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Transient engine operations are modeled and simulated with a 1-D code (GT Power) using heat release and emission data computed by a 3-D CFD code (Kiva3). During each iteration step of a transient engine simulation, the 1-D code utilizes the 3-D data to interpolate the values for heat release and emissions. The 3-D CFD computations were performed for the compression and combustion stroke of strategically chosen engine operating points considering engine speed, torque and excess air. The 3-D inlet conditions were obtained from the 1-D code, which utilized 3-D heat release data from the previous 1-D unsteady computations. In most cases, only two different sets of 3-D input data are needed to interpolate the transient phase between two engine operating points. This keeps the computation time at a reasonable level. The results are demonstrated on the load response of a generator which is driven by a medium-speed diesel engine.

To reduce the Body in White (BIW) mass, it is necessary to expand the application of Advanced High-Strength Steels (AHSS) to complex shaped parts. In order to apply AHSS to complex shaped parts with thinner gauge, high formability steel is required. However, higher strength steels tend to display lower elongations, compared with low/medium strength steels. Current AHSS are applied to limited parts for this reason. The new 1.2GPa material, with high formability, was developed to solve this issue. The mechanical property targets for the high elongation 1.2GPa material were achieved by precise metallurgical optimization. Many material aspects were studied, such as formability, weldabilty, impact strength, and delayed fracture. As the result of this development, 1.2GPa AHSS has been applied to a new vehicle launched in 2013.The application of this material was the 1st in the world, and achieved a 11kg mass reduction.

The use of virtual prototyping early in the design stage of a product has gained popularity due to reduced cost and time to market. The state of the art in vehicle simulation has reached a level where full vehicles are analyzed through simulation but major difficulties continue to be present in interfacing the vehicle model with accurate powertrain models and in developing adequate formulations for the contact between tire and terrain (specifically, scenarios such as tire sliding on ice and rolling on sand or other very deformable surfaces). The proposed work focuses on developing a ground vehicle simulation capability by combining several third party packages for vehicle simulation, tire simulation, and powertrain simulation. The long-term goal of this project consists in promoting the Digital Car idea through the development of a reliable and robust simulation capability that will enhance the understanding and control of off-road vehicle performance.

The paper describes a methodology to co-simulate, with high fidelity, simultaneously and in one computational framework, all of the main vehicle subsystems for improved engineering design. The co-simulation based approach integrates in MATLAB/Simulink a physics-based tire model with high fidelity vehicle dynamics model and an accurate powertrain model allowing insights into 1) how the dynamics of a vehicle affect fuel consumption, quality of emission and vehicle control strategies and 2) how the choice of powertrain systems influence the dynamics of the vehicle; for instance how the variations in drive shaft torque affects vehicle handling, the maximum achievable acceleration of the vehicle, etc. The goal of developing this co-simulation framework is to capture the interaction between powertrain and rest of the vehicle in order to better predict, through simulation, the overall dynamics of the vehicle.

Gas chromatographic methods for analyzing hydrocarbon species in vehicle exhaust emissions were compared in terms of their collection efficiency, detection limit, repeatability and number of species detected using cylinder gas and tailpipe emission samples. The main methods compared were a Tenax cold trap injection (TCT) method (C5-C12 HCs) and a cold trap injection (CTI) method (C2-C4 HCs; C5-C12 HCs). Our own direct (DIR) method was used to confirm the collection efficiencies. Both methods yielded good results, but the CTI method showed low collection efficiency for some C2-C4 HCs. Measurement of individual species is needed with this method for accurate analysis of tailpipe emissions. Both the CTI method and the TCT method combined with the DIR method for determining C2-C4 HCs yielded nearly the same ozone specific reactivity values for the NMHC species analyzed.

In a recent study, quantitative measurements were presented of in-cylinder spatial distributions of mixture equivalence ratio in a single-cylinder light-duty optical diesel engine, operated with a non-reactive mixture at conditions similar to an early injection low-temperature combustion mode. In the experiments a planar laser-induced fluorescence (PLIF) methodology was used to obtain local mixture equivalence ratio values based on a diesel fuel surrogate (75% n-heptane, 25% iso-octane), with a small fraction of toluene as fluorescing tracer (0.5% by mass). Significant changes in the mixture's structure and composition at the walls were observed due to increased charge motion at high swirl and injection pressure levels. This suggested a non-negligible impact on wall heat transfer and, ultimately, on efficiency and engine-out emissions.

