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Due to the integration of many interacting subsystems like hybrid vehicle management, energy management, distance management, etc. into the VCU platform the design steps for function development and calibration become more and more complex. This makes an aid necessary to relieve the development. Therefore, the aim of the proposed simulation-based development and calibration design is to improve the time-and-cost consuming development stages of modern VCU platforms. A simulation-based development framework is shown on a complex function development and calibration case study using an advanced powertrain concept with a plug-in hybrid electric vehicle (PHEV) concept with two electrical axles. Presenter Thomas Boehme, IAV GmbH

Due to the integration of many interacting subsystems like hybrid vehicle management, energy management, distance management, etc. into the VCU platform the design steps for function development and calibration become more and more complex. This makes an aid necessary to relieve the development. Therefore, the aim of the proposed simulation-based development and calibration design is to improve the time-and-cost consuming development stages of modern VCU platforms. A simulation-based development framework is shown on a complex function development and calibration case study using an advanced powertrain concept with a plug-in hybrid electric vehicle (PHEV) concept with two electrical axles.

The recent advance in the development of various hybrid vehicle technologies comes along with the need of establishing optimal energy management strategies, in order to minimize both fuel economy and pollutant emissions, while taking into account an increasing number of state and control variables, depending on the adopted hybrid architecture. One of the objectives of this research was to establish benchmarking performance, in terms of fuel economy, for real time on-board management strategies, such as ECMS (Equivalent Consumption Minimization Strategy), whose structure has been implemented in a SIMULINK model for different hybrid vehicle concepts.

The paper presents a survey of the opportunities to convert compression ignition heavy duty truck engines to work on single or dual fuel modes with CNG. In one popular option, the compression ignition engine is converted to spark ignition with throttle load control and port injection of the CNG. In another option of increasing popularity, the LNG is directly injected and ignited by direct injection of pilot Diesel. This latter option with direct injection of natural gas and diesel through separate injectors that are fully independent in their operation is determined to be the most promising, as it is expected to deliver better power density and similar part load fuel economy to Diesel.

The current legislation for industrial applications and construction equipment including earthmoving machines and crane engines allows different strategies to fulfill the corresponding exhaust emission limits. Liebherr Machines Bulle SA developed their engines to accomplish these limits using SCRonly technology. IAV supported this development, carrying out engine as well as SCR aftertreatment system and vehicle calibration work including the OBD and NOx Control System (NCS) calibration, as well as executing the homologation procedures at the IAV development center. The engines are used in various Liebherr applications certified for EU Stage IIIb, EPA TIER 4i, China GB4 and IMO MARPOL Tier II according to the regulations “97/68/EC”, “40 CFR Part 1039”, “GB17691-2005” and “40 CFR Parts 9, 85, et al.” using the same SCR hardware for all engine power variants of the corresponding I6 and V8 engine families.

To meet the requirements in relation to pollutants, CO2-emissions, performances, comfort and costs for 2025 timeframe, many technology options for the powertrain, that plays a key role in the vehicle, are possible. Beside the central aspect of reducing standard cycle consumption levels and emissions, consumer demands are also growing with respect to comfort and functionality. In addition, there is also the challenge of finding cost efficient ways of integrating technologies into a broad range of vehicles with different levels of hybridization. High degrees of electrification simultaneously provide opportunities to reduce the technology content of the internal combustion engines (ICE), resulting in a cost balancing compromise between combustion engine and hybrid technology. The design and optimization of powertrain topologies, functionalities, and components require a complex development process.

The quantitative assessment and comparison of different hybrid vehicle options has traditionally been done on the basis of measuring or estimating the vehicle's fuel economy over predefined drive-cycles. In general, little or no consideration has been given to the more subjective and difficult to quantify vehicle requirements, such as trying to understand which derivative will be the most “fun” vehicle to drive. A lack of understanding in this area of vehicle performance sufficiently early within the development life-cycle so as to be in a position to influence the vehicle design, can lead to a compromised powertrain architecture which will ultimately increase the risk of product failure. The work presented within this paper constitutes part of the overall design activities associated with the LIFECar programme. The aim of the LIFECar consortium is to manufacture a lightweight, fuel cell hybrid electric sports vehicle.

