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With the advent of this new era of electric-driven automobiles, the simulation and virtual digital twin modeling world is now embarking on new sets of challenges. Getting key insights into electric motor behavior has a significant impact on the net output and range of electric vehicles. In this paper, a complete 3D CFD model of an Electric Motor is developed to understand its churning losses at different operating speeds. The simulation study details how the flow field develops inside this electric motor at different operating speeds and oil temperatures. The contributions of the crown and weld endrings, crown and weld end-windings, and airgap to the net churning loss are also analyzed. The oil distribution patterns on the end-windings show the effect of the centrifugal effect in scrapping oil from the inner structures at higher speeds. Also, the effect of the sump height with higher operating speeds are also analyzed.

This paper introduces the characteristics of the 4 wheel independent driving/4 wheel independent steering (4WID/4WIS) electric vehicle (EV). Models of Subsystems and the vehicle are constructed based on Matlab/simulink. The vehicle model allows the inputs of different drive torques and steer angles of four wheels. The dynamic characteristics of drive motors and steer motors are considered, and also it can reflect the vehicle longitudinal dynamics change due to the increase of the mass and inertia of the four wheels. Besides, drive mode selection function that is unique to this type vehicle is involved. Simulations and analyses of crab, oblique driving and zero radius turning which are the special conditions of 4WID/4WIS EV are conducted. The results show that the model can reflect the dynamic response characteristics. The model can be used to the simulation analyses of handling, stability, energy saving and control strategies verification of 4WID/4WIS EVs.

The study focuses on understanding the air and oil flow characteristics within a ball bearing during high-speed rotation, with a particular emphasis on optimizing frictional heat dissipation and oil lubrication methods. Computational fluid dynamics (CFD) techniques are employed to analyze the intricate three-dimensional airflow and oil flow patterns induced by the motion of rotating and orbiting balls within the bearing. A significant challenge in conducting three-dimensional CFD studies lies in effectively resolving the extremely thin gaps existing between the balls, races, and cages within the bearing assembly. In this research, we adopt the ball-bearing structured meshing strategy offered by Simerics-MP+ to meticulously address these micron-level clearances, while also accommodating the rolling and rotation of individual balls. Furthermore, we investigate the impact of different designs of the lubrication ports to channel oil to other locations compared to the ball bearings.

Effective design of the lubrication path greatly influences the durability of any transmission system. However, it is experimentally impossible to estimate the internal distribution of the automotive transmission fluid (ATF) to different parts of the transmission system due to its structural complexities. Hybrid vehicle transmission systems usually consist of different types of bearings (ball bearings, thrust bearings, roller bearings, etc.) in conjunction with gear systems. It is a perennial challenge to computationally simulate such complicated rotating systems. Hence, one-dimensional models have been the state of the art for designing these intricate transmission systems. Though quantifiable, the 1D models still rely heavily on some testing data. Furthermore, HEVs (hybrid electric vehicles) desire a more efficient lubrication system compared to their counterparts (Internal combustion engine vehicles) to extend the range of operation on a single charge.

Due to the high cost of torque sensors, a calculation model of transient torque is required for real-time coordinating control purpose, especially in hybrid electric powertrains. This paper presents a feedforward calculation method based on mean value model of turbocharged non-EGR diesel engines. A fitting variable called fuel coefficient is defined in an affine relation between brake torque and fuel mass. The fitting of fuel coefficient is simplified to depend only on three variables (engine speed, boost pressure, injected fuel mass). And a two-layer feedforward neural network is utilized to fit the experimental data. The model is validated by load response test and ETC (European Transient Cycle) transient test. The RMSE (root mean square error) of the brake torque is less than 3%.

During a vehicle drive cycle, the oil in the engine oil pan sloshes very vigorously due to the acceleration of the vehicle. This can cause the pickup tube in the engine oil pan to become uncovered from oil and exposed to air, which affects the lubrication pump performance. Engine oil pan sloshing is inherently a 3D problem as the free oil surface is constantly changing. Multi-dimensional Computational Fluid Dynamics (CFD) methods are very useful to simulate such problems with high detail and accuracy but are computationally very expensive. Part of the engine lubrication system, such as the pump, can be modelled in 1D which can predict accurate results at relatively high computational speeds. By utilizing the advantages of both 1D and 3D CFD models, a coupled 1D-3D simulation approach has been developed to capture the detailed oil sloshing phenomenon in SimericsMP+ and the system level simulation is conducted in GT-SUITE where 3D spatial data is not required.

