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Current developments in automotive industry such as hybrid powertrains and the continuously increasing demands on emission control systems, are pushing complexity still further. Validation of such systems lead to a huge amount of test cases and hence extreme testing efforts on the road. At the same time the pressure to reduce costs and minimize development time is creating challenging boundaries on development teams. Therefore, it is of utmost importance to utilize testing and validation prototypes in the most efficient way. It is necessary to apply high levels of instrumentation and collect as much data as possible. And a streamlined data pipeline allows the fleet managers to get new insights from the raw data and control the validation vehicles as well as the development team in the most efficient way. In this paper we will demonstrate a data-driven approach for validation testing.

Beside the automotive industry, where 2-cylinder inline engines are catching attention again, twin-cylinder configurations are quite usual in the small engine world. From stationary engines and range-extender use to small motorcycles up to big cruisers and K-Cars this engine architecture is used in many types of applications. Because of very good overall packaging, performance characteristics and not least the possibility of parts-commonality with 4-cylinder engines nearly every motorcycle manufacturer provides an inline twin in its model range. Especially for motorcycle applications where generally the engine is a rigid member of the frame and vibrations can be transferred directly to the rider an appropriate balancing system is required.

An electromechanical gear is presented along with design examples utilizing the electromechanical gear in hybrid electric vehicle drive trains. The designs feature the electromechanical gear (the Transmotor) in place of traditional mechanical transmissions and/or gearing mechanisms. The transmotor is an electric motor suspended by its shafts, in which both the stator and the rotor are allowed to rotate freely. The motor thus can provide positive or negative rotational energy to its shafts by either consuming or generating electrical energy. A design example is included in which the transmotor is installed on the output shaft of an internal combustion engine. In this arrangement the transmotor can either increase or decrease shaft speed by applying or generating electrical power, allowing the ICE to operate with a constant speed.

Two parallel HEV control concepts: ‘thermostat’ and ‘power split’ are compared in this paper. To achieve a substantial improvement in fuel economy, the ‘thermostat’ or ‘on/off’ control technique intended to improve the fuel efficiency of a series HEV has been adopted and designed for parallel HEV. Among different ‘power split’ concepts developed for parallel hybrids only the ‘electrically assist’ algorithm is considered in this paper. These two control concepts are compared for three parallel HEV architectures: pre-transmission, post-transmission and continuous variable transmission hybrids. The comparison study also includes the effect of hybridization factor-the ratio of the electric power to the total propulsion power. The matrices of comparison are level of performance, energy consumption and exhaust emissions. The SAE J1711 partial charge test procedure is followed.

The use of state of the art simulation tools for effective front-loading of the calibration process is essential to support the additional efforts required by the new Real Driving Emission (RDE) legislation. The process needs a critical model validation where the correlation in dynamic conditions is used as a preliminary insight into the bounds of the representation domain of engine mean values. This paper focuses on the methodologies for correlating dynamic simulations with emissions data measured during dynamic vehicle operation (fundamental engine parameters and gaseous emissions) obtained using dedicated instrumentation on a diesel vehicle, with a particular attention for oxides of nitrogen NOx specie. This correlation is performed using simulated tests run within AVL’s mean value engine and engine aftertreatment (EAS) model MoBEO (Model Based Engine Optimization).

A concept of “driving situation awareness”-driven energy management system for parallel hybrid electric vehicles (HEVs) is introduced. The essential feature of the proposed energy management system is to assess the driving environment (in terms of facility type combined with traffic congestion level) using long and short term statistical features of the drive cycle. Subsequently, this knowledge is provided to a system that makes intelligent decisions with respect to the torque distribution and charge sustenance tasks. Simulation work was carried out for the validation of proposed system, and the results reveal its viability for energy management of parallel hybrid vehicles.

A Dual Power Split Electronic Continuously Variable Transmission (DPS-ECVT) with an input-split, output coupled, split-power-path configuration is proposed for improving overall system efficiency and range for electric vehicles. By modulating the power split ratio between the mechanical (planetary gear meshes) and electrical (Motor Generator Units) driveline components, a continuous range of gear ratios operating at higher efficiency is obtained. The proposed concept leverages two power-split units that lead to significantly reduced power flow through the electrical drivelines (compared with single speed EV transmissions as well as single power-split E-CVTs) while providing the same overall ratio spread for transmission operation.

