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An evaluation methodology has been developed for assessing the suitability of R-1234yf in vehicles. This relates primarily to evaluating the flammability of R-1234yf in the engine compartment during a frontal collision. This paper will discuss the process followed in the methodology, the technical rationale for this process, and the results of the analysis. The specific types of analysis included in the methodology are: exhaust-system thermal characterization, computer simulated crash tests, actual crash tests, teardown and examination of crashed parts, and releases of refrigerant onto hot exhaust manifolds. Each type of analysis was logically ordered and combined to produce a comprehensive evaluation methodology. This methodology has been applied and demonstrates that R-1234yf is difficult to ignite when factors that occur in frontal crashes are simultaneously considered.

This investigation utilizes a DFSS analysis approach to determine automatic transmission gear content required to minimize fuel consumption for various powertrain - vehicle systems. L18 and L27 inner arrays with automatic transmission design and shift pattern constraint parameters were varied to determine their relative influence on fuel consumption. An outer noise array consisting of two vehicles with various engines, final drive ratios and legislated emissions test cycles was used to make a robust transmission selection based on minimizing fuel consumption. The full details of the DFSS analysis method and assumptions are presented along with a detailed examination of the results. With respect to transmission design parameters, parasitic spinloss and gear mesh efficiency were found to be most important followed by the number of gears. The DFSS analysis further revealed that unique transmission design formulations are potentially required for widely varying engines.

For studying the effects of injection system properties and combustion chamber conditions on the penetration lengths of both the liquid and the vapor phase of fuel injectors in Diesel engines, a holistic injection model was developed, combining hydraulic and spray modeling into one integrated simulation tool. The hydraulic system is modeled by using ISIS (Interactive Simulation of Interdisciplinary Systems), a one dimensional in–house code simulating the fuel flow through hydraulic systems. The computed outflow conditions at the nozzle exit, e.g. the dynamic flow rate and the corresponding fuel pressure, are used to link the hydraulic model to a quasi–dimensional spray model. The quasi–dimensional spray model uses semi–empirical 1D correlation functions to calculate spray angle, droplet history and droplet motion as well as penetration lengths of the liquid and the vapor phases. For incorporating droplet vaporization, a single droplet approach has been used.

This paper presents a methodology to represent automatic transmission clutch-to-clutch shift dynamics with a two degree of freedom, lumped inertia model. The method of reducing the automatic transmission to a lumped, two inertia model as a function of shift and input shaft acceleration is detailed using a full kinematic representation of the automatic transmission. For a given clutch-to-clutch shift maneuver there are two dependent equations that utilize the two lumped inertias and represent the response of the transmission system from input to output shaft. Applicability of the method is shown for planetary automatic and layshaft dual clutch transmissions. Typical clutch-to-clutch shift maneuvers are illustrated with the two inertia model for power on upshifts and downshifts.

In automotive noise control, the hood liner is an important acoustic part for mitigating engine noise. The random incidence absorption coefficient is used to quantify the component level acoustic performance. Generally, air gaps, type of substrate materials, density of the substrate materials and Air Flow Resistivity (AFR) of the cover scrim are the dominant control factors in the sound absorption performance. This paper describes a systematic experimental investigation of how these control factors affect flat sample performance. The first stage of this study is full factorial measurement based on current available solutions from sound absorber suppliers. The acoustic absorption of different hood liner constructions, with variations in materials, density, air gaps, and scrims was measured.

This paper presents the most recent advancement in the vehicle development process using the one-step or auto Transfer Path Analysis (TPA) in conjunction with the superelement, component mode synthesis, and automated multi-level substructuring techniques. The goal is to identify the possible ways of energy transfer from the various sources of excitation through numerous interfaces to given target locations. The full vehicle model, consists of superelements, has been validated with the detailed system model for all loadcases. The forces/loads can be from rotating components, powertrain, transfer case, chain drives, pumps, prop-shaft, differential, tire-wheel unbalance, road input, etc., and the receiver can be at driver/passenger ears, steering column/wheel, seats, etc. The traditional TPA involves two solver runs, and can be fairly complex to setup in order to ensure that the results from the two runs are consistent with subcases properly labeled as input to the TPA utility.

