Automotive Engineering Commons^™

Crash Safety In The Introductory Physics Lab, Daniel Ludwigsen, Janet Brelin-Fornari, Joseph Neal

Daniel Ludwigsen

Crash Safety in the Introductory Physics Lab Abstract In the field of vehicle occupant protection and crash safety, the Deceleration Sled offers researchers a controlled, repeatable, and relatively cost-effective means to test interior parts such as safety restraint systems. The sled can accelerate a 2000 lb payload to achieve a speed of 40 mph before a hydraulically controlled deceleration models the deformation of the vehicle structure during a crash. Understanding the dynamics of the sled and interpreting test results incorporates many of the core concepts of a first course in introductory physics. This application of physics principles is the inspiration …

Optimizing Compressed Air Storage For Energy Efficiency, Brian Abels, J. Kelly Kissock

J. Kelly Kissock

Compressed air storage is an important, but often misunderstood, component of compressed air systems. This paper discusses methods to properly size compressed air storage in load-unload systems to avoid short cycling and reduce system energy use. First, key equations relating storage, pressure, and compressed air flow are derived using fundamental thermodynamic relations. Next, these relations are used to calculate the relation between volume of storage and cycle time in load-unload compressors. It is shown that cycle time is minimized when compressed air demand is 50% of compressor capacity. The effect of pressure drop between compressor system and storage on cycle …

Energy Efficient Process Heating: Insulation And Thermal Mass, Kevin Carpenter, J. Kelly Kissock

J. Kelly Kissock

Open tanks and exterior surfaces of process heating equipment lose heat to the surroundings via convection, radiation, and/or evaporation. A practical way of reducing heat loss is by insulating or covering the surfaces. This paper presents methods to quantify heat loss and energy savings from insulating hot surfaces and open tanks. The methods include radiation and evaporation losses, which are ignored by simplified methods. In addition, thermal mass, such as refractory, conveyor and racking equipment, acts as a heat sink and increases heating energy use in process heating applications. This paper presents lumped capacitance and finite-difference methods for estimating heat …

Improving Compressed Air Energy Efficiency In Automotive Plants: Practical Examples And Implementation, Nasr Alkadi, J. Kelly Kissock

J. Kelly Kissock

The automotive industry is the largest industry in the United States in terms of the dollar value of production [1]. U.S. automakers face tremendous pressure from foreign competitors, which have an increasing manufacturing presence in this country. The Big Three North American Original Equipment Manufacturers (OEMs)-General Motors, Ford, and Chrysler-are reacting to declining sales figures and economic strain by working more efficiently and seeking out opportunities to reduce production costs without negatively affecting the production volume or the quality of the product. Successful, cost-effective investment and implementation of the energy efficiency technologies and practices meet the challenge of maintaining the …

Energy Efficient Process Heating: Managing Air Flow, Kevin Carpenter, J. Kelly Kissock

J. Kelly Kissock

Much energy is lost through excess air flow in and out of process heating equipment. Energy saving opportunities from managing air flow include minimizing combustion air, preheating combustion air, minimizing ventilation air, and reconfiguring openings to reduce leakage.

This paper identifies these opportunities and presents methods to quantify potential energy savings from implementing these energy-savings measures. Case study examples are used to demonstrate the methods and the potential energy savings.The method for calculating savings from minimizing combustion air accounts for improvement in efficiency from increased combustion temperature and decreased combustion gas mass flow rate.

The method for calculating savings from …

Development Of A Spring-Based Automotive Starter, David H. Myszka, Jonathan Lauden, Patrick Joyce, Andrew P. Murray, Christoph Gillum

David Myszka

Automotive starting systems require substantial amounts of mechanical energy in a short period of time. Lead-acid batteries have historically provided that energy through a starter motor. Springs have been identified as an alternative energy storage medium and are well suited to engine-starting applications due to their ability to rapidly deliver substantial mechanical power and their long service life. This paper presents the development of a conceptual, spring-based starter. The focus of the study was to determine whether a spring of acceptable size could provide the required torque and rotational speed to start an automotive engine. Engine testing was performed on …

A Mechanical Regenerative Brake And Launch Assist Using An Open Differential And Elastic Energy Storage, David H. Myszka, Andrew P. Murray, Kevin Giaier, Vijay Krishna Jayaprakash, Christoph Gillum

