Automotive Engineering Commons^™

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

Mechanical and Aerospace Engineering Faculty Publications

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 …

Composite Tie Rod Research, Design And Testing For Sae Baja, Amanda M. Nauman

Williams Honors College, Honors Research Projects

Composite materials have become increasing popular in recent years. For the Baja SAE team, composites are typically only used for body panels. To grow as a team and to earn additional points in design competition, it was decided to explore composite use in mechanical applications, specifically for the tie rods. Research was conducted, looking into composite materials basics, types, and material properties. Additionally, manufacturing was explored, including a few projects separate from the tie rod application. 3D models were created after the materials were selected, and FEA analysis was conducted on the parts. Once theoretical testing was finished, the physical …

Designing A Heat Sink For Lithium-Ion Battery Packs In Electric Vehicles, Evan Foreman, Dylan Irvine, Aaron Jackson, Christopher Brandon Remington, Sam Endrizzi

Williams Honors College, Honors Research Projects

This report addresses the concepts and implementation of fluid cooled heat sink designs for an electric or hybrid vehicle battery. To determine the battery’s temperature and heat flux profile, testing was performed by measuring these values at multiple locations on a lithium-ion pouch battery using heat flux sensors and thermocouples during the charge and discharge cycles of the battery. Once the data was collected and analyzed, trendlines were fit to the heat flux data then used to create equations for the heat flux profile during the discharging stage. Each equation represented a specific region on the battery geometry. Four heat …

Inkjet Printing: Facing Challenges And Its New Applications In Coating Industry, Sadegh Poozesh

Theses and Dissertations--Mechanical and Aerospace Engineering

This study is devoted to some of the most important issues for advancing inkjet printing for possible application in the coating industry with a focus on piezoelectric droplet on demand (DOD) inkjet technology. Current problems, as embodied in liquid filament breakup along with satellite droplet formation and reduction in droplet sizes, are discussed and then potential solutions identified. For satellite droplets, it is shown that liquid filament break-up behavior can be predicted by using a combination of two pi-numbers, including the Weber number, We and the Ohnesorge number, Oh, or the Reynolds number, Re, and the Weber number, …

Addressing New Skills Needed For The Automotive Industry Through A Motorsports Educational Pathway, Vukica M. Jovanovic, Mileta M. Tomovic, Alok K. Verma, Nathan Luetke, Steve Branch

Engineering Technology Faculty Publications

The automotive industry has higher-skilled positions available that need engineers and engineering technologists qualified and capable to work in a high-paced, advanced manufacturing sector. Various educational programs across the country offer programs related to the motorsports area at the Associate of Science level. There are also various articu-lation agreements that enable students to continue their education to the baccalaureate level. These programs try to fill in the gap related to the skills shortage in systems and new design methods and processes. The main strength of such educational pathways is that students, who are trained to work as technicians with an …

Design Of The University Of Akron's 2015 Fsae Electric Vehicle Braking System, Nicholas D. Galbincea

Williams Honors College, Honors Research Projects

The following report encompasses the design of the 2015 University of Akron’s FSAE formula electric braking system. The system is one based on hydraulic braking and designed for a one man performance racing vehicle. The objective of the system is to convert the kinetic energy of the vehicle into thermal energy, allowing the vehicle to decelerate optimally and safely. The design includes three major categories: calculation and evaluation of the hydraulic system in order to select calipers and master cylinders, the design of the pedal box, and the design of the rotors.

