system uses a machine known as a winch-dozer, consisting of a pair of large back-to-back buckets which are drawn by cable across spoil piles, moving back and forth between a “tailblock” anchor and a “drawworks” winch unit developed as an attachment to a large crawler tractor. The system is expected to reduce the cost of reclamation leveling by 40-50%. The system permits more effective power utilization due to the blade system's light weight, induces caving of spoil banks, and permits moving spoil in both directions of blade travel.

The Texas Department of Transportation (TxDOT) began using an emulsified diesel fuel in July 2002. They initiated a simultaneous study of the effectiveness of this fuel in comparison to 2D on-road diesel fuel, which they use in both their on-road and off-road equipment. The study also incorporated analyses for the fleet operated by the Associated General Contractors (AGC) in the Houston area. Some members of AGC use 2D off-road diesel fuel in their equipment. The study included comparisons of fuel economy and emissions for the emulsified fuel relative to the conventional diesel fuels. Cycles that are known to be representative of the typical operations for TxDOT and AGC equipment were required for use in this study. Four test cycles were developed from data logged on equipment during normal service: 1) the TxDOT Telescoping Boom Excavator Cycle, 2) the AGC Wheeled Loader Cycle, 3) the TxDOT Single-Axle Dump Truck Cycle, and 4) the TxDOT Tandem-Axle Dump Truck Cycle.

This paper discusses the techniques and diagnostic significance of atomic absorption, atomic emission, and infrared spectrometric analysis of crankcase lubricants, with the use of supplementary data where pertinent. The parameters affecting used oil analytical data are discussed in terms of examples from Army general purpose vehicle test engines. Wear metals in used gear oils are also discussed and examples are given. Analytical methods and their applications are fully described, and the equipment and procedures for infrared spectroscopy and gas chromatography techniques are outlined.

Several wireless systems such as Dedicated Short Range Communication (DSRC), cellular, Wi-Fi, Bluetooth, and the Tire Pressure Monitoring System (TPMS) can be found on modern vehicles. In the future, Software Defined Radio (SDR) technology could be integrated into automobiles to increase the efficiency and adaptability of wireless communications systems. SDR is also a powerful tool for designing and testing new communications protocols. However there are also some security considerations associated with SDR. This paper will review some advantages of using SDR technology in the automotive domain as well as potential security issues. The authors are currently conducting research into the use of SDR technology to model wireless systems and investigate security threats in modern vehicular systems.

The process of developing, parameterizing, validating, and maintaining models occurs within a wide variety of tools, and requires significant time and resources. To maximize model utilization, models are often shared between various toolsets and experts. One common example is sharing aircraft engine models with airframers. The functionality of a given model may be utilized and shared with a secondary model, or multiple models may run collaboratively through co-simulation. There are many technical challenges associated with model sharing and co-simulation. For example, data communication between models and tools must be accurate and reliable, and the model usage must be well-documented and perspicuous for a user. This requires clear communication and understanding between computer scientists and engineers. Most often, models are developed by engineers, whereas the tools used to share the models are developed by computer scientists.

Simulation and testing are often done by different engineers in different departments of a company. This can lead to disconnects and unrealistic predictions, especially if the person doing simulations does not have an experimental background. On the other hand, experimental results can also include errors that result in misleading answers. It is important for the engineer doing either testing or simulation to have a good understanding for what results are plausible and what results might be suspect. This paper will provide examples where error crept into testing or simulation that could have been caught and corrected early if a good feel for “reasonable” results had been in place. The importance of understanding how a software package is analyzing the data will be explained, since settings buried deep within a menu structure can drive misleading results.

The engine intake process governs many aspects of the flow within the cylinder. The inlet valve is the minimum area, so gas velocities at the valve are the highest velocities seen. Geometric configuration of the inlet ports and valves, and the opening schedule create organized large scale motions in the cylinder known as swirl and tumble. Good charge motion within the cylinder will produce high turbulence levels at the end of the compression stroke. As the turbulence resulting from the conversion energy of the inlet jet decays fast, the strategy is to encapsulate some of the inlet jet in the organized motions. In this work the baseline port of a 2.0 L gasoline engine was modified by inserting a tumble plate. The work was done in support of an experimental study for which a new single-cylinder research engine was set up to allow combustion system parameters to be varied in steps over an extensive range. Tumble flow was one such parameter.