David Myszka

Regenerative brake and launch assist (RBLA) systems are used to capture kinetic energy while a vehicle decelerates and subsequently use that stored energy to assist propulsion. Commercially available hybrid vehicles use generators, batteries and motors to electrically implement RBLA systems. Substantial increases in vehicle efficiency have been widely cited. This paper presents the development of a mechanical RBLA that stores energy in an elastic medium. An open differential is coupled with a variable transmission to store and release energy to an axle that principally rotates in a single direction. The concept applies regenerative braking technology to conventional automobiles equipped with …

A Mechanical Regenerative Brake And Launch Assist Using An Open Differential And Elastic Energy Storage, David H. Myszka, Andrew P. Murray, Kevin Giaier, Vijay Krishna Jayaprakash, Christoph Gillum

Andrew P. Murray

Regenerative brake and launch assist (RBLA) systems are used to capture kinetic energy while a vehicle decelerates and subsequently use that stored energy to assist propulsion. Commercially available hybrid vehicles use generators, batteries and motors to electrically implement RBLA systems. Substantial increases in vehicle efficiency have been widely cited. This paper presents the development of a mechanical RBLA that stores energy in an elastic medium. An open differential is coupled with a variable transmission to store and release energy to an axle that principally rotates in a single direction. The concept applies regenerative braking technology to conventional automobiles equipped with …

Development Of A Spring-Based Automotive Starter, David H. Myszka, Jonathan Lauden, Patrick Joyce, Andrew P. Murray, Christoph Gillum

Andrew P. Murray

Automotive starting systems require substantial amounts of mechanical energy in a short period of time. Lead-acid batteries have historically provided that energy through a starter motor. Springs have been identified as an alternative energy storage medium and are well suited to engine-starting applications due to their ability to rapidly deliver substantial mechanical power and their long service life. This paper presents the development of a conceptual, spring-based starter. The focus of the study was to determine whether a spring of acceptable size could provide the required torque and rotational speed to start an automotive engine. Engine testing was performed on …

Industrial Solid-State Energy Harvesting: Mechanisms And Examples, Matthew Kocoloski, Carl Eger, Robin Mccarty, Kevin P. Hallinan, J. Kelly Kissock

J. Kissock

This paper explores the potential for solid-state energy harvesting in industrial applications. In contrast to traditional heat recovery, the output of solid-state devices is electricity, which can be readily used in virtually any plant. The progress in harvesting waste heat via thermoelectric and thermionic generators is described. With second law efficiencies now approaching 50% and 80% respectively, we show that these technologies are on the cusp of practical use. Finally, we present an example of energy harvesting using thermionic devices in an industrial application. The example considers energy harvesting from a furnace at a glass manufacturing facility where exhaust gases …

Energy Information Augmented Community-Based Energy Reduction, Kevin P. Hallinan, Harvey Enns, Stephenie Ritchey, Phil Brodrick, Nathan Lammers, Nichole Hanus, Mark Rembert, Tony Rainsberger

Harvey Enns

More than one-half of all U.S. states have instituted energy efficiency mandates requiring utilities to reduce energy use. To achieve these goals, utilities have been permitted rate structures to help them incentivize energy reduction projects. This strategy is proving to be only modestly successful in stemming energy consumption growth. By the same token, community energy reduction programs have achieved moderate to very significant energy reduction. The research described here offers an important tool to strengthen the community energy reduction efforts—by providing such efforts energy information tailored to the energy use patterns of each building occupant. The information provided most importantly …

Microscale Investigation Of Thermo-Fluid Transport In The Transition Fil, Region Of An Evaporating Capillary Meniscus Using A Microgravity Environment, Kenneth D. Kihm, Jeffrey S. Allen, Kevin P. Hallinan, David M. Pratt

Kevin Hallinan

In order to enhance the fundamental understanding of thin film evaporation and thereby improve the critical design concept for two-phase heat transfer devices, microscale heat and mass transport is to be investigated for the transition film region using state-of-the-art optical diagnostic techniques. By utilizing a microgravity environment, the length scales of the transition film region can be extended sufficiently, from submicron to micron, to probe and measure the microscale transport fields which are affected by intermolecular forces. Extension of the thin film dimensions under microgravity will be achieved by using a conical evaporator made of a thin silicon substrate under …

