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This paper presents the modeling of the transient phase of catalyst heating on a high-performance turbocharged spark ignition engine with the aim to accurately predict the exhaust thermal energy available at the catalyst inlet and to provide a “virtual test rig” to assess different design and calibration options. The entire transient phase, starting from the engine cranking until the catalyst warm-up is completed, was taken into account in the simulation, and the model was validated using a wide data-set of experimental tests. The first step of the modeling activity was the combustion analysis during the transient phase: the burn rate was evaluated on the basis of experimental in-cylinder pressure data, considering both cycle-to-cycle and cylinder-to-cylinder variations.

Nautilus S.p.A. and the Polytechnic of Turin, in cooperation with Blue Engineering, have developed a very versatile product, the ELETTRA Twin Flyers [6] (ETF), which consists in a very innovative remotely-piloted airship equipped with high precision sensors and communication devices. This multipurpose platform is particularly suitable for border and maritime surveillance missions and for telecommunication, both in military and civil area. To assess the actual maneuver capabilities of the airship [14], a prototype of reduced size and complexity has been assembled [16]. Before the flight tests a further assessment on the flight simulator is needed, because the first version of the software is tuned on the full scale prototype. Steady state performance and static stability of the demonstrator have been evaluated with CFD analysis.

One of the major issues coming out from low temperature fuel cells concerns the production of water vapor as a chemical reaction (between hydrogen and oxygen) by-product and its consequent condensation (at certain operating conditions), determining the presence of an amount of liquid water affecting the performance of the fuel cell stack: the production and the quantity of liquid water are strictly influenced by boundaries and power output conditions. Starting from this point, this work focuses on collecting all the required information available in literature and defining a suitable CFD model able to predict the production of liquid water within the fuel cell, while at the same time localizing it and determining the consequences on the PEM cell performances.

Computational Fluid Dynamics is a powerful instrument for PEM fuel cell systems development, testing and optimization. Considering the complication due to the multiple physical phenomena involved in the cell's operations, a good understanding of the micro-scale fluidic behavior in boundary layers is recommended: pressure drop along the reactants gas channels and the cooling channels has a sensible effect on parasite load in fuel cell systems (i.e. the power absorbed by the pump supplying the gases), as well as an important role in thermal transport. A correct thermal and fluid dynamic boundary layer prediction on the channel walls and the other contact surface with porous layers requires usually a dense finite element volumes discretization near wall, especially if laminar flows occur: therefore, the boundary layer computational cost tends to be the major one.

In the powertrain technology, designers must be careful on oil pan design in order to obtain the best noise, vibration and harshness (NVH) performance. This is a great issue for the automotive design because they affect the passengers' comfort. In order to reduce vibration and radiated noise in powertrain assembly, oil pan is one of the most critical components. The high stiffness of the oil pan permits to move up the natural modes of the component and, as a consequence, reduce the sound emission of the component itself. In addition, the optimized shape of the component allows the increase of natural frequency values of the engine assembly. The aim of this study is the development of a methodology to increase the oil pan stiffness starting from a sketch of the component and adding material where it is needed. The methodology is tested on a series of different models: they have the same geometry but different materials.

JUNO is an urban concept vehicle (developed at the Politecnico of Torino), equipped by an ethanol combustion engine, designed to obtain low consumptions and reduced environmental impact. For these goals the main requirements that were considered during the designing process were mass reduction and aerodynamic optimization, at first on the shape of the car body and then, thanks to add-on devices. JUNO’s aerodynamic development follows a defined workflow: geometry definition and modelling, CFD simulations and analysis, and finally geometry changes and CFD new verification. In this paper the results of the CFD simulations (using STARCCM+ and RANS k-ε) with a corresponding 1/1 scale wind tunnel tests made using the real vehicle. Particularly, the results in term of: total drag coefficient (Cx), total lift coefficient (Cz), the total pressure in the side and rear analyzing twenty different aerodynamics configurations made up of different combination of some aerodynamics add-on devices.

The use of Ducted Fuel Injection (DFI) for attenuating soot formation throughout mixing-controlled diesel combustion has been demonstrated impressively effective both experimentally and numerically. However, the last research studies have highlighted the need for tailored engine calibration and duct geometry optimization for the full exploitation of the technology potential. Nevertheless, the research gap on the response of DFI combustion to the main engine operating parameters has still to be fully covered. Previous research analysis has been focused on numerical soot-targeted duct geometry optimization in constant-volume vessel conditions. Starting from the optimized duct design, the herein study aims to analyze the influence of several engine operating parameters (i.e. rail pressure, air density, oxygen concentration) on DFI combustion, having free spray results as a reference.

