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Entry Level Dual-Clutch Transmission for India

IAV Automotive Engineering-Mirko Leesch, Erik Schreiterer
IAV India Pvt, Ltd.-Gitesh Mutha
Published 2017-01-10 by SAE International in United States
The paper presents a new 7-speed dual-clutch transmission (DCT) for transverse applications and a torque capacity of 200 Nm with an option for 300 Nm engine torque. Advantageously the system is designed for supplier parts of dual-clutch system, gear and clutch actuation, differential as well as bearings, synchronizers and additional standardized parts. The actuation could be also realized by an already developed hydraulic module which can be used and produced locally with supplier parts of valves, sensors and so on. Furthermore, the gear set is a state-of-the-art system which can be supplied by manual transmission manufacturer. Beside the cost focus. the DCT has a favorable gear set in terms of robustness and compactness. The design with a total length of 350 mm is realized through a common gear on the main shaft for each gear pair on the countershafts and multiple use of gears in the first speed. The influence of these dependencies on the series of ratios is quite less with this new transmission system. The reverse speed is realized without an idler gear…
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Evaluation of Accelerated Ash Loading Procedures for Diesel Particulate Filters

IAV Automotive Engineering-Fabian Sonntag
Technical University of Braunschweig-Peter Eilts
Published 2016-04-05 by SAE International in United States
There are numerous methods for accelerated ash loading of particulate traps known from literature. However, it is largely unknown if a combination of these methods is possible and which one generates the most similar ash compared to ash from real particulate filters. Since the influencing variables on the ash formation are not yet fully understood, ashing processes are carried out under carefully controlled laboratory conditions on an engine test bench. The first ashing takes place with low sulfated ash phosphorus and sulfur oil without any methods to increase the quantity of produced ash. The obtained ash is used as a reference and is compared hereinafter with the process examined. Four methods to increase the ash production ratio are investigated. The first one is an increase of the ash content of the lubrication oil through an increase of the additives in the oil. The second one is the additional generation of ash with a burner system where oil is injected into the flame. The next one is the injection of oil into the inlet manifold and…
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Experimental Investigation of Power Hop in Passenger Cars

IAV Automotive Engineering-Steffen Zemke, Ahmed Trabelsi
Leibniz Universität Hannover-Simon Eicke, Matthias Dagen, Tobias Ortmaier
Published 2015-06-15 by SAE International in United States
In this paper the power hop phenomenon is analyzed and important influencing factors are investigated. The results of driving tests on various road surfaces with different types of cars with longitudinal and transversal mounted engines as well as with front and rear wheel drive are presented. In order to understand and quantify the power hop effect the rotational speed of the individual wheels and the engine are measured. Additionally, the drive shaft torque, the engine movement in its bearings and the vertical deflection of the wheel with respect to the chassis are determined to get detailed knowledge about physical dependencies. It is shown that the rotational speed of the driven wheels is not a sufficient indicator to assess the occurrence of power hop by measurements. Alternatively, the measured longitudinal acceleration at the seat rail provides a good quantification. Nevertheless a detailed analysis of the rotational speed of the driven wheels points out great variations of the amplitude and frequency in dependence of the car. In case of power hop, the sensor information of the engine…
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Modular 7-Speed Hybrid Dual Clutch Transmission 7H-DCT280

IAV Automotive Engineering-Mirko Leesch, Jörg Müller, Jens Liebold
Published 2015-01-14 by SAE International in United States
The contribution presents a new structurally optimized 7-speed hybrid DCT for transverse applications. Advantageously the seven forward speeds can be provided with only two shafts. The space of the usually third shaft can be used for the electric motor or the mechanical reverse speed. This modular integration can be realized by using mostly identical parts for the components of the gear set and the transmission housing. The direct connection of the electric motor to the differential helps to avoid additional gear set loads and efficiency losses. Such modular transmissions will help in future to reduce development and production costs.
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Inversion-Based Intake Manifold Pressure Control System for Modern Diesel Engines

SAE International Journal of Engines

IAV Automotive Engineering-Frank Märzke, Ralf Meinecke, Michael Schollmeyer, Robert Frase
Clausthal University of Technology-Johannes Reß, Christian Bohn
  • Journal Article
  • 2014-01-1709
Published 2014-04-01 by SAE International in United States
An improved model-based two-degree of freedom control system for the intake manifold pressure in passenger car diesel engines is described in this paper. The aim of this control system is to track the air charge setpoint rapidly and precisely. To achieve this, an inverse model of the intake manifold dynamics is included in the feedforward control path. The system parameters which are necessary to calculate the inverse model are setpoints from other control loops in the gas system. These generated setpoint values allow for decoupling of the individual control loops in the gas system as far as possible. The parallel linear feedback controller is designed to further improve the accuracy of the control system. The calculated feedforward control signal and the feedback control variable additively generate the effective opened area of the intake throttle valve. Due to its model-based structure, the improved control system proposed will require less calibration effort than current production-code controllers and that the calibration can be partially carried out using simulation. This is also the main motivation for the development of…
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Optimal Catalytic Converter Heating in Hybrid Vehicles

