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.

Precipitate characterisation of an advanced high-strength low-alloy (HSLA) steel using atom probe tomography

Increased fuel economy, combined with the need for the improved safety has generated the development of new hot-rolled high-strength low-alloy (HSLA) and multiphase steels such as dual-phase or transformation-induced plasticity steels with improved ductility without sacrificing strength and crash resistance. However, the modern multiphase steels with good strength-ductility balance showed deteriorated stretch-flangeability due to the stress concentration region between the soft ferrite and hard martensite phases [1]. Ferritic, hot-rolled steels can provide good local elongation and, in turn, good stretch-flangeability [2]. However, conventional HSLA ferritic steels only have a tensile strength of not, vert, similar600 MPa, while steels for the automotive industry are now required to have a high tensile strength of not, vert, similar780 MPa, with excellent elongation and stretch-flangeability [1]. This level of strength and stretch-flangeability can only be achieved by precipitation hardening of the ferrite matrix with very fine precipitates and by ferrite grain refinement. It has been suggested that Mo [3] and Ti [4] should be added to form carbides and decrease the coiling temperature to 650 °C since only a low precipitation temperature can provide the precipitation refinement [4]. These particles appeared to be (Ti, Mo)C, with a cubic lattice and a parameter of 0.433 nm, and they were aligned in rows [4]. It was reported [4] that the formation of these very fine carbides led to an increase in strength of not, vert, similar300 MPa. However, the detailed analysis of these particles has not been performed to date due to their nanoscale size. The aim of this work was to carry out a detailed investigation using atom probe tomography (APT) of precipitates formed in hot-rolled low-carbon steel containing additions Ti and Mo.

The investigated low-carbon steel, containing Fe–0.1C–1.24Mn–0.03Si–0.11Cr–0.11Mo–0.09Ti–0.091Al at.%, was produced by hot rolling. The processing route has been described in detail elsewhere [5] European Patent Application, 1616970 A1, 18.01.2006.[5]. The microstructure was characterised by transmission electron microscopy (TEM) on a Philips CM 20, operated at 200 kV using thin foil and carbon replica techniques. Qualitative energy dispersive X-ray spectroscopy (EDXS) was used to analyse the chemical composition of particles. The atomic level of particle characterisation was performed at the University of Sydney using a local electrode atom probe [6]. APT was carried out using a pulse repetition rate of 200 kHz and a 20% pulse fraction on the sample with temperature of 80 K. The extent of solute-enriched regions (radius of gyration) and the local solute concentrations in these regions were estimated using the maximum separation envelope method with a grid spacing of 0.1 nm [7]. A maximum separation distance between the atoms of interest of dmax = 1 nm was used.

The microstructure of the steel consisted of two types of fine ferrite grains: (i) small recrystallised grains with an average grain size of 1.4 ± 0.2 μm; and (ii) grains with a high dislocation density (5.8 ± 1.4 × 1014 m−2) and an average grain size of 1.9 ± 0.1 μm in thickness and 2.7 ± 0.1 μm in length (Fig. 1a). Some grains with high dislocation density displayed an elongated shape with Widmanstätten side plates and also the formation of cells and subgrains (Fig. 1a). The volume fraction of recrystallised grains was 34 ± 8%.

Strain rate effects on the energy absorption of rapidly manufactured composite tubes

As a result of recent increases in fuel prices and the growing number of accident fatalities, the two major concerns of the automotive industry and their customers are now occupant safety and fuel economy {1, 2]. Increasing the amount of energy and optimizing the manner in which energy is absorbed within vehicle crush zones can improve occupant survivability in the event of a crash, while fuel economy is improved through a reduction in weight.  Axial crush tests were conducted on tubular specimens of Carbon/Epoxy (Toray T700/G83C) and Glass/Polypropylene (Twintex). This paper presents results from the tests conducted at quasi-static rates at Deakin Unniversity, Victoria Australia, and intermediate rate tests performed at the Oak Ridge National Laboratory, Tennessee  USA.   The quasi-static tests were conducted at 10mm/min (1.67x10-4m/s) using 5 different forms of initiation. Tests at intermediate rates were performed at speeds of 0.25m/s, 0.5m/s, 0.75m/s 1m/s, 2m/s and 4m/s. Quasi-static tests of tubular specimens showed high specific energy absorption (SEA) values with 86 kJ/kg for Carbon/Epoxy specimens. The SEA of the Glass/Polypropylene specimens was measured to be 29 kJ/kg. Results from the intermediate test rates showed that SEA values did not fall below 55kJ/kg for carbon specimens or 35kJ/kg for the Glass/Polypropylene specimens. When compared with typical steel and aluminium, SEA values of 15 kJ/kg and 30kJ/kg respectively, the benefits of using composite materials in crash structures is apparent.                                                                     

