Advanced Power Systems

• Studies to be conducted under higher in-cylinder flows with tumble planks installed in the intake port
• Studies of alternative geometry plugs
• Studies of plug orientation and gap
• Chemiluminescent imaging for combustion signature

The objective of this project is to develop the combustion system for a low-cost, low diesel contribution, high brake mean effective pressure (BMEP), high-efficiency premixed charge medium/heavy duty (MHD) natural gas engine and demonstrate the technology on an engine with peak thermal efficiency of up to 44%, diesel pilot contribution of 1-5%, and BMEP up to 25 bar. Emissions will be compliant with current Environmental Protection Agency (EPA) standards for heavy-duty (HD) on-road engines by using a three-way catalyst.

MTU Consortium in Diesel Engine Aftertreatment Research

Starting from a well-established research program and as a result of a Dept. of Energy 3 year project, we have significantly enhanced our laboratory, experimental methods and procedures, and modeling/estimator capability.  The faculty and students have produced thirteen publications from this research.

Consortium Goal:

The underling goal of the consortium is to develop and conduct precompetitive research on advanced aftertreatment systems through experimental engine methods, development and calibration of high fidelity models, and development and application of estimators and controllers. Achieving this goal will provide an improved understanding of the systems under dynamic and low temperature conditions characteristic of advanced medium and heavy duty diesel engines allowing the consortium members to apply this knowledge and models to improve system performance, reduce cost, and develop new approaches to diagnostics and increase robustness of their on-board-diagnostics.

Research Activities:

The existing facilities and an extensive model base will be used as developed in previous research including the current DOE program. This includes temperature controlled exhaust, positive torque drive cycles, and validated component models and estimators. Additionally we will add real-time functionality to perform aftertreatment estimation and control in the engine test cell.

The consortium research themes integrate fundamental and applied aspects of (1) Experimental Engine Studies (2) Modeling and Simulation and (3) Estimation, Control, and diagnostics. The proposed research is split into three major themes (I) Experimental, (II) Modeling, and (III) Estimation and Controls with a number of outcomes from the composite research program.

Areas of study will be determined based upon proposed research by MTU with input from the Partners to direct the research.

Based upon input from our partners and continuing some efforts from the DOE program, the following have been identified as key areas from which yearly research topics will be selected.

• Experimentally validated reduced order models and state estimation algorithms of aftertreatment components which are accurate for low temperature and dynamic operation.
• Quantify particulate matter (PM) maldistribution, loading, and NO2/PM ratio effects on passive and active regeneration, bio-fuel blends, and aging for catalyzed particulate filters (CPFs).
• Increased knowledge of ammonia (NH3) storage behavior, optimal NH3 loading, hydrocarbon (HC) poisoning, and aging for selective catalytic reduction (SCR) catalysts
• Understanding effect of sensor type/configuration on state estimation quality.
• Optimal reductant strategies for SCR operation and CPF regeneration.
• Integrated response and optimization of engine feedgas and aftertreatment systems
• Thermal control of the aftertreatment components for light-off, maintaining operational temperature, and regeneration relevant to engine low temperature operation and integration with exhaust energy recovery systems
• Fundamental studies of DEF introduction and functional responses – hydrolysis and pyrolysis
• Diagnostic concept development: Based upon existing virtual sensor and estimator work this will be translated into system and component diagnostics
• Sensor displacement by applying estimators and virtual sensors. For example, determining whether a NH₃ sensor is needed if an accurate SCR NH₃ storage model is available.
• Improved DPF PM estimation and measurement. Although systems are going to increase passive oxidation with engines moving to higher NO_X and lower PM, this is still an important research area to improve methods to accurately estimate CPF loading.
• Alternative and integrated aftertreatment technologies such as integrated SCR with PM filtration. Many fundamental questions remain about this technology including architecture of combining functions that still enable high passive PM oxidation and high NO_X conversion.
• PM Sampling and related diagnostic use. Quantifying the effect of sensor location on the ability to detect failures. does it matter where the sensor is and what the type of failure is. e.g.  For example, how does the location of the PM sensor impact the speed of CPF melt down detection and can this speed of detection be optimized?

• FEA models of the surrogate fixture will be created.
• FEA models will be used to explore the critical design factors in understanding the relationship between the energy input location/direction and the damage produced at the unit under test.
• Modal analysis will be performed on the surrogate fixture and unit under test to validate the FEA models.
• A shaker test will be performed on the surrogate fixture to explore the effects of input location and drive file shaping on the strains and acceleration measured at the unit under test.

• The Mobile Lab is entirely self-supportive and is setup at the client's location, thus course participants do not need to travel to training, and remain on-site should a job related emergency arise.
• All courses are delivered by professional educators with research and development expertise in their field.
• All courses include both direct learning through slides and whiteboard combined with fully integrated hands-on experiments. It has been consistently proven, that experiential learning such as this significantly enhances the participant's comprehension and retention the subject matter.
• As a University we can offer college credit for each course. This can be beneficial to employees pursuing an advanced degree.

1. Identify and purchase components for test cell.
2. Assemble, machine, and install components to bed plate.
3. Prove system functionality using an off the shelf gasoline engine.
4. Shipping of entire bedplate, dynamometer, and engine system.
5. Support the integration of the bed plate dynamometer system at MAHLE Powertrain LLC.'s desired location.