In a math-based control algorithm design, model-based simulation and testing are very important as an integral part of design process. There are many advantages of using modeling and simulation in the algorithm design. In this paper, Algorithm-in-the-Loop and Hardware-in-the-Loop approaches are adopted for a transmission control algorithm development. A practical approach is introduced on how to test the control algorithms with a reliable plant (virtual engine, transmission, and vehicle) model in the closed-loop simulation. In using combination of open-loop and closed-loop simulations, various key behavior test cases are developed and documented for the success of control algorithms development. Secondly, the same test cases are reused and verified against the production codes, which are automatically generated from the math-based control algorithm models.

A novel ambient dilution tunnel has been designed, tested and employed to measure the emissions from active parked regenerations of Diesel Particulate Filters (DPFs) for 2007 and 2010 certified heavy duty diesel trucks (HDDTs). The 2007 certified engine had greater regulated emissions than the 2010 certified engine. For a fully loaded 2007 DPF there was an initial period of very large mass emissions, which was then followed by very large number of small particle emissions. The Particle Size Distribution, PSD, was distributed over a large range from 10 nm to 10 μm. The parked regenerations of the 2010 DPF had a much lower initial emission pattern, but the second phase of large numbers of small particles was very similar to the 2007 DPF. The emission results during regeneration have been compared to total emissions from recent engine dynamometer testing of 2007 and 2010 DPFs, and they are much larger.

High-efficiency, clean-combustion strategies for heavy-duty diesel engines are critical for meeting stringent emissions regulations and reducing the costs of aftertreatment systems that are currently required to meet these regulations. Results from previous constant-volume combustion-vessel experiments using a single jet of fuel under quiescent conditions have shown that mixing-controlled soot-free combustion (i.e., combustion where soot is not produced) is possible with #2 diesel fuel. These experiments employed small injector-orifice diameters (≺ 150 μm) and high fuel-injection pressures (≻ 200 MPa) at top-dead-center (TDC) temperatures and densities that could be achievable in modern heavy-duty diesel engines.

Diesel particulate filter (DPF) is a widely used emission control device on diesel vehicles. The DPF captures the particulate matter coming from the engine exhaust and periodically burns the collected soot via the regeneration process. There are various trigger mechanisms for this regeneration, such as distance, time, fuel and simulation. Another method widely used in the industry is the pressure drop across the filter. During calibration, relation between the pressure sensor reading and soot mass in the filter is established. This methodology is highly effective in successful DPF operation as pressure sensor is a live signal that can account for any changes in engine performance over time or any unforeseen hardware failures. On the other hand, any erroneous feedback from the sensor can lead to inaccurate soot mass prediction causing unnecessary regenerations or even needless DPF plugging concerns.

A dog clutch, if successfully implemented in an automatic transmission, provides better packaging and the potential for improved fuel economy. The technical requirements for this concept are examined through modeling and simulation. As a first step, a physics-based component level model is developed that provides an understanding of the basic contact and impact dynamics. The model is compared to a built-in AMESim block to establish confidence. This component level model is then integrated into a powertrain system model within the AMESim environment. As a test bed, the powertrain model is exercised to simulate a friction plate to dog clutch shift in a 6-speed automatic transmission. The analysis helps to define the slip speed target at the onset of the dog clutch engagement while ensuring shift requirements are met. Finally, the model is validated by comparing the simulated results with measured dynamometer data.

The Oppenheim Correlation (OPC) is a new empirical algorithm, which allows a simple estimate of heat losses to the wall during the combustion in IC-engine. In present paper the results of different applications of OPC will be shown. Even if there are still several needs and ideas for further research it can be stated, that the OPC is a promising possibility of modeling the wall heat losses and due to its simplicity it has to be recommended to the engine community. The OPC can be used not only for didactics purposes, but also for quick simulation of wall heat losses and eventually for the on-line regulation of the cooling system.

This investigation utilizes energy analysis and statistical methods to optimize step gear automatic transmissions gear selection for fuel consumption. A full factorial matrix of simulations using energy analysis was performed to determine the optimal number of gears and gear ratios that provide the best fuel consumption performance for a particular vehicle - engine application. The full factorial matrix setup as a design of experiment (DOE) was applied to five vehicle applications, each with two engines to examine the potential differences that variations in road load and engine characteristics might have on optimal transmission gearing selection. The transmission gearing options considered in the DOE were number of gears, launch gear ratio and top gear ratio. Final drive ratio was also included due to its global influence on vehicle performance and powertrain operating speeds and torque.

