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A new laboratory test for measuring catalyst oxygen storage capacity has been developed. The test accurately predicts catalyst performance on the vehicle during transient A/F excursions and correlates well with vehicle CO and Nox tailpipe emissions. The test was subsequently used to facilitate improved oxygen storage capacity for new Pd-only washcoat formulations.

This paper provides an overview of the dual EGO sensor method for OBD-II catalyst efficiency monitoring. The processes governing the relationship between catalyst oxygen storage, HC conversion efficiency, and rear EGO sensor response are reviewed in detail. A simple physical model relating catalyst oxygen storage capacity and rear EGO sensor response is constructed and used in conjunction with experimental data to provide additional insight into the operation of the catalyst monitor. The effect that the catalyst washcoat formulation has in determining the relationship between catalyst oxygen storage capacity and HC conversion efficiency and its impact on the catalyst monitor is also investigated. Lastly, the effects of catalyst failure mode, fuel sulfur, and the fuel additive MMT on the catalyst monitor's ability to properly diagnose catalyst function are discussed.

Manual Materials Handling has been historically recognized as one of the more prevalent causes for work related lost time injuries. Many manufacturing facilities use Material Handling Systems (lift/ tilt tables, hoists, articulated arms), often to alleviate ‘ergonomic’ stressors as well as to optimize production. If not used appropriately, Material Handling Systems can create new ergonomic concerns, or in some cases increase the physical demands of a job. A strategy designed to optimize the fit between the operator, the appropriate equipment and the operation is addressed in this paper.

Automotive fuel vapor emissions that would otherwise evaporate into the atmosphere are being captured in activated carbon vapor storage canisters. Fuel vapor is loaded into the canisters via a direct connection to the fuel tank vapor dome. Hydrocarbons are desorbed from the activated carbon into the engine combustion cylinders using engine intake vacuum. The carbon canister capacity requirements have increased in recent years in order to meet both Enhanced Evaporative Emission regulations and the Clean Air Act emission requirements for On-board Refueling Vapor Recovery (ORVR). The higher capacity requirements have generated the need for larger volume canisters that can meet the emission requirements and still be designed within the space and packaging limits of the vehicle application. This paper describes the simultaneous engineering approach used at Ford Motor Company to design a large volume cylindrical shaped carbon canister.

There are a number of benefits from Ford Motor Company's participation in motorsports. This paper will describe how an engineering team developed a CAE process to assist in the design of a race car to meet impact requirements, with the technology transfer benefit of improved impact performance of composite structures in passenger cars. In 1997/98, a CAE process was developed and applied in the design and test of Formula One race car composite impact structures. For this particular engineering effort, a Ford proprietary software program, COMP-COLLAPSE, was the primary analysis tool that was utilized to successfully predict impact performance. As a result, COMP-COLLAPSE was used extensively in the design of race car composite impact structures. There were two beneficiaries from this effort: Race Vehicles: Improved vehicle impact performance as well as design improvement in crush efficiency, packaging, weight, and manufacturing.

Automotive display designers are faced with the task of providing more information to the driver through the implementation of an increased amount of on-board vehicle electronic systems. Package space in and around the instrument panel however, is at a premium. One remedy to this situation is the implementation of a dot matrix display with enough flexibility to fulfill several potential applications. Once a dot matrix display is integrated into a vehicle, information can be reformatted for presentation to the driver without redesigning the display device or its associated electronics. The system designer can then concentrate development resources on the remaining display subsystem components and issues such as user interface, display lighting, and packaging requirements for a specific application.

This paper describes the development of an analytical tool for the design automation of the temperature blend door mechanism in an automotive HVAC system. The function of the blend door is to control the temperature of the air blown into the cabin interior by regulating the mix of air passing through the heater core. The objective in the design process is to achieve a prescribed function of temperature with respect to control position at the instrument panel. The control effort to effect the desired temperature change is also another important consideration for customer satisfaction. The current design process is empirical in nature and relies on laboratory and vehicle testing with prototypes. The process is also iterative in nature and may continue until the end of the overall design cycle of the complete air handling subsystem. A parametric feature-based computer model, described subsequently in detail, allows for virtual prototyping of the blend door control mechanism.

This paper describes a study which was carried out to assess the potential for using a gasoline burner to heat the catalytic convertor during cold start. The results showed the catalyst/burner concept to be a promising LEV/ULEV capable technology. On a 1993 Ford Grand Marquis equipped with a catalyst burner system, catalyst light-off was achieved in less than 15 seconds while cold start HC emissions during the first 60 seconds of the FTP test were reduced by 60%. In addition, data are presented which compare the performance of the catalyst/burner to an electrically heated catalyst. In the tests performed, the catalyst/burner system out performed the EHC. Practical considerations, however, such as safety, durability, system integration, and packaging still need to be addressed.

Here we present a latent heat storage device which is used to provide “quick/supplemental” heat to the vehicle's conventional heating system. First, we present data from actual in-vehicle cold weather tests. Data are presented for heater and defroster performance tests, emissions tests and cold start tests after extended soaks. Secondly, heater performance predictions are made using a computer simulation program. Finally, the actual heater performance results are compared with the computer simulation.

A laboratory flow reactor test has been developed to examine hydrocarbon (HC) storage for diesel catalysts. Light-off testing alone has not been sufficient to rank diesel oxidation catalysts (DOCs) in agreement with vehicle HC conversions over the European driving cycle. HC emissions are important because of Stage II combined HC+NOx standard. During cold start and much of the ECE driving cycle, inlet catalyst temperatures on diesel passenger cars spend much time below 200°C. This is where more than half of the HC mass can be emitted. To be effective, DOCs must achieve sufficiently low HC light-off temperatures, or incorporate materials such as zeolites that trap HC until light-off is achieved. Consideration of both HC storage and light-off results together improve ranking of DOCs similar to vehicle ranking. Three supplier DOCs have been evaluated.