1. Preliminary pressure data for setup of analysis is to be provided by HRA.
2. Full data set data is to be provided by HRA over a range of speeds at full load and knock levels. A minimum of 300 cycles per test point is recommended. Data should including pressure based knock intensity and knock peak-to-peak on a cycle-by-cycle basis at fixed ignition-timings.
3. Analyze single cylinder engine data provided by HRA. Data to include continuous cycle data of knock intensity and knock peak-to-peak. Data should be provided at fixed ignition timing with increments around the knock level for targeted control. Data will be analyzed to determine stochastic knock characteristics and applicability to use a lognormal distribution as its pdf. If the data is found not to follow characteristics of a lognormal distribution, other distributions will be explored but this will impact timing and associated detection and control
4. Based up characteristics of the knock and knock pdf's, the feedback metric and set points for control will be determined.

Confidential

Pyrolysis is the thermochemical breakdown of organic matter into oil and gas products in inert atmosphere in the temperature range 350 to 600 °Celsius. Ensuring that the heating rate of the organic matter is faster than approximately 100 Celsius/sec (i.e. fast pyrolysis) ensures that the yield of product bio-oil is maximized. Through the process of fast pyrolysis, followed by bio-oil upgrading woody and herbaceous organic matter can be converted to liquid transportation fuels, including gasoline, diesel and jet fuel.

 This project consists of two primary tasks. The first task will design, manufacture, test and operate two lab-scale paddle fast pyrolysis systems for rapid evaluation of biomass sample performance in fast pyrolysis conversion to bio-oil. Tests of several materials (minimum of 10) will be conducted to demonstrate operation of the reactors. The second task will develop a preliminary reaction model that predicts the loss of carbon, hydrogen, and oxygen (CHO) molecules from the solid feedstock for the experiments.

This project is a collaboration of the Idaho National Laboratory (INL) and Michigan Technological University (MTU). INL will provide the biomass feedstocks for the fast pyrolysis experiments and will also be responsible for chemical characterization of the feedstocks. MTU will first design and fabricate a small prototype paddle fast pyrolysis reactor capable of processing a minimum of 50 mg of material per minute. MTU will conduct preliminary tests using the small prototype reactor and will use the data to design and fabricate a second reactor that is capable of processing a minimum of 200 mg of material per minute. Preliminary tests using both reactors will determine whether the design concept is scalable. In this project, MTU will be responsible for conducting fast pyrolysis tests using the test reactors and for developing the preliminary predictive reaction models. MTU will retain ownership of one of the fast pyrolysis reactors and will deliver the other reactor to INL. If the reactor design and associated reaction model are successful, future work outside of the current project may design and fabricate a third reactor capable of processing l kg of material per hour (16,667 mg/min).

 Task 1: Design and fabricate a small prototype paddle fast pyrolysis reactor. Use the prototype reactor to conduct preliminary experiments on select feedstocks.

Task 2: Design and fabricate a second paddle fast pyrolysis reactor. The second reactor shall be capable of processing a minimum of 200 mg of material per minute.

Task3: Conduct validation tests with either reactor using a minimum of ten feedstocks. Each feedstock will be tested a minimum of four times to estimate repeatability. For the tests, INL will provide a minimum of 20 kg of each feedstock, which will be divided into a minimum of six consistent specimens. Solid and liquid products from each test will be delivered to INL for analysis. INL will analyze the solid products for CHON and total mineral content and the liquid products for CHON, water, and TAN. The liquid product may also be analyzed for sulfur, density, viscosity, pH, and product distribution using GC-MS or GC-FID. INL will characterize the raw feedstocks for elemental composition (CHONS), carbohydrate/fiber analysis (cellulose, hemicellulose, and lignin), mineral content, and heating value. INL will provide instructions for sample storage and transport for analytical analysis.

Task 4: Develop a preliminary reaction model that predicts the loss of carbon, hydrogen, and oxygen (CHO) molecules from the solid feedstock for the experiments. In addition, the preliminary reaction model will predict the fate of these removed organic compounds as partitioned in the remaining solid char, in either the primary non-condensable gas (CO and C0₂) and primary condensable species (pyrolysis oil and water). No secondary reactions will be interpreted in the preliminary model. The reaction model will be able to include up to three stages at potentially different operating conditions to resolve the mass losses as the fast pyrolysis reaction progresses from mild to severe conditions. These three stages can potentially produce three distinct gas/vapor species, that in-tum could be targeted for fuel/chemical production or conversion.

1. Preparing a mount for the new injector labs
2. Setting up the hardware for the tests
3. Running the tests following test matrix
4. Post processing the raw test images
5. Analyze for characterization

Project Description

The objective is to develop an automated oil sampling system to work on Cummins' heavy duty vehicle test fleet to collect oil samples at a scheduled interval or upon request via electronic trigger from a service tool.

 The work in this first phase is to perform the following tasks:

Review existing technologies - This task is to review and summarizing existing technical information including reports, standards, patents, and commercial systems specifications and concepts. Additionally, systems develop for other analogous applications for automated sampling will be investigated and summarized. This will provide background for design concepts.

 Requirement specifications

Requirement specifications will be guided based upon findings in task 3.1 and requirements gathering. Predominately the requirements gathering will be accomplished by discussion and consultation with the Cummins team. Requirements will feed the concept design. The students will examine one of the HD vehicles in the APS Lab fleet for further information.

 Concept Design

Based upon the requirement and technology review design concepts will be analyzed. Concepts will be ranked based upon ability to meet requirements, ease of integration on vehicle, complexity, and cost. From the initial concepts, one proposed system will be selected for analysis and design. The concept design will include the following.

1. Operational principle(s)

2. Hardware interface specifications

3. Software interface specifications

4. Software requirements

5. Layout of major components

6. Estimated development timing and cost including engineering, bill of material, fabrication cost, testing, and documentation.