The results and findings of the proceeding report …

Designing A Heat Sink For Lithium-Ion Battery Packs In Electric Vehicles, Dylan Irvine, Evan Foreman, Christopher B. Remington, Aaron Jackson, Sam Endrizzi

Williams Honors College, Honors Research Projects

This report addresses the concepts and implementation of fluid cooled heat sink designs for an electric or hybrid vehicle battery. To determine the battery’s temperature and heat flux profile, testing was performed by measuring these values at multiple locations on a lithium-ion pouch battery using heat flux sensors and thermocouples during the charge and discharge cycles of the battery. Once the data was collected and analyzed, trendlines were fit to the heat flux data then used to create equations for the heat flux profile during the discharging stage. Each equation represented a specific region on the battery geometry. Four heat …

Binder Jet Additive Manufacturing Of Stainless Steel-Hydroxyapatite Bio-Composite, Don Suranga Dhanushka Uduwage

All Graduate Theses, Dissertations, and Other Capstone Projects

This study was conducted to create a bio-composite with a porous structure using the binder-jet printing additive manufacturing process. The samples were printed by changing the parameters such as layer thickness, roller speed, sintering time and sintering temperature of the X1-Lab binder jet additive manufacturing printer. The samples were printed 80% stainless steel 316 mixed with 20% Calcium Phosphate Tribasic by volume. Eight experiments were attempted to print according to the fractional factorial design of experiment. The effects of changing parameters on the mechanical properties of the new bio-composite was tested using ASTM E-09 compressive strength standards. The compression testing …

Air Flow And Rain Water Penetration Analysis On Generator Enclosures Using Cfd Simulations, Sasanka Andawatta Kankanamge

All Graduate Theses, Dissertations, and Other Capstone Projects

Rain water penetration testing on power generator units requires a number of complicated procedures, requiring many resources. As such, a Computational Fluid Dynamics (CFD) tool, "FloEFD for Creo" is used to study the water penetration behavior on a OM924 diesel power generator enclosure in a computational environment. First, the three governing equations in fluid dynamics are derived and explained using simple methods. Next, behavior of rain water droplets upon impact is briefly discussed. Air velocity, volumetric flow rate and static pressure drop were measured physically in the OM924 generator enclosure. Then, a CFD model for the OM924 enclosure was developed …

Computational Fluid Dynamics Modeling Of The Effects Of Water Injection In A Diesel Engine, Rabun Z. Wallace

College of Graduate Studies: Theses & Dissertations

Water injection has been used in internal combustion engines for many years. It has been used to cool combustion temperatures, reduce emissions, and in some instances clean carbon buildup from the cylinder. Research has shown that the water to fuel mass ratio is most effective between 20-30%, so the upper and lower limit were used for simulations in Converge CFD. To validate the CFD model, a case without water injection was compared to experimental data from Sandia National Laboratory. The predicted in-cylinder pressure and heat release rate showed good agreement with the experimental data. Cases were run with the injection …

Run-Time Hev Engine-Generator Power-Speed Optimization For Fuel Consumption And Emissions Reduction, Chester Paul Rowe Ii

Doctoral Dissertations and Master's Theses

As fuel economy and emissions standards become more stringent, Plug-in Hybrid Electric Vehicles (PHEV) using series architectures are being increasingly explored. Due to the decoupling of the Internal Combustion Engine (ICE) from the road, the primary control challenge in this architecture is the optimization of an ICE control law. A run-time Genset speed controller is presented for use during the charge-sustaining mode in a Series PHEV to find the optimal operating parameters for a conventional diesel engine coupled to an electric generator in terms of minimized fuel consumption and emissions generation. On board vehicle sensors provide real time data to …

Development Of A System Architecture For Unmanned Systems Across Multiple Domains, Charles Randall Breingan Jr.

