Browse Topic: Air cleaners

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This SAE Standard encompasses connectors between two cables or between a cable and an electrical component and focuses on the connectors external to the electrical component. This document provides environmental test requirements and acceptance criteria for the application of connectors for direct current electrical systems of 60 V or less in the majority of heavy-duty applications typically used in off-highway machinery. Severe applications can require higher test levels or field-testing on the intended application.
CTTC C2, Electrical Components and Systems
This SAE Standard outlines the requirements for a preformed thermosetting hose intended for use in heavy-duty vehicle engines, such as air cleaner inlet, crank case vent, or air cleaner to turbo or to engine inlet.
Non-Hydraulic Hose Committee
One of the advantages of the internal combustion engine is that it can function with relatively simple intake air filtration. Provided that dust is kept out, air entering the engine can ensure that the necessary combustion process takes place. So, a relatively simple dust filter will do the job. By comparison, hydrogen fuel cells are far more sensitive to air quality. Other pollutants can affect both fuel-cell performance and the lifetime of the fuel-cell stack. At the recent IAA Transportation Show in Hanover, Germany, Donaldson Filtration Solutions displayed tailored solutions through its range of cathode air filters. These typically rely on multiple layers - including activated carbon, an acid and base layer, and a dust filter - to screen out sulphur dioxide, nitrogen oxides and ammonia, while allowing for customization to protect against butane, toluene and other unwanted compounds.
Kendall, JohnGehm, Ryan
The author has developed UV based photocatalytic air purification system (Mathur, 2021, 2122, 2023) that can eliminate all pathogens from the cabin air including COVID-19. In this study, the focus is to determine the risk of infection due to pathogens/germs in the cabin of an automobile. Author has determined the risk of infection by using Wells-Riley model and conducted CFD analysis to determine propagation of virus in cabin as a function of: 1 Cabin Volume & Number of Occupants (Wells-Riley Model in OSA mode): (i) Cabin volume from: Small Sedan, Large Sedan and a SUV; with 4 occupants (males & females); Number of infector 1; Air flowrate (m3/min); (ii) A 15-seater minibus – with 10 occupants (males); Number of infectors 1 & 2; Air flowrate (m3/min) 2 CFD to simulate 4 occupants and 1 infector in an automotive cabin – Current investigation is for talking, coughing and sneezing with blower off in Recirc mode wit (i) Infector in the front seat; (ii) Infector in the rear seat. Based on this investigation, following is a brief summary of the important variables affecting risk of infection: (i) Cabin volume, Cabin air flowrate, Lung capacity – males and females/Number of breath/min, Number of occupants, Number of infectors, Number of quanta; (ii) CFD Analysis: This investigation consists of simulating the propagation of virus laced saliva particles (droplets) coming out from an occupant’s mouth while sitting in the front & rear of the cabin. Occupants (infectors) were simulated by talking, coughing and sneezing through CFD. This was done in recirculation mode with blower on and off. The following are the important finding from this study: Cabin % relative humidity, Cabin internal volume, Seat geometry, Location (front or rear) of the infector (occupant) talking, coughing and sneezing, Occupant (Infector) height. Detailed analysis has been presented in this paper that will be helpful in developing mitigating strategies to control the spread of virus in an automobile cabin.
Mathur, Gursaran
TOC
Tobolski, Sue
In order to meet future emission targets and to achieve better fuel efficiency, closed loop air mass control strategies have become essential across all vehicle segments. Closed loop airmass control mandates measuring fresh air mass entering the engine combustion chamber. However, in Naturally Aspirated (NA) engines, while measuring airmass using conventional air mass sensors (AMS), heavy pulsations in the Air-intake results in errors which would impact closed loop airmass control and lead to inconsistencies in emissions. To address this issue, we studied different approaches using AMS with Resonator, differential pressure sensor across the intake air filter and Lambda based airmass control. Based on this empirical study we found that modelling air mass with differential pressure sensor (Delta-P) using Bernoulli’s principle (Flow rate ∝ √Differential pressure) results in higher accuracies compared to conventional methods. This solution gives accurate, cost-effective Air mass modelling in single or two cylinder naturally aspirated engines which are prevalent in Light Commercial Vehicle (LCV) segment for BS6 market. The research provides a detailed explanation of the Air mass modeling approach using Delta-P sensor across Intake Air-filter and its implementation, along with the issues and mitigation measures involved.
