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To meet future needs for heavy truck cooling, a novel high performance radial compact cooling system (CCS) was developed. Measurements with a prototype system were conducted in a component wind tunnel and with truck-installed systems in a climatic vehicular wind tunnel. The CSS is compared to conventional axial and side-by-side systems. In comparison with a conventional axial system, the performance per unit volume of the CCS is 42% higher, the noise level is about 6 dB lower and the power consumption of the radial fan is 70% of the axial fan leading to significant savings in fuel consumption.

A Vehicle-Engine-Cooling (VEC) system computer simulation model was used to study the transient performance of control devices and their temperature settings on oil, coolant and cab temperatures. The truck used in the study was an International Harvester COF-9670 cab over chassis heavy-duty vehicle equipped with a standard cab heater, a Cummins NTC-350 diesel engine with a McCord radiator and standard cooling system components and aftercooler. Input data from several portions of a Columbus to Bloomington, Indiana route were used from the Vehicle Mission Simulation (VMS) program to determine engine and vehicle operating conditions for the VEC system computer simulation model. The control devices investigated were the standard thermostat, the Kysor fan-clutch and shutter system. The effect of shutterstat location on shutter performance along with thermostat, shutter and fan activation temperature settings were investigated for ambient temperatures of 32, 85 and 100°F.

Water-cooled charge air cooling is being considered as part of various technology solutions in response to 2007 US, 2010 US, EU4 and EU5 emissions standards. As manufacturers determine appropriate engine and vehicle solutions to meet the upcoming emissions standards, charge air cooling requirements are increasing due to higher turbocharger outlet temperatures and pressures, higher EGR rates, and requests for intake manifold temperature control to manage combustion and exhaust temperatures. Valeo and EMP have collaborated on the development and testing of a water cooled charge air cooler (WCCAC), controlled by a 12 volt brushless motor coolant pump. The system design addresses material temperature limitations of air-air aluminum CAC's and has the potential to simplify the packaging of the air induction system.

In order to fulfill the technical requirements of a high-efficiency low-emissions off-road horizontal diesel engine, a unique design is proposed and optimized in this paper for the cooling water jacket structure with a forced-cooling closed-loop cooling system. The cooling water flow rate, temperature, and pressure at the inlet and several other critical locations of the cooling water jacket were measured and analyzed at different engine operating conditions for the water jacket designs. A numerical simulation model of the coolant flow and the cooling system was built and used to analyze the thermal/fluid characteristics of the coolant flow in the water jacket. The impact of different structural and packaging design parameters on coolant flow and heat transfer was investigated. The design deficiency of an original (earlier) design of the water jacket was pointed out and an improved design was proposed.

A lumped-parameter thermal network model, based on the analogy between heat transfer and electric current flow, is presented for hybrid powertrain cooling systems. In order to optimally select the powertrain components that are commercially viable and meet performance, emission, fuel economy and life targets, it is necessary to consider the influence of cooling architecture. Especially in electric and hybrid vehicles, temperature monitoring is important to increase power and torque utilization while preventing thermal damages. Detailed thermal models such as FEA and CFD are considered for component level assessments as they can locate thermal hotspots and identify possible design changes needed. However, for the system level analysis, the detailed numerical models are not suitable due to the requirement of high computation effort.

Abstract Turbocharging can provide a low cost means for increasing the power output and fuel economy of an internal combustion engine. Currently, turbocharging is common in multi-cylinder engines, but due to the inconsistent nature of intake air flow, it is not commonly used in single-cylinder engines. In this article, we propose a novel method for turbocharging single-cylinder, four-stroke engines. Our method adds an air capacitor-an additional volume in series with the intake manifold, between the turbocharger compressor and the engine intake-to buffer the output from the turbocharger compressor and deliver pressurized air during the intake stroke. We analyzed the theoretical feasibility of air capacitor-based turbocharging for a single-cylinder engine, focusing on fill time, optimal volume, density gain, and thermal effects due to adiabatic compression of the intake air.

Abstract Three-dimensional patterns representing crosshatched plateau-honed cylinder bores based on two-dimensional Fast Fourier Transform (FFT) of measured surfaces were generated and used to calculate pressure flow, shear-driven flow, and shear stress factors. Later, the flow and shear stress factors obtained by numerical simulations for various surface patterns were used to calculate lubricant film thickness and friction force between piston ring and cylinder bore contact in typical diesel engine conditions using a mixed lubrication model. The effects of various crosshatch honing angles, such as 30°, 45°, and 60°, and texture heights on engine friction losses, wear, and oil consumption were discussed in detail. It is observed from numerical results that lower lubricant film thickness values are generated with higher honing angles, particularly in mixed lubrication regime where lubricant film thickness is close to the roughness level, mainly due to lower resistance to pressure flow.