Doctoral Dissertations and Master's Theses

In the unmanned systems industry, there is no common standard for systems components, connections and relations. Such a standard is never likely to exist. Needless to say, a system needs to have the components that are required for the application, however, it is possible to abstract the common functionality out of an individual implementation. This thesis presents a universal unmanned systems architecture that collects all of the common features of an unmanned system and presents them as a set of packages and libraries that can be used in any domain of unmanned system operation. The research and design of the …

High Voltage Rear Electric Drivetrain Design For A Parallelthrough-The-Road Plug-In Hybrid Electric Vehicle, Adam Garrett Fogarty

Open Access Theses

Purdue University was selected as one of 15 universities to participate in a three year Advanced Vehicle Technology Competition (AVTC) called EcoCar2: Plugging Into the Future. The vehicle built by the Purdue team was a Parallel-Through-The-Road Plug-in Hybrid Electric Vehicle (PTTR PHEV). The vehicle utilized a B20 diesel powertrain to power the front wheels, as well as a custom electric drivetrain to power the rear wheels. Using this vehicle during the final year of the competition, the team was successful in placing 4th overall as well as 2nd in the category of Well-To-Wheel (WTW) Greenhouse Gas Emissions. A stock 2013 …

Algorithm Development And Analysis For Advanced Enginetechnologies Including Piezoelectric Fuel Injection And Variablevalve Actuation, Bradley W. Pietrzak

Open Access Theses

As vehicle emissions standards and fuel economy constraints become increasingly strict, the automotive industry must employ the use of advanced engine technologies to overcome these challenges. Fuel injection rate shaping and cylinder deactivation (CDA) are two such technologies, and both of them require the design and implementation of algorithms using various hardware and software tools.

Fuel injection rate shaping is one path towards cleaner and more efficient diesel engines. Piezoelectrically-actuated fuel injectors are well-suited for rate shaping operation, but are difficult to control. Control-related challenges arise primarily due to the lack of measurements available in a fuel injection system on-engine, …

Development Of Sound Quality Metrics For Gear Rattle In Diesel Engines, Brandon Sobecki

Open Access Theses

Sound quality is an important factor in the design of competitive diesel engines. The noise produced by specific components and mechanisms in the engine can play a significant role in determining the perceived quality of the overall noise and in turn the perceived quality of the engine. The goal of the present research is to characterize the sounds produced by the phenomenon known as gear rattle and to develop a model that can be used to assess gear rattle levels in a way that connects directly with human perception of rattle. Most previous work in this area has been focused …

Msu Xtreme: Minnesota State University, Mankato's Entry Into The "Clean Snowmobile Challenge 2001", Scott Betcher, Allen Caldwell, Nathan Lindeman, Brian Mandelkow, Dave Maniak, Randy Rohlf, James Skuya, Dennis Swanson, Aaron Wolff, Mark Brandl, Dan Dobesh, Ryan Erickson, Jeff Gillen, Jan Smith, Jason Wilkie

Journal of Undergraduate Research at Minnesota State University, Mankato

Minnesota State University, Mankato’s Automotive Engineering Technology program formed a team to enter the Clean Snowmobile Challenge 2001. Selections for the organization’s machine included a 2001 Polaris Edge Chassis specially outfitted with a 2000 500 cc two-stroke Polaris engine. Modifications to the snowmobile were made specifically for Clean Snowmobile Challenge 2001 events. Acceleration, emissions, cold start, noise, fuel economy/range, handling/drivability, hill climb, and static display made up the list of events featured in the competition. MSU Xtreme has modified the snowmobile in every area with special emphasis on emissions and handling. Testing and analysis of the sled’s systems brought the …

Formula-Sae Wireless Data Logger, Eric Holland

Journal of Undergraduate Research at Minnesota State University, Mankato

The Formula-SAE (Society of Automotive Engineers) race car requires an onboard data logger to obtain and record the performance information received from the Fuel Injection Controller. This data is needed for analyzing the engine performance of the race car. It is advantageous to have this unit transmit the data via a wireless link to a handheld monitoring tool. Having user interface, like a LCD screen and a keypad, would make the monitoring tool easy to use. Also making the monitoring tool communicate with a PC would offer the beneficial features of saving and printing data. By having the PC connectivity, …

Development Of Nhtsa’S Side Impact Test Procedure For Child Restraint Systems Using A Deceleration Sled : Part 2, Janet Brelin-Fornari, Sheryl Janca

Mechanical Engineering Grants

This report presents the results of the continued research and development of child seat side impact tests using the deceleration sled at Kettering University’s Crash Safety Center. The objective of this test series was to gain further insight into the sensitivity of the side impact test fixture response. Test variations included speed of impact, weight of the fixture, and impact characteristics. Additionally, 20 child restraint system (CRS) specific tests were conducted using a fixed set of test parameters.

