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Powertrain electrification is becoming increasingly common in the transportation sector to address the challenges of global warming and deteriorating air quality. This paper introduces a novel “Build Your Hybrid” approach to experience and test various hybrid powertrain concepts. This approach is applied to the light commercial vehicles (LCV) segment due to the attractive combination of a Diesel engine and a partly electrified powertrain. For this purpose, a demonstrator vehicle has been set up with a flexible P02 hybrid topology and a prototype Hybrid Control Unit (HCU). Based on user input, the HCU software modifies the control functions and simulation models to emulate different sub-topologies and levels of hybridization in the demonstrator vehicle. Three powertrain concepts are considered for LCVs: HV P2, 48V P2 and 48V P0 hybrid. Dedicated hybrid control strategies are developed to take full advantage of the synergies of the electrical system and reduce CO2 and NOx emissions.

Dimethyl ether (DME) is an alternative to diesel fuel for use in compression-ignition engines with modified fuel systems and offers potential advantages of efficiency improvements and emission reductions. DME can be produced from natural gas (NG) or from renewable feedstocks such as landfill gas (LFG) or renewable natural gas from manure waste streams (MANR) or any other biomass. This study investigates the well-to-wheels (WTW) energy use and emissions of five DME production pathways as compared with those of petroleum gasoline and diesel using the Greenhouse gases, Regulated Emissions, and Energy use in Transportation (GREET®) model developed at Argonne National Laboratory (ANL).

Recent applied mathematics research on the properties of the invertible shift-invariant discrete wavelet transform has produced new ways to visualize, separate, and synthesize impulsive sounds, such as thuds, slaps, taps, knocks, and rattles. These new methods can be used to examine the joint time-frequency characteristics of a sound, to select individual components based on their time-frequency localization, to quantify the components, and to synthesize new sounds from the selected components. The new tools will be presented in a non-mathematical way illustrated by two real-life sound quality problems, extracting the impulsive components of a windshield wiper sound, and analyzing a door closing-induced rattle.

Scalograms based on shift-invariant orthonormal wavelet transforms can be used to analyze impulsive and transient sounds in the presence of more stationary sound backgrounds, such as wind noise or drivetrain noise. The visual threshold of detection for impulsive features on the scalogram (signal energy content vs. time and frequency,) is shown to be similar to the audible threshold of detection of the human auditory system for the corresponding impulsive sounds. Two examples of impulsive sounds in a realistic automotive sound background are presented: automotive interior rattle in a vehicle passenger compartment, and spark knock recorded in an engine compartment.

After the success of the 4-cylinder 1.9-liter TDI and SDI direct-injection diesel engines in the Passat, Jetta and Polo classes, a new 3-cylinder TDI has been developed for use in the "Lupo 3L,' a compact car with a fuel consumption of 3 liters per 100 km. A new injection system with unit injectors, together with a fully electronically controlled engine management system featuring drive-by-wire- technology, a turbocharger with variable turbine geometry and a fully automated mechanical gearbox and clutch, for the first time ensures the potential to meet the stringent D4 exhaust emissions level and to achieve excellent fuel economy. The wheel-torque based engine and gearbox management systems optimize engine operation in terms of efficiency and emissions.

This work describes a single camera based object distance estimation system. As technology on vehicles is constantly advancing on the road to autonomy, it is critical to know the locations of objects in 3D space for safe behavior of the vehicle. Though significant progress has been made on object detection in 2D sensor space from a single camera, this work additionally estimates the distance to said object without requiring stereo vision or absolute knowledge of vehicle motion. Specifically, our proposed system is comprised of three modules: vision based ego-motion estimation, object-detection, and distance estimation. In particular, we compensate for the vehicle ego-motion by using pin-hole camera model to increase the accuracy of the object distance estimation.

A DMS (Driver Monitoring System) is one of the most important safety features that assist in the monitoring functions and alert drivers when distraction or drowsiness is detected. The system is based in a DSMC (Driver Status Monitoring Camera) mounted in the vehicle's dash, which has a predefined set of operational requirements that must be fulfilled to guarantee the correct operation of the system. These conditions represent a trade space analysis challenge for each vehicle since both the DSMC and the underlying vehicle’s requirements must be satisfied. Relying upon the camera’s manufacturer evaluation for every iteration of the vehicle’s design has proven to be time-consuming, resources-intensive, and ineffective from the decision-making standpoint.