Y, PavanShanmugam, BalajiR, Rachana
The need for effective control systems is exacerbated by tighter pollution regulations and consumer demands for highly efficiently vehicles especially in the passenger segment. The air flow estimation of engine and accordingly controlling the fuel removes the lacuna of modern gasoline engines. The hot wire type mass air flow sensor is commonly used for air flow measurement, and it generally mounted in clean side piping to prevent damage to air mass flow sensor. The right estimation of air flow is possible by getting uniform flow over the different engine operating speed and load conditions. The placement of air flow sensor becomes critical considering the engine layout and packaging constraints and meeting the sensor mounting requirements. The deviation in mounting of air flow sensor will lead to consequently impact of engine performance and emissions. In our new developed air intake system for passenger vehicle application, torque oscillations were observed over engine operating speeds and load conditions. The air flow oscillations and signal were further evaluated to understand issue. The detail study of air flow signal was carried out over different engine operating range with air filter box layouts. In this paper, extensive work were carried out to understand impact of air flow signal variation. The different air intake layout were evaluated along with sensor mounting to minimize signal disturbance to get proper estimation of air flow. The detailed study with final air intake system was finally evaluated. Boodanur, R., Panwar, A., Kulkarni, S., and Jadhav, A. [1] described the Air Intake System Optimization for Passenger Car Engine.
Sonone, Sagar DineshZope, MaheshGhadge, GaneshDwivedi, AnilJadhav, AashishKolhe, Vivek MPanwar, Anupam
The On-Board Diagnostics (OBD) system can detect problems with the vehicle’s engine, transmission, and emissions control systems to generate error codes that can pinpoint the source of the problem. However, there are several wear and tear parts (air filter, oil filter, batteries, engine oil, belt/chain, clutch, gear tooth) that are not diagnosed but replaced often or periodically in motorcycles/ power sports applications. Traditionally there is a lack of availability of in-field and on-board assistive tools to diagnose vehicle health for 2wheelers. An alert system that informs the riders about health and remaining useful life of their motorcycle can help schedule part replacements, ensuring they are always trip-ready and have a stress-free ownership and service experience. This information can also aid in the correct assessment during warranty claims. With the increase of onboard sensors on vehicles, there has been a notable increase in the availability of condition-monitoring data such as vibration, temperature, pressure, voltage, and other electrical and mechanical parameters. The connectivity device on the motorcycle can transmit this onboard real time data to the cloud for analysis to derive the information of useful life of these components. This paper presents an edge-plus-cloud architecture with part of the algorithm in the Engine Control Unit (ECU) and final processing done on the cloud. Various sensor signals and other vehicle operating parameters are collected and processed using a combination of Machine learning, Fast Fourier Transform, Regression models and other data analytical algorithms. Based on the analysis, information transmitted back from cloud/ Edge device to Vehicle Instrument cluster/ Mobile App/ Web UI to inform rider before the failure has occurred, along with real time data of the remaining useful life of these components.
Vijaykumar, SrikanthSabu, AbhijithPRADHAN, DEBAYANShrivardhankar, Yash
In India, around 70 million people travel by public transport buses. With rising air pollution across cities, there is a need to safeguard passengers from inhaling polluted air. Contaminants in such polluted air could be fine to coarse dust (2.5 micron to 100 micron), exhaust gases (oxide of sulphur, nitrogen and carbon), total volatile organic compounds, bacteria and viruses arising out of covid-19 pandemic. Passengers commuting in buses are continuously inhaling air that is re-circulating through the Air Conditioning system (AC) and also comes in contact with multiple co-passengers and touch points. This air potentially carries a high dose of contaminants and inhalation of such air can lead to health issues. Vehicle manufacturers intend to provide clean air inside the vehicle cabin by configuring various Air Purification systems (AP) which reduce air contaminants in the closed space of a cabin. Currently, the technology and concepts for Air Purification systems continue to be adapted from existing stationary applications such as homes, buildings and office areas. Test conditions for assessing the performance of Air Purification systems in stationary and automotive applications are different. The challenge therefore lies in developing an appropriate validation approach to assess Air Purification system in automotive application considering real-world scenarios. This study discusses a comprehensive objective method to evaluate the performance of an Air Purification system deployed on buses, equipped with an air conditioning system. It examines the selection of test cases, test cycles and ambient conditions that can be applied on a prospective Air Purification system with a view to minimize dust and gaseous contaminants in the cabin. The test results once obtained, will assist vehicle manufacturers to identify areas of improvements in their product and develop a lineup of actions and solutions to enhance Vehicle Interior Air Quality (VIAQ), which will safeguard passengers from air contaminants inside the vehicle cabin. The outcome of this work will assist vehicle manufacturers to establish a structured validation process for evaluation of an Air Purification system