Future electronics and photonics systems, weapons systems, and environmental control systems in aircraft will require advanced thermal management technology to control the temperature of critical components. Two-phase Thermal Management Systems (TMS) are attractive because they are compact, lightweight, and efficient. However, maintaining stable and reliable cooling in a two-phase flow system presents unique design challenges, particularly for systems with parallel evaporators during thermal transients. Furthermore, preventing ingress of liquid into a vapor compressor during variable-gravity operation is critical for long-term reliability and life. To enable stable and reliable cooling, a highly stable two-phase system is being developed that can effectively suppress flow instability in a system with parallel evaporators. Flow stability is achieved by ensuring that only single-phase liquid enters the evaporators.

OBD (On Board Diagnosis) has been applied to detect malfunctions in powertrains. OBD requirements have been extended to detect various failures for ensuring the vehicle emission control system being normal. That causes further costs for additional sensors and software works. Two layers diagnosis system is proposed for a passenger car gearbox system to detect changes from normal behavior. Conventional physical constraints based diagnosis is placed on the base layer. Model based diagnosis and specific symptom finding diagnosis are built on the second layer. Conventional physical constraints based diagnosis is direct and effective way to detect the failure of system if the detected signals exceed their normal ranges. However under the case of system failure with related signals still remain in normal ranges, the conventional detection measures can not work normally. Under this case, Model based diagnosis is proposed to enhance the functionality of diagnosis system.

The European Emissions Stage 5b standard for diesel passenger cars regulates particulate matter to 0.0045 g/km and non-volatile part/km greater than 23 nm size to 6.0x10₁₁ as determined by the PMP procedure that uses a heated evaporation tube to remove semi-volatile material. Measurement artifacts associated with the evaporation tube technique prevents reliable extension of the method to a lower size range. Catalytic stripper (CS) technology removes possible sources of these artifacts by effectively removing all hydrocarbons and sulfuric acid in the gas phase in order to avoid any chemical reactions or re-nucleation that may cause measurement complications. The performance of a miniature CS was evaluated and experimental results showed solid particle penetration was 50% at 10.5 nm. The sulfate storage capacity integrated into the CS enabled it to chemically remove sulfuric acid vapor rather than rely on dilution to prevent nucleation.

In contrast to conventional powertrains from internal combustion engine vehicles (ICEV), the tribological performance of powertrains of electric vehicles (EVs) must be further evaluated by considering new critical operating conditions such as electrical environments. The operation of any type of electric motor produces shaft voltages and currents due to various hardware configurations and factors. Furthermore, the common application of inverters intensifies this problem. It has been reported that the induced shaft voltages and currents can cause premature failure problems in tribological components such as bearings and gears due to accelerated wear and/or fatigue. It is ascribed to effects of electric discharge machining (EDM), also named, sparking wear caused by shaft currents and poor or increasingly diminishing dielectric strength of lubricants. A great effort has been done to study this problem in bearings, but it has not yet been the case for gears.

In the present work, a scalable simulation methodology is presented that enables the assessment of the impact of SI-engine cycle-to-cycle combustion variations on fuel consumption and hence CO2 emissions on three different levels of modeling depth: in-cylinder, steady-state engine and transient engine and vehicle simulation. On the detailed engine combustion chamber level, a 3D-CFD approach is used to study the impact of the turbulent in-cylinder flow on the cycle-resolved flame propagation characteristics. On engine level, cycle-to-cycle combustion variations are assessed regarding their impact on indicated mean effective pressure, aiming at estimating the possible fuel consumption savings when cyclic variations are minimized. Finally, on the vehicle system level, a combined real-time engine approach with crank-angle resolved cylinder is used to assess the potential fuel consumption savings for different vehicle drivecycle conditions.

In order to meet current and future emission and CO2 targets, an efficient vehicle thermal management system is one of the key factors in conventional as well as in electrified powertrains. Global vehicle simulation is already a well-established tool to support the vehicle development process. In contrast to conventional vehicles, electrified powertrains offer an additional challenge to the thermal conditioning: the durability of E-components is not only influenced by temperature peaks but also by the duration and amplitude of temperature swings as well as temperature gradients within the components during their lifetime. Keeping all components always at the preferred lowest temperature level to avoid ageing under any conditions (driving, parking, etc.) will result in very high energy consumption which is in contradiction to the efficiency targets.

