Frank Will

A new method to warm up lubricating oil to improve the fuel efficiency during cold start

Cold start driving cycles exhibit an increase in friction losses due to the low temperatures of metal and media compared to normal operating engine conditions. These friction losses are responsible for up to 10% penalty in fuel economy over the official drive cycles like the New European Drive Cycle (NEDC), where the temperature of the oil even at the end of the 1180 s of the drive cycle is below the fully warmed up values of between 100°C and 120°C. At engine oil temperatures below 100°C the water from the blow by condensates and dilutes the engine oil in the oil pan which negatively affects engine wear. Therefore engine oil temperatures above 100°C are desirable to minimize engine wear through blow by condensate. The paper presents a new technique to warm up the engine oil that significantly reduces the friction losses and therefore also reduces the fuel economy penalty during a 22°C cold start NEDC. Chassis dynamometer experiments demonstrated fuel economy improvements of over 7% as well as significant emission reductions by rapidly increasing the oil temperature. Oil temperatures were increased by up to 60°C during certain parts of the NEDC. It is shown how a very simple sensitivity analysis can be used to assess the relative size or efficiency of different heat transfer passes and the resulting fuel economy improvement potential of different heat recovery systems system. Due to its simplicity the method is very fast to use and therefore also very cost effective. The method demonstrated a very good correlation for the fuel consumption within ±1% compared to measurements on a vehicle chassis roll.

Temperature variations at nano-scale level in phase transformed nanocrystalline NiTi shape memory alloys adjacent to graphene layers

The detection and control of the temperature variation at the nano-scale level of thermo-mechanical materials during a compression process have been challenging issues. In this paper, an empirical method is proposed to predict the temperature at the nano-scale level during the solid-state phase transition phenomenon in NiTi shape memory alloys. Isothermal data was used as a reference to determine the temperature change at different loading rates. The temperature of the phase transformed zone underneath the tip increased by ∼3 to 40 °C as the loading rate increased. The temperature approached a constant with further increase in indentation depth. A few layers of graphene were used to enhance the cooling process at different loading rates. Due to the presence of graphene layers the temperature beneath the tip decreased by a further ∼3 to 10 °C depending on the loading rate. Compared with highly polished NiTi, deeper indentation depths were also observed during the solid-state phase transition, especially at the rate dependent zones. Larger superelastic deformations confirmed that the latent heat transfer through the deposited graphene layers allowed a larger phase transition volume and, therefore, more stress relaxation and penetration depth.

Combustion Simulations for a Self Controlling Variable Compression Ratio Connecting Rod

Variable compression ratio enables an engine to achieve increased efficiency at part loads, where the majority of driving occurs, without sacrificing full load power requirements or increasing the risk of engine knock. Although over 100 patents and patent applications exist none of these systems has been commercialized yet due to issues related to feasibility, cost and frictional loss. A new approach of a self controlling variable compression ratio connecting rod is presented that does not need a friction intensive external activation and that could even be retrofitted. The potential in fuel consumption and exhaust emission reduction as well as increased power and torque output for this concept has been verified in combustion simulations utilizing the latest research results related to the dynamic heat transfer in the combustion chamber from Professor Kleinschmidt from the University of Siegen, Germany. The self controlling variable compression ratio connecting rod allows the con rod to compress at high load conditions thereby increasing cylinder volume to alleviate combustion pressures and temperatures and therefore limit knock onset. The biggest efficiency gains can be achieved at medium load where the reduction of heat loss during the compression of the connecting rod plays a major role additional to the well known efficiency gains of an increased compression ratio. The combustion simulation results shows fuel consumption can be reduced by between 3% and 5% during part load and wide open throttle operation at various engine speeds. Emissions are also reduced significantly; particularly NOx and CO emissions were reduced by up to 35%.The self controlling variable compression ratio connecting rod allows the con rod to compress at high load conditions thereby increasing cylinder volume to alleviate combustion pressures and temperatures and therefore limit knock onset. The biggest efficiency gains can be achieved at medium load where the reduction of heat loss during the compression of the connecting rod plays a major role additional to the well known efficiency gains of an increased compression ratio.The combustion simulation results shows fuel consumption can be reduced by between 3% and 5% during part load and wide open throttle operation at various engine speeds. Emissions are also reduced significantly; particularly NOx and CO emissions were reduced by up to 35%.

Tomorrow's Car - For Today's People: Can Tilting Three Wheeled Vehicles be a Solution for the Problems of Today and the Future?

The current automotive industry and todays car drivers are faced with every increasing challenges, not previously experienced. Climate Change, financial issues, rising fuel prices, increased traffic congestion and reduced parking space in cities are all leading to changes in consumer preferences and the requirements of modern passenger vehicles. However, despite the shift in the industry dynamics, the principal layout of a car hasn’t changed since its invention. The design of a ’conventional’ vehicle is still principally a matchbox with four wheels, one at each corner. The concept has served its purpose well for over 100 years, but such a layout is not suited to solving today’s problems. To address the range of problems faced by the industry, a number of alternative commuting vehicles have been developed. Yet the commercialization of these ‘alternative’ vehicles has yet to be successful. This is largely due failure of these vehicles to meet the changing demands of the industry and the limited understanding of consumer behaviour, motivation and attitudes. Deakin University’s Tomorrow’s Car concept tackles all of these problems. The vehicle is a novel three-wheeler cross over concept between a car and a motorbike that combines the best of both worlds. The vehicle combines the low cost, small size and ‘fun’ factor of a motorbike together with the safety, comfort and easy to drive features of a car produce a vehicle with a fuel efficiency better than either car or scooter. Intensive market research has been conducted for various major potential markets of alternative vehicles including India, China and Australia. The research analysed consumer attitudes in relation to narrow tilting vehicles, and in particular towards Deakin’s Tomorrow’s Car (TC). The study revealed that a relatively large percentage of consumers find such a concept very appealing. For the other consumers, the overall appearance and perception of safety and not the actual safety performance were found to be the most impeding factors of such vehicles. By addressing these issues and marketing the vehicle accordingly the successful commercialization of Tomorrow’s Car can be ensured.

Experimental and numerical analysis of engine gas exchange, combustion and heat transfer during warm-up

This paper presents experimental and computational results obtained on an in line, six cylinder, naturally aspirated, gasoline engine. Steady state measurements were first collected for a wide range of cam and spark timings versus throttle position and engine speed at part and full load. Simulations were performed by using an engine thermo-fluid model. The model was validated with measured steady state air and fuel flow rates and indicated and brake mean effective pressures. The model provides satisfactory accuracy and demonstrates the ability of the approach to produce fairly accurate steady state maps of BMEP and BSFC. However, results show that three major areas still need development especially at low loads, namely combustion, heat transfer and friction modeling, impacting respectively on IMEP and FMEP computations. Satisfactory measurement of small IMEP and derivation of FMEP at low loads is also a major issue. Measurements of fuel consumption were then collected during warm up for different configurations of the cooling system, with a standard mechanical water pump (MWP) and an electrical water pump (EWP), at a constant BMEP and engine speed. Simulations were performed by using the previous model to compute IMEP and FMEP. Modeling friction during warm-up, when temperatures of head metal, block metal, coolant and oil are well below hot steady values and decoupled to some extent (split or no flow coolant tests) proves to be challenging. Computational results complement the experimental data, demonstrating the utility of the integrated approach in improving the design of the cooling system for faster warm-up.