Nimsatkar, Shubham VijayTadigadapa, SureshAli, IrfanGupta, SajalKhandekar, Dhiraj
The author has been conducting research on UV based photocatalytic air purifier systems for the past 5 years to eliminate living organic germs, bacteria, pathogens, etc. from the cabin air. An HVAC system has been developed by using a filter impregnated by titanium di-oxide (TiO2) with UV lights to improve and maintain cabin air quality. The author has designed and constructed a 3rd generation HVAC unit for cabin air purification for automobiles that is based on UV photocatalytic process by using UV-C LEDs to eliminate viruses that typically exist in conditioned space. The author has conducted tests with HVAC unit to determine power consumptions of air purification systems. An HVAC unit that employs a HEPA (high efficiency particulate air filter) filter is compared with the same HVAC unit with UV & titanium dioxide based photocatalytic system. The pressure drops of the HEPA, particulate and TiO2 filters have been investigated that contribute to the overall energy consumption. The energy consumption of the UV-C & UV-A LEDs are also taken into account for the overall energy consumption analysis and comparison with the base system. Tests were conducted in the laboratory to determine pressure drops of the above two systems to compute energy consumption. Based on the testing, the measured power consumption of an HVAC unit with a HEPA filter is on average higher by 57% (27~71% over the airflow range) over an UV based photocatalysis system. Detailed test data and analysis is presented in the paper. The designed system can be used for conventional vehicles, EVs, ride sharing and for autonomous vehicles.
Mathur, Gursaran
The purpose of this SAE Recommended Practice is to establish a testing procedure to determine the performance capability of heavy-duty vehicle cooling systems to meet Original Equipment Manufacturer or end user thermal specifications to ensure long term reliable vehicle operations. The recommendations from the present document are intended for heavy-duty vehicles including, but not limited to, on- and off-highway trucks, buses, cranes, drill rigs, construction, forestry, and agricultural machines.
Cooling Systems Standards Committee
Vehicle interior air quality is usually determined by the levels of in-cabin air pollutants, such as particulate matter (PM), gaseous air pollution (volatile organic compounds [VOCs], oxides of nitrogen [NOx], and carbon monoxide [CO]), and carbon dioxide [CO2], which reflect the freshness of indoor air. Nowadays, cabin air filters play a key role in preventing outdoor air pollutants transporting inside vehicles; hence, in-cabin air quality can be strongly associated with the filtration performance of cabin air cleaning solutions. However, challenges are existing in a standard method for assessing the performance of a cabin air filter in real-life driving conditions. This study is to develop a low-cost mobile test method for monitoring in-vehicle PM and CO2 and evaluating the performances of cabin air filters while driving the vehicles. The results reveal that certain boundary conditions are important to have a proper method for evaluating the particle removal efficiency. For example, recirculation ventilation can lead to high PM2.5 removal efficiency regardless of the status and performance of a cabin air filter, and the remarkable increase in CO2 in a short time is an obvious indicator of the activation of recirculation. Fresh air ventilation is effective in maintaining the in-cabin freshness without the built-up of interior CO2; however, drivers can be exposed to a high level of PM2.5 concentrations with cabin air filters of poor performance. For the vehicles involved in this study, the average PM2.5 removal efficiencies were about 17-50% under fresh air with existing installed cabin air filters (more than 3 months since installed). With a brand-new filter (original cabin air filter and CabinAir Nordzone™ filter), the vehicle could filter out about 80-86% of outdoor PM2.5. The application of ionization technology together with the Nordzone™ filter was proven to further enhance the PM2.5 removal efficiency by up to 97%. Future work would be of great interest to investigate the aging performance of those optimized cabin air filters and the contribution of ionization, as a promising technology to improve the performance of cabin air filters, on those aged filters in real-driving environments.
