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Video

1D Simulation and Experimental Analysis of a Turbocharger Compressor for Automotive Engines under Unsteady Flow Conditions

2012-02-15
Zero-dimensional, one-dimensional, and quasi-dimensional models for simulation of SI and CI engines with respect to: engine breathing and boosting; SI combustion and emissions; CI combustion and emissions; fundamentals of engine thermodynamics; thermal management; mechanical and lubrication systems; system level models for controls; system level models for vehicle fuel economy and emissions predictions. Presenter Fabio Bozza, Universita di Napoli
Video

2-Stroke CAI Combustion Operation in a GDI Engine with Poppet Valves

2012-06-18
In order to extend the CAI operation range in 4-stroke mode and maximize the benefit of low fuel consumption and emissions in CAI mode, 2-stroke CAI combustion is revived operating in a GDI engine with poppet valves, where the conventional crankcase scavenging is replaced by boosted scavenging. The CAI combustion is achieved through the inherence of the 2-Stroke operation, which is retaining residual gas. A set of flexible hydraulic valve train was installed on the engine to vary the residual gas fraction under the boosting condition. The effects of spark timing, intake pressure and short-circuiting on 2-stroke CAI combustion and its emissions are investigated and discussed in this paper. Results show the engine could be controlled to achieve CAI operation over a wide range of engine speed and load in the 2-stroke mode because of the flexibility of the electro-hydraulic valvetrain system. Presenter Yan Zhang, Brunel University
Video

5000 Hours Aging of THERBAN® (HNBR) Elastomers in an Aggressive Biodiesel Blend

2012-05-23
TERBAN® hydrogenated nitrile rubber (HNBR) is a specialty elastomer used in demanding engineering applications such as the automotive, heavy duty, and industrial markets. It has excellent combination of heat, oil and abrasion resistance in addition to its high mechanical strength, very good dynamic and sealing properties. This paper will present data on aging HNBR for five thousand hours in an aggressive and un-stabilized B30A biodiesel fuel blend (70% ULSD, 30% SME, and an aggressive additive package) and explore the effect of HNBR polymer properties and vulcanizate composition on the performance in such fuel blends. Presenter Victor Nasreddine
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A Comparative Study On-Dynamometer Performance Evaluation of Fly Ash Containing Non Ferrous Organic and Low-Metallic Disc Brake Pads for Passenger Vehicles and Thereby Promoting a Very Cheap Inorganic Filler Available in Abundance (SAE Paper 2020-01-1613)

2020-11-03
A number of functional and non- functional fillers are invariably used for friction material composites. In recent years disposal of fly ash has been a big challenge due to low availability of damping sites. Current work investigates the characterization of Low -metallic and Organic composites made with fly ash with variable concentrations and evaluated for braking performance (SAE J2522) & wear (SAE J2707) on a brake inertia dynamometer. Composites have been characterized for their physical, thermal, mechanical and tribological performance. Low-metal based composites (LMBC) have shown better thermal resistance than non-ferrous organic formulation based composites (NFOC). Mechanical properties such as hardness, shear strength and compressibility have been found to be similar for both the composites. NFOC composites have shown better wear resistance while acquiring slightly lower coefficient of friction values.
Video

A Methodology to Assess the Capabilities of a Cluster of Companies: The Case of "Torino Piemonte Aerospace"

2012-03-21
The increasing complexity of aerospace products and programs and the growing competitive pressure is facilitating the aggregation of small, medium and large enterprises of certain geographical regions into more integrated and collaborative entities (clusters). Clusters are by their same nature formed by heterogeneous companies, with huge differences not only in size but also for their core competences: such a diversity is a strength of the cluster, but it also increases its complexity. The purpose of this paper is to describe a benchmarking methodology that can be adopted to assess the performances of companies belonging to a cluster from different perspectives: economics and financials, competitive differentiators, specific know how, business strategies, production and logistic effectiveness, quality of core and supporting processes.
Video

A Pathway to Lean Engine Operation: Pre-Chamber Jet Ignition Combustion

2012-05-10
Turbulent Jet Ignition is an advanced spark initiated pre-chamber combustion system for otherwise standard spark ignition engines. Combustion in the main chamber is initiated by jets of partially combusted (reacting) pre-chamber products which provide a high energy ignition source. The resultant widely distributed ignition sites allow relatively small flame travel distances enabling short combustion durations and high burn rates. This presentation outlines development of this combustion concept in a modern normally aspirated PFI production engine. Experimental results have highlighted high thermal efficiency (42.8%), significant fuel economy improvement (>20%), low engine out NOx (<10 ppm), knock limit extension, high load capability (>13 bar IMEPn) and high speed operation (5500 rev/min). Presenter William P Attard, MAHLE Powertrain LLC
Video

