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2023 | Buch

Digitalization in wind tunnels increases efficiency and quality in development and validation Kapitel lesen Erstes Kapitel lesen

23. Internationales Stuttgarter Symposium

Automobil- und Motorentechnik

herausgegeben von: André Casal Kulzer, Hans-Christian Reuss, Andreas Wagner

Verlag: Springer Fachmedien Wiesbaden

Buchreihe : Proceedings

Enthalten in: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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Über dieses Buch

Band I
In einer sich rasant verändernden Welt sieht sich die Automobilindustrie fast täglichmit neuen Herausforderungen konfrontiert: Der problematischer werdende Rufdes Dieselmotors, verunsicherte Verbraucher durch die in der Berichterstattungvermischte Thematik der Stickoxid- und Feinstaubemissionen, zunehmendeKonkurrenz bei Elektroantrieben durch neue Wettbewerber, die immer schwierigerwerdende öffentlichkeitswirksame Darstellung, dass ein großer Unterschiedzwischen Prototypen, Kleinserien und einer wirklichen Großserienproduktion besteht.Dazu kommen noch die Fragen, wann die mit viel finanziellem Einsatz entwickeltenalternativen Antriebsformen tatsächlich einen Return of Invest erbringen, wer dienotwendige Ladeinfrastruktur für eine Massenmarkttauglichkeit der Elektromobilitätbauen und finanzieren wird und wie sich das alles auf die Arbeitsplätzeauswirken wird.Für die Automobilindustrie ist es jetzt wichtiger denn je, sich den Herausforderungenaktiv zu stellen und innovative Lösungen unter Beibehaltung des hohenQualitätsanspruchs der OEMs in Serie zu bringen. Die Hauptthemen sind hierbei,die Elektromobilität mit höheren Energiedichten und niedrigeren Kosten der Batterienvoranzutreiben und eine wirklich ausreichende standardisierte und zukunftssichereLadeinfrastruktur darzustellen, aber auch den Entwicklungspfad zum schadstofffreienund CO2-neutralen Verbrennungsmotor konsequent weiter zu gehen. Auch dasautomatisierte Fahren kann hier hilfreich sein, weil das Fahrzeugverhalten dann –im wahrsten Sinne des Wortes - kalkulierbarer wird.Dabei ist es für die etablierten Automobilhersteller strukturell nicht immer einfach,mit der rasanten Veränderungsgeschwindigkeit mitzuhalten. Hier haben Start-upseinen großen Vorteil: Ihre Organisationsstruktur erlaubt es, frische, unkonventionelleIdeen zügig umzusetzen und sehr flexibel zu reagieren. Schon heute werdenStart-ups gezielt gefördert, um neue Lösungen im Bereich von Komfort, Sicherheit,Effizienz und neuen Kundenschnittstellen zu finden. Neue Lösungsansätze,gepaart mit Investitionskraft und Erfahrungen, bieten neue Chancen auf dem Weg derElektromobilität, der Zukunft des Verbrennungsmotors und ganz allgemein für dasAuto der Zukunft.