A vehicle's performance depends greatly on the operating conditions, such as journey type, driving behavior etc. Driving patterns vary with geographical location and traffic conditions. In today's global economy where automobile industries are concerned with both local and international markets, it becomes necessary to investigate vehicle performance for driving cycles of different countries and develop vehicle designs which are appropriate to the consumer's market. This paper concentrates on the issues related to designing hybrid electric vehicles. A method of optimizing the size of the principal hardware components of hybrid vehicles such as, electric motors, internal combustion engines, transmissions and energy storage devices based on the demands of different drive cycles is discussed in the paper.

Upcoming, increasingly stringent greenhouse gas (GHG) as well as emission limits demand for powertrain electrification throughout all vehicle applications. Increasing complexity of electrified powertrain architectures require an overall system approach combining modular component technology with integration and industrialization requirements when heading for further significant efficiency optimization. At the same time focus on reduced development time, product cost and minimized additional investment demand reuse of current production, machining, and assembly facilities as far as possible. Up to date additive manufacturing (AM) is an established prototype component, as well as tooling technology in the powertrain development process, accelerating procurement time and cost, as well as allowing to validate a significantly increased number of variants. The production applications of optimized, dedicated AM-based component design however are still limited.

Force and moment measurements, and surface flow patterns have been obtained for a one-fifth scale model of a single-engine general aviation aircraft utilizing a 15% thick natural laminar flow wing section. The data is for typical pre- and post-stall angles of attack, aircraft yaw attitudes, surface roughness and Reynolds number conditions. Results from a separate study of the wing alone are also given for comparison. This comparison shows that the fuselage/tail assembly acts as a lifting body. The aerodynamic characteristics show marked deterioration with increasing surface roughness. In addition, the studies indicate that the transition on the wing is characterized by laminar short bubble separation. The aerodynamic characteristics are somewhat unaffected by the presence of mini-tufts. The flow visualization photographs clearly show the transition and separation regions, and document the effects of variations in angle of attack and yaw on wing body interference.

The automotive domain has seen safety engineering at the forefront of the industry’s priorities for the last decade. Therefore, additional safety engineering efforts, design approaches, and well-established safety processes have been stipulated. Today many connected and automated vehicles are available and connectivity features and information sharing are increasingly used. This increases the attractiveness of an attack on vehicles and thus introduces new risks for vehicle cybersecurity. Thus, just as safety became a critical part of the development in the late 20th century, the automotive domain must now consider cybersecurity as an integral part of the development of modern vehicles. Aware of this fact, the automotive industry has, therefore, recently taken multiple efforts in designing and producing safe and secure connected and automated vehicles.

For nearly twenty years, DiMethyl Ether has been known to be an outstanding fuel for combustion in diesel cycle engines. Not only does it have a high Cetane number, it burns absolutely soot free and produces lower NOx exhaust emissions than the equivalent diesel. However, the physical properties of DME such as its low viscosity, lubricity and bulk modulus have negative effects for the fuel injection system, which have both limited the achievable injection pressures to about 500 bar and DME's introduction into the market. To overcome some of these effects, a common rail fuel injection system was adapted to operate with DME and produce injection pressures of up to 1000 bar. To understand the effect of the high injection pressure, tests were carried out using 2D optically accessed nozzles. This allowed the impact of the high vapour pressure of DME on the onset of cavitation in the nozzle hole to be assessed and improve the flow characteristics.

The recent growing interest in electric vehicle (EV) and hybrid electric vehicle (HEV) demands for an efficient, reliable and economical motor drive for electric propulsion. However, searching for a suitable traction motor becomes quite involved when vehicle dynamics and system architecture are considered. This paper makes an in-depth investigation on two highly important traction motor characteristics, extended speed range-ability and energy efficiency, from vehicular system perspective. The influences of these two motor drive features on a pure EV, a post-transmission, and two pre-transmission parallel HEV with 20% and 50% hybridization are studied in this paper. Two EV-HEV software packages ‘V-ELPH’ developed by Texas A&M University and ‘ADVISOR’ from NREL are used for simulation purposes. Based on the results in this paper, a systematic method is developed regarding the selection of traction drives for EV and HEV propulsion systems.

Light duty diesel vehicles continue to win recognition and market shares in Europe due to their convincing economy, reliability and driveability features. The diesel boom finds a fresh rationale in the CO2 emission legislation to come, however, the competitiveness of diesel cars may be impaired in future in consequence of the progression of the exhaust emission legislation and its impact on vehicle cost. This paper reviews the technologies currently pursued on the side of the engine and its subsystems, as well as the exhaust gas aftertreatment concepts required to satisfy the European legislation. An integral system approach is suggested, aiming at an optimum match of vehicle design parameters, transmission gear and the engine including aftertreatment elements and control.