Powertrain system optimization for a heavy-duty hybrid electric bus

This research concerns the design of a powertrain system for a plug-in parallel diesel hybrid electric bus equipped with a continuously variable transmission (CVT) and presents a new design paradigm for the plug-in hybrid electric bus (HEB). The criteria and method for selecting and sizing powertrain components equipped in the plug-in HEB are presented. The plug-in HEB is designed to overcome the vulnerable limitations of driving range and performance of a purely electric vehicle (EV), and it is also designed to improve the fuel economy and exhaust emissions of conventional buses and conventional HEBs. Optimization of the control strategy for the complicated and interconnected propulsion system in the plug-in parallel HEB is one of the most significant factors for achieving higher fuel economy and lower exhaust emissions in the hybrid electric vehicle (HEV). In this research, the proposed control strategy was simulated to prove its validity using the ADVISOR (advanced vehicle simulator) analysis simulation tool.     

Development of a path planning system using mean shift algorithm for driver assistance

The longitudinal and lateral vehicle control techniques have been widely used in several active driver assistance systems. The adaptive cruise control, lane keeping assistant control, vehicle platooning and stop-and-go control are typical examples of the most important applications. In this study, a novel path planning method is proposed considering the driving environment such as road shape, ego vehicle and surrounding vehicles’ movement. The relative distance and velocity between the ego vehicle and surrounding vehicles are identified with respect to the predicted lane shape in front of the ego vehicle. Based on the identified information, the road shape and surrounding vehicles are mapped into the intensity image and the desired vector for the ego vehicle’s movement is determined by the maximum intensity density tracing method. The desired vehicle path is followed by the acceleration/deceleration control and the steering assist control, respectively. In order to evaluate the performance of the proposed system, simulations are conducted and compared with ACC systems.     

Optimal design of the exhaust system layout to suppress the discharge noise from an idling engine

At the idle engine speed, the exhaust discharge noise is influenced by resonances in the whole system, which is composed of connecting pipes and silencers. This pipe resonance radiates a high level of low frequency discharge noise, which is dominated by the low order harmonics of the engine firing frequency. This low frequency noise deteriorates the vehicle’s interior noise level and quality. The following study attempted to optimize the layout of an exhaust system to minimize low frequency noise by changing the position of silencers and the lengths of inlet and outlet pipes in each silencer. After modeling the exhaust system using four-pole parameters, the acoustical performance of the system was evaluated using the system insertion loss. In the optimization, the virtual attenuation coefficient, which corresponds to the amount of attenuation coefficient required for the silencers, was calculated to find a minimum value for the layout. The simulated annealing method, which is also known as finding an optimal, was employed in searching for the optimized exhaust layout. Test examples of two cases, for two and six design variables, were used. When the number of design variables was two, the positions of the center and rear silencers were considered. When the number of design variables was six, the positions of the two silencers and the lengths of the inlet and outlet pipes were considered. Three typical layouts for the exhaust system of each case were designed, including the given system and an optimal system. By comparing the predicted and measured discharge noise level, it was confirmed that the optimized exhaust layout has a higher noise reduction than the other layout designs.     

Large-eddy simulation of air entrainment during diesel spray combustion with multi-dimensional CFD

Large-Eddy Simulation (LES) was used to perform computations of air entrainment and mixing during diesel spray combustion. The results of this simulation were compared with those of Reynolds Averaged Navier Stokes (RANS) simulations and an experiment. The effect of LES on non-vaporizing and vaporizing sprays was evaluated. The validity of the grid size used for the LES analysis was confirmed by determining the subgrid-scale (SGS) filter threshold on the turbulent energy spectrum plot, which separates a resolved range from a modeled one. The results showed that more air was entrained into the jet with decreasing ambient gas temperatures. The mass of the evaporated fuel increased with increasing ambient gas temperatures, as did the mixture fraction variance, showing a greater spread in the profile at an ambient gas temperature of 920 K than at 820 K. Flame lift-off length sensitivity was analyzed based on the location of the flame temperature iso-line. The results showed that for the flame temperature iso-line of 2000oC, the computed lift-off length values in RANS matched the experimental values well, whereas in LES, the computed lift-off length was slightly underpredicted. The apparent heat release rate (AHRR) computed by the LES approach showed good agreement with the experiment, and it provided an accurate prediction of the ignition delay; however, the ignition delay computed by the RANS was underpredicted. Finally, the relationships between the entrained air quantity and mixture fraction distribution as well as soot formation in the jet were observed. As more air was entrained into the jet, the amount of air-fuel premixing that occurred prior to the initial combustion zone increased, upstream of the lift-off length, and therefore, the soot formation downstream of the flame decreased.     

Reliability-based topology optimization based on bidirectional evolutionary structural optimization using multi-objective sensitivity numbers

Reliability-based topology optimization (RBTO) is used to obtain an optimal topology satisfying given constraints, as well as to consider uncertainties in design variables. In this study, RBTO was applied to obtain an optimal topology for the inner reinforcement of a vehicle’s hood based on bidirectional evolutionary structural optimization (BESO). A multi-objective topology optimization technique was implemented to obtain the optimal topology for two models with different curvatures while simultaneously considering the static stiffness of bending, torsion, and natural frequency. A performance measure approach (PMA) with probabilistic constraints formulated in terms of the reliability index was employed to evaluate the probabilistic constraints. The optimal topology obtained by RBTO was evaluated and compared to that obtained by deterministic topology optimization (DTO). A more suitable topology was obtained through RBTO than DTO even though the final volume obtained by RBTO was generally slightly greater than that obtained by DTO. The multiobjective optimization technique based on BESO can be applied very effectively with topology optimization for a vehicle’s hood reinforcement.     