Inhaltsverzeichnis

Frontmatter

Aerodynamics

Frontmatter
Digitalization in wind tunnels increases efficiency and quality in development and validation
Abstract
For shorter development cycles with ever-increasing vehicle features testing efficiency is key. At the same time, quality assurance requirements are constantly growing, which can be seen in all fields of vehicle development. However, especially in large and costly test facilities, like wind tunnels, these topics can become pressing issues.
The digitalization of the whole test process increases the efficiency and supports quality goals imposed by regulations like WLTP or ISO17025. This starts with the management of test requirements and the related test requests. Continues with highly efficient test execution and the complete documentation of the tests and does not end with the reliable and searchable storage of the results. Yet, it goes further to tailored and automated analysis and reporting functionalities and includes auxiliary processes like asset and calibration management, process monitoring and maintenance planning.
This paper illustrates how standard software solutions can assist these processes to achieve efficiency and quality. These solutions support the customers of aerodynamic and thermal wind tunnels, the operational management of the facilities as well as the operators of the test cells. Numerous application levels benefit from such solutions: from the test management in the office to gateway applications bridging the gap between classic IT infrastructures and the test cells to test automation and data recording.
Jan D. Jacob
Wind Tunnel Testing Methodology for Autonomous Vehicle Optical Sensors in Adverse Weather Conditions
Abstract
The transportation sector has been making great strides in recent years toward developing autonomous vehicles (AVs), which are envisioned to benefit society in terms of safety, convenience, and precision. AVs rely heavily on optical sensors such as LiDARs and cameras to perceive the environment in order to navigate and identify objects. During adverse weather conditions, sensor performance degrades. However, the extent of degradation is not very well understood; one of the reasons for this is the lack of standardized testing methodology. Although outdoor testing is the most realistic, it faces issues with uncontrolled and unrepeatable variables, whereas indoor testing in a wind tunnel is more controlled and convenient to vary desired testing conditions. A comprehensive methodology to quantify sensor perceptions in different weather conditions is presented. Traditionally, precipitation is simulated using spray nozzles, but this method tends to produce unrealistic droplet characteristics. Therefore, a more realistic precipitation simulation system is designed and implemented into both full-scale and model-scale wind tunnels. The system is capable of simulating different droplet size distributions and the perceived intensities at the sensors during different driving speeds. The methods of quantifying a sensor’s visibility and object detection accuracy inside a wind tunnel are discussed with sample results. These are crucial elements for the safe operations of AVs.
Wing Yi Pao, Long Li, Joshua Howorth, Martin Agelin-Chaab, Langis Roy, Julian Knutzen, Alexis Baltazar y Jimenez, Klaus Muenker

Cyber Security

Frontmatter
Virtual IDS as new means for Cyber Security in-vehicle protection
Abstract
This paper presents a new patent-pending approach for in-vehicle cyber security, designed from the bottom up to address the emerging direction of vehicle networks and computing. The virtual IDS approach changes the current paradigm of network security by providing full IDS functionality for all in-vehicle traffic (CAN and Ethernet) from a single instance.
Lara Popova, Markus Maier
Automotive Cybersecurity: The gap between theoretical risks and real attacks on your vehicle
Abstract
In 2022, over 250 cybersecurity incidents in the automotive sector have been reported by Upstream’s AutoThreat® researchers. Despite the advent of the UN R155 regulation and the increasing budget dedicated to product cybersecurity, hackers still manage to breach vehicles. Does it mean that all these efforts are in vain, and attacks are inevitable? Not exactly. Concepts like security-by-design and zero trust are more and more taken into consideration during the product development phase. The processes now include risk analysis, security concepts and other security artefacts, as well as security controls that are implemented and tested. However, despite this approach and new mindset, the main objective may be missed: the vehicle must be protected against attacks in the field, so the risks must be mitigated in practice. This is the real challenge that should guide all car manufacturers’ actions. Current product security is a one-way street towards the finished car. They lack the integration of technologies and processes that allow for feedback and experiences from the field to be reflected during development. We will highlight the potential root causes to this mismatch between regulation side effects, human influence factor in processes and lack of indicators to measure the real risks in the field. Finally, we will offer an approach to tackle this issue and to close the gap between theory and practice in risk management, while reducing security costs.
Théo Tamisier, Anna Eildermann, Bernhard Kurz, Robin Liebe, Sebastian Spindler
Automotive cybersecurity and its importance for the development of future vehicles
Abstract
Connectivity in current and future vehicles is becoming increasingly important, not only improving passenger comfort and safety, but also potentially posing threats. To ensure a high level of safety this paper presents the top issues as important levers for optimizing cybersecurity for the automotive industry and their significance for the development of future vehicles. In addition, existing regulations and standards are highlighted and new approaches for the implementation of cybersecurity and the essential aspects of a V&V strategy are explained.
Thomas Thurner, Gerhard Di Mattio