• Update to a 2.0 l engine
• Update to a new combustion feedback controller
• Evaluation of production intent sensors on engine via comparison of signal to instrument grade sensors,
• Optimization of combustion metrics and controls for combustion phasing and stability,
• Correcting individual cylinder A/F's to meet emissions based upon individual cylinder air charge and IMEP
• Develop combustion control techniques for dynamic engine operation such as a binning concept for spark, fuel, and dilution
• Application of combustion metrics and emissions for crank-start to include setup and measurement of HC and CO/C02 via fast analyzers

Confidential

Overview:

Michigan Tech supports the 2014 Heroes Alliance Young Urban Intellectual Summit.

Through this support, Michigan Tech Mobile Lab Staff will have three unique wheelchairs on display. The wheelchairs have been developed by engineering students at Michigan Tech to improve the mobility of disabled individuals. The wheelchairs are designed to be highly capable in off-road situations, allowing disabled individuals to experience and enjoy the outdoors. The Staff on hand will describe how the team identified a critical biomedical need, and engineered a solution. Participants will be able to sit in all three wheelchairs, and speak with Staff regarding the details of the project. Participants will have the opportunity to personally test the manual wheelchair.

Overview:

Verification and Validation (V&V) of controller designs for complex dynamic systems is currently too costly and time consuming. The V&V process for a typical modem automotive electronic control unit can take about two man-years, and it can easily cost 5-6 million dollars. A large number of errors detected during independent V&V are errors that are introduced during the initial stages of controller development. V&V would cost 10 times less if those errors could be identified and fixed during the early stages of controller software design. Reducing cost and time of V&V is a major challenge for all complex control systems - a challenge that will be addressed in this project.

A critical gap occurs when uncertainty in controller software/hardware implementation is not considered as part of the controller design. This gap leads to the need for many V&V iterations and results in costly controller design. This project intends to fill this gap by (i) modeling and quantification of uncertainty that arises from controller implementation imprecisions, (ii) design of robust controllers to overcome implementation uncertainty, and (iii) development of an adaptive control framework to update uncertainty bounds from implementation imprecisions.

The outcome of this project will be a novel, easily verifiable controller design that can minimize V& V iterations for complex industrial control systems, thereby reducing cost. The control framework will be generic, and it will be applicable to a wide range of nonlinear control systems.

This multi-disciplinary research will be carried by scholars from UC Berkeley and Michigan

Tech. Toyota Motor Company will be the industrial partner for this project. The project will broadly reach industry and K-12 students through outreach activities that will be designed and implemented.

Intellectual Merit:

There are three main areas of intellectual merit for this project. The first area is filling the gap between control engineering and software/hardware engineering disciplines for improved controller design. The second area is the development of a novel generic control theory for easily verifiable controllers that can be widely applied to complex industrial control systems.

The third area is the development of control-oriented uncertainty models to characterize the implementation imprecision for industrial controllers, particularly for quantization and fixed-point arithmetic imprecisions. The overall expected outcome from these three main contributions will be an uncertainty-adaptive, easily verifiable control theory framework that industry can adapt to controller design processes to minimize the time and cost of controller development.

OVERVIEW

Evaluate, and develop the durability and performance of E3 spark plugs when installed in a Natural Gas fueled application. To keep costs low, and lead times short, a Natural Gas fueled generator set is used as the testbed for this work. Work with E3 to develop additional testing programs on other specific engines, such as large truck engines and / or evaluate the combustion performance of the spark plug in Natural Gas applications.

EXPERIMENTATION PLAN

The testbed for this durability testing is a 30 kW Natural Gas fueled generator set. The genset is powered by a 4-cylinder GM engine. The engine is turbocharged, and therefore is capable of achieving a high specific load. The 4-cylinder engine allows for one or two baseline spark plugs and two or three spark plugs under test to be evaluated. As the objective of the testing is durability, the test bed is lightly instrumented providing only the most critical parameters needed for spark plug durability evaluation and / or engine control. Engine load is varied in two or three steps, with approximately equal time spent in each step over the course of the testing. One of the steps is 100% load. The other loads include a mid-load and / or a low-load. The speed is the generator required speed of 1800 RPM. After approximately every 50 hours of operation all spark plugs are removed and their gap measured, and their visual condition noted. After approximately every 100 hours of operation the spark plugs  also have photographs recorded, the mass of the spark plug recorded, and the electrical resistance of the core, and the resistance to the shell recorded. Additionally every 100 hours intermediate test results including data recorded on the spark plug itself (gap, resistance, mass, etc.) as well as engine data (EGT, load profile, etc.} sent to E3. After approximately every 350 hours of operation the engine undergoes maintenance including oil and filter changes, and new ignition components (distributor cap, rotor, and spark plug wires) to ensure all spark plugs are receiving a high quality "signal" throughout the testing. At this time the compression and leakdown rate of the engine is also measured to ensure the engine remains mechanically sound and / or all cylinders are approximately equal.

A group of researchers at Michigan Tech and REL propose to design, develop, integrate, and test a CNG tank that will have a conformable shape for efficient storage in a light-duty pick-up truck. Michigan Tech is well known for its research in automotive technology, design optimization via simulation, and aluminum material research. REL is the leader in design and manufacturing of aluminum conformable pressure tanks.

This research will be conducted in two phases. Phase 1 (1 year) will be a proof-of concept phase in which existing technology will be used to fabricate, integrate, and test a conformable tank for a light-duty truck using existing materials technology and fabrication techniques. In Phase 1, the materials development effort will initiate.

The Phase 1 tank is a simple rectangular box geometry to demonstrate capability of non-cylindrical shapes. The end of Phase 2 (2 years) will result in a conformable tank with an optimized internal structure and improved lightweight material for greater efficiency, capacity and durability. The optimized tank will be integrated and tested on a light-duty pick-up truck that has been converted for CNG.