The paper presents the main results of a study on the simulation of energy efficient management of on-board electric and thermal systems for a medium-size passenger vehicle featuring a parallel-hybrid diesel powertrain with a high-voltage belt alternator starter. A set of advanced technologies has been considered on the basis of very aggressive fuel economy targets: base-engine downsizing and friction reduction, combustion optimization, active thermal management, enhanced aftertreatment and downspeeding. Mild-hybridization has also been added with the goal of supporting the downsized/downspeeded engine performance, performing energy recuperation during coasting phases and enabling smooth stop/start and acceleration. The simulation has implemented a dynamic response to the required velocity and manual gear shift profiles in order to reproduce real-driver behavior and has actuated an automatic power split between the Internal Combustion Engine (ICE) and the Electric Machine (EM).

Automotive manufacturers are facing stronger and stronger pressure to optimize all aspects related to fuel consumption of cars, and aerodynamic drag makes no exception, due to increasing government enforcing rules for the reduction of the emissions and the increasing influence of aerodynamic performance on fuel consumption with WLTC and RDE driving cycles. Nowadays, CFD simulation is a common tool across automotive industries for the assessment and the optimization of vehicle resistance in the design phase. The full power of these numerical methods of studying many design variants in advance of experimental testing, however, can be fully exploited when coupled with optimization techniques, always keeping into account constraints and aesthetical demands. On the other hand, a massive use of CFD optimization can lead to unaffordable computational efforts or a limitation of the design exploration space.

In this work, a methodology for building and calibrating the kinetic scheme for the 1D CFD model of a zone-coated automotive Diesel Oxidation Catalyst (DOC) by means of a Genetic Algorithm (GA) approach is presented. The methodology consists of a preliminary experimental activity followed by a modelling, optimization and validation process. The tested aftertreatment component presents zone coating, with the front brick side covered with Zeolites in order to ensure hydrocarbons trapping at low temperature, and Platinum Group Metal (PGM), while the rear brick side presents an alumina washcoat with a different PGM loading. Reactor scale samples representative of each coating zone were tested on a Synthetic Gas Bench (SGB), to fully characterize the component’s behavior in terms of Light-off and hydrocarbons (HC) storage for a wide range of inlet feed compositions and temperatures, representative of engine-out conditions.

Polymer electrolyte membrane (PEM) fuel cells will play a crucial role in the decarbonization of the transport sector, in particular for heavy duty applications. However, performance and durability of PEMFC stacks is still a concern especially when operated under high power density conditions, as required in order to improve the compactness and to reduce the cost of the system. In this context, the optimization of the geometry of hydrogen and air distributors represents a key factor to improve the distribution of the reactants on the active surface, in order to guarantee a proper water management and avoiding membrane dehydration.

The unsteady flow effects in two different close coupled catalytic converters were investigated in order to achieve a better understanding of the steady state experimental tests which are usually performed to evaluate a flow distribution. Firstly the validity of a CFD model was achieved through a comparison of some steady state simulations with the results of HWA experimental measurements. Several different formulations of the uniformity index, that were found in literature, were then compared, trying to highlight the strengths and shortcomings of each one. Further information was derived from a comparison of the two catalysts that were tested to achieve a general methodology that would be useful for future analysis. Finally, a new approach to evaluate the flow distribution using a steady state analysis was proposed by comparing the results of a transient simulation that was obtained for a whole engine cycle.

Fuel cells are considered one of the promising technologies as possible replacement of Internal Combustion Engine (ICE) for the transportation sector due to their high efficiency, ultra-low (or zero) emissions and for the higher drive range. The Membrane Electrode Assembly (MEA) is what mainly influences the Fuel Cell FC performance, durability, and cost. In PEMFC the proton conductivity of the membrane is a function of the humidification level of the FC membrane, hence the importance of keeping the membrane properly humidified to achieve the best possible fuel cell performance. To have the optimal water content inside the fuel cell’s membrane several strategies could be adopted, dealing with the use of external device (such as membrane humidifier) or to adopt an optimal set of parameters (gas flow rate and temperature for example) to use the water produced at fuel cell cathode as humidity source. The aim of this paper is to study the behavior of a FC vehicle humidification system.

