automotive-industry

Case Study 1 : EHRS for Indian Hatchback: Fuel economy benefit

Objective: Evaluate EHRS fuel economy benefit for Indian 1.2L gasoline NA hatchback

Approach:

  • MATLAB – Simulink based forward looking powertrain model for conventional manual transmission vehicle was developed and validated
  • Engine friction effect was modeled as function of oil temperature
  • EHRS system is modeled just after TWC to evaluate fuel economy benefit with faster warm up of engine coolant

Pune city real drive cycles was studied to determine effect of EHRS

Conclusion:

EHRS system has limited benefits considering development cost of system

Recommendation:

For Indian passenger cars, EHRS system need to focus on continuous heat recovery rather than engine warm-up

Case Study 2 : Variable runner length for maximizing volumetric Efficiency

Objective: Evaluate benefits of continuously variable runner length on volumetric efficiency

 Approach:

  • GT Power model validation for intake pressure fluctuations of 0.6L single cylinder engine
  • DOE simulation to determine dependency of volumetric efficiency and runner length
  • Based on DOE results, proposed optimum variable runner length depending on engine speed

Conclusion:

Frequency analysis of intake pressure fluctuations → maximum volumetric efficiency occurs at 4th order fundamental frequency during intake valve closed and 1st order fundamental frequency during suction stroke

Recommendation:

Engines with wide speed range, continuous variable intake runner length can fetch better volumetric efficiency


Case Study 3 : DI engine coolant flow optimization

Objective: Reduce overheating and gasket failure for single cylinder DI engine

 Approach:

  • Engine dyno testing to measure coolant flow, temperature and engine operating condition
  • Design modification to balance flow distribution

Conclusion:

For baseline design, coolant flow was bypassing to outlet without effectively cooling cylinder head

Recommendation:

Flow from cylinder barrel was forced to cross cylinder head by modifying liner to head flow connections and maintaining pressure drop nearly constant

 

Case Study 4 : TEG: Fuel economy benefit on light duty truck

Objective: TEG integration for FE benefit on 6L NA gasoline engine

Approach:

  • MATLAB – Simulink based forward looking vehicle powertrain model was developed and validated with test data (which is backbone of PowertrainLive)
  • TEG model was integrated as 3D map dependent on exhaust mass flow and temperature
  • Engine exhaust mass flow and temperatures were predicted using engine speed and torque

 

Conclusion:

TEG location for optimum performance was identified as close coupled with 3rd CAT

Recommendation:

TEG power generation capability need to be increased to realize potential fuel economy benefit


Case Study 5 : Cold ambient engine heat rejection modeling

Objective: Predict engine heat rejection for 2L GTDi engine at -20 deg C ambient temperature

 Approach:

  • Engine thermodynamic model development for predictive combustion using Ricardo WAVE
  • Model validation for steady state operating points at warm condition
  • Predict engine heat rejection for steady state operation at -20 deg C
  • Predict effect of spark timing, and air-fuel ratio on heat rejection

Conclusion:

Predictive combustion model was developed to estimate effect of spark timing, air-fuel ratio on engine heat rejection

Recommendation:

This approach can be used by HVAC teams to optimize cold start engine warm-up