Overview

Hands-on education with the Michigan Tech Mobile Lab will be utilized to deliver the training to Ford employees during Ford's annual training week in October of 2013.

Audience

This training is intended for Engineers, Managers, and Technicians who are either new to the area of Hybrid Electric Vehicles, or wish to broaden their knowledge to assist in vehicle integration or communication with colleagues across various HEV subsystems. An engineering degree is recommended, but not required for this training. The proposed sessions are designed for a maximum of 20 participants. There is no minimum number of participants.

Outline

The proposed hands-on training covers several topics in HEV's and EV's. The hands-on training takes place over 5 days and is comprised of 6 topical modules. The material is a mix of traditional direct learning and hands-on experimentation with data analysis and discussion. The direct learning portion is taught from the Mobile Lab's classroom, which seats up to 20 participants. The hands-on experimentation will be conducted utilizing a multitude of the Mobile Lab's equipment which may include production hybrid vehicles, a configurable hybrid vehicle, vehicle chassis dynamometer, and hybrid powertrain test cells. Each module is repeated at least 3 times, allowing for as many as 60 participants to be exposed to that particular subject matter. Participants can attend all 6 modules, or choose to only attend those which they find will be the most beneficial to them.

Objective:

Investigate and characterize five injectors including the effect of nozzle hole details on spray characteristics under a baseline set of conditions with options for charge gas variants and combustion characterization.

Overview:

Tests will be conducted in Michigan Tech's optically accessible combustion vessel (CV) research facility. Existing hardware in the facility will be used; including a high pressure diesel fuel system capable of pressures to 400 MPa, high speed imaging for liquid, vapor and combustion, and custom solenoid/piezo drivers which are tunable to the desired wave-form via John Deere.

A Fixture will be designed and fabricated to interface the injector into the combustion vessel. This injector fixture will include a heating-cooling system to control the injector temperature independent of the charge gas conditions and chamber wall temperature.

OVERVIEW

This Statement of Work (SOW) proposes an experimental study to assess the impacts of a spark plug, employing advanced geometry and technology, on the performance of a modern automotive engine. Phase I of the study will be a proof of concept test to generate preliminary engine based results at a limited speed and load condition. Phase II of the study will be expanded to focus on a wider range of operating conditions including full-load and part-load operating conditions, and will examine performance parameters including brake power, fuel consumption, and combustion stability, as well as diagnostic parameters including combustion phasing, burn rates, bum duration, Mean Effective Pressures and their cyclic variation, Indicated Efficiency, and engine out emissions. Phase II testing will also include optical studies in Michigan Tech's unique Combustion Vessel.

OBJECTIVES

The objectives of this experimental study are to:

1. Compare the PowerSTAR Spark Plug to the production spark plug under full-load conditions, primarily examining the effect on engine output, with spark timing and A/F optimized for each spark plug, as well as with the engine ECU parameters left as calibrated.

2. Compare the PowerSTAR Spark Plug to the production spark plug under part-load conditions, primarily examining the potential of the PowerSTAR spark plug to increase the dilution tolerance, and increase combustion stability.

3. Compare the PowerSTAR Spark Plug to the production spark plug in an optical combustion vessel.

This continues work from the Ford DOE Program1 on "Advanced Gasoline Turbocharged Direct Injection (GTDI) Engine Development," for which Michigan Tech was subcontracted to conduct. The following is the proposed SOW for continuation of the ignition research areas with additional studies in an optical engine.

The proposed work is broken into the three components, (1) combustion lab, (2) metal engine, and (3) optical engine studies. The advantage of this workflow is that details on the Ignition system can be synergistically studied at multiple stages with specific instrumentation to determine the underlining principles behind the drivers for ignition system requirements and performance under highly stressed operation resulting from lean/dilute operation with in-cylinder flow.

1. Combustion Laboratory

Studies in the Combustion lab in the combustion vessel build on work conducted during the DOE program. In this work isolated ignition events can be studied in detail under controlled thermodynamic and flow conditions. The combustion lab is instrumented with a Ford provided Variable Output Ignition System (VOIS) capable of driving four coils with variable dwell, phasing, and quenching to a single spark-plug. The combustion vessel is highly configurable with instrument ports and window ports. The combustion vessel can be setup and arranged to cover a wide array of optical studies under conditions representative of in-cylinder conditions. The thermodynamic conditions are generated by controlling the fuel mixture composition and stoichiometry through mixing individual gases (fuel, 0 21 N21 C021 etc.), pressure, and temperature.

The flow conditions are set by using a shrouded fan system.  By changing the fan configuration, fans' speed and shroud, the flow past the spark plug electrode can be controlled. As a result the ignition (break-down, arc and glow discharge) and initial flame kernel development can be studied with high speed imaging and other diagnostics.  The proposed work is to conduct 200 tests in which the conditions will be determined by direction of Ford technical staff in consultation with Michigan Tech. These tests are broken up into multiple stages.

2. Metal Engine

The metal engine work continues on the V6 3.SL IVCT engine that is setup for testing at Michigan Tech in a dynamometer engine test cell. It has the Ford PCM with ability to integrate prototype code via ATI no-hooks, a prototype EGR system controlled by a prototyping ECU, the Ford Variable Output Ignition System (VOIS) for dual coil per cylinder control, and instrumentation including cylinder pressure transducers coupled with a combustion analysis tool. Additionally a high speed 10M samples per second, long record length, National Instrument system has been incorporated for measurement of ignition system secondary characterization. This coupled with the cylinder pressure combustion analysis tool provides characterization of ignition system performance with combustion metrics including combustion phasing, combustion durations (0-10, 10-90% mass faction bum, combustion variability through coefficient of variance (COV) and lowest net value (LNV) of IMEP and percent misfires. In-cylinder flow motion can be set to low or high by inserting tumble planks in the intake ports.

