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Electronic control units (ECUs) offer a modular, networked approach to real time machine control and diagnostics. Software embedded in these controllers offer agile and customizable solutions because of the intimate relationship with the ECU hardware and its inputs/outputs. In an idealistic view, embedded software should support the machine's life - 30 years or longer. Developing and maintaining software for these systems requires a strategy. A framework demonstrating common building blocks and long-term centralized support for ECUs on a machine is presented. This strategy reduces the detailed knowledge of the specific machine controls needed by ECU developers and provides the components and infrastructure key to extending the life and functionality of the ECU.

A 10 KWe dual-mode space power system concept has been identified which is based on INEL's Small Externally-fueled Heat Pipe Thermionic Reactor (SEHPTR) concept. This power system will enhance user capabilities by providing reliable electric power and by providing two propulsion systems; electric power for an arc-jet electric propulsion system and direct thrust by heating hydrogen propellant inside the reactor. The low thrust electric thrusters allow efficient station keeping and long-term maneuvering. The direct thrust capability can provide tens of pounds of thrust at a specific impulse of around 730 seconds for maneuvers that must be performed more rapidly. The direct thrust allows the nuclear power system to move a payload from Low Earth Orbit (LEO) to Geosynchronous Earth Orbit (GEO) in less than one month using approximately half the propellant of a cryogenic chemical stage.

Many automated guided golf cars using the electromagnetic guide technology are used in Japan to obtain more convenient and safer golf play. Now this technology is beginning to be used outside of the golf course as an on-demand people mover system. This paper presents an example of the engineering system of automated guided golf cars along for the 2 principles of automated guided vehicle. The first principle is “the steering control system including the automatic sensitivity adjustment function”, and the other principle is “the vehicle speed control system”.

A vehicle model is an important factor in the development of vehicle control systems. Various vehicle models having different complexities, assumptions, and limitations have been developed and applied to many different vehicle control systems. A 14 DOF vehicle model that includes a roll center as well as non-linear effects due to vehicle roll and pitch angles and unsprung mass inertias, is developed. From this model, the limitations and validity of lower order models which employ different assumptions for simplification of dynamic equations are investigated by analyzing their effect on vehicle roll response through simulation. The possible limitation of the 14 DOF model compared to an actual vehicle is also discussed.

This paper discusses the methodology setup for grill opening area prediction at the early development phase of the product development lifecycle, using a commercially available 1D simulation tool- AMESIM. Representative under hood has been modeled using Grill, Condenser, Radiator, intercooler, fan, and engine components. Vehicle velocity is used as an input to derive the airflow passing through the grill and other under-hood components based on ram air coefficient, pressure drop through different components (Grill, Heat exchanger, Fan & Engine). This airflow is used to predict the top tank temperature of the radiator. Derived airflow is correlated with airflow obtained from CFD simulation. A balance has been achieved between cooling drag & fan power consumption at different grill opening areas for target top tank temperature. Top tank temperature has been predicted at two different extreme engine heat rejection operating points.

For the thermal management of an automobile, the induced airflow becomes necessary to enable the sufficient heat transfer with ambient. In this way, the components work within the designed temperature limit. It is the engine-cooling fan that enables the induced airflow. There are two types of engine-cooling fan, one that is driven by engine itself and the other one is electrically driven. Due to ease in handling, reduced power consumption, improved emission condition, electrically operated fan is becoming increasingly popular compared to engine driven fan. The prime mover for electric engine cooling fan is DC motor. Malfunction of DC motor due to overheating will lead to engine over heat, Poor HVAC performance, overheating of other critical components in engine bay. Based upon the real world driving condition, 1D transient thermal model of engine cooling fan motor is developed. This transient model is able to predict the temperature of rotor and casing with and without holes.

This paper describes new 2 stroke fuel injected spark ignition outboard motor equipped with unique oxygen sensor feed back control system to assure constantly optimized air/fuel ratio. First, the general concept and the engineering target of commercial model are explained, and then the design and arrangement of oxygen sensor feedback fuel injection control system are described. Common automotive oxygen sensor is utilized in this system, and it is devised to overcome the problems inherent in 2-stroke engines. This paper also describes the controlled combustion system that enhances consistent and stable performance, and improves fuel efficiency. Applying these technologies, 40% less fuel consumption in cruise range was demonstrated by the comparative test with conventional fuel injected 2-stroke model.

