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The Nexus vehicle was designed and built for Transport Canada at the University of Saskatchewan to demonstrate that a safety compliant single passenger commuter vehicle could attain extremely low fuel consumption rates at modest highway speeds. Experimentally determined steady state fuel consumption rates of the Nexus prototype ranged from 1.6 L/100 km at 61 km/hr up to 2.8 L/100 km at 121 km/hr. Fuel consumption rates for the Society of Automotive Engineers (SAE) driving cycle tests were 4.5 L/100 km for the SAE Urban cycle and 2.0 L/100 km for the SAE Interstate 55 cycle. The efficiency of the power train was determined using a laboratory dynamometer, enabling the road test results to be compared to the results from an energy and performance simulation program. Predicted fuel economy was in good agreement with that determined experimentally. Widespread use of single passenger commuter vehicles would substantially reduce current transportation energy consumption.

An analytical model based on “vortex sound” theory was investigated for predicting the frequency, the relative magnitude, the onset, and the offset of self-sustained interior pressure fluctuations inside a vehicle with an open sunroof. The “buffeting” phenomenon was found to be caused by the flow-excited resonance of the cavity. The model was applied to investigate the optimal sunroof length and width for a mid-size sedan. The input parameters are the cavity volume, the orifice dimensions, the flow velocity, and one coefficient characterizing vortex diffusion. The analytical predictions were compared with experimental results obtained for a system which geometry approximated the one-fifth scale model of a typical vehicle passenger compartment with a rectangular, open sunroof. Predicted and observed frequencies and relative interior pressure levels were in good agreement around the “critical” velocity, at which the cavity response is near resonance.

It is not uncommon for complex engineering products to undergo several design iterations due to changing market expectations or inadequate performance. In such circumstances, a prototype is generally available that could be used for performance analysis before a revision to the design is made. The availability of a prototype can be an invaluable tool for the analysis of the impact of potential design changes on the system performance. In this paper, a process is proposed for the derivation of a physical model that could be used for design analysis. The process uses model identification for determination of model complexity and numerical optimization for estimation of model parameters. This process is applied to a new pneumatic fan clutch system that has been developed to improve the efficiency of engine temperature regulation in heavy-duty commercial vehicles. This system is currently in a prototype phase and its detailed physical model is required for design trade-off analysis

A new prototype of a single unit till-planting system suitable for Egyptian soil was designed, constructed, and tested under soil bin and field conditions. Measurements were taken for draft, soil mean weight diameter, and seedling emergence. Results indicated that there are potential benefits of using this system rather to other tillage systems under dry and hard soil conditions. An optimum seedbed was created for rapid seedling emergence. Combinations of tillage, planting, and fertilizer application were performed in a single operation to reduce power and time requirements for crop production.

A feedback controller bas been developed using robust control techniques to control the sound radiated from turbulent flow driven plates. The control design methodology uses frequency domain loop shaping techniques. System uncertainty, sound pressure level reductions, and actuator constraints are included in the design process. For the wind noise problem, weighting factors have been included to distinguish between the importance of modes that radiate sound and those that do not radiate. The wind noise controller has been implemented in the quiet wind tunnel facility at the Ray W. Herrick Laboratories at Purdue University. A multiple-input, multiple-output controller using accelerometer feedback and shaker control was able to achieve control up to 1000 Hz. Sound pressure level reductions of as much as 15 dB were achieved at the frequencies of the plates modes. Overall reductions over the 100-1000 Hz band were approximately 5 dB.

Until recently, the aerodynamic design of large transport trucks has often ignored an important contribution to drag caused by the accessory rearview mirrors. In this study, three commercially available truck mirrors are tested full-scale in a wind tunnel at highway speeds. The actual drag forces and the coefficients of drag based on frontal and glass areas are compared for various mirror angles, with and without a convex-mirror attachment. All three mirror types produced significantly high drag forces which were used to estimate the fuel consumption attributed to mirror aerodynamic resistance. A standard rearview mirror, with mounting brackets, set was found to exhibit a drag coefficient, based on the glass area, of 1.81, which would increase the drag of a typical (Cd = 0.7, Af = 4.5m2) truck by about 8.5 percent.