The Ford VIOS system drives two coils per cylinder and when used with variable duration (short, medium, long, and extra-long) coils with controlled dwells can provide a wide range of ignition energy profiles including continuous and discontinuous discharges with variable delays and individual durations. The system drives all 6 cylinders with secondary measurements on cylinder 1. Additionally quenching has been added to truncate the tail of the glow discharge for additional energy-phasing-duration control for cylinder 1. Supplemental measurements of secondary voltage and current are measured in the DAQ systems.

Standard tests include:

• EGR and lean sweeps at constant speed I load to identify dilution limits as a function of coil energy and discharge duration
• Dwell sweeps with varying coils
• Coil 8 delay sweeps where the interval between the first coil (A) and second call discharges is changed
• Restrike and quenching with variable energy and delay

3. Optical Engine

Michigan Tech has been working with Mahle Powertrain (MPT) on the development and integration of an optical engine for research at Michigan Tech for research purposes. To develop the setup and controls for the engine, MTU has setup a 2013 2.0L EcoBoost metal engine. Finalization of the development on the metal engine was completed in December of 2013.  The engine is setup with standard DI side mount injection and single coil ignition. The engine controls are done via a rapid prototyping controller. As part of this work MTU will develop controls for a dual coil ignition system for the engine. The system will perform individual control for the dwell and phasing of the two coils with a diode pack similar to the Ford VIOS to drive to a single spark plug. Ford will provide necessary coils and plugs for study. Optionally MTU will setup for N₂/C0₂ gas dilution as a surrogate for external EGR.

The proposed work is to conduct 4 weeks of testing once the engine setup is complete starting in April. The tests will be broken up into 4 phases each 1 week in duration. The test conditions will be determined by direction of Ford technical staff in consultation with Michigan Tech.

The Michigan Tech Mobile Lab, will be utilized to deliver hands-on, short duration, high-impact Science Technology Engineering and Math (STEM) based explorations at the 2013 Heroes Alliance Parental Boot Camp on August 17th, 2013.

The outreach activities will be setup and delivered by the Mobile Lab's trained team of Staff and Students. The STEM outreach activities will be organized to follow a systems level approach and will be themed around sustainable transportation. Upon approaching the lab, participants will be greeted and introduced to the concept of sustainable transportation, the importance of the concept, and the role that Scientists and Engineers play in this area. Also at this time, participants will learn that Hybrid Vehicles are one element of sustainable transportation, and will learn the basics of hybrid vehicles by seeing actual production and educational based hybrid vehicles.

Upon entering the lab, participants will have the opportunity to explore several work stations, each with a Mobile Lab Mentor. The explorations at the work stations are designed to show participants how each of the major subsystems of a Hybrid Vehicle works, and how important STEM is in continuing to improve those subsystems and move along the pathway towards sustainable transportation.

Explorations may include:

• How it works: Electric Machines

• How it works: Batteries

• How it works: Engines

• How it works: Aerodynamics

• How it works: Controls

• Powertrain Testing

• Vehicle Testing

• Effect of Vehicle Parameters on Performance

The exploration Mentor can adjust the activity depth and content "on the fly" such that the activity is exciting and educational to the wide range of participants that attend public outreach events

OVERVIEW

This Statement of Work (SOW) proposes a support structure to assist Heroes Alliance in administering an afterschool program in the Detroit Michigan area. Through this afterschool program, the youth (grades 9-12) will design and build a small electric vehicle, showing them the power of STEM, giving them confidence in their own capabilities, and inspiring them to pursue a STEM career where they can continue to give back to society. Construction of such a vehicle however, presents a complex engineering challenge, but one in which Michigan Tech proposes to support through on-site and off-site coaching, engineering design, and consultation.

OBJECTIVES

The objectives of the proposed Michigan Tech involvement in this project are to support Heroes Alliance in the successful design and build of an electric vehicle, which will in turn teach the value of STEM to high school youth.

WORK PLAN

It is proposed that a Michigan Tech Mobile Lab Staff Engineer be assigned to support this project. It is understood that the youth will meet for 3-4 hours per day, Monday through Thursday, each week beginning April 2014, and continuing to September 2014. Michigan Tech Staff will travel to Heroes Alliance in Detroit for one week long visit per month for the 6 month duration of the project. If, through subsequent discussions with Heroes Alliance Leadership, it is deemed useful, the Michigan Tech Configurable Hybrid Electric Vehicle will be brought to Heroes Alliance, tt is felt that this vehicle would prove to be a valuable educational resource and provide a source of excitement and motivation to the youth during this project, especially in the early months before their own vehicle starts "taking shape

Overview

Hands-on education with the Michigan Tech Mobile Lab will be utilized to deliver the training to John Deer employees during training week in September 2014.

Audience

This training is intended for Engineers, Managers, and Technicians who are either new to the area of Instrumentation & Experimental Methods and the Fundamentals of Diesel Engines, or wish to broaden their knowledge to assist in vehicle integration or communication with colleagues across various subsystems. An engineering degree is recommended, but not required for this training. The proposed sessions are designed for a maximum of 20 participants. There is no minimum number of participants.