High temperature components in internal combustion engines and exhaust systems must withstand severe mechanical and thermal cyclic loads throughout their lifetime. The combination of thermal transients and mechanical load cycling results in a complex evolution of damage, leading to thermomechanical fatigue (TMF) of the material. Analytical tools are increasingly employed by designers and engineers for component durability assessment well before any hardware testing. The DTMF model for TMF life prediction, which assumes that micro-crack growth is the dominant damage mechanism, is capable of providing reliable predictions for a wide range of high-temperature components and materials in internal combustion engines. Thus far, the DTMF model has employed a local approach where surface stresses, strains, and temperatures are used to compute damage for estimating the number of cycles for a small initial defect or micro-crack to reach a critical length.

A quasi-dimensional multi-zone model for diesel spray combustion has been developed. The model contains most of the physical processes of diesel spray combustion, and is simplified and economical. The zone formation is based on the fuel injection parameters. For the wall jet penetration velocity, a new equation is used based on the effect of the impinging free jet on the wall jet. For the fuel evaporation, an approximate solution of the instantaneous variations of droplet diameter is given in the simple algebraic equations based on the individual effect of the evaporation and the heat transfer from ambient gas. The soot emission sub-model calculates the soot concentration. This model has been applied for a direct injection diesel engine. The calculated results have shown a reasonable agreement with the experimental results. A parametric study has been carried out.

Dry dual clutch transmission (DCT) has played an important role in the high performance applications as well as low-cost market sectors in Asia, with a potential as the future mainstream transmission technology due to its high mechanical efficiency and driving comfort. Control system simplification and cost reduction has been critical in making dry DCT more competitive against other transmission technologies. Specifically, DCT clutch actuation system is a key component with a great potential for cost-saving as well as performance improvement. In this paper, a new motor driven clutch actuator with a force-aid lever has been proposed. A spring is added to assist clutch apply that can effectively reduce the motor size and energy consumption. The goal of this paper is to investigate the feasibility of this new clutch actuator, and the force-aid lever actuator's principle, physical structure design, and validation results are discussed in details.

Transport vehicles consume a large amount of fuel with low efficiency, which is significantly affected by drivers' behaviors. An assessment system of eco-driving pattern for buses could identify the deficiencies of driver operation as well as assist transportation enterprises in driver management. This paper proposes an assessment method regarding drivers' economic efficiency, considering driving conditions. To this end, assessment indexes are extracted from driving economy theories and ranked according to their effect on fuel consumption, derived from a database of 135 buses using multiple regression. A layered structure of assessment indexes is developed with application of AHP, and the weight of each index is estimated. The driving pattern score could be calculated with these weights.

Rotating clutches play an important role in automatic transmissions (AT), dual-clutch transmissions (DCT) and hybrid transmissions. It is very important to continually improve the transmission systems in the areas such as simplifying actuator designs, reducing cost and increasing controllability. A new concept of electrical motor driven actuation using a wedge mechanism, a wedge clutch, demonstrates potential benefits. This wedge clutch has the characteristics of good mechanical advantage, self-reinforcement, and faster and more precise controllability using electrical motor. In this paper, a new rotating wedge clutch is proposed. It presents a challenge since the motor actuator has to be stationary while the clutch piston is rotating. A new mechanism to connect the motor to the wedge piston, including dual-plane bearings and two mechanical ramp linkages, is studied. The design and verification of the physical structure of the actuator are discussed in detail in the paper.

The earth's fossil energy is not limitless, and we should be taking advantage of the highly developed fields of science and technology to utilize it more efficiently and to create a fully environmentally friendly life. Considering the prodigious amount of vehicles in the world today, even a small improvement in their energy-saving performance could have a significant impact. In this paper, a new type of electro-hydraulic power steering (EHPS) system is described. It has two main advantages. First, it can significantly decrease the demand on the motor so that it can be used for a wider range of vehicles. Second, its pressure-flow characteristic can be programmed and is more flexible than hydraulic power steering (HPS) system. A prototype with a 500 W motor was applied to a truck with a front load of 2,700 kg, and static steer sweep tests were conducted to validate its feasibility.

Understanding process induced fiber orientation distribution of composite body panels using nondestructive techniques is of prime interest. A compression molded sheet molding compound (SMC) panel is a good example of composite panels which are heavily affected by the molding process. Determination of the directionally dependent local coefficient of linear thermal expansion by digital image correlation yields information that is utilized to determine the local fiber misorientation and calculate the local SMC tensile modulus. In our current study, this methodology is utilized to determine the directional CLTE, permitting evaluation of the SMC properties in a multitude of directions not possible in destructive testing techniques. After obtaining the directionally dependent CLTE, a micromechanical approach is utilized to calculate the local SMC tensile modulus and glass fiber misorientation angle.