A Study on Optimization of Brake Feeling and Method for Flexible Brake with Integrated Electronic Booster (SAE Paper 2020-01-1642)

2020-11-05
Throughout the automotive industry, the application of an integrated electronic booster (IEB) system has been actively applied following with diversify powertrain types and expand autonomous vehicles.[1, 2] Compared to the existing vacuum boosters, the performance advantages of IEB are 1) robustness against environmental changes, 2) rapid hydraulic reactivity, etc., and the advantages of cost / university are 1) flexibility for powertrain changes 2) weight saving 3) package simplification. Although IEB has a great advantage in performance and cost, it still needs a lot of research in various fields to realize the braking feeling, which is the performance of the emotional aspect, similar to the existing system. [3, 4]
Video

AS13100 Executive Overview Part 1: The Aerospace Industry

2021-03-02
AS13100 creates a single, harmonized set of requirements that are aligned to AS9100 and AS9145 for the aerospace engine supply chain. In doing this, it will significantly reduce the number of customer-specific requirements and help to create a common language for quality.
Video

AS13100 Executive Overview Part 2: Formation of AESQ

2021-03-02
The Aerospace Engine Supplier Quality Strategy Group (AESQ) has a vision to establish, deploy, and maintain a common set of quality requirements that enable the global aero engine supply chain to be truly competitive through lean, capable processes and a culture of continuous improvement.
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AS13100 Executive Overview Part 3: The Need for AS13100

2021-03-02
The AESQ wants to simplify, harmonize and create a common language through AS13100. Although there's already an aerospace standard called AS9100, the engine manufacturers have had to put supplemental requirements around this because they're expected to flow down the requirements from their regulator, the customer, and their own business. Because of the criticality of the engine and the potential consequence of any non-conformance, many of the requirements are far more stringent than you would get on any other commodity on the aircraft. The purpose of AS13100 is to take these supplemental requirements and build it into a single standard.
Video

Advanced Combustion & System Engineering - Affordable Fuel Economy?

2012-05-10
Future fuel economy targets represent a significant challenge to the automotive industry. While a range of technologies are in research and development to address this challenge, they all bring additional cost and complexity to future products. The most cost effective solutions are likely to be combinations of technologies that in isolation might have limited advantages but in a systems approach can offer complementary benefits. This presentation describes work carried out at Ricardo to explore Intelligent Electrification and the use of Stratified Charge Lean Combustion in a spark ignition engine. This includes a next generation Spray Guided Direct Injection SI engine combustion system operating robustly with highly stratified dilute mixtures and capable of close to 40% thermal efficiency with very low engine-out NOx emissions.
Video

Advanced Testing of Electric Drives and Motors

2012-05-16
This presentation will cover an overview of challenges and key discussion points for advanced electric motor and drive testing . Voiko will visit some examples of how D&V approaches these issues and also some suggestions for how the industry can view these intriguing problems as opportunities. The presentation will also delve into current testing developments that involve resolver, load bank and power measurement devices by highlighting solutions in the market today. There will also be a cursory look into the future of electric motor testing and what we can expect in the near term. Presenter Voiko Loukanov, D&V Electronics Limited
Video

Advances of Virtual Testing and Hybrid Simulation in Automotive Performance and Durability Evaluation

2012-02-15
Virtual testing is a method that simulates lab testing using multi-body dynamic analysis software. The main advantages of this approach include that the design can be evaluated before a prototype is available and virtual testing results can be easily validated by subsequent physical testing. The disadvantage is that accurate specimen models are sometimes hard to obtain since nonlinear components such as tires, bushings, dampers, and engine mounts are hard to model. Therefore, virtual testing accuracy varies significantly. The typical virtual rigs include tire and spindle coupled test rigs for full vehicle tests and multi axis shaker tables for component tests. Hybrid simulation combines physical and virtual components, inputs and constraints to create a composite simulation system. Hybrid simulation enables the hard to model components to be tested in the lab.
Video

An Experimental Analysis on Diesel/n-Butanol Blends Operating in Partial Premixed Combustion in a Light Duty Diesel Engine

2012-06-18
This paper reports results of an experimental investigation performed on a commercial diesel engine supplied with fuel blends having low cetane number to attain a simultaneous reduction in NOx and smoke emissions. Blends of 20% and 40% of n-butanol in conventional diesel fuel have been tested, comparing engine performance and emissions to diesel ones. Taking advantage of the fuel blend higher resistance to auto ignition, it was possible to extend the range in which a premixed combustion is achieved. This allowed to match the goal of a significant reduction in emissions without important penalties in fuel consumption. The experimental activity was carried on a turbocharged, water cooled, 4 cylinder common rail DI diesel engine. The engine equipment included an exhaust gas recirculation system controlled by an external driver, a piezo-quartz pressure transducer to detect the in-cylinder pressure signal and a current probe to acquire the energizing current to the injector.
Video