Outline

The proposed hands-on training covers two topics 1) Instrumentation & Experimental Methods and 2) Fundamentals of Diesel Engines and takes place over 5 days. The material is a mix of traditional direct learning and hands-on experimentation with data analysis and discussion. The direct learning portion is taught from the Mobile Lab's classroom, which seats up to 20 participants. The hands-on experimentation will be conducted utilizing a multitude of the Mobile Lab's equipment which may include production hybrid vehicles, a configurable hybrid vehicle, vehicle chassis dynamometer, and hybrid powertrain test cells. Each topic is 2.5 days of training.

Ford Diesel Spray Studies: Rate of Injection Measurement Phase 2

Overview:

To supplement the acquired rate of injection (ROI) data from the initial momentum flux measurements, additional tests will be undertaken to characterize the initial transient rate of injection spray development. This will include investigating the effect of impingement distance on the transient rate of injection, accomplished through the use of differing anvil lengths. Tests will be conducting using the standard Baseline B multi-hole Injector. An option to look at the hole to hole variations in transient ROI development and to correlate this to the Bosch ROI is included along with other testing and analysis options.

Objectives

Utilizing the impingement momentum flux method for ROI, determine the following:

Characterize the influence of impingement distance on the measured transient rate of injection by measuring at 4 distances (nozzle exit to anvil).

Options are included for the following:

• Characterize the plume to plume differences at early injection and compare to the Bosch ROI by appropriately phasing and summing the individual nozzle impingement ROI measurements.
• Model the impact of ROI distance using the momentum flux model of Naber and Siebers (1) extended to transient spray momentum flux by Musculus and Kattke (2)
• Image the impingement with high speed micro-photography.  Imaging will be acquired of the first impingement only, through the Plexiglass viewing port on the ROI fixture.

This work will utilize the developed ROI fixture from Phase 1 testing and the existing DAQ system, but will require hardware modifications in the form of different anvils. Included would be characterization at different injection pressures and impingement distances.

OVERVIEW

Supporting the 2014 Macomb Community College CAAT Conference with the Michigan Tech Mobile Lab. Additionally the Mobile Lab will provide 1-day of open house style engagement for the Students, Faculty, and Staff of Macomb Community College the day before the CAAT conference.

OBJECTIVES

The objectives of the proposed Michigan Tech involvement in this project are:

1. Provide an open house of the Mobile Lab,

2. Provide a location for a short presentation on HEV Technology prior the CAAT Rid & Drive.

WORK PLAN

The Mobile Lab will provide an open house, during which the Lab will be open to any persons including Macomb Community College Students, Faculty, Staff, and the general public. During this time there will be two Mobile Lab Staff on hand to talk to the guests about various vehicle technologies, experimental technologies, educational programs or opportunities at Michigan Tech, etc. Various demonstrations can also be provided during this period of time on a case by case basis depending on the individuals attending the open house.

During the CAAT Conference the Mobile Lab will provide an open-house experience beginning at 8AM and will continue until the Ride and Drive begins. At the beginning of the Ride and Drive, participants of the ride and drive will be given a short presentation on HEV Technology from within the Mobile Lab prior to driving the vehicles obtained by Macomb Community College. The presentation can be repeated as many times as necessary as the Ride and Drive event continues.

Additionally, Mobile Lab Staff can assist in delivery of the short presentation to give the Macomb Community College Faculty a break throughout the evening. Two Mobile Lab Staff will be on-hand throughout the CAAT Conference event.

Project Relevance

The Renewable Fuel Standard within the Energy Independence and Security Act of 2007 sets the required quantities of renewable fuels required in the marketplace, over a 14-year period. In order to meet the renewable fuel requirement of 2012, the ethanol content in gasoline increased above 10%.

E15 is slowly replacing E10 at fuel stations, which means snowmobiles and other recreational vehicles will be required to operate on a fuel that they have not been calibrated for. While a majority of current research projects focus on automotive applications of renewable fuels, little work to date has focused on recreational power sports applications. The effects of renewable fuels on open-loop systems, such as those on most recreational vehicles, are highly unknown and thus produce concern on the part of owners and manufacturers.

The state of Minnesota has over 250,000 registered snowmobiles, the highest number in the United States. However, E15 is not currently approved for use in these vehicles due to detrimental impacts and limited test data. A recent study conducted by Michigan Technological University and funded by the Department of Energy, found that E15 fuel in snowmobiles caused increased exhaust system temperature and NOx emissions, reduced carbon monoxide and 1,3 butadiene emissions, degraded cold-start performance, and increased fuel consumption. The engine calibrations were not modified for E15, and thus the data represents the situation of misfueling a snowmobile with E15.

The goal of this project is to determine the required calibration changes to minimize the negative impacts from higher oxygen concentration fuel while also taking advantage of improved fuel properties to increase fuel economy, reduce emissions, and improve performance. In addition, evaluating what sensors are required to implement the calibration changes in a real-time manner will be assessed. This data ultimately improves the recreational manufacturer's acceptance of these new fuels, because they understand the required changes necessary to successfully implement the fuels.

 Benefit of the Project to Minnesota Corn Farmers

Creating a high demand for corn products is important for Minnesota farmers. E15 fuel has increased the demand for corn-based fuel but it is not approved for use in recreational engines and vehicles. To maximize the demand for higher alcohol content fuel, all vehicles must be legally allowed to use it. This project provides real-world data that recreational engine and vehicle manufacturers can use to determine the impact of higher oxygen concentration fuel on their products and thus implement the necessary changes to take advantage of the new fuel properties. Exploiting the benefits of ethanol blended fuels helps offset the reduction in fuel economy and increased exhaust temperature. This in turn improves the acceptance of these new blends and ultimately the demand for corn-based fuel.