The paper deals with the reduction of pollutant emissions in urban areas by considering a Zero-Emission Zone (ZEZ) in which hybrid electric vehicles (HEVs) are allowed to be driven without using the internal combustion engine, as several cities have planned to realize in the next decades. Moreover, since vehicle connectivity has spread more and more in the last years, a vehicle-to-network (V2N) communication system has been taken into account to retrieve real-time navigation data from a map service provider and thus reconstructing the so-called electronic horizon, which is a reconstruction of the future conditions of the vehicle on the road ahead. The speed profile and the road slope are used as input for an on-board predictive control strategy of a plug-in HEV (PHEV). In particular, a dedicated algorithm predicts the amount of necessary energy to complete the city event in full-electric mode, giving a state of charge (SoC) target value.

This paper proposes a current limits distribution control strategy for a parallel hybrid electric vehicle (parallel HEV) which includes an advanced powertrain concept with two electrical driving axles. One of the difficulties of an HEV powertrain with two electrical driving axles is the ability to distribute the electrical current of one high voltage battery appropriately to the two independent electrical motors. Depending on the vehicle driving condition (i.e., car maneuver) or the maximization of the entire efficiency chain of the system, a suitable control strategy is necessary. We propose an input-output feedback linearization strategy to cope with the nonlinear system subject to input constraints. This approach needs an external, state dependent saturation element, which translates the state dependent control input saturation to the new feedback linearizing input and therefore preserves the properties of the differential geometric framework.

This paper proposes a current limits distribution control strategy for a parallel hybrid electric vehicle (parallel HEV) which includes an advanced powertrain concept with two electrical driving axles. One of the difficulties of an HEV powertrain with two electrical driving axles is the ability to distribute the electrical current of one high voltage battery appropriately to the two independent electrical motors. Depending on the vehicle driving condition (i.e., car maneuver) or the maximization of the entire efficiency chain of the system, a suitable control strategy is necessary. We propose an input-output feedback linearization strategy to cope with the nonlinear system subject to input constraints. This approach needs an external, state dependent saturation element, which translates the state dependent control input saturation to the new feedback linearizing input and therefore preserves the properties of the differential geometric framework.

One challenge for the development of commercial vehicles is the reduction of CO2 greenhouse, where hydrogen can help to reduce the fleet CO2. For instance, in Europe a drop in fleet consumption of 15% and 30% is set as target by the regulation until 2025 and 2030. Another challenge is EURO VII in EU or even already approved CARB HD Low NOx Regulation in USA, not only for Diesel but also for hydrogen combustion engines. In this study, first the requirements for the combustion and after-treatment system of a hydrogen engine are defined based on future emission regulations. The major advantages regarded to hydrogen combustion are due to the wide range of flammability and very high flame speed numbers compared to other fossil based fuels. Thus, it can be well used for lean burn combustion with much better fuel efficiency and very low NOx emissions with an ultra lean combustion. A comprehensive experimental investigation is performed on a HD 2 L single-cylinder engine.

Water Injection (WI) has become a key technology for increasing combustion efficiency in modern GDI turbocharged engines. In fact, the addition of water mitigates significantly the occurrence of knock, reduces exhaust gas temperatures, and opens the possibility to reach optimum heat release phasing even at high load. This work presents the latest development of a model-based WI controller, and its experimental validation on a GDI TC engine. The controller is based on a novel approach that involves an analytic combustion model to define the spark advance (SA) required to reach a combustion phase target, considering injected water mass effects. The calibration and experimental validation of the proposed controller is shown in detail in the paper.

The newest legislative trends enforce a significant decrease in CO2 emissions for commercial vehicles. For instance, in Europe a drop in fleet consumption of 15% and 30% is set as target by the regulation by 2025 and 2030. The use of carbon-neutral fuels offers possibilities regarding net-zero CO2 emissions - although not yet considered by the rules. Another challenging aspect is the drastic tightening of NOx emissions limits for future legislations, which is approved or being discussed both for the United States and for the EU. The current work describes the potentials of an innovative fuel, marketed as Gane fuel regarding performance, efficiency and emission behavior. First, the properties of the developed fuel are described: Gane is made from methanol blended with water and is tailored for diffusive combustion. The fuel blending is so defined to fulfill the combustion requirements.

Further tightening of NOx emission standards as well as CO2 emission limits for commercial vehicles are currently under discussion. In the on-road market, lowering NOx emissions up to 90%, down to 0.02 g/bhp-hr, has been proposed by CARB and is evaluated by US EPA. Testing for in-service conformity using a portable emission measurement system (PEMS) is currently under review in the US. In Europe, CO2 emission limits are anticipated and a CO2 monitoring program is ongoing. PEMS legislation has been recently tightened and further restrictions can be expected. Stage V legislation has been introduced in Europe and it is foreseeable that further tightening of off-road standards will take place in the future. This study deals with virtual development and evaluation of future engine and exhaust aftertreatment (EAT) technology solutions to fulfill the diverse future emission requirements with emphasis on off-road applications.