Data Science

Frontmatter
Digital Twin Concepts for Autonomous and Electric Vehicle Testing
Abstract
The pace of innovation in the automotive industry is growing exponentially. Digital transformation has reached automotive with the move towards soft-ware-defined vehicles and digital twins to accelerate the definition, design, and production of cars, modules, and sensors. Automotive innovators need to push the boundaries of engineering to solve design, emulation, and test challenges quickly. When validating the functionality of a new vehicle in the real world, everything around it is a variable. Automakers control none of them, which poses a problem when testing the car’s functionality to a high degree of confidence. This paper discusses how testing in the lab using digital twins gives automotive OEMs control. We show the role of test and measurement in getting to the digital twin approach and how they are used in design and development, to help determine the impact of each variable in a testing scenario, which can then be repeatably and reliably tracked and measured.
Thomas Goetzl, Sven Kopacz, Henrik Liebau
From the road to the datacenter fast and smart data recording to speed up ADAS/AD development
Abstract
Developing and testing autonomous driving (AD) systems requires the analysis and storage of more data than ever before. Next-generation Automotive enterprises are fully data-driven. They are focused on unlocking and activating the intrinsic value of the data in their development cycle using the combined practices of continuous integration (CI) and continuous delivery (CD). In this process the data can be created and accessed at the core or on the edge. Modern data loggers capture huge amounts of scenes and scenario data with smart recording technology under the control of a cloud-based AV fleet management solution.
Frank Kraemer
Data Mining as an essential Tool for Data Driven Vehicle Development
Abstract
In an environment of steadily increasing competitiveness, data driven product development offers a great opportunity for automotive manufacturers. Vehicle usage data can be used, for example, to optimize technical components for their real-life stress or to develop new customer functions based on real user behavior. With the increasing interconnectedness of modern vehicles, usage data in the form of vehicle bus signals can be used for data-driven development. However, the use of this data often poses a challenge because it was designed for internal communication of the vehicle rather than for later analysis. Accordingly, this paper presents how data mining (DM) methods can be used to extract customer behavior from this data. The central idea of the presented methods is the derivation and enrichment of the vehicle bus signals with metadata of the vehicle usage, for example but not exclusively by applying statistical methods like machine learning. The method of metadata enrichment is embedded in an adapted version of the Cross Industry Standard Process for Data Mining (CRISP-DM). The developed methods are presented based on concrete application examples and finally a general recommendation for action for data-driven product development in the automotive sector is derived
Jan Wegener, Sebastiaan van Putten, Jens Neubeck, Andreas Wagner

Development Methods

Frontmatter
Developing Systems with Technical Cleanliness Requirements – Constraints and New Approaches
Abstract
In the manufacture of components and systems for electromobility, almost all functional and safety-relevant components are now subject to limit values for particle cleanliness. What began 25 years ago for individual components in the area of the power train for combustion engines can now be found across the board in systems of the electric power train.
So far, attempts have always been made to ensure the necessary component cleanliness through measures in production and assembly. However, it is now becoming increasingly clear that the required technical cleanliness cannot be reliably produced with this approach alone. In this article, the limits of technical cleanliness for the materials and manufacturing processes used today will be shown. Even if further optimization and investments are made here, this alone is not expedient.
The only viable way to achieve the high cleanliness specifications is to integrate development and construction into the process in a different way than before. The degree of cleanliness to be achieved in the later product and at what cost is already largely determined by the design. So far, development has usually only been responsible for creating the cleanliness specifications, but not for their accessibility. How a rethinking can take place here and what expedient approaches there are for this will be presented and explained in the article.
Markus Rochowicz

Mobility Solutions (Poster)