High gas prices combined with demand for improved fuel economy have prompted increased interest in diesel engine applications for both light-duty and heavy-duty vehicles. The development of aftertreatment systems for these vehicles requires significant investments of capital and time. A reliable and robust qualification testing procedure will allow for more rapid development with lower associated costs. Qualification testing for DPFs has its basis in methods similar to DOCs but also incorporates a PM loading method and regeneration testing of loaded samples. This paper examines the effects of accelerated loading using a PM generator and compares PM generator loaded DPFs to engine dynamometer loaded samples. DPFs were evaluated based on pressure drop and regeneration performance for samples loaded slowly and for samples loaded under accelerated conditions. A regeneration reactor was designed and built to help evaluate the DPFs loaded using the PM generator and an engine dynamometer.

Laser-induced exciplex fluorescence has been applied to the mixture formation process in the combustion chamber of an optically-accessible four-cylinder in-line spark-ignition engine in order to distinguish between liquid and vapor fuel distribution during the intake and compression stroke for different injection timings. The naphthalene/N,N,N′N′-tetramethyl p-phenylene diamine (TMPD) exciplex system excited at 308nm with a broadband XeCl excimer laser is used to obtain spectrally-separated, single-shot fluorescence images of the liquid or vapor phase of the fuel. For different timings of the fuel injector this technique is applied to obtain crank-angle-resolved images of the resulting mixture in the combustion chamber. The fluorescence light is detected with an intensified slow-scan CCD-camera equipped with appropriate filters.

To support its recycling efforts, Ford Motor Company is using a Raman based instrument, the RP-1, co-developed with SpectraCode Inc. to identify unknown polymeric parts. Our recycling initiative involves detailed dismantling of our vehicles into individual parts, calculating the percentage recyclability and making recommendations for the future use of recycled polymers. While Ford has voluntarily adopted the SAE J1344 marking protocol for identifying part material composition, a large number of unmarked parts still exist and require identification. This identification is being done with the help of RP-1. To facilitate this identification, we have generated an accurate reference library of Raman spectra for comparison to those of unknown materials. This paper will describe the techniques that were used to develop and refine the RP-1 reference library to identify automotive polymers, especially black/dark plastics.

Successful application of turbocharger technology to the Ford 2.3L OHC engine requires management of thermal loading. The 1979/1980 2.3L draw-thru carbureted engine was octane and spark advance limited, requiring calibration to worse case 91 RON conditions. Since no adaptive calibration control was possible relatively late ignition timing compromised engine performance. To improve performance, driveability, fuel economy and emission control, work was initiated in mid 1980 on a blow-thru electronic fuel injected engine scheduled for 1983½ production. Program assumptions were issued specifying a tuned EFI blow-thru inlet system, exhaust manifold mounted AiResearch T03 turbocharger with integral wastegate and 8.0:1 compression ratio with a dished piston. Also included were base engine revisions to accommodate increased thermal and mechanical loads.

Ford's new 2.3 Litre I-4 Turbocharged Engine and Powertrain was specifically developed to match the new 1979 Mustang/ Capri. This engine/vehicle combination was developed to provide the customer excellent vehicle performance, good fuel economy and driveability. Extensive vehicle and dynamometer work was done to match the turbocharger to the engine and optimize in-vehicle mid-range to high end performance. The relatively high compression ratio (9.0:1) was retained from the naturally aspirated engine to preserve low end manual transmission vehicle performance before turbocharger boost. Revisions to basic engine components and structures to insure durability will be discussed.

EcoBoost engines constitute one of the strategies used by Ford Motor Company to deliver engines with improved fuel economy and performance. However, turbochargers exhibit many inherent NVH challenges that need to be addressed in order to deliver refined engines that meet customer’s expectation. One of these challenges is the turbocharger 1st order synchronous noise due to the interaction between the manufacturing tolerances of the rotating components and the dynamic behavior of the rotor. This paper discusses an MBD/FEA/BEM based method to predict the nonlinear dynamic behavior of the rotor semi floating bearing, its impact on the bearing loads and the resulting powerplant noise due to the interaction with the turbocharger imbalance level.

