Development of an Engine Test Cell for Rapid Evaluation of Advanced Powertrain Technologies using Model-Controlled Dynamometers

Steiber, Joe; Trader, Angela; Treichel, Ben; Tsujimoto, Daisuke; Reese, Ronald; Bedard, Mark; Musial, Marc

doi:10.4271/2006-01-1409

Cited by 7 publications

(4 citation statements)

References 2 publications

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“…Because of the delay in the occurrences, the resulting warranty costs could be enormous [3] . Dynamometer testing is an effective method to evaluate engine durability and to characterize the engine's fuel consumption, emissions, and performance [4] . However, dynamometer testing is expensive and time-consuming.…”

Section: Introductionmentioning

confidence: 99%

An Integrated Virtual Engineering Methodology to Evaluate Manufacturing Residual Stress in Cylinder Blocks through Casting and Quenching

Jan

Swisher

Ali

et al. 2021

Heat Treating Conference

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Engine cylinder block cracking is a costly engine component failure that is often discovered late, either in the product verification phase by dynamometer testing or after product launch during vehicle operations. It is well established that the crack issues are related to the residual stress induced in the casting and heat treatment processes. To identify the quality risk in a short turn-around time and a cost-effective fashion, using computer simulations to evaluate the state of stress during casting and heat treat processes is the trend in automotive industry. In recent years, CAE methodologies have advanced significantly in both CFD and FEA to model the casting process, the quenching process, the residual stress, and the high cycle fatigue (HCF). However, calculating the final stress in the cylinder block requires several CAE software tools to work together as an integrated, streamlined engineering method and these CAE tools could be very different in meshing topologies, numerical methods, data structure, and post-processing capabilities. The intent of this research is to develop an integrated virtual engineering methodology combining casting simulation, computational fluid dynamics and finite element method to simulate the manufacturing process from the beginning of casting, through water quenching heat treatment, to engine dynamometer testing. The methodology involves three CAE tools, MAGMASOFT®, AVL FIRETM/FIRETM-M and ABAQUS, and considerable amounts of research and development work are concentrated on the validation of each individual numerical method and tools for data exchange between the software tools.

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Section: Introductionmentioning

confidence: 99%

An Integrated Virtual Engineering Methodology to Evaluate Manufacturing Residual Stress in Cylinder Blocks through Casting and Quenching

Jan

Swisher

Ali

et al. 2021

Heat Treating Conference

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“…14,15 Instead of depending on engine maps, researchers have recently developed hardware-in-the-loop experimental set-ups, which use a vehicle simulation to actuate the engine dynamometer in real time, and can accurately capture the transient behaviour of the engine during a drive cycle. 16,17 Although this approach could potentially provide the most realistic fuel economy predictions, the associated cost can be prohibitive. Moreover, the engine technology in question may still be in early development, and hardware may not be available.…”

Section: Introductionmentioning

confidence: 99%

A comprehensive engine to drive-cycle modelling framework for the fuel economy assessment of advanced engine and combustion technologies

Ortiz-Soto

Assanis

Babajimopoulos

2011

International Journal of Engine Research

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A comprehensive engine to drive-cycle modelling framework has been developed for evaluating fuel economy improvements of new engine technologies. The framework comprises three key components: (a) full engine system models and routines for the generation of engine performance and fuel consumption maps; (b) an improved experimental heat release analysis and model calibration tool, which was created by coupling an in-house heat release analysis program to an engine cycle simulation, and which can be used for model calibration and validation when experimental data are available; and (c) an integrated vehicle modelling and drive-cycle simulation platform for fuel economy assessment. The framework implementation has been demonstrated through a fuel economy study of three engine and combustion technologies: a conventional spark-ignition (SI) engine, a high compression ratio SI engine with early intake valve closing (EIVC), and a homogeneous-charge compression ignition engine (HCCI) employing a recompression valve strategy, used in dual-mode SI-HCCI operation. Simulation results for three drive cycles indicate potential fuel economy gains of the order of 7–11% for the high-compression EIVC SI engine and 7–21% for the dual-mode HCCI engine configurations. Further analysis of the latter, however, reveals frequent mode switching and short excursions in the HCCI region, which could be a challenge during practical implementation, and potentially result in reduced fuel economy gains.

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“…In Engine-in-the-loop (EIL) vehicle simulation, the "real component", or the "faithful physical replicas", is the engine control hardware and software together with a physical engine; while the "real-time simulated component", or the "virtual simulation", is the vehicle and driver. The interaction between the engine and the vehicle system, which includes the driveline, tire and road interface, and vehicle body etc., is replaced by the engine and a transient dynamometer that emulates a real vehicle [5,[7][8][9][10]. There are specific reasons why such a combination is used.…”

Section: Introductionmentioning

confidence: 99%

Development of an Engine-in-the-loop Vehicle Simulation System in Engine Dynamometer Test Cell

Jiang¹,

Smith²,

Kitchen³

et al. 2009

SAE Technical Paper Series

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To meet the ever increasing requirements for engines and vehicles in the areas of performance, fuel economy, emission, and meanwhile reduce product development time,Hardware-in-the-loop (HIL) simulation is increasingly used in automotive control system development.Engine-in-the-loop (EIL) vehicle simulation, which is a specific form of HIL simulation, is an approach in which a physical engine (together with its control unit) is coupled to virtual vehicle and driver models through a high power, low inertia engine dynamometer in the engine test cell environment. EIL can be used to perform powertrain control development, as well as engine and vehicle performance evaluation. Because of its advantages in repeatability and flexibility etc., especially for transient operating mode study, EIL has become a powerful tool and will be more widely used in the near future.Design and implementation of an EIL vehicle simulation system is described. Driver and vehicle simulation models are developed and executed in real time on a high-speed system controller. A highly responsive permanent magnet AC engine dynamometer and a vehicle acceleration pedal are controlled such that the dynamometer loads the connected engine as a real vehicle would and the simulated vehicle speed trace follows the targeted driving cycle. With this system, developers can perform transient engine control development before whole vehicle integration is available. Vehicle parameters, including driveline configurations can be easily modified and the effect on engine and vehicle performance can be studied. An application example of simulating a 10-15 mode emission test cycle is given. The result verifies the effective performance of the system in simulating vehicle dynamics and shows its great potential in engine and vehicle system development.

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Development of an Engine Test Cell for Rapid Evaluation of Advanced Powertrain Technologies using Model-Controlled Dynamometers

Cited by 7 publications

References 2 publications

An Integrated Virtual Engineering Methodology to Evaluate Manufacturing Residual Stress in Cylinder Blocks through Casting and Quenching

An Integrated Virtual Engineering Methodology to Evaluate Manufacturing Residual Stress in Cylinder Blocks through Casting and Quenching

A comprehensive engine to drive-cycle modelling framework for the fuel economy assessment of advanced engine and combustion technologies

Development of an Engine-in-the-loop Vehicle Simulation System in Engine Dynamometer Test Cell

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