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It is well known that backpressure is one of the important parameters to be minimised during the exhaust system development. Unfortunately, during the first phases of an engineering process of a new engine, engine prototypes are not available yet. Due to this the exhaust system backpressure is generally evaluated using simulation software, and/or measuring the backpressure by a flow rig test at room temperature. Goal of this paper is to compare exhaust backpressure results obtained respectively: i) at the room temperature flow rig; ii) at the engine dyno bench; iii) by simulation with one of the most common 1D fluidodynamics simulation tool (Gt-Power). A correlation of the three different techniques is presented.

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.

A prototype vehicle (PV) is equipped to test powertrain and active chassis systems with innovative control strategies for safety and energy saving. Additional sensors installed on-board allow the measurement and estimation of new information useful to the vehicle dynamic control. The PV was based on a serial production passenger car with Electronic Stability Control (ESC). Testing activities on Controller Area Network (CAN) and ESC Electronic Control Unit (ECU) are carried out to compare the vehicle dynamic performance obtainable using serial production rather than customized control strategies, while maintaining the same hardware. The PV is also utilized to provide reverse engineering analysis about the implemented control strategy for the ESC working in serial production mode.

In this study, a new EGR control technique, based on the estimate of the oxygen concentration in the intake manifold, was firstly investigated through numerical simulation and then experimentally tested, both under steady state and transient conditions. The robustness of the new control technique was also tested and compared with that of the conventional EGR control technique by means of both numerical simulation and experimental tests. Substantial reductions of the NOx emissions under transient operating conditions were achieved, and useful knowledge for controlling the EGR flow rate more accurately was obtained.

The engine acoustic character has always represented the product DNA, owing to its strong correlation with in-cylinder pressure gradient, components design and perceived quality. Best practice for engine acoustic characterization requires the employment of a hemi-anechoic chamber, a significant number of sensors and special acoustic insulation for engine ancillaries and transmission. This process is highly demanding in terms of cost and time due to multiple engine working points to be tested and consequent data post-processing. Since Neural Networks potentially predicting capabilities are apparently un-exploited in this research field, the following paper provides a tool able to acoustically estimate engine performance, processing system inputs (e.g. Injected Fuel, Rail Pressure) thanks to the employment of Multi Layer Perceptron (MLP, a feed forward Network working in stationary points).

Chassis Control Systems development methodology is nowadays strongly based on analyzing performance by using PC vehicle dynamics simulation. Generally, the overall design, test bench and road validation process is continuously accompanied by simulation. The Base Model Simulator was developed by the Vehicle Dynamics Group at the Department of Mechanics of Politecnico di Torino both to satisfy this requirement and for educational purposes. It considers a complete vehicle dynamics mathematical model, including driver, powertrain, driveline, vehicle body, suspensions, steering system, brakes, tires. The Base Model Simulator takes in account the suspensions system elastokinematics, including, for example, automatic computation of camber variation during the vehicle roll motions. Tire model considered are either Pacejka's models or experimental data.

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.

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.

A numerical model for simulating a Common Rail Piezo Indirect Acting fuel injection-system under steady state as well as transient operating conditions was developed using a commercial code. A 1D flow model of the main hydraulic system components, including the rail, the rail to injector connecting pipe and the injector, was applied in order to predict the influence of the injector layout and of each part of the hydraulic circuit on the injection system performance. The numerical code was validated through the comparison of the numerical results with experimental data obtained on a high performance test bench of the Moehwald-Bosch MEP2000/ CA4000 type. The developed injection-system mathematical model was applied to the analysis of transient flows in the hydraulic circuit paying specific attention to the fluid dynamics internal to the injector.

Nowadays control system development in the automotive industry is evolving rapidly due to several factors. On the one hand legislation tightening is asking for simultaneous emission reduction and efficiency increase, on the other hand the complexity of the powertrain is increasing due to the spreading of electrification. Those factors are pushing for strong design parallelization and frontloading, thus requiring engine calibration to be moved much earlier in the V-Cycle. In this context, this paper shows how, coupling well known physical 1D engine models featuring predictive combustion and emission models with a fully physical aftertreatment system model and longitudinal vehicle model, a powerful virtual test rig can be built. This virtual test rig can be used for powertrain virtual calibration activities with reduced requirement in terms of experimental data.

The necessity for further reductions of in-cylinder pollutant formation and the opportunity to minimize engine development and testing times highlight the need of engine thermodynamic cycle simulation tools that are able to accurately predict the effects of fuel, design and operating variables on engine performance. In order to set up reliable codes for indicated cycle simulation in SI engines, an accurate prediction of heat release is required, which, in turn, involves the evaluation of in-cylinder turbulence generation and flame-turbulence interaction. This is generally pursued by the application of a combustion fractal model coupled with semi-empirical correlations of available geometrical and thermodynamical mass-averaged quantities. However, the currently available correlations generally show an unsatisfactory capability to predict the effects of flame-turbulence interaction on burning speed under the overall flame propagation interval.

The vehicle sideslip angle is one of the most important variables for evaluating vehicle dynamics. The potential value of such a variable for obtaining significant improvements over current stability control systems is widely recognized. However, its direct measurement requires the use of complex and expensive devices which cannot be used in production cars. Large research efforts has been devoted to the problem of estimating the sideslip angle from other variables currently measured by standard Electronic Stability Control (ESC) sensors. However, at the best of author's knowledge, until now no application to production cars is known. In this paper, a new sideslip angle estimation technology is presented.