Drag reduction of a pickup truck by a rear downward flap

The drag reduction of a pickup truck by a rear flap add-on was examined through CFD simulations and wind tunnel experiments. When installed at the rear edge of the roof, the flap increased the cabin back surface pressure coefficient, causing the downwash of the bed flow to be inclined on the tailgate. Thus, the attachment of the bed flow to the tailgate was eliminated; consequently, the drag coefficient was reduced with increasing flap length and downward angle despite the enlarged reverse flow in the wake. However, the drag coefficient did not decrease any further after a specific downward angle was reached because the bed flow increased the drag force at the tailgate and the flap lowered the pressure field above the flap. To maximize the drag reduction effect, the rear downward flap should be designed to have an optimum downward angle.     

Design and use of an eddy current retarder in an automobile

In this study, the structure and working principles of an eddy current retarder acting as an auxiliary brake set is introduced in detail. Based on the principle of energy conservation, a mathematical model was developed to design a retarder whose nominal brake torque is 1, 900 N·m. According to the characteristics of the eddy current retarder, an exclusive test bed was developed and used for brake performance measurements. The main technical parameters, such as the brake characteristics, temperature characteristics and power consumption, were measured with the test bed. The test data show that the brake torque of the eddy current retarder obviously decreased in the continuous braking stage and that there is a certain amount of brake torque in the normal driving state because of the remnant magnetism of the rotor plate. The mathematical model could be used to design an eddy current retarder. The exclusive test bed could be used for optimization of an eddy current retarder as well as for R&D of a series of products.     

Nano-particle emission characteristics of European and Worldwide Harmonized test cycles for heavy-duty diesel engines

This study was conducted for the experimental comparison of particulate emission characteristics between the European and World-Harmonized test cycles for a heavy-duty diesel engine as part of the UN/ECE PMP ILCE of the Korea Particulate Measurement Program. To verify the particulate mass and particle number concentrations from various operating modes, ETC/ESC and WHTC/WHSC, were evaluated. Both will be enacted in Euro VI emission legislation. The real-time particle emissions from a Mercedes OM501 heavy-duty golden engine with a catalyst based uncoated golden DPF were measured with CPC and DMS during daily test protocol. Real-time particle formation of the transient cycles ETC and WHTC were strongly correlated with engine operating conditions and after-treatment device temperature. The higher particle number concentration during the ESC #7 to #10 mode was ascribed to passive DPF regeneration and the thermal release of low volatile particles at high exhaust temperature conditions. The detailed average particle number concentration equipped for golden DPF reached approximately 4.783E+11 #/kWh (weighted WHTC), 6.087E+10 #/kWh (WHSC), 4.596E+10 #/kWh (ETC), and 3.389E+12 #/kWh (ESC). Particle masses ranged from 0.0011 g/kWh (WHSC) to 0.0031 g/kWh (ESC). The particle number concentration and mass reduction of DPF reached about 99%, except for an ESC with a reduction of 95%.     

Optimization of drying performance considering driving conditions

Compressed air can be used as an energy source for brake systems in medium-heavy and heavy-duty commercial vehicles. The moisture in compressed air, which is due to high temperature and humidity, can be eliminated by using an air dryer. In this paper, drying performance data for a cartridge were obtained and used to develop a drying performance program, to predict the moisture and relative humidity in the air tanks of vehicles. The on-load time, off-load time, air flow, duty cycle, humidity and dew point temperature were calculated according to air consumption. The validity of the program was verified, and it was shown to be able to predict humidity changes in the air tank. The air tank capacity was increased from 100 to 130 to reduce the duty cycle. Therefore, the regeneration rate decreased from 18% to 15%, but the dew point depression temperature (ΔT) remained above 30°C. The duty cycle decreased from 50% to 43%, and the total operation time and power consumption of the air compressor were reduced. In conclusion, fuel savings were obtained by changing the parameters to optimize the system.     

Derivation and validation of nonlinear governing equations for an analysis of vehicle handling

Nonlinear governing equations used to analyze the handling of a ground vehicle are derived from the Lagrange equations of motion. The derived equations are coded using VBA (Visual Basic for Applications) embedded in Microsoft’s Excel Software and simulated in the time domain using the 4th-order Runge-Kutta method. A total of six degrees of freedom are used in the equations; three of these are the directional translation, lateral translation, and yaw of a platform (unsprung) on the base of an inertial ground coordinate, and the other three are the roll, pitch, and yaw of a body (sprung) by a platform-fixed coordinate. Four driving torques and four wheel angles of all tires are used as input control parameters. A simplified Calspan tire model is adopted for the generalized forces of the equations. This is a combined model that can be used to obtain tractional (or braking) and side forces using the inputs of the directional and side-slip ratios and the vertical force. The VBA code realized in this study is validated by comparisons with trimmed equilibrium results and the test data cited in published papers. The major characteristics of this study are: (1) the coordinate systems of the equations are mixed with the inertial frame and the platform-fixed frame, and, as a result, almost all types of driving conditions with long mileages can be simulated; (2) vertical movement is eliminated due the focus on the handling analysis; (3) the body-yaw degree of freedom is separated from the platform-yaw degree of freedom; and (4) the programming is performed by VBA, which is rarely used in the vehicle dynamics field.