This paper examines the powertrain and braking efficiency of a wide spectrum of light duty vehicles to illustrate the range of efficiencies that exist and to isolate the contribution of hybrid and non-hybrid powertrains in reducing fuel consumption. The paper also examines the change in vehicle energy demands, e.g. aerodynamics and rolling resistance from 2005 models to 2010 models to highlight the role that vehicle energy consumption reduction plays in determining total fuel consumption. EPA fuel economy certification data is analyzed using the metrics of vehicle limited fuel consumption and powertrain and braking efficiency. From the data, conclusions are drawn to create a list of the ten most efficient powertrains, based on the powertrain and braking efficiency metric, and the ten vehicles with the lowest vehicle limited fuel consumption. These metrics provide an informative basis for current and future technology evaluations.

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.

Due to the general requirements in the automotive industry to reduce the power consumption, fuel consumption rate and CO2 emission a new HID (High Intensity Discharge) bulb with only 25W is under development for front lighting systems. A first headlamp integrated in a hybrid vehicle is now launched as a first application in the market. The current regulation in ECE allows to get rid of the mandatory headlamp cleaning system and the automatic leveling requirement once the 25W HID bulb is applied. The reason for this is the objective luminous flux of the 25W HID bulb, which emits less than 2000 lm, a boundary defined in the regulation, where a headlamp cleaning and an automatic leveling is requested. That simplifies especially the integration in smaller vehicles and electric and hybrid vehicles. The paper describes the special design of the headlamp, the projector unit, the light performance, packaging advantages and future outlook of further applications in the near future.

This paper describes the set-up and testing of a single cylinder 25cc, air cooled, 4-stroke Spark Ignition (SI) engine converted to run in Homogeneous Charge Compression Ignition (HCCI) mode with the aid of various combustion control systems. The combustion control systems were investigated regarding their effects on combustion stability and heat release phasing. Engine operation was compared with unique findings from previous work done on a very small 2-stroke HCCI engine. HCCI engine operation was possible between 1000 - 4000 rpm when using Diethyl Ether (DEE) as the test fuel. Maximum operational fuel-air equivalence ratio (Φ) was 0.75 when operating without Exhaust Gas Recirculation (EGR). This relatively high equivalence ratio was attainable due to thermal gradients induced by the high surface area to volume ratio of the small engine combustion chamber, resulting in high chamber heat transfer.

Sundstrand has been investigating 270-Vdc/hybrid 115-Vac electrical power generating systems (EPGS) technology in preparation for meeting the electrical power generating system (EPGS) requirements for future aircraft (1). Systems such as the one being investigated are likely to be suitable for the More-Electric Aircraft (MEA) concepts presently under industry and military study. The present Sundstrand single-channel testbed is being further expanded to better understand the electrical system performance characteristics and power quality requirements of an MEA in which traditional mechanical subsystems are replaced by those of a “more-electric” nature. This paper presents the most recent Sundstrand 270-Vdc system transient performance data, and describes the modifications being made to the 270-Vdc/hybrid 115-Vac testbed.

The upcoming latest 3-wet Technology is the most ideal design for a Green field project as well as for a brown field facility which provides the best of both worlds. The foremost take away for a brown field project emanates from this technology which demands a smaller foot prints & hence could accommodates a capacity higher than what was perceived during the green field project planning thus saving millions of dollar of investment & giving that extra capacity which today the BRIC countries are thriving for. Apart from making the ideal investment choice, 3 Wet Technology provides impetus to business case in terms of reduction of VOC emission, Energy consumption, Material and labor cost and gaining on Green Environment front as well as leading to smart and Efficient-Paint-Process. The paper depicts the journey of roll out of 3-Wet process in Ford India and creating the bench mark in terms of product quality and process standards and manufacturing practices.