Nanocharacterization Of Bio-Silica Using Atomic Force And Ultrasonic Force Microscopy, Vinaypreet S. Gill, Kevin P. Hallinan, N. S. Brar

Kevin Hallinan

Nanotechnology has become central to our research efforts to fabricate relatively smaller size devices, which are more versatile than their older and larger predecessors. Silica is a very important material in this regard. Recently, a new biomimetically inspired path to silica production has been demonstrated. This processing technique was inspired from biological organisms, such as marine diatoms, which produce silica at ambient conditions and almost neutral ph with beautiful control over location and structure. Recently, several researchers have demonstrated that positional control of silica formed could be achieved by application of an electric field to locate charged enzymes responsible for …

Leveraging Students’ Passion And Creativity: Ethos At The University Of Dayton, Margaret Pinnell, Malcolm Daniels, Kevin P. Hallinan, Gretchen Berkemeier

Kevin Hallinan

The Engineers in Technical Humanitarian Opportunities of Service-learning (ETHOS) program was developed in the spring of 2001 by an interdisciplinary group (electrical, chemical, civil and mechanical) of undergraduate engineering students at the University of Dayton (UD). ETHOS was founded on the belief that engineers are more apt and capable to appropriately serve our world if they have an understanding of technology’s global linkage with values, culture, society, politics, and the economy. Since 2001, the ETHOS program at UD has grown and changed. From conceptualization, to implementation, to maturation and national recognition, the program has addressed challenges of academic acceptance, programmatic …

Experimental Verification Of Source Temperature Modulation Via A Thermal Switch In Thermal Energy Harvesting, Robin Mccarty, D. Monaghan, Kevin P. Hallinan, Brian Sanders

Kevin Hallinan

This paper provides a description of research seeking to experimentally verify the effectiveness of a thermal switch used in series with TE devices for waste heat recovery for constant and variable source heat input and for variable source thermal capacitance (mass). Using an experimental set-up comprised serially of a fixed heat source, a variable thermal resistance air gap serving as a thermal switch, a thermoelectric device and a heat sink, the time-averaged power output to power input ratios improved up to 15% and 30% respectively for constant and variable heat input in certain design space conditions. The experimental results, as …

Industrial Solid-State Energy Harvesting: Mechanisms And Examples, Matthew Kocoloski, Carl Eger, Robin Mccarty, Kevin P. Hallinan, J. Kelly Kissock

Kevin Hallinan

This paper explores the potential for solid-state energy harvesting in industrial applications. In contrast to traditional heat recovery, the output of solid-state devices is electricity, which can be readily used in virtually any plant. The progress in harvesting waste heat via thermoelectric and thermionic generators is described. With second law efficiencies now approaching 50% and 80% respectively, we show that these technologies are on the cusp of practical use. Finally, we present an example of energy harvesting using thermionic devices in an industrial application. The example considers energy harvesting from a furnace at a glass manufacturing facility where exhaust gases …

Energy Information Augmented Community-Based Energy Reduction, Kevin P. Hallinan, Harvey Enns, Stephenie Ritchey, Phil Brodrick, Nathan Lammers, Nichole Hanus, Mark Rembert, Tony Rainsberger

Kevin Hallinan

More than one-half of all U.S. states have instituted energy efficiency mandates requiring utilities to reduce energy use. To achieve these goals, utilities have been permitted rate structures to help them incentivize energy reduction projects. This strategy is proving to be only modestly successful in stemming energy consumption growth. By the same token, community energy reduction programs have achieved moderate to very significant energy reduction. The research described here offers an important tool to strengthen the community energy reduction efforts—by providing such efforts energy information tailored to the energy use patterns of each building occupant. The information provided most importantly …

Electro-Hydrodynamic Pumped Hydraulic Actuation With Application To Active Vibration Control, Ahmad Reza Kashani, Sung Kang, Kevin P. Hallinan

Kevin Hallinan

A new type of actuation device has been conceptualized that meets the needs of both large displacement, force and bandwidth within a package more compact than currently available magnetostrictive and stack-type piezoelectric actuators of similar rating. This concept relies on micro-scale electrohydrodynamic (EHD) pumping of a dielectric liquid within small channels. Configured as an actuator, the EHD pump(s) would be used to move fluid between two reservoirs—each having a compliant membrane that interfaces to the world to provide the means to achieve vibration cancellation or micro actuation. Ordinarily limited to generating flow in macroscale applications, the EHD pump, when operating …