Frontmatter
HElmar-LiMo 2040: Sustainable Urban Living and Mobility Concept
Abstract
How can individual mobility in urban areas be maintained alongside scooters and cargo bikes if conventional vehicles are foreseeably no longer allowed to enter city centers? And how can urban living be combined with individual mobility in a sustainable and socially acceptable way? LiMo-2040 attempts to provide answers to these questions. It is a sub-project of “Helmar” [Schuler et al. 2021] and uses a modular vehicle concept to pursue a holistic approach according to the criteria: • As light as possible • As compact as possible • As simple (cost-effective) as possible.
Hugo Gabele, Torben Ossendorf, Fabian Schmid, Martin Ziegler
Implementation of What-if Scenarios in Coupled Vehicle and Traffic Co-simulation of Urban Areas
Abstract
The increase in individual traffic in urban areas and increasing demands for environmental protection and energy efficiency are prompting major structural changes, not only in the traffic infrastructure, but also in vehicle guidance, towards automated and connected driving functions. While a standalone microscopic traffic simulations can predict the impact of infrastructural changes on traffic flow, it is only when coupled with a sophisticated vehicle simulation that a complete mapping of realistic traffic situations needed for safeguarding automated driving is possible. Coupling a vehicle simulator enables the representation of traffic actions in a photorealistic virtual 3D environment, as well as the integration and validation of sensor-based driving functions on sub-microscopic level and the extraction of critical scenarios of the real world. This publication illustrates the implementation of a real-time coupled co-simulation based on a digital twin of Ingolstadt from the research project SAVeNoW. This includes the integration of a consistent static virtual environment in both the traffic simulator SUMO and the Unreal Engine™ based vehicle simulator Tronis®, as well as the exchange of dynamic information between the two co-simulators to enable conflict-free synchronization. Furthermore, the specific implementation of what-if scenarios in the traffic simulator and the correct representation of these scenarios in the vehicle simulator are discussed.
M. Kulig, K. Schreiner, J. Brodersen, C. Stadler, M. Obstbaum, M. Keckeisen
Can New Business Models Make Charging Stations More Successful?
Abstract
Public charging stations are urgently needed for the successful transformation of electromobility. The infrastructure lags far behind planned figures, so that politicians and environmentalists already see the transformation of electromobility at risk. Neither the politicians, the car manufacturers nor even the mineral oil companies are prepared to make these investments. New players are entering the market and attempting to occupy this business segment through new concepts such as roaming from the mobile industry, but none of these are economically successful.
The predominant problem is that electromobility has not only given rise to new technologies and market players, but also requires new value chains that must evolve into value networks. Furthermore, it has become clear that the existing business concepts and business models of fuel stations cannot be transferred to charging stations and that innovative approaches are needed. A promising concept are sustainable business models. They extend conventional business models based on value proposition, value creation and delivery and value capture with additional elements of environmental sustainability and social aspects. In combination with the development of an eco-system for electromobility, it is possible to satisfy the needs of customers for more sustainability and at the same time be economically successful.
Rudolf Schnee, Nathalie Kroichvili, Daniela Chrenko, Reiner Kriesten
Deep Learning and Geo-Fencing Based Free Parking Spot Detection Using a Camera Mounted on a Truck
Abstract
The global shipping industry is experiencing rapid growth due to increased demand for commodities driven by e-commerce and digital technology. This growth has created new challenges for the logistics industry, which must improve efficiency, accuracy, and speed. Automation of logistics processes is an important research topic that can help address these challenges by reducing human error, increasing efficiency, and saving labor and energy costs. An important area of focus for logistics yard automation is vehicle management, and understanding parking occupancy is critical to better inventory management and faster operations. This study analyzes existing parking space detection methods and evaluates their feasibility in specific logistics scenarios, identifying new challenges and potential benefits of logistics yard automation. Our proposed solution is based on deep learning and Geofence, which exploits the standardization of parking spaces in the logistics park area and combines a deep learning model to estimate the distance and declination of the exchanged bodies within the screen without the need for additional 3D sensors. Our approach offers significant advantages in terms of deployment cost, operational flexibility, and utilization of additional information. It shows the powerful performance of deep learning in object detection on the one hand, and the great application potential of geo-fencing on the other hand, providing a new way of thinking for future parking spot detection.
Lei YE, Ebin Zacharias, Hans Christian Reuss, Kun Gao

New Technologies (Poster)

Frontmatter
Multiscale Simulations of Carbon-Based Composites for the Design of Sustainable Automotive Parts
Zusammenfassung
Energy absorption during an impact is very important in a vehicle’s bumper system. This work aims to study the improvement of energy absorption and intrusion characteristics of bumpers made of carbon nanotube-reinforced polymers in comparison with conventional materials used in the automotive industry. A parametric investigation is conducted by simulation of impact using contact finite element methods, while the composite material is modeled using multiscale methods, based on computational homogenization. The immense computational requirements associated with the aforementioned methods are addressed by a surrogate modeling technique, which utilizes neural networks, trained to predict the nonlinear stress-strain relationship of the composite. The obtained results suggest that the energy absorption of the bumper system increases significantly for the bumpers made of reinforced polymer. Our future goal is to deploy this model on exascale HPC systems for performing material optimization to find the optimal material configurations that will maximize the vehicle’s crashworthiness.
Kostantinos Margaronis, Vasileios Merevis, Rahul Banerjee, Ioannis Kalogeris, Philippe Mauri, Arijit Mallick, Stefanos Pyrialakos, Vissarion Papadopoulos, Martin Obstbaum, Victor Faessler
Precise Rotationally Symmetrical Speed Sensor with Detection of Direction of Rotation
Abstract
In many applications with magnetic field-based speed sensors and passive target wheels, the rotatability of the sensor due to rotational symmetry is an important application criterion (reduction of the number of variants and thus of costs); likewise, air gap-independent tooth mapping and, increasingly, rotational direction detection are often required. Rotational symmetry can preferably be achieved by a single sensor element on the axis of rotation. A specially designed asymmetrical shape of the teeth of the sensor wheel is then required for the detection of the direction of rotation. In this concept, a suitable evaluation algorithm of the magnetic field over tooth and gaps of the sensor wheel is proposed, so that a precise tooth mapping almost independent of the air gap is possible—at least for one tooth edge (rising or falling edge).
Klemens Gintner