Engine start-up (cranking) can be an important source of particle emissions from vehicles. With the penetration of GDI vehicles in the global vehicle fleet, it is important to analyze and understand the contribution of start-up particle emissions from GDI vehicles, and the potential effects of fuel properties on that process. In this work, chassis dynamometer based investigation on the effect of several gasoline fuels (commercial and blended) on both, naturally aspirated and turbocharged GDI vehicles were conducted to understand the importance of engine start up, in particular, cranking. 10 commercially available gasoline fuels were tested on a naturally aspirated 2010 model year GDI vehicle, 3 among these commercially available fuels were tested on another 2009 model year turbocharged GDI vehicle, and 8 blended gasoline fuels were tested on 12 other GDI vehicles (7 turbocharged and 5 naturally aspirated) ranging in model years 2011-2015.

The design of helical Intake ports for swirl generation is a process that has been developed over a number of years through primarily empirical methods. A number of design rules have been established that enable designers to develop ports that approach the state-of-the-art for maximum swirl generation with minimum pressure loss. More recently, computer-aided design (CAD) tools have been introduced that permit geometry and features to be accurately defined by mathematical surface descriptions, and to be parameterized such that derived geometry is updated automatically along with parent features. The author has developed a parametric design approach for helical ports that incorporates the lessons learned from experience into a systematic design procedure. This procedure takes advantage of the current CAD capabilities to expedite the design process and improve the result.

Atmospheric corrosion of steels, aluminum alloys, and Al-clad aluminum alloys is a problem for many civil engineering structures, commercial and military vehicles, and aircraft. Paint is usually the primary means to prevent the corrosion of steel bridge components, automobiles, trucks, and aircraft. Under ideal conditions, the coating provides a continuous layer that is impervious to moisture. At present, maintenance cycles for commercial and military aircraft and ground vehicles, as well as engineered structures, is based on experience and appearance rather than a quantitative determination of coating integrity. To improve the maintenance process and reduce costs, sensors are often used to monitor corrosion. The present suite of sensors designed to detect corrosion and marketed to predict the lifetime of the engineered components, however, are not useful for determining the condition of the protective paint coatings.

SCR-on-filter, or SCRoF, is an emerging technology for different market segments and vehicle applications. The technology enables simultaneous particulate matter trapping and NOX reduction, and provides thermal management and aftertreatment packaging benefits. However, there is little information detailing the lubricant derived exposure effects on functional SCR performance. A study was conducted to evaluate the impact of various oil consumption pathways on a light duty DOC and SCRoF aftertreatment system. This aftertreatment system was aged utilizing an engine test bench modified to enable increased oil consumption rates via three unique oil consumption pathways. The components were characterized for functional SCR performance, ash morphology, and ash deposition characteristics. This included utilizing techniques, such as SEM / EDS, to evaluate the ash structures and quantify the ash elemental composition.

Southwest Research Institute developed an Autonomous Ground Vehicle (AGV) capable of navigating in urban environments. The paper first gives an overview of hardware and software onboard the vehicle. The systems onboard are classified into perception, intelligence, and command and control modules to mimic a human driver. Perception deals with sensing from the world and translating it into situation awareness. This awareness is then fed into intelligence modules. Intelligence modules take inputs from the user to understand the need to navigate from its current location to another destination and, then, generate a path between them on urban, drivable surfaces using its internal urban database. Situational awareness helps intelligence to update the path in real time by avoiding any static/moving obstacles while following traffic rules.