Exhaust gas air-fuel ratio (A/F) sensors are common devices in powertrain feedback control systems aimed at minimizing emissions. Both resistive (using TiO2) and electrochemical (using ZrO2) mechanisms are used in the high temperature ceramic devices now being employed. In this work a new mechanism for making the measurement is presented based on the change in the workfunction of a Pt film in interaction with the exhaust gas. In particular it is found that the workfunction of Pt increases reversibly by approximately 0.7 V at that point (the stoichiometric ratio) where the exhaust changes from rich to lean conditions. This increase arises from the adsorption of O2 on the Pt surface. On returning to rich conditions, catalytic reaction of the adsorbed oxygen with reducing species returns the workfunction to its original value. Two methods, one capacitive and one thermionic, for electrically sensing this workfunction change and thus providing for a practical device are discussed.

A new type of screw pump has inherent design features (e.g. balanced design, low bearing loads, wear-adjustable rotors, low rubbing loads, …) which may allow efficient, reliable, and maintainable operation in numerous applications, particularly for pumping low-viscosity fluids. Initial tests on an 87 gal/min prototype pumping lubricating oil at pressures up to 500 lb/in2 and speeds up to 1800 rev/min achieved good performance with little wear over 3400 hours of operations. Performance projections indicate volumetric efficiencies of 50 percent should be reached using the existing prototype pumping 1200 lb/in2 water in one stage.

Anybody knows that contamination in oil is always harmful to hydraulic and lubricating systems. Contaminants inevitably exist in the oils of hydraulic and lubrication systems and cause tribological problems. In order to prevent such tribological problems due to contaminants, various oil cleaners have been developed and applied to hydraulic and lubricating systems. They have greatly contributed to improving the reliability of the systems. Since sophisticated hydraulic systems with proportional valves or servo valves, which are sensitive to oil contamination, became popular, fine filters like 3 micron or 1 micron are additionally used. However contamination problems have been revived. The authors have investigated the causes of hydraulic and lubricating problems and found that polymerized oil oxidation products were as harmful as solid particles. They are of molecular size and cannot be removed by mechanical filtration.

Reliability research in hybrid ceramic bearings involves life testing of hybrid bearings and ceramic specimens. New materials for bearings like advanced ceramics have emerged for evaluation in recent years. In fatigue testing to determine the stress-life relationship, the number of sample size in life testing can be limited by consideration of cost and testing time. In the testing of ceramics, some researchers have relied on the use of a stepwise multiple loading approach to increase the failure data points. In this paper, a maximum likelihood method is applied to test data with multiple loads to estimate the stress-life exponent. This method treats the data at different loads or steps at once. Test data from three fatigue experiments using silicon nitride materials have been analyzed to obtain the stress-life exponents. Also, Weibull plots of the ‘equivalent lives' have been presented for all test specimens tested at different loads and load steps.

Abstract Due to the incoming phase out of fossil fuels from the market in order to reduce the carbon footprint of the automotive sector, hydrogen-fueled engines are candidate mid-term solution. Thanks to its properties, hydrogen promotes flames that poorly suffer from the quenching effects toward the engine walls. Thus, emphasis must be posed on the heat-up of the oil layer that wets the cylinder liner in hydrogen-fueled engines. It is known that motor oils are complex mixtures of a number of mainly heavy hydrocarbons (HCs); however, their composition is not known a priori. Simulation tools that can support the early development steps of those engines must be provided with oil composition and properties at operation-like conditions. The authors propose a statistical inference-based optimization approach for identifying oil surrogate multicomponent mixtures. The algorithm is implemented in Python and relies on the Bayesian optimization technique.

The performance of radial lip seals in either vehicular or industrial applications is a significant factor in the perceived quality of products. Lubricant leakage is high on the list of customer complaints or dissatisfaction. Radial lip seal suppliers have been working closely with vehicle manufacturers to improve the performance of their products. Much progress has been made. Advances from this point will depend not only on improvements in sealing technology but also on improvements in the control of the entire sealing system.

Despite the best preventative measures, ruptured hoses, spills and leaks do occur with the use of all hydraulic equipment. Although these releases do not usually produce an RCRA (Resource Conservation and Recovery Act) regulated waste, they are often reportable events. Clean-up and subsequent administrative procedures involve additional costs, labor, and work delays. Concerns about these releases, especially when they involve Sandia National Laboratories, New Mexico (SNL) vehicles hauling waste on public roads, prompted their Fleet Services Department (FS) to seek an alternative to conventional petroleum-based hydraulic fluids. Since 1996, SNL has participated in a pilot program, along with the University of Northern Iowa (UNI) Ag-Based Industrial Lubricants (ABIL) Research Program and selected vehicle manufacturers, to field test in twenty of its vehicles, hydraulic fluid produced from soybean oil.