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

Mechanical and Aerospace Engineering Faculty Publications

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 …

Development Of Nhtsa’S Side Impact Test Procedure For Child Restraint Systems Using A Deceleration Sled : Part 1, Janet Brelin-Fornari, Sheryl Janca

Mechanical Engineering Grants

This report presents the results of the research and development of the child seat side impact tests performed at Kettering University’s Crash Safety Center for NHTSA. The tests were conducted using a deceleration sled. The objective of this testing was to obtain data for the development of a side impact test procedure for child restraint systems.

Decreasing The Power Consumption Of Hybrid Electric Vehicle Architectures, Domenic Leo Barsotti

Doctoral Dissertations and Master's Theses

This paper presents the challenges seen by current automotive manufacturers in their investigation of more fuel efficient vehicles. The two main areas for improvement are aerodynamics and passive cooling of electrical systems. Aerodynamics of an Ahmed body is investigated with a drag reduction system proposed utilizing slot jets at the rear of the bluff body . Two separate systems show a decrease in drag of 16 and 25%. The paper also investigates the use of a phase change material for a hybrid electric vehicles energy storage system cooling. Phase change materials take advantage of the latent heat of fusion to …

Anti-Icing Coatings And Methods, Russell G. Alger

Michigan Tech Patents

A method of inhibiting or preventing bonding between snow or ice and a substrate. The method includes applying an adhesive to the substrate, broadcasting an aggregate onto the adhesive, the aggregate having the capacity to receive an anti-icing chemical into the aggregate, and applying the antiicing chemical onto the aggregate so that at least a portion of the anti-icing chemical is received into at least a portion of the aggregate.

The Effects Of Layer Thickness On Dry-Sliding Wear Of Binder Jet Additively Manufactured Stainless Steel And Bronze Composite, Cody Ingenthron

All Graduate Theses, Dissertations, and Other Capstone Projects

Pin on disk wear testing was used to compare additively manufactured binder jet metal matrix composites. The process parameters were changed. The layer thickness and applied forces were varied for the experimental study. Three different layer thicknesses used were, 50μm, 100μm, and 200μm. The pin used was a 420 stainless pin. The wear characteristics of the disk were examined using pin-on-disc method. The material tested was a composite of 420 stainless steel, and 90-10 bronze. Samples were weighed before, during, and after the test to determine differences in mass. Wear tracks were examined using a Scanning Electron Microscope. The results …

Loading Path Determination For Tube Hydroforming Process Of Automotive Component Using Apdl, E. Masoumi Khalil Abad, Amir Ghazanfari, R. Hashemi

Faculty Publications, Mechanical Engineering

In this study, an extended stress-based forming limit diagram (FLD) for prediction of necking based on the Marciniak and Kucznski (M-K) model is represented and applied in tube hydroforming. The bulge forming of a straight tube is simulated by finite element method and verified with published experimental data. This adaptive simulation technique is based on the ability to detect the onset and growth of defects (e.g., bursting and wrinkling) and to promptly readjust the loading paths. Thus, a suitable load path is determined by applying Adaptive Simulation Method in ANSYS Parametric Design Language (APDL).

Development Of A Hybrid Vehicle Powertrain Test Laboratory, Bennet Samuel Soundarraj

Doctoral Dissertations and Master's Theses

During the last two years, Embry-Riddle Aeronautical University has installed and tested a fully functional eddy-current chassis dynamometer testing facility on campus. An automotive test facility requires a systems engineering approach to install, calibrate and commission a chassis dynamometer. This thesis shows that, the dynamometer test facility was successfully installed, commissioned and documented to safely support the power train development and testing. We can currently test the EcoCAR vehicle and a number of other front-wheel-drive vehicles at our university campus using the eddy current chassis dynamometer.