This paper describes the development of a generic test cell software designed to overcome many vehicle-component testing difficulties by introducing modern, real-time control and simulation capabilities directly to laboratory test environments. Successfully demonstrated in a transmission test cell system, this software eliminated the need for internal combustion engines (ICE) and test-track vehicles. It incorporated the control of an advanced AC induction motor that electrically simulated the ICE and a DC dynamometer that electrically replicated vehicle loads. Engine behaviors controlled by the software included not only the average crankshaft torque production but also engine inertia and firing pulses, particularly during shifts. Vehicle loads included rolling resistance, aerodynamic drag, grade, and more importantly, vehicle inertia corresponding to sport utility, light truck, or passenger cars.

Research has shown that there are many factors that affect the long-term performance of nitrogen oxides (NOx) control systems used in diesel engine applications. However, if the NOx emissions can be accurately monitored, it might be possible to restore performance by making adjustments to the control systems. This paper presents results from a study that tested the durability of 25 NOx sensors exposed to heavy-duty diesel exhaust for 6,000 hours. The study, conducted by the Advanced Petroleum-Based Fuels - Diesel Emission Controls (APBF-DEC) project, tested the sensors at various locations in the exhaust stream.

This program involved the detailed evaluation of a novel laser-based in-exhaust ammonia sensor using a diesel fuel-based burner platform integrated with an ammonia injection system. Test matrix included both steady-state modes and transient operation of the burner platform. Steady-state performance evaluation included tests that examined impact of exhaust gas temperature, gas velocity and ammonia levels on sensor response. Furthermore, cross sensitivity of the sensor was examined at different levels of NOX and water vapor. Transient tests included simulation of the FTP test cycles at different ammonia and NOX levels. A Fourier transform infrared (FTIR) spectrometer as well as NIST traceable ammonia gas bottles (introduced into the exhaust stream via a calibrated flow controller) served as references for ammonia measurement.

Fossil fuel consumption is a significant factor in terms of both economic and environ-mental impact of on- and off-highway systems. Because fuel consumption can be directly tied to equipment efficiency, gains in efficiency can lead to reduction in operating costs as well as conservation of nonrenewable resources. Fluid performance has a direct effect on the efficiency of a hydraulic system. A procedure has been developed for measuring a fluid's effect on the degree to which mechanical power is efficiently converted to hydraulic power in pumps typical of off-highway applications.

Fuel conservationists will welcome this practicable proposal for converting railroads from diesel fuel to propane gas propulsion. Propane is no newcomer to the fuel family, but the advantages of economy, simplicity of operation, minimal maintenance, and extended life of equipment, as presented in this paper, show up its unexploited and extensive potential use in all mobile units. This careful study includes experimental results and data especially applied to railroad engines, even to conversion plans for existing engines that allows an interchangeable fuel system to accommodate present supply and variable cost factors in the United States.

The United States and Europe are mandating increasingly severe diesel fuel specifications, particularly with respect to sulfur content, and in some areas, aromatics content. This trend is directed towards reducing vehicle exhaust emissions and is generally beneficial to fuel quality, ignition ratings, and stability. However, laboratory studies, as well as recent field experience in Sweden and the United States, indicate a possible reduction in the ability of fuels to lubricate sliding components within the fuel injection system. These factors, combined with the trend toward increasing injection pressure in modern engine design, are likely to result in reduced durability and failure of the equipment to meet long-term emissions compliance. The U.S. Army Belvoir Fuels and Lubricants Research Facility (BFLRF) located at Southwest Research Institute (SwRI) developed an accelerated wear test that predicts the effects of fuel lubricity on injection system durability.

A combustion-based analytical method, initially developed by the Southwest Research Institute (SwRI) referred to as the Constant Volume Combustion Apparatus (CVCA), has been further researched/developed by an SwRI licensee (Advanced Engine Technology Ltd.) as an Ignition Quality Tester (IQT) for laboratories and refineries. The IQT software/hardware system permits rapid and precise determination of ignition quality for middle distillate fuels. Its features, such as low fuel volume requirement, complete test automation, and self-diagnosis, make it highly suitable for commercial oil industry and research applications. Operating and test conditions were examined in the context of providing a high correlation with cetane number (CN), as determined by the ASTM D-613 method. Preliminary investigation indicates that the IQT results are highly repeatable (± 0.30 CN), providing a high sensitivity to CN variation over the 33 to 58 CN range.