A light weight,multifunctional plastic reinforcement has been developed for the outer body panels of vehicles. This new plastic reinforcement,composed mainly of polyvinylchloride resin, epoxy resin and an organic foaming agent, provides a 63% weight reduction over conventional plastic reinforcements, while adding the damping function to outer body panels. This paper introduces the process followed in developing the new plastic reinforcement and describes its characteristics. This new plastic reinforcement is already employed in the Nissan S-Cargo model, and it will be adopted in other passenger car models to be released in the near future.

Research is under way on an engine system [1] that achieves a variable compression ratio using a multiple-link mechanism between the crankshaft and pistons for the dual purpose of improving fuel economy and power output. At present, there is no database that allows direct judgment of the feasibility of the specific sliding parts in this mechanism. In this paper, the feasibility was examined by making a comparison with the sliding characteristics and material properties of conventional engine parts, for which databases exist, and using evaluation parameters based on mixed elasto-hydrodynamic (EHD) lubrication calculations. In addition, the innovations made to the mixed EHD calculation method used in this study to facilitate calculations under various lubrication conditions are also explained, including the treatment of surface roughness, wear progress and stiffness around the bearings.

Maintaining reliability of the connecting rod bearing is a very important subject, and the following is a problem that needs to be overcome. Predicting reliability has generally depended on minimum oil film thickness (M.O.F.T), but recently, the engines of passenger cars which have greater power and speed potential than conventional ones are sometimes run beyond their M.O.F.T. limit (a degree of roughness around the crank shaft's axis.) In such a case, it is so difficult to predict reliability according to M.O.F.T., that we need a new index which directly shows seizure and wear. For this purpose, we found that the crank shaft pin temperature can be a key cause of seizure and wear according to an analysis of the relationship between its temperature and the seizure and wear caused intentionally. Using this method, we confirmed that the combination of bearing and crank shaft materials is very important for preventing seizure and wear.

Variable flux permanent magnet synchronous machines (VFPMSMs) have been designed by using finite element analysis (FEA) to evaluate speed-torque capability considering requirement for magnetization state (MS) manipulation. However, due to its unique characteristic to change the MS, numerous combinations of design parameters need to be evaluated to achieve a final design. To accelerate the design process, this paper presents a method that consists of an equivalent magnetic circuit model and a process to obtain magnet width and thickness that satisfy target maximum torque and power factor (P.F.) capability. This model includes magnet operating point analysis under given magnet width and thickness condition to achieve target MS and avoid demagnetization at full load. This analysis provides desired stator magnetomotive force, magnet and stator induced flux linkage. Therefore, expected torque and P.F. capability is calculated.

A dynamic powertrain system model of the High Mobility Multi-Wheeled Vehicle (HMMWV) was created in the Powertrain Control Research Laboratory (PCRL) at the University of Wisconsin-Madison. Simulink graphical programming software was used to create the model. This dynamic model includes a Torsen differential model and a Hyrda-matic 4L80-E automatic transmission model as well as several other powertrain component models developed in the PCRL. Several component inertias and shaft stiffnesses are included in the dynamic model. The concepts of modularity, flexibility, and user-friendliness were emphasized during model development so that the system model would be a useful design tool. Simulation results from the model are shown.

Sophisticated product designs enrich people's lives and social demands for creation of good designs are quite strong. In the automobile industry, good design quality is one of the principal factors for determining market competitiveness. In this situation where good design quality is required of every product, the authors have developed a CAD/CAM system which makes it possible to create good and accurate designs by translating designers' ideas directly and quickly into high quality CAD models, a capability that has long been desired. With this high performance system, freely formed curves and surfaces can be easily manipulated with a man-machine interface familiar to industrial designers accutomed to the conventional design process. The system also integrates photo-realistic rendering, stereography and NC milling machines for verifying differences between the realized shape and the image in the designer's mind.

A new transparent type electrochromic device (ECD) has been developed. It consists of two electrochromic thin films facing each other, one of “prussian blue” (PB) and the other of tungsten trioxide (WO3). PB exhibits a high intensity of coloration and is blue in the oxidized state and transparent in the reduced state. By electrodeposition, the PB layer can be formed on large substrates at low cost. This ECD has been applied to large, curved automotive glass. It reversibly turns from dark blue to transparent at low operating voltage and maintains the same intensity of coloration without the aid of an external power supply. Compared with photochromic glass, it achieves a greater color change in a shorter time and its light absorption can be changed at will. It shields passengers from the discomfort of glare and heat flow through glass.