OVERVIEW

Following a project to evaluate the AUTOEKG FSA8 on four vehicles "Diagnosing Induction System Degradation and Evaluation of Remedial Chemicals in Automotive Engines," it has been mutually determined by ITW and Michigan Tech that additional testing should take place. The additional testing will be done on a population of 30 vehicles, but will not include the extensive tests and measurements taken during the first study.

The population of 30 vehicles will allow for more statistically significant results. The study will be advertised in a Michigan Tech newsletter to find willing participants. Participants will be incentivized with a pre-paid gift card. The volunteered vehicles will first be examined by the research team to ensure the vehicles meet the requirements of the project. After choosing 30 suitable vehicles, each vehicle will be scheduled for an appointment at the Advanced Power Systems Research Center. During this appointment each of the vehicles will have borescope images taken of at least 1 intake valve, and have EKGFSA scores recorded. A portion of the vehicles will have their fuel systems cleaned using ITW chemical products, while a portion will remain as a control group. The owners will be instructed to consume 1 tank of fuel, then bring their vehicle back In for a follow-up appointment, where once again EKGFSA scores will be recorded and borescope images collected. Following this work, results will be summarized and presented to ITW in a web conference. A written report will also be issued.

Overview

This is continues work from the Ford Dept. of Energy Program on "Advanced Gasoline Turbocharged Direct Injection (GTDI) Engine Development."

Work will continue on the 3.SL IVCT engine that is instrumented and controlled at Michigan Tech. It has the Ford PCM with ability to integrate prototype code via ATI no-hooks, a prototype EGR system controlled by a prototyping ECU, a prototyping Ford Tribox controller for closed loop pressure sensing and combustion control, and instrumentation including cylinder pressure transducers.

At Ford's discretion a different engine will be provided by Ford to instrument and replace the 3.SL. MTU will instrument and install the engine according to the tasks below.

 Objectives:

Combustion Sensing and Control via feedback from in-cylinder pressure sensors is broken down into the following subtasks.

a. Evaluation of production intent sensors on engine via comparison of signal to instrument grade sensors.

b. Optimization of combustion metrics for combustion phasing and stability.

c. Development of methods of improved torque estimation from cylinder pressure measures (e.g, net IMEP).

d. Develop combustion control techniques for dynamic engine conditions.

e. Investigate cylinder Air/Fuel balancing and cylinder air charge estimation.

f. Develop adaptive correction techniques for combustion control and integrate and test.

1. Provide analytical analysis of dynamic vehicle traces provided by Ford.

Scope

Michigan Tech Staff Member, support Northcentral Technical College (NTC} faculty in the preparation and delivery of course materials at NTC during the Fall 2013 semester. To support the courses the Michigan Tech Staff Member will spend three weeks at NTC working with NTC faculty in the classroom and lab.

The specific courses and utilization within those courses will be left to the discretion of NTC within the scope of the staff experience. Examples of collaboration could Include guest lectures, assisting NTC Instructors In the lab, and development of new educational apparatus, class projects, and learning modules.

Introduction/ Abstract

Torque converter torus designs have evolved from axially long and round shapes to axially thin and elliptical shapes as automatic transmission content has increased in numbers of gears and in damping capability of the torque converter clutch. Future designs will include torque converters with even thinner tori with the torque converter to be used strictly as a vehicle launch device and the converter clutch applied in low gear at low vehicle speed.  These changes result in improved vehicle fuel economy, however, thinner torus torque converters are at increased risk for high levels of cavitation. The fluid in a small torus torque converter versus large at the same level of torque has greater pressure gradients across the blades of the converter pump, turbine, and stator. Greater pressure gradients result in lower pressures on the low pressure side of converter element blades which can lead to cavitation. Smaller torus converters also contain less transmission fluid which can lead to localized regions of higher temperature, further contributing to increased risks for high levels of cavitation. Understanding torque converter cavitation and noise characteristics, and the Influences of design parameters and operating conditions on cavitation level is vital to enabling new generations of transmission designs.

This research seeks to build upon knowledge gained from previous torque converter cavitation and noise studies executed at MTU. Previous research has established that moderate levels of cavitation are present in many torque converters under normal operating conditions. This research intends to quantify the level of cavitation present under normal and overload operating conditions and to develop a method to compare designs relative to design parameters and loading.

 Introduction

Starting in 1997, extensive research was conducted into techniques for detecting the presence of cavitation in the flow field of an operating torque converter. These studies have produced novel methodologies for sensing the onset of cavitation and quantifying its intensity at various operating conditions using microwave telemetry and specially instrumented torque converters. In 2000, a separate project was undertaken to develop a technique to acquire and evaluate noise generated by a torque converter during operation using acoustic measurements. Large quantities of data were acquired in both vehicles and in the dynamometer lab, advanced software was used to disassemble the noise spectrum into its critical components. Very successful measurement and analysis methodologies were developed, but no attempt was made to utilize these tools on converters of widely different sizes and designs. In 2004, a project was undertaken in which converters of different sizes and designs were operated over a range of charge pressures and torques at the stall operating condition. Noise data was acquired during the tests, processed by the recently developed numerical techniques, and non-dimensionalized or otherwise correlated against the converter's design and load parameters. The acoustical method of cavitation sensing was employed to similarly define the influence of converter design on cavitation potential. This data was used to validate the dimensional analysis approach to cavitation prediction suggested by the earlier work. To provide the precision and repeatability necessary for testing performed, both the dynamometers and hydraulic system of the test facility were updated to full computer control. The body of work has nicely correlated the cavitation characteristics of torque converters at stall conditions. In 2007, a project was initiated to characterize torque converter cavitation through a range of speed ratio operation and normal input torque and power levels. Test data was analyzed to develop dimensionless models to predict the speed ratio for cavitation desinense based on torque converter design parameters and operating conditions.