A Study Of The Fundamental Operations Of A Capillary Driven Heat Transfer Device In Both Normal And Low Gravity Part 1-Liquid Slug Formation In Low Gravity, Jeffrey S. Allen, Kevin P. Hallinan, Jack Lekan

Kevin Hallinan

Research has been conducted to observe the operation of a capillary pumped loop (CPL) in both normal and low gravity environments in order to ascertain the causes of device failure. The failures of capillary pumped heat transport devices in low gravity; specifically; evaporator dryout, are not understood and the available data for analyzing the failures is incomplete. To observe failure in these devices an idealized experimental CPL was configured for testing in both a normal-gravity and a low-gravity environment. The experimental test loop was constructed completely of Pyrex tubing to allow for visualization of system operations. Heat was added to …

Clean Energy Infrastructure Educational Initiative, Kevin P. Hallinan, James A. Menart, Robert Gilbert

Kevin Hallinan

The Clean Energy Infrastructure Educational Initiative represents a collaborative effort by the University of Dayton, Wright State University and Sinclair Community College. This effort above all aimed to establish energy related programs at each of the universities while also providing outreach to the local, state-wide, and national communities. At the University of Dayton, the grant has aimed at: solidfying a newly created Master's program in Renewable and Clean Energy; helping to establish and staff a regional sustainability organization for SW Ohio. As well, as the prime grantee, the University of Dayton was responsible for ensuring curricular sharing between WSU and …

A Comprehensive Optimized Model For On-Board Solar Photovoltaic System For Plug-In Electric Vehicles: Energy And Economic Impacts, Mahmoud M. Abdelhamid

Mahmoud M Abdelhamid

Muscle Synergies Improve Estimation Of Knee Contact Forces During Walking, Benjamin Fregly, Jonathan Walter, Allison Kinney, Scott Banks, Darryl D'Lima, Thor Besier, David Lloyd

Allison Kinney

This study investigates whether use of subject-specific muscle synergies can improve optimization predictions of muscle excitation patterns and knee contact forces during walking. Muscle synergies describe how a small number of neural commands generated by the nervous system can be linearly combined to produce the broad range of muscle electromyographic (EMG) signals measured experimentally. By quantifying the interdependence of individual EMG signals, muscle synergies provide dimensionality reduction for the neural control redundancy problem. Our hypothesis was that use of subjectspecific muscle synergies to limit muscle excitation patterns would improve prediction of muscle EMG patterns at the hip, knee, and ankle …

Muscle Synergy Constraints Improve Prediction Of Knee Contact Force During Gait, Benjamin Fregly, Jonathan Walter, Allison Kinney, Scott Banks, Darryl D'Lima, Thor Besier, David Lloyd

Allison Kinney

Knowledge of patient-specific muscle and joint contact forces during activities of daily living could improve the treatment of movement-related disorders (e.g., osteoarthritis, stroke, cerebral palsy, Parkinson’s disease). Unfortunately, it is currently impossible to measure these quantities directly under common clinical conditions, and calculation of these quantities using computer models is limited by the redundant nature of human neural control (i.e., more muscles than theoretically necessary to actuate the available degrees of freedom in the skeleton). Walking is a particularly important task to understand, since loss of mobility is associated with increased morbidity and decreased quality of life. Though numerous musculoskeletal …

Evaluation Of Different Optimal Control Problem Formulations For Solving The Muscle Redundancy Problem, Friedl De Groote, Allison Kinney, Anil Rao, Benjamin Fregly

Allison Kinney

This study evaluates several possible optimal control problem formulations for solving the muscle redundancy problem with the goal of identifying the most efficient and robust formulation. One novel formulation involves the introduction of additional controls that equal the time derivative of the states, resulting in very simple dynamic equations. The nonlinear equations describing muscle dynamics are then imposed as algebraic constraints in their implicit form, simplifying their evaluation. By comparing different problem formulations for computing muscle controls that can reproduce inverse dynamic joint torques during gait, we demonstrate the efficiency and robustness of the proposed novel formulation.