Powertrain Efficiency

Frontmatter
The Electromechanically Deactivating Valve Train—From Concept to Mass Production in a Modular Engine Family
Abstract
Switchable roller finger follower systems are state-of-the-art in modern engines but often suffer from hydraulic actuation. Schaeffler developed an electromechanically switchable roller finger follower system for the application in the new modular BMW inline six and inline four-cylinder engines for the usage in mild hybrid powertrains with P1 electric machine. The system enables the deactivation of the exhaust valves to cut off oxygen flow to the catalyst, reduce drag torque in overrun mode, increase recuperation and even enables electric driving in mild hybrid applications. Details of the system design including the application to the four and six-cylinder engines are described, as well as several new production processes which were developed to realize the system in a high-volume production.
Frank Himsel, Thomas Werblinski, Wolfgang Christgen

Powertrain Systems (Poster)

Frontmatter
Highly Dynamic Battery Management Test System with Real-time Electrochemical Impedance Simulation
Zusammenfassung
Simulations and hardware-in-the-loop (HiL) systems play a key role in the development and testing of battery management systems (BMS). In a HiL system the analyzed BMS is connected to an emulated battery pack and the sensor signals are calculated by a real-time model. The BMS functions to be tested include diagnostic functions for monitoring state-of-charge, temperature, and state-of-health of a battery. Recent developments show the potential of electrochemical impedance spectroscopy (EIS) simulation to derive these characteristic battery data faster and more accurately than before. Thus, the safety of a battery electric vehicle can be increased and the remaining range can be predicted more accurately.
In order to test BMS with EIS simulation using a HiL emulator, the emulator must be able to calculate battery models at cell level with sufficient accuracy and return an ultrafast voltage response to an AC signal from the BMS. This ultrafast HiL for the next generation of BMS was developed and successfully tested via a hybrid real-time simulation comprising an physical/electrochemical model based on Newman’s approach coupled with an equivalent circuit. Furthermore, the core of the HiL is a newly developed cell simulation board on which this model is calculated.
Michael Schwalm, Tatjana Dabrowski, Franz Dengler
Modular Drive and Design Technologies for Small Commercial Vehicles in Batch Production
Abstract
The individualization of small commercial vehicles for the inner-city delivery, last mile, will intensified in the future by environmental, logistical framework conditions adapted and must be implemented.adaptations both in the choice of drive and the vehicle conception including the infrastructure will support the logistical request for a vehicle.
Jürgen Erhardt
Investigation and DoE Optimization of Rotor Carriers for a Axial Flux Machine
Abstract
The update of the Mercedes-Benz strategy from “Electric first” to “Electric only” is accelerating the transformation towards an emission-free future and placing the focus on fully electric drives (Mercedes-Benz, www.​daimler.​com/​konzern/​strategie/​mercedes-benz-strategy-update-electric-drive.​html, last accessed 2021/06/22.). In addition to radial flux motors, which have been very common to date, axial flux motors offer new possibilities for drive topologies due to their comparatively small axial installation space and serve as enabler for compact dual drive units, for example. The special potential of axial flux motors lies in their combination of an extraordinary power-to-size and power-to-weight ratio with the highest level of efficiency. (Yasa Limited, www.​yasa.​com/​technology/​, last accessed 2021/12/2;3. The Yokeless And Segmented Armature Machine Developed For The LIFECar, University of Oxford, Hilary;).
Taking the general requirements for the electric motor as a basis, the aim is to derive the mechanical requirements and determine the properties of the component parts. The standards for laminated sheet packages of radial flux motors that specify the electromagnetic and mechanical properties have been defined. So far, laminated sheet packages in the form of laminated back iron for rotors of axial flux motors have been specified in terms of their electromagnetic properties exclusively. The relevant standards therefore do not take into account any requirements relating to the axial strength and stiffness of laminated back iron. In this paper the author focuses on simulation and experimental validation of these mechanical properties of axial flux rotor back iron.
M. Fuchslocher, T. Albrecht, S. Henzler, M. Bargende, A. C. Culzer, M. Soeprapto