Mode And Implementation Of A Hybrid Control System For A 2-Mode Hybrid Electric Vehicle, Zhenhua Zhu

Graduate Theses, Dissertations, and Problem Reports (ETD)

Automotive transportation consumes more than 71% of the world's total petroleum energy. The vehicle will have to use less because it will take less than 30 years to consume the rest of the proven conventional oil reservoir if the fuel consumption keeps the current trend. One of the methods to improve the vehicle efficiency is to develop Hybrid Electric Vehicle (HEV). An HEV combines an internal combustion engine (ICE) and electric motor(s) powered by batteries or capacitors to achieve better fuel economy. Among the HEVs, 2-Mode HEV combines an ICE and two electric motors with two planetary gear sets and …

Development Of A Supervisory Control Unit For A Series Plug-In Hybrid Electric Vehicle, Brian Neal Harries

Doctoral Dissertations and Master's Theses

A Series PHEV was chosen, as ERAU's entry into EcoCAR2 through a multidisciplinary architecture selection process. The series architecture was chosen for its mechanical feasibility, consumer acceptability and its performance on energy consumption simulations. The Series PHEV architecture was modeled using Matlab, Simulink, and dSPACE ASM tools, to create a plant model for controller development. A supervisory controller was developed to safely control the interactions between powertrain components. The supervisory control unit was tested using SIL and HIL methodologies. The supervisory controller was developed with an emphasis on fault detection and mitigation for safety critical systems. A power management control …

Modeling, Identification, Validation And Control Of A Hybrid Maglev Ball System, Ahmed Elhussein E. Mekky

Mechanical & Aerospace Engineering Theses & Dissertations

In this thesis, the electrodynamics of a single axis hybrid electromagnetic suspension Maglev system was modeled and validated by applying it to a single axis hybrid maglev ball experiment. By exploring its linearized model, it was shown that the single axis hybrid Maglev ball has inherently unstable dynamics. Three control scenarios were explored based on the linearized model; (1) Proportional, Deferential (PD) control, (2) Proportional, Deferential, Integral (PID) and (3) PID controller with pre-filtering. This thesis has shown that a PID controller with a pre-filtering technique can stabilize such a system and provide a well-controlled response.

A parametric system identification …

The Engineering Process For The Design Of A Motorcycle Chassis And Suspension, Derek J. Noce

Doctoral Dissertations and Master's Theses

The thesis objective is to define and establish an engineering process for the design of a modern motorcycle chassis and suspension. The engineering process focuses on the interdisciplinary fields of engineering dealing with design and structural optimization. Specialized software, such as Motorcycle Kinematics, MATLAB, CATIA, HEEDS Professional, and NASTRAN are utilized. Motorcycle Kinematics is used to set up the preliminary motorcycle geometry, and MATLAB is a used to analyze the kinematics and stability of the motorcycle based on this geometry. CATIA (Computer Aided Three-Dimensional Interactive Application) is used to graphically illustrate the geometry of the motorcycle in three dimensional space. …

Development And Implementation Of A Fault Mitigating Control System For A Biodiesel Plug-In Hybrid Electric Vehicle For The Ecocar: The Next Challenge Competition, Sean Christopher Carter

Doctoral Dissertations and Master's Theses

The automotive industry is continuously developing, and with it hybrid vehicle technology is a growing field of interest. The design of the electric vehicle is a pressing matter and grows in complexity with new powertrain components such as power inverters and transmission systems that use electric motors. As a control system develops, the architecture always comes back to systems engineering documentation to find safety protocols, solutions to problems through fault testing, and validating and verifying the control architecture throughout the whole process. Testing and evaluation plans are required more than ever and are constantly being updated and implemented in today's …