Material Properties And Microstructural Characterization Of Specimens, T.J. Silverman, Allison Kinney, B. South, W. Yong, J.H. Koo

Allison Kinney

The HiQ upgrade to the 3D Systems Vanguard selective laser sintering (SLS) machine incorporates a revised thermal calibration system and new software. This paper quantifies differences in mechanical and morphological properties of specimens built first using a Vanguard HS (high-speed) system and again using the same system with the HiQ upgrade applied. Standard specimens are built from DuraForm PA material and tested for tensile modulus, tensile strength, elongation at break, flexural modulus and Izod impact strength. The design of the specimen battery, the conduction of the tests and the significance of the results are discussed. The upgrade is found to …

Synergies Controls Improve Prediction Of Knee Contact Forces And Muscle Excitations During Gait, Benjamin Fregly, Jonathan Walter, Allison Kinney, Scott Banks, Darryl D'Lima, Thor Besier, David Lloyd

Allison Kinney

This study investigates whether use of muscle excitation controls constructed from subjectspecific muscle synergy information can improve optimization prediction of knee contact forces and muscle excitations during walking. Muscle synergies quantify how a large number of experimental muscle electromyographic (EMG) signals can be reconstructed by linearly mixing a much smaller number of neural commands generated by the nervous system. Our hypothesis was that controlling all muscle excitations with a small set of experimentally calculated neural commands would improve prediction of knee contact forces and leg muscle excitations compared to using independently controlled muscle excitations.

Comparison Of Material Properties And Microstructure Of Specimens Built Using The 3d Systems Vanguard Hs And Vanguard Hiq+Hs Sls Systems, T.J. Silverman, Allison Kinney, W. Yong, J.H. Koo

Allison Kinney

The HiQ upgrade to the 3D Systems Vanguard selective laser sintering (SLS) machine incorporates a revised thermal calibration system and new control software. The paper compares the tensile modulus, tensile strength, elongation at break, flexural modulus, Izod impact resistance and microstructure of two batteries of standard specimens built from recycled Duraform PA (Nylon 12). The first set is built on a Vanguard HS system and the second on the same system with the HiQ upgrade installed. The upgrade reduces user intervention, decreases total build time and improves surface finish. However, using the default processing parameters, tensile, flexure and impact properties …

Why Toyota And Honda Topped The 2002 J.D. Power Quality Study, Susan Lightle, Kenneth Yale Rosenzweig, John Talbott

Kenneth Y. Rosenzweig

Toyota again topped the annual J. D. Power and Associates quality study released in late May of 2002. Toyota scored the highest mark ever with l 07 defects per l 00 vehicles, while Honda came in second with 113 defects. The study was based on responses of approximately 65,000 new car owners queried during their first 90-days of ownership. These results do not surprise us, as we have been fortunate to make numerous sojourns to the Toyota plant in Georgetown, Kentucky, and observe the manufacturing processes. These trips were normally facilitated by a former Japanese student of ours, Minako Yanke, …

Metacomposites Protection System Against Primary Blast Injury, Kwek Tan, C. Sun

Dr. Kwek-Tze Tan

There is an increasing use of improvised explosive devices (IEDs) in terrorist and insurgent activities. Exposure to blast is becoming more frequent. Blast related injuries can be inflicted at various levels. Primary blast injury results from blast wave-induced changes in atmospheric pressure, causing organs and tissues to rupture due to shearing and stretching at different rates. Secondary blast injury results from objects put in motion by the blast wind impacting a person. Tertiary blast injury results from a person being blown into solid objects by the blast wind. This paper deals with the protection system against primary blast injury by …

Cord Load Characteristics In Bias And Belted-Bias Tires, Joseph Walter, George Hall

Dr. Joseph D. Walter

Two improved versions of a recently developed miniature force transducer were used to measure cord loads at the crown, shoulder, and sidewall of bias and belted-bias automobile tires under different testing conditions. As a transducer at a given location passes through the footprint, a “basic shape” for the cord force pattern is generated for straight ahead rolling and cornering. Factors such as wheel load, inflation pressure, obstacle impact, tire speed, rim width, and frictional properties of the tire-drum interface can affect the total force excursion and/or the base line value but do not affect the basic shape of the patterns. …