Smart Engineering

Frontmatter
A Data Mining Process Model to Support the Development of Energy Systems of Electric Vehicles
Abstract
The development processes for electric vehicles are becoming increasingly demanding, partly due to the high complexity of the energy systems. Furthermore, the developers have to handle various usage requirements of the systems and diverse user behavior. Here, inductive development approaches can help developers deal with high complexities by identifying interrelationships. This work introduces a Data Mining Process Model for Energy Systems development (DMPMES) that has been adapted for the energy system’s highly technical domain to support the developers in their work. The model represents an interdisciplinary process requiring expertise in data science, data engineering, and the development of energy systems. It systematically supports the quick usage of fleet data, the building of algorithms, and the investigation of them and their outputs. The first application studies are discussed, where fleet data was used to investigate the system behavior under actual operating conditions and thus discovered anomalies in the energy systems. Machine learning algorithms can find these anomalies, which are investigated afterward. In this way, the developers are supported in their work, learning complex interrelationships and previously unknown knowledge about the energy system through the application of the DMPMES. Consequently, the DMPMES is a helpful tool that supports the systematic use of inductive development approaches in energy systems.
Stefan Hörtling, Katharina Bause, Albert Albers

Zero-Impact-Emissions

Frontmatter
A Comparative Study of CDA vs LIVC on 11L Diesel Engine and Stock After Treatment System
Abstract
Diesel engines for commercial vehicles are called to deal with more stringent emissions regulations. Variable Valve Train solutions are a building block of the strategy to meet new emissions limits. Several studies are available combining CDA or LIVC with upgraded engine architectures and after treatment systems. But what is the net contribution of CDA vs LIVC in regard to the engine emissions and fuel consumption? To answer this question Eaton, in collaboration with FEV, has executed an investigation on an 11L commercial engine and its stock after treatment system, by replacing the standard VT with Eaton switchable rockers capable to deliver either CDA and LIVC functions. CDA rockers have been installed on 3 cylinders, while LIVC rockers have been installed on all the cylinders. All the other engine components were kept as they are.
Nicola Andrisani, Giuseppe Sammito
Using Virtualization for Possible Trade-offs Between EU7 Start Budget Criteria and Drivability
Abstract
Upcoming EU7 legislation, shortage of time, of budgets, and of availability of test vehicles at a wider variant portfolio will lead to an increase of complexity with significant impact on development of Engine Control Unit (ECU) functionalities. Virtualization is a key success factor to face these new challenges. Within a Bosch project, a virtual vehicle to calibrate emission use cases is established in a Software-in-the-Loop environment. The modular approach is flexible to be tailored for various topologies of vehicles. Arbitrary cycle scenarios with flexible boundary conditions can be simulated. It offers multiple new opportunities, including timesaving, cost-efficient and location-independent benefits. It is usable for multiple software and calibration tasks on different levels of complexity. Based on a use case the benefits and opportunities for future tasks are shown. Critical cold start emissions are simulated. For this condition different calibration measures, such as torque limitation and drive-off delay are analyzed. Their impact on the trade-off between emissions and drivability is considered and put into context with EU7 start budget criteria, a distance-based emission limit. The use of virtualization enables a systematic identification of emission reduction potential and leads to the development of new calibration strategies. New methodologies and automation processes have been elaborated. Virtualization is a chance of mastering future complexity in ECU development.
Lukas Behr, Mauro Cao, Johannes Brenner
Zero-impact Emissions From a Gasoline Car with Advanced Emission Controls and E-fuels
Abstract
The legislative framework for new Internal Combustion Engines for the next years is currently being defined, with the review of the light-duty CO2 emissions standards and Euro 7 proposal to regulate pollutant emissions under a wide range of driving conditions. Despite a −100% tailpipe-only CO2 target by 2035, some perspective is kept for the potential role of vehicles running exclusively on e-fuels.