In any engine cooling system, de-aeration capability of the system plays a very critical role to avoid over heating of an engine. In general, with recovery bottle engine cooling system there is one vent hose from radiator pressure cap to the recovery bottle and coolant in the bottle is exposed to atmospheric pressure. From this vent hose air bubbles will move to recovery bottle from the engine and radiator when pressure in the system exceeds pressure cap setting. With this arrangement, de-aeration from the engine will happen when thermostat opens only and till that time air bubbles will be in the engine only and in this time there will be chance of overheating at some critical conditions because of air pockets in to the engine water jacket and the entrained air in the cooling circuit. Also, secondly 100 % initial filling cannot be achieved.

Extensive testing was performed on both the ring-gear and hypoid-gear churning used to move the oil in the axle bowl to lubricate tandem axles. The gear pump test results were used to establish the pump characteristics, as well as the volumetric and mechanical efficiencies. The churning test results were used to formulate an empirical model used in an analysis to predict the energy loss. All testing was done with SAE 90W and 140W lubricants. The results from these experiments, along with some analytical formulations, were used and incorporated into a computer program. The results of the component testing showed that the hypoid-gear churning loss is a large energy loss, amounting to as much as 1.5 horsepower per axle. Since the energy losses in the gear pump amounted to only 0.2 horsepower, around a one horsepower savings per axle is achievable by lubricating the entire axle with the gear pump.

As a promising solution to improve fuel efficiency of a long-haul heavy duty truck with diesel engine, organic Rankine cycle (ORC) based waste heat recovery system (WHR) by utilizing the exhaust gas from internal combustion engine has continuously drawn attention from automobile industry in recent years. The most attractive concept of ORC-based WHR system is the conversion of the thermal energy of exhaust gas recirculation (EGR) and exhaust gas from Tailpipe (EGT) to kinetic energy which is provided to the engine crankshaft. Due to a shift of the operating point of the engine by applying WHR system, the efficiency of the overall system increases and the fuel consumption reduces respectively. However, the integration of WHR system in truck is challenging by using engine cooling system as heat sink for Rankine cycle. The coolant mass flow rate influences strongly on the exhaust gas bypass which ensures a defined subcooling after condenser to avoid cavitation of pump.

In heavy duty (HD) trucks cruising on expressway, about 60% of input fuel energy is wasted as losses. So it is important to recover them to improve fuel economy of them. As a waste heat recovery system, a Rankine cycle generating system was selected. And this paper mainly reports it. In this study, engine coolant was determined as main heat source, which collected energies of an engine cooling, an EGR gas and an exhaust gas, for collecting stable energy as much as possible. And the exergy of heat source was raised by increase coolant temperature to 105 deg C. As for improving the system efficiency, saturation temperature difference was expanded by improving performance of heat exchanger and by using high pressure turbine. And a recuperator which exchanges heat in working fluid between expander outlet and evaporator inlet was installed to recover the heat of working fluid at turbine generator. Then a working fluid pump was improved to reduce power consumption of the system.

Low heat rejection engine (LHRE) technology reduces the heat transfer from the gases in the cylinder of an internal combustion engine by insulating the walls of the combustion chamber. This technology has the potential for gains in fuel efficiency, cooling system size decrease, the use of alternative fuels, etc. Research on many experimental LHRE's has been reported in the literature. However, these engines have used ceramic material and they have two major problems that need to be overcome. They are: (1) the need for a high temperature lubrication system, and (2) brittleness of the ceramics. To overcome these limitations, a novel LHRE design has been developed in this study. In this design, a high temperature superalloy HAYNES®230™ (USN N06230)' is used instead of ceramics, and conventional low temperature lubrication can be employed. A 3.5 HP one cylinder low heat rejection Diesel engine was developed in this study and tested for 1001 hours without failure.

A methodology for design and development of commercial vehicle cooling system is derived with an objective to minimize part cost, engineering resources and time to market. This approach is very useful in companies with more variant of engines and vehicles. For this it is identified to have a common cooling system for a set of engines. A systematic approach to develop cooling system based on heat rejection is conceptualised. Engines are classified based on heat loads in to various groups. The cooling package selected for a particular group is independent of type of vehicle (bus or truck), cab (day, sleeper, FES or FBS), Type of drive (LHD or RHD), Emission norm (BSIII or BSIV) and fuel (Diesel or CNG). These packages will cover up the entire range of vehicles and engines. The packaging space available for each group is derived and the cooling package size is finalised. Fan and fan pulley options are listed based on air flow and fuel efficiency requirements.