Tracked vehicles are widely used for agriculture, construction and many other areas. Due to high emissions, hybrid electric driveline has been applied to tracked vehicles. The hybrid powertrain design for the tracked vehicle has been researched for years. Different from wheeled vehicles, the tracked vehicle not only requires high mobility while straight driving, but also pursues strong steering performance. The paper takes the hybrid track-type dozers (TTDs) as an example and proposes an optimal design of a novel power-split powertrain for TTDs. The commercial hybrid TTD usually adopts the series hybrid powertrain, and sometimes with an extra steering mechanism, which has led to low efficiency and made the structure more complicated. The proposed three-planetary-gear power-split hybrid powertrain can overcome the problems above by utilizing the characteristics of planetary gear sets.

The design and development of electric vehicles involves many unique challenges. One such challenge involves accurately predicting driveline abuse torque loads early in the design cycle to aid with sizing drive-unit and driveline components. Since electrified drivelines typically lack a torque-limiting “fuse” element such as a torque converter or slipping clutch, they can be vulnerable to sudden transient events involving high wheel acceleration or deceleration. Component sizing must account for the loads caused by such events, and these loads must be accurately quantified early on when vehicle parameters haven’t been finalized yet. Early load predictions can be made by completing abuse maneuver simulations where key parameters are varied to gauge their influence on simulated loads. Understanding how these parameters impact loads allows for better risk assessment during the design process, as these parameters will inevitably change until a final design is iterated upon.

De-centralized brake actuation – that is, brake systems that incorporate individual actuators at each wheel brake location to both provide the apply energy and the modulation of braking force – is not a new area of study. Typically realized in the form of electro-mechanical brake calipers or drum brakes, or as “single corner” hydraulic actuators, de-centralized actuation in braking systems has already been deployed in production on General Motor EV1 Electric Vehicle (1997) in the form of electric drum brakes and has been studied continually by the automotive industry since then. It is frequently confused with “brake by wire,” and indeed practical implementations of de-centralized actuation are a form of brake by wire technology. However, with millions of vehicles on the road already with “brake by wire” systems - the vast majority of which have centralized brake actuation – the future of “brake by wire” is arguable settled.

Velocity prediction on hilly road can be applied to the energy-saving predictive control of intelligent vehicles. However, the existing methods do not deeply analyze the difference and diversity of road slope driving characteristics, which affects prediction performance of some prediction method. To further improve the prediction performance on road slope, and different road slope driving features are fully exploited and integrated with the common prediction method. A rolling prediction-based multi-scale fusion prediction considering road slope transition driving characteristics is proposed in this study. Amounts of driving data in hilly sections were collected by the advanced technology and equipment. The Markov chain model was used to construct the velocity and acceleration joint state transition characteristics under each road slope transition pair, which expresses the obvious driving difference characteristics when the road slope changes.

This paper presents a study of LPG lean burn in a motorcycle SI engine. The lean burn limits are compared by several ways. The relations of lean burn limit with the parameters, such as engine speed, compression ratio and advanced spark ignition etc. are tested. The experimental results show that larger throttle opening, lower engine speed, earlier spark ignition timing, larger electrode gap and higher compression ratio will extend the lean burn limit of LPG. The emission of a LPG engine, especially on NOx emission, can be significantly reduced by means of the lean burn technology.

In light-duty direct-injection (DI) diesel engines, combustion chamber geometry influences the complex interactions between swirl and squish flows, spray-wall interactions, as well as late-cycle mixing. Because of these interactions, piston bowl geometry significantly affects fuel efficiency and emissions behavior. However, due to lack of reliable in-cylinder measurements, the mechanisms responsible for piston-induced changes in engine behavior are not well understood. Non-intrusive, in situ optical measurement techniques are necessary to provide a deeper understanding of the piston geometry effect on in-cylinder processes and to assist in the development of predictive engine simulation models. This study compares two substantially different piston bowls with geometries representative of existing technology: a conventional re-entrant bowl and a stepped-lip bowl. Both pistons are tested in a single-cylinder optical diesel engine under identical boundary conditions.

Internal combustion engines, as the dominant power source in the transportation sector and the primary contributor to carbon emissions, face both significant challenges and opportunities in the context of achieving carbon neutral goal. Biofuels, such as biodiesel produced from biomass, and zero-carbon fuel ammonia, can serve as alternative fuels for achieving cleaner combustion in internal combustion engines. The dual-fuel combustion of ammonia-biodiesel not only effectively reduces carbon emissions but also exhibits promising combustion performance, offering a favorable avenue for future applications. However, challenges arise in the form of unburned ammonia (NH3) and N2O emissions. This study, based on a ammonia-biodiesel duel-fuel engine modified from a heavy-duty diesel engine, delves into the impact of adjustments in the two-stage injection strategy on the combustion and emission characteristics.