Modelling the side impact of carbon fiber tubes

Metallic tubes have been extensively studied for their crashworthiness as they closely resemble automotive crash rails. Recently, the demand to improve fuel economy and reduce vehicle emissions has led automobile manufacturers to explore the crash properties of light weight materials such as fibre reinforced polymer composites, metallic foams and sandwich structures in order to use them as crash barriers. This paper discusses the response of carbon fibre reinforced polymer (CFRP) tubes and their failure mechanisms during side impact. The energy absorption of CFRP tubes is compared to similar Aluminium tubes. The response of the CFRP tubes during impact was modelled using Abaqus finite element software with a composite fabric material model. The material inputs were given based on standard tension and compression test results and the in-plane damage was defined based on cyclic shear tests. The failure modes and energy absorption observed during the tests were well represented by the finite element model.

Backward modelling and look-ahead fuzzy energy management controller for a parallel hybrid vehicle

This paper focuses on a parallel hybrid electric vehicle. It first develops a model for the vehicle using the backward-looking approach where the flow of energy starts from wheels and spreads towards engine and electric motor. Next, a fuzzy logic-based strategy is developed to control the operation of the vehicle. The objectives of the controller include managing the energy flow from engine and electric motor, controlling transmission ratio, adjusting speed, and sustaining battery's state of charge. The controller examines current vehicle speed, demand torque, slope difference, state of charge of battery, and engine and electric motor rotation speeds. Then, it determines the best values for continuous variable transmission ratio, speed, and torque. A slope window scheme is also developed to take into account the look-ahead slope information and determine the best vehicle speed for better fuel economy. The developed model and control strategy are simulated. The simulation results are presented and discussed. It is shown that the use of the proposed fuzzy controller reduces fuel consumption.

Look-ahead intelligent energy management of a parallel hybrid electric vehicle

Improving fuel efficiency in vehicles can reduce the energy consumption concerns associated with operating the vehicles. This paper presents a model for a parallel hybrid electric vehicle. In the model, the flow of energy starts from wheels and spreads toward engine and electric motor. A fuzzy logic based control strategy is implemented for the vehicle. The controller manages the energy flow from the engine and the electric motor, controlling transmission ratio, adjusting speed, and sustaining battery's state of charge. The controller examines the vehicle speed, demand torque, slope difference, state of charge of battery, and engine and electric motor rotation speeds. It then determines the best values for continuous variable transmission ratio, speed, and torque. A slope window method is formed that takes into account the look-ahead slope information, and determines the best vehicle speed. The developed model and control strategy are simulated using real highway data relating to Nowra-Bateman Bay in Australia, and SAE Highway Fuel Economy Driving Schedule. The simulation results are presented and discussed. It is shown that the use of the proposed fuzzy controller reduces the fuel consumption of the vehicle.

Effect of noise factors in energy management of series plug-in hybrid electric vehicles

It has been demonstrated that charge depletion (CD) energy management strategies are more efficient choices for energy management of plug-in hybrid electric vehicles (PHEVs). The knowledge of drive cycle as a priori can improve the performance of CD energy management in PHEVs. However, there are many noise factors which affect both drivetrain power demand and vehicle performance even in identical drive cycles. In this research, the effect of each noise factor is investigated by introducing the concept of power cycle instead of drive cycle for a journey. Based on the nature of the noise factors, a practical solution for developing a power-cycle library is introduced. Investigating the predicted power cycle, an energy management strategy is developed which considers the influence of temperature noise factor on engine performance. The effect of different environmental and geographic conditions, driver behavior, aging of battery and other components are considered. Simulation results for a modelled series PHEV similar to GM Volt show that the suggested energy management strategy based on the driver power cycle library improves both vehicle fuel economy and battery health by reducing battery load and temperature.