Battery Electric Vehicles (BEVs) and Hybrid Electric Vehicles (HEVs) are becoming relevant in the transportation sector, and it is therefore of utmost importance to find a solution to allow batteries to work safely and in a correct temperature range in which performance degradation and/or thermal runaway do not occur. For this purpose, a Battery Thermal Management System (BTMS) is required to ensure the correct operation of the battery pack. The design and control of an efficient BTMS is a complex task, in which multiple technical fields are involved. The paper mainly focuses on the thermal problems affecting the BTMS and sets two main goals: 1) to provide a comparison of two possible BTMS solutions, analyzing constraints and thermal performance for the design task; 2) to present a battery thermal 1D model able to describe the battery module behavior in real-time application to be implemented in a BMS control.

The fuel injection plays a crucial role in determining the mixture formation process in Gasoline Direct Injection (GDI) engines. Pollutant emissions, and soot emissions in particular, as well as phenomena affecting engine reliability, such as oil dilution and injector coking, are deeply influenced by the injection system features, such as injector geometric characteristics (such as injector type, injector position and targeting within the combustion chamber) and operating characteristics (such as injection pressure, injection phasing, etc.). In this paper, a new CFD methodology is presented, allowing a preliminary assessment of the mixture formation quality in terms of expected soot emissions, oil dilution and injector coking risks for different injection systems (such as for instance multihole or swirl injectors) and different injection strategies, from the early stages of a new engine design.

The use of composite materials is very important in automotive field to meet the European emission and consumption standards set for 2020. The most important challenge is to apply composite materials in structural applications not only in racing vehicles or supercars, but also in mass-production vehicles. In this paper is presented a real case study, that is the suspension wishbone arm (with convergence tie and pull-rod system) of the XAM 2.0 urban vehicle prototype, that it has the particular characteristics that of the front and rear, and left and right suspension system has the same geometry. The starting point has been an existing solution made in aluminum to manufacture a composite one.

A numerical-experimental analysis of a new generation Common Feeding (CF) fuel injection system, equipped with last generation solenoid injectors that feature pressure-balanced pilot-valves, has been developed. The main feature of the CF system is that it removes the accumulator from the high-pressure layout of the standard Common Rail (CR). In the CF apparatus, the high-pressure pump is connected directly to the injectors, and a small accumulation volume is integrated in the pump high-pressure circuit. The hydraulic performance of the CF system, including the injectors with the pressure-balanced pilot-valve, has been compared with that of the standard CR system in terms of injected masses, fuel leakages, high-pressure and injected flow-rate time histories. A previously developed advanced one-dimensional code for CR type systems has been adapted for the simulation of the CF high-pressure layout.

Heat transfer in the combustion chamber of s.i. engines operating under knocking conditions has been detected and analyzed. Measurements have been carried out, cycle by cycle, on a CFR laboratory engine by means of a dedicated instrument and an original method. The relationship between heat transfer and knock intensity has been analyzed on a statistical basis, emphasizing knock intensity influence on heat transfer distribution. Moreover, the share of heat transfer more closely related to knock intensity has been highlighted: heat transfer is shown not to be significantly affected by knock intensity under light-to-medium knock conditions; on the contrary, the influence becomes evident under medium-to-heavy knock conditions. Eventually, heat transfer indexes influenced by knock intensity have been evaluated, allowing a comparison of knock-related thermal properties of fuels.

An integrated theoretical and experimental investigation was carried out in order to evaluate the effects that the pump delivery-valve assembly can produce on the performance of a pump-line-nozzle fuel-injection system with a distributor-type pump for automotive diesel engines. Four distinct delivery valves, one constant-pressure valve, one reflux-hole and two relief-volume valves, were separately fitted to the pump and for each configuration of the delivery assembly the system behavior was analyzed under full-load steady-state operations in a wide pump angular-speed range. Fuel injection-rate as well as local pressure time-histories were investigated, paying specific attention to the occurrence and temporal evolution of cavitation phenomena in the pressure pipe and injector nozzle, after the valve closure. The flow across the delivery-valve assembly was theoretically examined in order to ascertain any instability sources as possible causes of cyclic fluctuations.

XAM is a two-seat city vehicle prototype developed at the Politecnico di Torino, equipped with a hybrid propulsion system to obtain low consumptions and reduced environmental impact. The design of this vehicle was guided by the requirements of weight reduction and aerodynamic optimization of the body, aimed at obtaining a reduction of resistance while guarantying roominess. The basic shape of the vehicle corresponding to the requirements of style, ergonomics and structure were deeply studied through CFD simulation in order to assess its aerodynamic performance (considering the vehicle as a whole or the influence of the various details and of their changes separately). The most critical areas of the body (underfloor, tail, spoiler, mirrors, A-pillar) were analyzed creating dedicated refinement volumes.