An experimental program was conducted to verify the reduction in fuel consumption achievable with aerodynamic improvements to intercity buses. Wind tunnel model tests were used to develop effective aerodynamic improvements and full-scale road tests to validate the results. Greyhound Lines coach models MC-7 and MC-8 were tested with head- and crosswinds. Aerodynamic drag of the MC-7 was reduced 17 percent at zero yaw. Drag of the MC-8 initially was higher; it was reduced 27 percent at zero yaw by the best fairing. Both low-drag configurations were less sensitive to crosswinds than the original models; significant drag reduction was maintained to 15 degrees yaw angle. Fuel consumption measurements made with aerodynamic fairings installed on an MC-7 showed that the low-drag bus used 11.7 percent less fuel at a steady 55 mph. The cost of the full-scale modifications was estimated at $ 1,500 each for a retrofit kit and no added cost to produce on new vehicles.

A flow divider valve is a device which allows a single stream of fluid to be split into two paths according to a predetermined ratio and independent of variations or differences in the load pressures. A flow combiner valve combines two paths of fluid into one stream such that the ratio of the flow rates coming into the valve remains independent of any variation or difference between the inlet pressures. This paper describes the design, operation and performance of an integrated flow divider/combiner valve. This design maintains the small flow dividing/combining error of high precision valves (less than 1.5% at rated flow) but incorporates the shuttle valve into the main spool system. This new design reduces the weight of the valve by 20% reducing the cost by approximately 10%. The new structure simplifies the construction of high precision valves and reduces a source of flow dividing/combining error (leakage).

NO and soot emissions from Diesel engines are dependent on several parameters related to the engine design and operating conditions. Multidimensional models are increasingly employed to study the effect of these parameters. In this paper, a multidimensional model for flows, sprays and combustion in engines is employed to study the dependence of NO and soot formation and oxidation on injection timing, injection pressure, chamber temperature, EGR and ignition delay, and compare the computed trends with those observed in experimental studies reported in the literature. Computations are carried out in a typical heavy-duty Diesel engine and additional computations in a constant volume chamber are used to clarify the engine results when appropriate. For several parametric changes, the experimentally observed trends are reproduced. However, several limitations are identified. The structure of the computed combusting jet has differences with those suggested from recent experiments.

The mobility modeling technique is applied to the structure-borne noise path through a vehicle suspension. The model is developed using measured FRF data taken on the isolated components of the suspension and body structure of a midsize sedan. Several important modeling issues of suspensions are resolved. It was determined that multiple degrees of freedom are required to model the coupling at joints between the suspension and body structure. The investigation also demonstrated that bushings should not be included in the measurements used to develop these models and should be added later using simplified bushing parameters. The importance of transfer mobility information between the various suspension attachments was also investigated. The agreement between the mobility model predictions and the measured FRF data for the overall system is better than similar data published in the literature to date.

Energy budgets for future Controlled Ecological Life-Support Systems (CELSS) must balance not only with respect to primary productivity (i.e., photosynthesis) vs. utilization steps (human maintenance plus preparative and recycling processes), but also with respect to necessary and desired nonlife-support activities of crews (e.g., exploration, research). Present objectives of the NSCORT program at Purdue University include identification of critical paths for biomass conversion to desired forms with energetics and rate-constant properties that are compatible with life-support sustainability within a CELSS. Physico-chemical recycling systems working in conjunction with bioregenerative ones likely will be required to keep time constants of critical processes within reasonable limits.

This work is based on comparative study of oilseed flax fibre and glass fibre reinforced composite boards for potential application in automotive industries. The material characterizations of flax and glass fibre-composites using unsaturated polyester as matrix were evaluated. Vacuum infusion was used for fabrication of composites. Flexural, tensile, water absorption and color tests were conducted on the composite boards. The density and the moisture content of flax/glass fibre mats were also measured. Three types of composite boards, including flax, glass and flax-glass sandwich were developed and characterized.

The range of applications of heavy duty diesel engines is quite diverse. The development of diesel engines has been characterized by a steady increase in power to weight ratios, with the turbocharger being the key component in achieving this increased performance. The turbocharger, consisting of a radial or axial flow turbine and a radial flow compressor, presents perhaps one of the most challenging tasks facing the turbomachinery designer. This is, to a p a t extent, due to the highly unsteady environment in which the turbocharger operates. The time scales of this unsteadiness range fiom those on the order of exhaust valve frequency to those associated with transient operation during acceleration and deceleration. In order to predict the time-accurate performance of the turbocharger in this environment, a range of dynamic models can be envisioned spanning the range from quasi-steady assumptions to full viscous flow solvers.