The car as a self-contained microcosm is undergoing radical changes due to the advances of electronic technology. We need to rethink what a "car'' really is and the role of electronics in it. Electronics is now essential to control the movements of a car, of the chemical and electrical processes taking place in it, to entertain the passengers, to establish connectivity with the rest of the world, to ensure safety. What will an automobile manufacturer's core competence become in the next few years? Will electronics be the essential element in car manufacturing and design? We will address some of these issues and we will present some important developments in the area of system design that can strongly impact the way in which a car is designed.

Evaluation of one year of in-use operating data from first generation Chevrolet Volt Extended-Range Electric Vehicle (E-REV) retail customers determined trip initial Internal Combustion Engine (ICE) starts were reduced by 70% relative to conventional vehicles under the same driving conditions. These Volt drivers were able to travel 74% of their total miles in EV without requiring the ICE's support. Using this first generation Volt data, performance of the second generation Volt is projected. The Southern California Association of Governments (SCAG) Regional Travel Survey (RTS) data set was also processed to make comparisons between realistic PHEV constraints and E-REV configurations. A Volt characteristic E-REV was found to provide up to 40 times more all-electric trips than a PHEV over the same data set.

The strain-induced diffusionless shear transformation of retained austenite to martensite during straining of transformation induced plasticity (TRIP) assisted steels increases strain hardening and delays necking and fracture leading to exceptional ductility and strength, which are attractive for automotive applications. A novel technique that provides the retained austenite volume fraction variation with strain with improved precision is presented. Digital images of the gauge section of tensile specimens were first recorded up to selected plastic strains with a stereo digital image correlation (DIC) system. The austenite volume fraction was measured by synchrotron X-ray diffraction from small squares cut from the gage section. Strain fields in the squares were then computed by localizing the strain measurement to the corresponding region of a given square during DIC post-processing of the images recorded during tensile testing.

For the computation of the equilibrium combustion temperature and pressure of hydrocarbon fuel in air, an original set of eighteen equations is enlarged by the energy and mass balance, and the procedure is applied to the cases of constant volume and of constant pressure combustion. Examples of engine combustion, including the effects of air-fuel ratio and the effect of water injection or exhaust gas recirculation, are treated; the results of computation are presented in graphs. The procedure of transformation and coding of the equation system for the solution on an electronic computer is described.

A comparison of welding techniques was performed to determine the most effective method for producing aluminum tailor-welded blanks for high volume automotive applications. Aluminum sheet was joined with an emphasis on post weld formability, surface quality and weld speed. Comparative results from several laser based welding techniques along with friction stir welding are presented. The results of this study demonstrate a quantitative comparison of weld methodologies in preparing tailor-welded aluminum stampings for high volume production in the automotive industry. Evaluation of nearly a dozen welding variations ultimately led to down selecting a single process based on post-weld quality and performance.

The ever-increasing regulatory requirement on CO2 emissions drives efficiency improvement of vehicle powertrain systems. In this context, three mega trends have been happening in the automotive transmission industry. First, future automatic transmissions will have more gear steps to offer a broader ratio spread and finer ratio steps, which may enable the engine to operate at its efficient regions more often. Second, engine downsizing with boosted power and flexible cylinder deactivation have been become the technology trend to achieve better thermal efficiency. These engine technologies demand improved transmission dampers with greater isolation capabilities to drive future transmission dampers to be equipped with softer springs. Third, future transmissions will be more efficient due to new architectures and incremental subsystem improvements.

The fact that, in our times, the execution of the exothermic process of combustion (‘heat release”) remains virtually uncontrolled is astonishing. Upon an attempt to rationalize this anomaly on historical grounds, technological means to rectify this astounding state of affairs are presented. They are based on the premise that, in the course of this process, the cylinder-piston enclosure is, in effect, a full-fledged chemical reactor. The salient feature of control is then active intervention into chemical reaction by turbulent jets. Principal elements of the control system are, as in any feedback mechanism, (1) sensors, (2) actuators and (3) a governor. The object of the first is to measure the profile of pressure - the useful output of the process. The second consists of a set of turbulent jet generators for injection of fuel and its mixing with air, as well as for ignition.