Analysis of Heat Pipe Impact on PCM Based Battery Thermal Management

2020-11-04
We have performed a numerical and experimental study on the impact of adding heat pipes to a PCM based battery thermal management system. Phase change materials (PCMs) are used as a battery thermal management system to absorb heat by melting in a specific temperature range, leading to a temporary constant and uniform temperature around battery cells. They also can be used as mechanical support for battery cells and safety measure to prevent fire propagation in case of thermal runaway. The main drawback of these materials is their low thermal conductivities. Our proposed approach is the integration of heat pipes with PCM as a hybrid system to take advantage of both technologies including the temperature peak absorption and structural support of PCM along with very high effective thermal conductivity, temperature uniformity and passive operation of heat pipes. Flat heat pipes integrated with PCM are tested with 18650 cells under various C-rates and ambient temperatures.
Video

Analysis of Various Operating Strategies for a Parallel-Hybrid Diesel Powertrain with a Belt Alternator Starter

2012-05-30
The sustainable use of energy and the reduction of pollutant emissions are main concerns of the automotive industry. In this context, Hybrid Electric Vehicles (HEVs) offer significant improvements in the efficiency of the propulsion system and allow advanced strategies to reduce pollutant and noise emissions. The paper presents the results of a simulation study that addresses the minimization of fuel consumption, NOx emissions and combustion noise of a medium size passenger car. Such a vehicle has a parallel-hybrid diesel powertrain with a high-voltage belt alternator starter. The simulation reproduces real-driver behavior through a dynamic modeling approach and actuates an automatic power split between the Internal Combustion Engine (ICE) and the Electric Machine (EM). Typical characteristics of parallel hybrid technologies, such as Stop&Start, regenerative braking and electric power assistance, are implemented via an operating strategy that is based on the reduction of total losses.
Video

Anodization: Recent Advancements on Corrosion Protection of Brake Calipers (SAE Paper 2020-01-1626)

2020-11-03
Brake calipers for high-end cars are typically realized using Aluminum alloys, with Silicon as the most common alloying element. Despite the excellent castability and machinability of Aluminum-Silicon alloys (AlSix), anodization is often required in order to increase its corrosion resistance. This is particularly true in Chlorides-rich environments where Aluminum can easily corrode. Even if anodization process is known for almost 100 years, anodization of AlSix -based materials is particularly challenging due to the presence of eutectic Silicon precipitates. These show a poor electric conductivity and a slow oxidation kinetics, leading to inhomogeneous anodic layers. Continuous research and process optimization are required in order to develop anodic layers with enhanced morphological and electrochemical properties, targeting a prolonged resistance of brake calipers under endurance corrosive tests (e.g. >1000 hours Neutral Salt Spray (NSS) tests).
Video

Assessing the Efficiency of a New Gasoline Compression Ignition (GCI) Concept

2020-10-02
A practical Gasoline Compression Ignition (GCI) concept is presented that works on standard European 95 RON E10 gasoline over the whole speed/load range. A spark is employed to assist the gasoline autoignition at low loads; this avoids the requirement of a complex cam profile to control the local mixture temperature for reliable autoignition. The combustion phasing is controlled by the injection pattern and timing, and a sufficient degree of stratification is needed to control the maximum rate of pressure rise and prevent knock. With active control of the swirl level, the combustion system is found to be relatively robust against variability in charge motion, and subtle differences in fuel reactivity. Results show that the new concept can achieve very low fuel consumption over a significant portion of the speed/load map, equivalent to diesel efficiency. The efficiency is worse than an equivalent diesel engine only at low load where the combustion assistance operates.
Video

Automated Transition from 3D to Integrated Vehicle Model in System Simulation

2020-11-03
The pace of change that the automotive industry is experiencing in the recent years is unprecedented. For legislative and market driven reasons, the automobile is moving away from the internal combustion as the sole means of propulsion towards more innovative system architectures. Almost every new vehicle is electrified to a certain degree, ranging from mild hybrids to battery and fuel-cell electric vehicles, which significantly increases the number of components and systems that need to be integrated and balanced to ensure the maximum efficiency of the powertrain. Combining this with the increased amount of vehicle variants present on the market, it becomes clear that engineers must consider many scenarios. Powertrain components, such as e.g. the battery, e-machine, power electronics can operate safely and efficiently only in a very narrow temperature band. Therefore, thermal management is critical.
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