The feasibility of controlling the threshing cylinder of a conventional corn combine with electro hydraulic elements controlled by a digital computer was concluded. The laboratory experiments attained the performance index established after consultation with manufacturers and farmers

A unique concept for a multi-body test rig enabling the simulation of longitudinal, steering and vertical dynamics was developed at the Institute for Mechatronic Systems (IMS) at TU Darmstadt. A prototype of this IMS test rig is currently being built. In conjunction with the IMS test rig, the Vehicle Terrain Performance Laboratory (VTPL) at Virginia Tech further developed a full car, seven degree of freedom (7 DOF) simulation model capable of accurately reproducing measured displacement, pitch, and roll of the vehicle body due to terrain excitation. The results of the 7 DOF car model were used as the reference input to the multi-body IMS test rig model. The goal of the IMS/VTPL joint effort was to determine whether or not a controller for the IMS test rig vertical actuator could accurately reproduce wheel displacements due to different measured terrain constraints.

Grazing flows over open windows or sunroofs may result in “flow buffeting,” i.e. self-sustained flow oscillations at the Helmholtz acoustic resonance frequency of the vehicle. The associated pressure fluctuations may cause passenger fatigue and discomfort. Many solutions have been proposed to solve this problem, including for example leading edge spoilers, trailing edge deflectors, and leading edge flow diffusers. Most of these control devices are “passive” i.e. they do not involve dynamic control systems. Active control methods, which do require dynamic controls, have been implemented with success for different cases of flow instabilities. Previous investigations of the control of flow-excited cavity resonance have used mainly one or more loudspeakers located within the cavity wall. In this study, oscillated spoilers hinged near the leading edge of the cavity orifice were used. Experiments were performed using a cavity installed within the test section wall of a wind tunnel.

The Porous Ceramic Tube - Nutrient Delivery System (PCT-NDS) offers means to control water availability to plants under non-standard gravities. It is hypothesized that control can be obtained by applying suction pressure within the ceramic tubes. The research objectives include verifying the presented control equation for the PCT-NDS under micro-(less than 1 g) and hyper- (greater than 1 g) gravities. Experiments were conducted on a KC-135 subjecting the system to near-zero to 2 g's and to sustained hyper-gravities upto 10 g's using a centrifuge. Results indicated that the water availability can be controlled through applied suction pressure.

The object of the work reported here was to relate the acoustic intensity level measured near the contact patch of a driven tire on a passenger vehicle with the passby noise levels measured at a sideline microphone during coast and cruise conditions. Based on those measurements it was then possible to estimate the tire noise contribution to the passby level measured when the vehicle under test was accelerating. As part of this testing program, data was collected using five vehicles at fourteen passby sites in the United States: in excess of 800 data sets were obtained.

Flax, which is known for its linens and oils that are used for industrial products, can also be utilized as a cost effective and environmentally acceptable approach to the creation of a partially biodegradable biocomposite. Biocomposite material is investigated by combining recycled tire rubber, flax and linear low density polyethylene (LLDPE). The manufacturing process which be used to fabricate the biocomposite product included Extrusion and Compression Molding. Optimizing and studying the composition percentages of the compounds were studied in this paper. Moreover, the properties of the product were observed by using tensile test, tearing test, water absorption test, hardness test and Differential Scanning Calorimetry.

Pelleted animal feeds are processed from ground and mixed feedstocks. The ingredients are pressed through an array of dies at pressures exceeding 35 MPa. Cubing is a related process, producing larger, more fibrous blocks from chopped materials. The end product is a hardened agglomerated mass that needs to be capable of withstanding subsequent handling operations. The measurement of the durability of the product is very important to the processors and feed handlers. The existing ASAE durability tester (S267) is not adequately sensitive to compare the hardness of pellets and cubes. A new tester, with a working principle based on impact and shear, has been developed and refined for usability. The unit can accommodate pelleted and cubed material varying in size and hardness. The paper discusses the development history of the unit and presents some experimental data from its application.