The development and calibration of modern combustion engines is challenging in the area of continuously tightening emission limits and the necessity for meeting real driving emissions regulations. A focus is on the knowledge of the internal engine processes and the determination of pollutants formations in order to predict the engine emissions. A physical model-based development provides an insight into hardly measurable phenomena properties and is robust against changing input data. With increasing modeling depth the required computing capacities increase. As an alternative to physical modeling, data-driven machine learning methods can be used to enable high-performance modeling accuracy. However, these are dependent on the learned data. To combine the performance and robustness of both types of modeling a hybrid application of data-driven and physical models is developed in this paper as a grey box model for the exhaust emission prediction of a commercial vehicle diesel engine.

A kinetic energy recover system (KERS) captures the kinetic energy that results when brakes are applied to a moving vehicle. The recovered energy can be stored in a flywheel or battery and used later, to help boost acceleration. KERS helps transfer what was formerly wasted energy into useful energy. In 2009, the Federation Internationale de l’Automobile (FIA) began allowing KERS to be used in Formula One (F1) competition. Still considered experimental, this technology is undergoing development in the racing world but has yet to become mainstream for production vehicles. The Introduction of this book details the theory behind the KERS concept. It describes how kinetic energy can be recovered, and the mechanical and electric systems for storing it. Flybrid systems are highlighted since they are the most popular KERS developed thus far. The KERS of two racing vehicles are profiled: the Dyson Lola LMP1 and Audi R18 e-tron Quattro.

The application of hybridization technology is now widely regarded as a significant step forward to reduce fuel consumption and hence CO₂ emissions for ground vehicles. Many programs and much research has been done on these technologies in the automotive market, however little work has been done in the very cost sensitive market sector of the small motorcycle. This paper introduces and discusses the application of a low-cost hybrid technology to small motorcycles and scooters, and reviews some of the initial trade-offs through the use of a new hybrid simulation model developed at Cranfield University. The study being presented assessed the existing Energy Storage Systems (ESS) in the market. This list was reduced, omitting options which posed a clear safety or cost risk, or solutions which would disproportionally increased the Gross Vehicle Weight (GVW). Also omitted were storage options which could not be production ready in the near term, 3 - 5 years.

Currently known hybrid systems are technically complex, cost-intensive and referring to this for many end-customers not available. Under this boundaries IAV has developed a cost-optimal concept of an efficient and modular powertrain platform for electric and hybrid vehicles. The system is based on one unity gear-set for up to three speeds, which enables seamless shifting with only one friction based clutch. With this platform powertrains can be realized by using a maximum number of carry over parts (COP) for electric vehicles as well as for hybrids. The derivable hybrid powertrains of the platform system are designed for 48V electric motors (EM) which enables the maximum cost potential in combination with the realized gear set and transmission technology. The real simple powertrain platform concept is furthermore scalable for different vehicle segments optionally with or without a hybrid option.

After the realization of very low exhaust gas emissions and corresponding OBD requirements to fulfill Euro VI and Tier 4 legislation, the focus in heavy-duty powertrain development is on the reduction of fuel consumption and thus CO₂ emissions again. Besides this, the total vehicle operation costs play another major role. A holistic view of the overall powertrain system including the combustion process, exhaust gas aftertreatment, energy recuperation and energy storage is necessary in order to obtain the best possible system for a given application. A management system coordinating the energy flow between the different subsystems while guaranteeing low exhaust emissions plays a major part in operating such complex architectures under optimal conditions.

This paper shows the main results of a research activity carried out in order to investigate the impact of different hybridization concepts on vehicle fuel economy during standard homologation cycles (NEDC, FTP75, US Highway, Artemis). Comparative analysis between a standard passenger vehicle and three different hybrid solutions based on the same vehicle platform is presented. The following parallel hybrid powertrain solutions were investigated: Hybrid Electric Vehicle (HEV) solution (three different levels of hybridization are investigated with respect to different Electric Motor Generator size and battery storage/power capacity), High Speed Flywheel (HSF) system described as a fully integrated mechanical (kinetic) hybrid solution based on the quite innovative approach, and hydraulic hybrid system (HHV). In order to perform a fare analysis between different hybrid systems, analysis is also carried out for equal system storage capacities.