The research established that moderate levels of cavitation are present with no adverse effects in many production torque converters functioning under normal operating conditions. There are no complaints of objectionable noise from cavitation and no evidence of material wear or damage due to the implosion of cavitation bubbles. As torque converter torus designs continue to get smaller, this may no longer be the case. This study proposes to develop a method to measure and quantify the level of cavitation in a torque converter, determine criteria for acceptable levels of cavitation, test a matrix of torque converter designs for cavitation, and perform dimensional analysis to create a model capable of predicting cavitation level based on design parameters and operating conditions

Introduction

Soil compaction is a function of numerous variables such as vertical tire load, lug and cavity shape, tire width and diameter, bias or radial construction, dynamic loading, tire pressure, soil type, moisture content and wheel slippage. Soil compaction testing facilities utilize various methods for loading the tire, measuring compaction and tire-soil interface for a broad range of tires, loading conditions, soil moisture, etc.

Problem Statement

The proposed work is the design and fabrication of a tire test fixture to measure the influence of tire pressure, vertical and draw bar loads on soil compaction for agricultural and off-road tires. The fixture will apply calibrated vertical and draw bar loads. The stress distribution in the soil pan will be measured with pressure pads.

Water Management Modeling for Cold Start

Material Property and Segmented Cell Measurements The objective of this task is measurement of material and transport properties required as inputs for the Anode GDL Model and FEA Model being developed at Michigan Technological University (MTU) and Los Alamos National Lab (LANL) respectively.

 GDL Modeling for Cold Start The objective of this task is to determine the most relevant GDL material and transport properties for enabling improved cold-start response. An existing water transport model for hydrophobic GDLs will be modified to accommodate hydrophilic anode GDLs in conjunction with state-of-the-art catalyst layers and membranes.The Anode GDL model will be used to develop a mechanistic understanding of anode GDL material properties that have a significant affect on low-temperature transient response and cold startup. GDL, MEA Model Integration The Anode GDL model is a 'local' model focused on a land-channel section of the GDL. This model can be used to track the location of the product water and where evaporation will occur. However the Anode GDL model cannot predict cell performance. The FEA model is a 'cell-level' model that can be used to predict performance response, but requires bulk property relationships for the GDL-FEA interface. For this task, the parameter output of the two models will be integrated. The Anode GDL model will, based on a land-channel unit cell provide bulk transport predictions as source terms for the FEA model. The FEA model will provide the flux conditions for the Anode GDL model. The model integration will be iterative and will need to be conditioned with single-cell experiments.

The objective of this task is to develop a design methodology, or design tool, that can be used to predict fuel cell performance for unique combinations of fuel cell component. Michigan Tech will work closely with LANL on this task. Model Validation This task is focused on the design and conduct single-cell experiments for the purpose of generating data sets specifically for model validation; as opposed to cell performance or durability testing. Experiments  may incorporate  segmentation in order to collect spatially and temporally varying current distribution and to potentially control voltage and current distribution for model validation purposes. The experiments will be conducted at 3M.  Michigan Tech and LANL will provide guidance on experiment conditions to use for validation tests

Project Summary

Studying the nonlinear dynamics of fluid-structure interaction provides insights into a widespread physical topic which makes appearances in many scientific disciplines and several branches of Engineering. These phenomena manifest themselves at a wide range of scales and present excellent opportunities for scientific discovery with a richness of technical application. In cases like a rotor blade or an insect wing, where a body is subject to a complex motion due to the intrinsic operation of a certain mechanism or the dynamics of its control system, the scientific challenge is still greater.

 The objective of the CAREER program proposed is to provide a better understanding of the underlying physics in slender-body aeroelastic dynamics through improved mathematical computational models of the multiphysics process. The program is divided into three overlapping phases each of them building upon previous work the PI has published. The first phase focuses on a new series of adaptive algorithms, based on the hybrid (or vorticity-velocity) formulation of the Navier-Stokes equations. The kinematic laplacian equation (KLE) technique will be used to create a complete decoupling of the two hybrid variables in a  vorticity-in-time/velocity-in-space split approach. The resulting global scheme is intrinsically compatible with non-linear adaptive ODE algorithms, providing a way in which the submodels for the different problems involved (flow, structure, control-system dynamics, etc.) may be treated individually as rnodules that interface with the main ODE routine. This allows for the simultaneous analysis of the aeroelastic problem together with any innovative control strategy into a single computationally-efficient self-adaptive algorithm. The second phase consists of qualitative studies on vortex-shedding and wake dynamics behind oscillating bodies, which play a critical role in the aeroelasic problem. In the third phase, quantitative studies on prototypes of innovative wind-turbine blades, and their associated control strategies, will be conducted.

 Intellectual Merit

The intellectual merit of this work is the advancement of computational mathematical models for the complex multiphysics problems involving fluid-structure-control interaction that are present in many engineering designs, providing also a fundamental tool for a better understanding of the underlying physics. The experimental analysis of these coupled multiphysics problems is extremely difficult. In some cases (like wind-turbine blades), huge size differences complicate extrapolation of experimental data from the wind tunnel to the prototype scale. In others (like the lifting surfaces used in Micro-Air-Vehicle applications inspired in the flapping-wing biological mechanisms observed in bird and insect flight), the sheer task of placing sensors on a small-scale mechanisrn in complex rototranslational motion becomes almost insurmountable. If

successful, the innovative mathematical models proposed here would improve the efficiency and flexibility of the computational implementation and provide a way to tackle these difficulties.