In the 42V Mild Hybrid System introduced into market by Toyota for the first time in the world, the crankshaft using belt(s) drives the motor/generator (MG). The set-up employs an inverter unit to control the MG electronically. This paper describes the system configuration, operations, characteristic features and development results of the new power control system. The focus is on the MG, the inverter-for-MG-control and energy regeneration, as well as DC/DC converter for the power supply to the 14V devices.

FOUR-WHEEL STEERING (4WS) is beginning to find widespread use as a new approach to improving vehicle dynamics, especially in the medium and high speed ranges. Steering the rear wheels in the same phase as the front wheels enhances vehicle stability. Four-wheel steering systems have an even greater potential to improve stability and steering response through suitable control over the transient characteristics of the rear wheel steer angle. This paper traces the course of Nissan research and development work on four-wheel steering and the evolution of Nissan's HICAS (4WS) technology. It also describes research activities under way on vehicle dynamics using a newly developed Simulator Vehicle, equipped with a front and rear angle transient control system which makes it possible to vary the dynamic characteristics of the vehicle instantaneously and at will while driving.

The long time needed for the application and the money involved are some of the main obstacles preventing the CNG vehicles market penetration, costs are always too high and application time always too long compared with the relatively small volumes. Besides the activities to be carried out on the original engine control system to integrate the gas system are unwelcome by the OEM as they require a re-validation of already validated components/systems. This issue became more critical since the EOBD system has been installed into the vehicles as the extremely heavy validation activity are jeopardized by the gas system and the major part of the calibration/validation work shall be repeated. A new gas control system has been developed with the aims to achieve the best performances in terms of power, driveability, emissions, without any modifications on the OEM system, very short application time and costs.

In order to meet the new stringent emission limits for small handheld power tools technologies like methods to improve the scavenging process and after treatment devices are deployed. Additionally, professional machines such as chain saws add particular requirements to avoid mechanical failures. By precise control of the carburetion it is possible to yield the necessary reduction of the emission level yet to maintain the performance of the engine. Thus, the development of an Electronically Controlled Carburetion System to reduce the exhaust emissions of small IC engines for handheld power tools was initiated at the WHZ, Germany. Key requirements of such a system are: low cost, high reliability, low electrical power consumption, high accuracy in metering the fuel demand of the engine. First results are promising. A correlation between exhaust gas temperature and the fuel demand of the engine was confirmed for both, wide open throttle and part load operation.

This paper describes the wing and engine ice protection system, used on all 777 aircraft. The 777 ice protection system is unique in two ways: it has an advanced control system which minimizes aircraft power consumption. In addition, the system was procured by the prime contractor, Boeing, as a fully integrated subsystem from a single supplier.

Modern gearboxes are meticulously engineered with three primary objectives: enhancing load-carrying capacity, minimizing noise, vibration, and harshness (NVH), and optimizing efficiency. Efficiency, in particular, holds paramount significance due to gearboxes’ substantial influence on energy consumption. One effective strategy for boosting efficiency involves curbing churning losses, stemming from the movement of oil within the gearbox housing. Computational fluid dynamics (CFD) techniques have emerged as invaluable tools for visualizing oil flow dynamics within gearboxes and pinpointing avenues for mitigating churning losses. In the context of electric vehicles (EVs), specifically battery electric vehicles (BEVs), extending their driving range is a top priority. Achieving this hinges on the design of an efficient gearbox.

With growing concern about global warming, alternatives to fossil fuels in internal combustion engines are searched. In this context, hydrogen is one of the most interesting fuels as it shows excellent combustion properties such as laminar flame speed and energy density. In this work a CFD methodology for 3D-CFD in-cylinder simulations of engine combustion is proposed and its predictive capabilities are validated against test-bench data from a direct injection spark-ignition (DISI) prototype. The original engine is a naturally aspirated, single cylinder compression ignition (Diesel fueled) unit. It is modified substituting the Diesel injector with a spark plug, adding two direct gas injectors, and lowering the compression ratio to run with hydrogen fuel. A 3D-CFD model is built, embedding in-house developed ignition and heat transfer models besides G-equation one for combustion.