Flow control over aerodynamic shapes in order to achieve performance enhancements has been a lively research area for last two decades. Synthetic Jet Actuators (SJAs) are devices able to interact actively with the flow around their hosting structure by providing ejection and suction of fluid from the enclosed cavity containing a piezo-electric oscillating membrane through dedicated orifices. The research presented in this paper concerns the implementation of zero-net-mass-flux SJAs airflow control system on a NACA0015, low aspect ratio wing section prototype. Two arrays with each 10 custom-made SJAs, installed at 10% and 65% of the chord length, make up the actuation system. The sensing system consists of eleven acoustic pressure transducers distributed in the wing upper surface and on the flap, an accelerometer placed in proximity of the wing c.g. and a six-axis force balance for integral load measurement.

Antilock Braking System (ABS) is designed to prevent wheels from locking, in order to enhance vehicle directional stability during braking manoeuvres. Basically, ABS closed-loop control logic uses tyres slip as control variable. Slip is estimated by comparing vehicle reference speed with the angular speed of each wheel. Thus it is crucial to correctly estimate the longitudinal vehicle speed, in order to get a control system capable of good performance. The control is also affected by road condition; since vehicles are not equipped with sensors able to measure the tyre/road friction coefficient, an other estimation has to be performed. The paper presents an algorithm for the estimation of longitudinal speed, based on the measurements of the four wheel angular speed. A method to assess the road friction, commonly known as “learning phase” is also described: it is carried out during the early stage of the active control intervention and relies on the wheel rotation sensors as well.

Different EGR system layouts (a Long Route, a Short Route, and a combination of the two) were evaluated by means of both numerical simulation and experimental tests. In particular, a one-dimensional fluid-dynamic engine model was built in order to evaluate the potential of a Long Route EGR system as well as the potential of different EGR combinations between Long and Short Route. By means of the one-dimensional model, used as a virtual test bench, the estimations of the NOx emissions, based on the Extended Zeldovich Mechanism (EZM), for the different solutions, were compared and valuable information for the calibration of the coordinated EGR LR, EGR SR and Variable Geometry Turbine (VGT) control systems was obtained.

The paper deals with the methodology implemented by Magneti Marelli and Politecnico di Torino Vehicle Dynamics Research group to develop and verify the software of active chassis and powertrain control systems through a Hardware-In-the-Loop automated procedure. It is a general procedure which can be adopted for all the active chassis control systems, not only for their development but also for the verification of their reliability. The steps of the procedure are described in the first part of the paper. The specific application on which this paper is focused concerns robotized gearboxes.

As an era of autonomous driving approaches, it is necessary to translate handling comfort - currently a responsibility of human drivers - to a vehicle imbedded algorithm. Therefore, it is imperative to understand the relationship between perceived driving comfort and human driving behaviour. This paper develops a methodology able to generate the information necessary to study how this relationship is expressed in highway overtakes. To achieve this goal, the approach revolved around the implementation of sensor Data Fusion, by processing data from CAN, camera and LIDAR from experimental tests. A myriad of variables was available, requiring individuating the key-information and parameters for recognition, classification and understanding of the manoeuvres. The paper presents the methodology and the role each sensor plays, by expanding on three main steps: Data segregation and parameter selection; Manoeuvre detection and processing; Manoeuvre classification and database generation.

The current trend towards an increasing electrification of road vehicles brings to life a whole series of unprecedent design issues. Among these, the ageing process that affects the lifetime of lithium-ion based energy storage systems is of particular importance since it turns out to be extremely sensitive to the variation of battery operating conditions normally occurring especially in hybrid electric vehicles (HEVs). This paper aims at analyzing the impact of operating conditions on the predicted lifetime of a parallel-through-the-road plug-in HEV battery both from thermal and ageing perspectives. The retained HEV powertrain architecture is presented first and modeled, and the related energy management system is implemented. Dedicated numerical models are also discussed for the high-voltage battery pack that allow predicting its thermal behavior and cyclic ageing.

Diesel engines with their embedded control systems are becoming increasingly complex as the emission regulations tighten, especially concerning NOx pollutants. The combustion and emission formation processes are closely correlated to the intake manifold O2 concentration. Consequently, the performance of the engine controllers can be improved if a model-based or sensor-based estimation of the O2 concentration is available. The paper addresses the modeling of the O2 concentration in a turbocharged diesel engine. Dynamic models, compared to generally employed steady state maps, capture the dynamic effects occurring over transients, when the major deviations from the stationary maps are found. Dynamic models positively affect the control system making it more effective and, exploiting information coming from sensors, they provide a more robust prediction performance. Firstly, a Nonlinear Output Error model (NOE), with simulation focus, fed with four inputs is presented.

The paper presents a simulation methodology created to support an integrated safety system development process which was tested for the side impact collision load case. The methodology is based on the coupled and complementary use of two software packages: PreScan and Madymo. PreScan was utilized for designing two traffic scenarios and the sensing and control systems for the side collision recognition, while Madymo was utilized for assessing the effects of pre-crash deployment of thorax airbag. The collision conditions from the scenarios were used as input to define a Madymo side collision model of the host vehicle and to investigate and optimize several airbag deployment parameters: pre-crash deployment time, airbag permeability, vent hole size and vent hole opening time.