The use of variable geometry turbocharging (VGT) as an aid to performance enhancement has been the subject of much interest for use in high-speed, light-duty automotive diesel applications in recent times (4). One of the key benefits anticipated is the improved transient response possible with such a device over the conventional fixed geometry turbine with wastegate. The transient responses of two different types of variable geometry turbocharger have been investigated on a dynamic engine test bed. To demonstrate the effect of the turbocharger on the entire system a series of step changes in engine load at constant engine speed were carried out with the turbocharger and exhaust gas recirculation (EGR) systems under the control of the engine management microprocessor. Results are presented which compare the different performance and emissions characteristics of the devices. Some control issues are discussed with a view to improving the transient response of both types.

A methodology is developed that incorporates high resolution CFD flowfield information and a particle trajectory simulation, aimed at addressing Paint Transfer Efficiency (PTE) for bell sprayers. Given a solid model for the bell sprayer, the CFD simulation, through automeshing, determines a high resolution Cartesian volume mesh (14-20 million cells). With specified values of the initial shaping air, transient and steady-state flow field information is obtained. A particle trajectory visualization tool called SpraySIM uses this complicated flowfield information to determine the particle trajectories of the paint particles under the influence of drag, gravity and electrostatic potential. The sensitivity of PTE on shaping air velocity, charge-to-mass ratio, potential, and particle diameter are examined.

The formation of soot during the first phase and the oxidation of soot during the later phase of the combustion in a direct-injection diesel engine have been investigated in detail by an extinction method. The experiments were performed in a 1.9 l near-production high-speed four-cylinder in-line direct-injection diesel engine for passenger cars for different rates of exhaust gas recirculation (EGR) and for different fuels. The measurements result in crank angle resolved and cycle-averaged soot mass concentrations in the piston bowl and the combustion chamber. The results show that with increasing EGR-rates the amount of soot formed is increased only slightly but the amount of soot oxidized during combustion decreases significantly. This is assumed to be the main reason for the increase of soot in the exhaust gas with increasing EGR-rates.

Historically, fuel cost conscious customers have tended to purchase diesel passenger cars. However, with increasing competition from alternative fuels and lean burn and direct injection gasoline fuelled engines, diesel engined vehicles currently face tough challenges from the point of fuel economy and emissions. In gasoline engines, low viscosity friction modified oils have demonstrated their potential for reducing internal engine friction and thus improving fuel economy, without adversely effecting engine durability. These fuel economy improvements have led to the introduction of such a low viscosity friction modified 5W-30 oil as the initial and service fill for the majority of Ford products sold in Europe. The trend towards even lower viscosities continues. To assess the potential benefits and issues of moving to 5W-20 in diesel engines, a short pilot study has been conducted using a Ford 1.8l direct injection diesel engine.

Wavelets are a powerful mathematical tool used to multi-resolution time-frequency decomposition of signals, in order to analyze them in different scales and obtain different aspects of the information. Despite being a relatively new tool, wavelets have being applied in several areas of human knowledge, especially in signal processing, with emphasis in encoding and compression of image, video and audio. Based on a previous successful applications (FRAZIER, 1999) together a commitment to quality results, this paper evaluates the use of the Discrete Wavelet Transform (DWT) as an compression algorithm to reduce the amount of data collected in road load signals (load history) which are used by the durability engineering teams in the automotive industry.

An investigation was conducted to elucidate, how the latest turbocharged, direct injection Volkswagen diesel engine generation with cylinder pressure based closed loop control, to be launched in the US in 2008, reacts to fuel variability. A de-correlated fuels matrix was designed to bracket the range of US market fuel properties, which allowed a clear correlation of individual fuel properties with engine response. The test program consisting of steady state operating points showed that cylinder pressure based closed loop control successfully levels out the influence of fuel ignition quality, showing the effectiveness of this new technology for markets with a wide range of fuel qualities. However, it also showed that within the cetane range tested (39 to 55), despite the constant combustion mid-point, cetane number still has an influence on particulate and gaseous emissions. Volatility and energy density also influence the engine's behavior, but less strongly.

Pilot injection has been used widely in diesel engines for its NOx and noise reducing characteristics. In this paper, its impacts to the particle emissions were studied using a light-duty common-rail Euro 4 diesel engine with different pilot injection strategies. Three steady-state engine modes were selected from the EU legislative diesel engine test cycle to represent low, medium and high engine speeds and loads. The quantities and injection timings of the pilot injection strategies were then varied. The particle number concentration and size distributions were investigated along with the smoke and regulated gas emissions such as the NOx trade-off. These results indicate how a pilot injection alongside a main injection can increase the particle size compared to a single main injection event. Furthermore, the split injection was closely related to the engine mode.