The flexibility, high performance, and cost benefits of microprocessors have been effectively applied to the field of automotive emissions testing. This paper describes the use of microprocessors in drivers aid, SHED testing, dynamometer coast down calibration and vehicle storage techniques. The successful implementation of microcomputers into emissions measurement systems have provided the automotive industry with a cost-effective, powerful and dependable tool for use in meeting the increasingly stringent emissions and fuel economy testing requirements for the 80's and beyond.

This project developed and evaluated a catalyst system for oxides of nitrogen control to achieve target reduction levels established for the Inter-Industry Emission Control (IIEC) Program, with concurrent control of the hydrocarbons and carbon monoxide. The major effort described is the evaluation of catalysts and the development of a suitable exhaust gas-temperature environment. The objective was met, with the exception of long-term durability, by using a pelleted, nonnoble metal catalyst and a special container design.

This paper summarizes results from a large study on the release of NOx from a lean NOx trap during rich purges. Under certain purge conditions, some NOx trap formulations have the propensity to release some of the NOx stored during previous lean operation without reducing it. This purge NOx release was examined for different NOx trap formulations. The purge NOx release was evaluated for one of the formulations as a function of several variables, including the aging condition of the trap, the trap temperature, the trap volume, the purge A/F ratio, the purge flow rate, and the amount of NOx stored. The effect of hot lean pretreatments on the purge NOx release was studied. In addition, the effect of the rhodium level on the purge NOx release was examined. Mechanisms for the NOx release are proposed that are consistent with the observed data. The results indicate that the purge NOx release is very low for thermally aged traps and is primarily a concern for fresh or stabilized traps.

Presented in this paper is an on-line method for estimating the oxygen storage capacity contained within a catalyst. The oxygen storage capacity of a catalyst changes over time due to catalyst brick temperatures, poisoned catalyst sites, and thermal aging. Information regarding the current oxygen storage capacity of a catalyst is advantageous in the development of robust emission control strategies and on-board diagnostics. The method of collecting the oxygen storage capacity information is extremely important for measurement accuracy and repeatability. Furthermore, the information must be obtained in such a way that it is transparent to the operator and may be implemented on-line during normal drive cycles. This on-line method for estimation of oxygen storage capacity of a catalyst has been demonstrated on a Ford F150 platform with an underbody catalyst.

A model of Ford's current FTP based OBD-II catalyst monitor has been developed and used in determining the optimal monitored catalyst volume for several LEV applications. The model predictions were found to agree reasonably well with the available experimental data. Furthermore, the results of this study indicate that the optimal monitored catalyst volume for meeting LEV requirements is vehicle application specific. As a result, it is concluded that a general guideline for sizing of the monitored catalyst volume for LEVs will most likely be inadequate and could result in grossly suboptimal catalyst monitor function for some applications. The model which is described in this paper offers a potentially more effective means of determining the best monitored catalyst volume for a given vehicle application. It should be possible to utilize this model during the early phase of a vehicle program in order to provide for the optimal packaging of the catalyst monitor sensor (CMS).

Rear end break-away, or skate, is a phenomenon that occurs when live axle equipped vehicles are driven aggressively on rough, winding roads. This paper reviews instrumented dynamic testing of a specially built vehicle. Initial testing linked skate to the tramp oscillation mode of the rear axle. Two variables were evaluated for reducing skate: shock absorber valving and shock absorber placement. The principal conclusion of this work is that although some reductions in skate are possible by adjusting shock absorber valving, optimum control of skate is facilitated by packaging the shock absorbers near the wheels.

The design and construction of the rail transit simulator for the dynamic testing of automobiles, trucks and components is described. The test facility features seven servo-controlled hydraulic actuators, along with associated electronics to simulate vehicle environmental conditions during rail shipment. This ability to simulate the shipping environment in the laboratory has effectively reduced the cost and the time required to evaluate designs.

The selection process of key engine design variables to maximize peak power subject to fuel economy and packaging objectives is formulated as an optimization problem readily solved with nonlinear programming. The merit of this approach lies not in finding a single optimal engine, but in identifying a family of optimal designs dependent on parameter changes in the constraint set. Sensitivity analysis of the optimum to packaging parameters, fuel economy parameters, and manufacturing parameters is presented and discussed in the context of product development decisions.

The Service Bay Diagnostic System (SBDS) will be designed to assist the dealership technician in diagnosing and repairing Ford Motor vehicles. The system hardware will be configured around a Service Bay Computer with mass storage capability and auxiliary service equipment. Major system features include: guided service writer/customer interaction, interactive vehicle diagnostics, information management. capabilities, and an additional aid to identifying intermittent failures through the use of a portable over-the-road data acquisition device. In order to assist the technician in properly diagnosing the causal factor, the Service Bay Computer System will also be enhanced through the use of an expert system knowledge base.

An approximate theoretical treatment is presented for the large deformation of non-linear viscoelastic cylindrical blocks bonded between rigid end-plates. The measured compressive force relaxation of two blocks of different initial radius to height ratios is shown to be in good agreement with the theoretical predictions for a carbon-black filled vulcanizate. Measurements of dynamic stiffness k* (=k1+jk2) for various compressive pre-loads and a frequency range of .05 to 30 Hz were also conducted. The measured values for the storage stiffness, k1 are shown to be in good agreement with the theoretical predictions, but poor correlation between experiment and theory is obtained for the loss stiffness, k2. Discrepancies between experimental and analytical results are attributed to the approximations employed to make the analysis mathematics more tractable rather than to the basic theory involved.