This study investigates a gasoline demonstrator vehicle equipped with a 48 V mild-hybrid powertrain and a 1.5 L direct injection engine. The innovative emission control system consists in project phase 1 of a three-way catalyst (TWC) in close-coupled position, in combination with an underfloor catalysed gasoline particulate filter (cGPF), second TWC and ammonia slip catalyst (ASC). In a project phase 2, an electrically pre-heated catalyst (EHC) is integrated in the close-coupled TWC canning.
Pollutant emission tests on reference E10 fuel are conducted on a challenging chassis dyno test for cold-start emissions at 23 and −10 °C. The results show the system achieves near-zero pollutant emissions when the emissions control system is warm. The initial cold-start peak is reduced compared to already low Euro 6d levels. All data is within the Euro 7 boundary conditions and limits of the Euro 7 proposal.
Tests were repeated on Blue Gasoline and e-gasoline, confirming ultra-low pollutant emissions while achieving significant CO2 emissions reduction on a Well-to-Wheel basis.
Joachim Demuynck, Dirk Bosteels
Numerical Investigation on the Mechanism of Tumble Caused Cycle-to-Cycle Variation of High-Tumble Spark-Ignition Engine
Zusammenfassung
Due to increasingly strict emission regulations, improving and optimizing the combustion process is one of the main research focuses of internal combustion engine development. Combustion instability is a significant parameter, which affects the emission level, and it is reflected by cycle-to-cycle variation. Therefore, understanding the reasons for cycle-to-cycle variation is crucial for the internal combustion design. This paper investigates the causes of cycle-to-cycle variation of a spark-ignition engine through the 3D large eddy simulations done by CONVERGE v3.0. The analysis focuses on the mechanism and consequences of intake tumble flow variation. The variation of tumble ratio between cycles is found to cause fluctuation in turbulent kinetic energy, which will result in different combustion processes. Moreover, according to the results the tumble variation is attributed to the random turbulent eddies in a specific area between the cylinder head and inflow. Comparing tumble variations under different engine specifications, it is found that reducing the size of this area e.g., by changing cylinder head geometry or delaying intake valve opening, contributes to the smaller tumble variation.
Ye Feng, Niklas Mirsch, Michael Grill, André Casal Kulzer, Marco Günther, Stefan Pischinger
3D-CFD Full Engine Simulation of Post-Oxidation by Means of Secondary Air Injection
Abstract
The current and future development of internal combustion engines must face several challenges related to the upcoming new emissions regulations. For the design of new low-emission concepts, cold start conditions are of crucial importance. Reducing the time needed to reach the light-off temperature by the TWC is crucial to meet the increasingly stringent emission standards. There are many possible strategies to heat up the catalyst. Among them, post-oxidation is particularly promising because it is simple, reliable and cost-effective. The following investigation focuses on the implementation of post-oxidation by means of secondary air injection in a four-cylinder, turbocharged, direct injection spark ignition engine. Secondary air injection is implemented by adopting an air pump to inject fresh air in the proximity of the exhaust valves. The investigation is based on detailed measurements that are carried out at the test-bench, which have been confirmed by 3D-CFD simulations. The test bench role is relevant to understand which conditions are more crucial for the post-oxidation, so these operating points can be deeply investigated by means of 3D-CFD. The 3D-CFD analysis relies on two approaches: a full engine model from upstream the air filter to downstream the catalyst, including a 0D model of the turbocharger; a detailed model of the exhaust manifold from the exhaust valves up to the turbine inlet for the implementation of chemical reaction mechanism.
Mario Pipolo, André Casal Kulzer, Marco Chiodi, Madan Kumar, Yasuo Moriyoshi
Backmatter
Metadaten
Titel
23. Internationales Stuttgarter Symposium
herausgegeben von
André Casal Kulzer
Hans-Christian Reuss
Andreas Wagner
Copyright-Jahr
2023
Electronic ISBN
978-3-658-42236-3
Print ISBN
978-3-658-42235-6
DOI
https://doi.org/10.1007/978-3-658-42236-3

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