IAV Automotive Engineering-Thomas Boehme, Matthias Schultalbers
Univ. of Rostock-Markus Schori, Torsten Jeinsch
Published 2014-04-01 by SAE International in United States
In this paper, a hybrid optimal control problem (HOCP) for the optimal heating of the three-way catalytic converter is solved. We propose a model for a hybrid vehicle that beneath State of Charge and fuel consumption includes thermal system states like engine cooling water temperature and catalytic converter temperature. Since models for noxious emissions with appropriate computational demand are not yet available for optimization purposes, an artificial state that resembles the emissions produced is introduced. A hybrid optimal control problem is then formulated for the beginning of the FTP-75 drive cycle whose target is to minimize the energy loss during the catalytic converter and engine cooling water heating phase. The corresponding input values to be optimized are continuous variables as ignition angle and cylinder charge as well as discrete decisions such as different injection schemes. As additional constraint, an upper limit is imposed on the artificial emissions state. A self-developed algorithm is then used to optimize the system with respect to the constraints and results are presented accordingly. The results obtained provide a valuable help…
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Solutions of Hybrid Energy-Optimal Control for Model-based Calibrations of HEV Powertrains

IAV Automotive Engineering-Thomas Juergen Boehme, Benjamin Frank, Matthias Schultalbers
University of Rostock-Markus Schori, Bernhard Lampe
Published 2013-04-08 by SAE International in United States
In this paper optimal control problems for hybrid powertrain vehicles with different drive-modes are considered and solved using numerical techniques. This leads to the formulation of hybrid optimal control problems. The aim is to find optimal controls and optimal switchings between the drive-modes to minimize a cost function resembling fuel consumption. The problem is nonlinear and subject to constraints concerning both controls and state. The techniques include indirect methods as well as direct optimization methods. Efficiency and accuracy are evaluated for all methods using simulation studies. An experimental test on a near mass-production vehicle confirms the usability of the direct optimization approach.
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Optimal Design Strategies for Different Hybrid Powertrain Configurations Assessed with European Drive Cycles

IAV Automotive Engineering-Thomas Juergen Boehme, Bernd Becker, Michael Ruben-Weck, Matthias Rothschuh, Alexander Boldt, Christoph Rollinger, Robert Butz, Heiko Rabba
University of Rostock-Wolfgang Drewelow
Published 2013-04-08 by SAE International in United States
The quality of the powertrain design has a significant impact on the fuel consumption and emissions of hybrid vehicles. Lack of experience with these relatively new technologies, the enormous variety of hybrid powertrain configurations, and the multitude of components make this area an ideal application for computer-based modeling and optimizations. Global optimization techniques have the advantage to explore systematically the design space to find the optimal configuration space. In this paper, a systematic procedure for an optimal design of hybrid powertrain configurations using an evolutionary algorithm is proposed. It will be shown that the design steps for parallel and power-split configurations are quite similar. This results in a computing approach with high synergy effects and the ability to exchange components seamless to compare different ‘virtual’ configurations.
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Application of an Optimal Control Problem to a Trip-Based Energy Management for Electric Vehicles

SAE International Journal of Alternative Powertrains

IAV Automotive Engineering-Thomas Juergen Boehme, Florian Held, Christoph Rollinger, Heiko Rabba, Matthias Schultalbers
University of Rostock-Bernhard Lampe
  • Journal Article
  • 2013-01-1465
Published 2013-04-08 by SAE International in United States
A trip-based energy management strategy for electric vehicles (EVs) is proposed. It can use deterministic routing information obtained from, nowadays, available navigation systems and determines stochastic descriptions of process uncertainties such as stop events as unpredictable disturbances. A dynamic programming algorithm is used to calculate the optimal control trajectories required to reach the target destination safely and to suggest the driver an optimal driving style to maximize the battery range. The algorithm is implemented on a rapid prototyping platform using MATLAB/Simulink. Simulations and experimental results obtained from an EV prototype car are presented.
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Investigations on a Catalyst Heating Strategy by Variable Valve Train for SI Engines

SAE International Journal of Engines

IAV Automotive Engineering-Wolfram Gottschalk, Gunnar Kirstein, Olaf Magnor, Matthias Schultalbers, Robert Wetten
  • Journal Article
  • 2012-01-1142
Published 2012-04-16 by SAE International in United States
The objective of this investigation was to evaluate the effects of a variable intake and exhaust valve timing in terms of opening, closing, opening duration, lift curve and number of active valves per pair on a four cylinder direct-injecting SI engine for the catalyst heating idling phase at the beginning of an NEDC emission test procedure. The first step evaluated the engine behavior at a reference point of operation. Its parameters in valve timing were adjusted to match the valve timing of the base production engine. The second step investigated the effects of an earlier exhaust valve opening while the exhaust valve closing time was kept and the exhaust valve opening duration was extended. The third step was to answer the question for the optimum number of exhaust valves in order to minimize the wall heat losses inside the cylinder head. The optimum 3V exhaust valve timing has been defined as the basis for exhaust valve timing for steps four and five. The fourth step contained the variation of intake valve opening and closing. The…
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