Gasoline engines employ various mechanisms for improvement of fuel consumption and reduction of exhaust emissions to deal with environmental problems. Direct fuel injection is one such technology. This paper presents a new quasi-dimensional combustion model applicable to direct injection gasoline engine. The Model consists of author's original in-cylinder turbulence and mixture homogeneity sub model suitable for direct fuel injection conditions. Model validation results exhibit good agreement with experimental and 3D CFD data at steady state and transient operating conditions.

The flow through diesel fuel injector nozzles is important because of the effects on the spray and the atomization process. Modeling this nozzle flow is complicated by the presence of cavitation inside the nozzles. This investigation uses a two-dimensional, two-phase, transient model of cavitating nozzle flow to observe the individual effects of several nozzle parameters. The injection pressure is varied, as well as several geometric parameters. Results are presented for a range of rounded inlets, from r/D of 1/40 to 1/4. Similarly, results for a range of L/D from 2 to 8 are presented. Finally, the angle of the corner is varied from 50° to 150°. An axisymmetric injector tip is also simulated in order to observe the effects of upstream geometry on the nozzle flow. The injector tip calculations show that the upstream geometry has a small influence on the nozzle flow. The results demonstrate the model's ability to predict cavitating nozzle flow in several different geometries.

An engine cycle simulation code with detailed chemical kinetics has been developed to study Homogeneous Charge Compression Ignition (HCCI) combustion with hydrogen as the fuel. In order to attain adequate combustion duration, resulting from the self-accelerating nature of the chemical reaction, fuel and temperature inhomogeneities have been brought to the calculation by considering the combustion chamber to have various temperature and fuel distributions. Calculations have been done under various conditions including both perfectly homogeneous and inhomogeneous cases, changing the degree of inhomogeneity. The results show that intake gas temperature is more dominant on ignition timing of HCCI than equivalence ratio and that there is a possibility to control HCCI by introducing appropriate temperature inhomogeneity to in-cylinder mixture.

The method for measuring air-fuel ratio is generally based on analysis of the exhaust gas components and its calculations. A new instrument has been developed which uses this method, but it attaches an oxygen sensor for exhaust gas analysis to the exhaust pipe and calculates the air-fuel ratio directly from the sensor output using a microprocessor. The response time of this instrument is 100 milliseconds and because it does not require an exhaust gas sampling system its weight is only 2.5 kg. This paper describes the operation theory, construction and characteristics of this instrument, as well as the results of air-fuel ratio of measurements on engines and vehicles using this instrument in a transient state.

A robotic driver has been designed on the basis of an analysis of a human driver's action in following a given driving schedule. The self-learning algorithm enables the robot to learn the vehicle characteristics without human intervention. Based on learned relationships, the robotic driver can determine an appropriate accelerator position and execute other operations through sophisticated calculations using the future scheduled vehicle speed and vehicle characteristics data. Compensation is also provided to minimize vehicle speed error. The robotic driver can reproduce the same types of exhaust emission and fuel economy data obtained with human drivers with good repeatability. It doesn't require long preparation time. Thereby making it possible to reduce experimentation work in the vehicle development process while providing good accuracy and reliability.

This paper describes a simple engine model at idling and it applies particularly to idle speed control. Through linearization in the neighborhood of the nominal operating points (650 rpm), the engine is expressed as a reduced-order constant coefficient state variable (2 state) model. It was produced through the system order-reduction method. The strategy for controlling idle speed uses the Linear Quadratic and Integral (LQI) optimal control theory. The tracking controller was designed using a state variable engine model, and the performance index was minimized. Since state variables are artificially introduced, they are not directly accessible. Therefore, they must be estimated in accordance with a stored dynamic model (i.e. observer), in which the engine dynamic behavior is estimated on the basis of a state variable model which represents the engine's internal states, in determining controlling values.

Technologies for improving the fuel economy of gasoline engines have been vigorously developed in recent years for the purpose of reducing CO2 emissions. Increasing the compression ratio is an example of a technology for improving the thermal efficiency of gasoline engines. A significant issue of a high compression ratio engine for improving fuel economy and low-end torque is prevention of knocking under a low engine speed. Knocking is caused by autoignition of the air-fuel mixture in the cylinder and seems to be largely affected by heat transfer from the intake port and combustion chamber walls. In this study, the influence of heat transfer from the walls of each part was analyzed by the following three approaches using computational fluid dynamics (CFD) and experiments conducted with a multi-cooling engine system. First, the temperature rise of the air-fuel mixture by heat transfer from each part was analyzed.