Cha, YingyingYin, ChunyangDu, JieeXia, TianAn, WeiZhang, Shaojun
HVAC systems of passenger cars and especially their air purification performance gained prominence during the last years. One reason is the overall increased attention to air quality and its effect on human health. Recently, the WHO further tightened the recommended values for many pollutants. This will likely intensify the trend to more complex systems for improving the air purification functionalities. But, up to now there is no standard method for air purification performance testing. Existing standards cover the vehicle cabin air quality only regarding material emissions. Several studies address assessing the performance of air purification functionalities in most cases by real driving tests typically performed in urban areas. This approach results in proper values for the basic efficiency of single systems. But the level of pollutants in real environments differ considerably, which makes a comparison of different systems or varying application parameters at least complex. Hence, the aim of this study was to provide a controllable lab test environment for testing the whole vehicle with its HVAC system regarding its air purification performance. An atmosphere of KCl particles (focus on PM2.5) was chosen for representing the pollutant class of particulate matter. In addition, CO2 was identified as an important pollutant, whose source is not the surrounding environment but the vehicle passengers. Literature reveals that the CO2 concentrations within the vehicle cabin can reach critical concentrations, especially for air-recirculation mode and for a higher number of passengers. Hence, a system for dosing CO2 was set up. It has five channels to simulate the CO2 exhalation of up to five passengers. Its usability was tested by comparing the resulting CO2 concentrations to an experiment with real passengers. At the end a feasible lab test environment was created. Furthermore, introduction of other pollutants (e.g., CO, O3, NOx, biological matter) is also possible.
Brunnermeier, Matthias
This document deals with ground and flight test of airplane installed Environmental Control Systems (ECS), Figure 1. The ECS provide an environment, controlled within specified operational limits of comfort and safety, for humans, animals, and equipment. These limits include the following: pressure, temperature, humidity, ventilation air velocity, ventilation rate, wall temperature, audible noise, vibration, and environment composition (ozone, contaminants, etc.). The ECS are composed of equipment, controls, and indicators that supply, distribute, recycle and exhaust air to maintain the desired environment.
AC-9 Aircraft Environmental Systems Committee
This document describes methodologies to determine the causes blow-by oil consumption caused by the power cylinder.
Piston and Ring Standards Committee
This document describes methodologies to determine the causes of high oil consumption caused primarily by the power cylinder system.
Piston and Ring Standards Committee
The purpose of the article is to evaluate the cooling performance efficiency of a Compressed Natural Gas (CNG) medium commercial vehicle with a viscous fan, fresh air cleaner, and choked air cleaner in comparison with limits prescribed in the Indian Standard (IS) 14557. Due to the increase in CNG availability, a shift is observed in the market demand for CNG vehicles. The earlier CNG vehicle duty cycle was limited to plain roads and some limited cities, but now vehicles are being used for a short trip to nearby hilly routes thereby shifting the application of the use of a CNG vehicle. CNG vehicles can now be operated in hilly areas where power and torque demand is maximum and operates at lower vehicle speeds and in lower gears. The subjected vehicles are designed for haulage applications to operate with conventional fixed fans, which are permanently engaged, and smaller radiators. The subjected vehicle was previously designed as per the requirements of the existing road application with a fixed fan and small radiator. Vehicle configuration was modified to the viscous fan and bigger radiator available as off-the-shelf components from the component suppliers. Viscous fans operate only when the coolant temperature goes beyond certain limits for better cooling performance of the engine, lower cabin noise, and higher fuel efficiencies. The main objective of this article is to compare the thermal behavior in different vehicle configurations by data acquisition and thereby establish the fact that subjected CNG vehicles can be used in difficult terrains due to broad CNG availability with maximum performance. The results obtained during the experiment with a smaller fixed fan and bigger viscous fan are at an ambient temperature above 35°C and, for a time, more than 5 minutes as specified in IS 14557. Base data is collected with the existing configuration of a vehicle with a small fixed fan and small radiator. Afterward vehicle configuration is changed to the viscous fan and bigger radiator and tested at conditions worse than as specified in the test standard, i.e., ambient temperature more than 35°C and, for a time, more than 5 minutes to ensure driveability in all terrains. Then the experiment is conducted at maximum power condition with fresh air cleaner and choked air cleaner. Another experiment is conducted to check the worst-case running in maximum torque condition with fresh air cleaner and choked air cleaner. After establishing the results in the first and second experiments, another two experiments were conducted to check the actual performance of the vehicle in plains and hilly route simulation as well.
Gupta, MohitYadav, DevendraSingh, Pushpinder
This document considers the cooling of equipment installed in equipment centers, which usually consist of rack-mounted equipment and panel mounted equipment in the flight deck. Instances where these two locations result in different requirements are identified. This document generally refers to the cooled equipment as E/E equipment, denoting that both electrical and electronic equipment is considered, or as an E/E equipment line-replaceable-unit (LRU). The majority of cooled equipment takes the form of LRUs. The primary focus of this document is E/E equipment which uses forced air cooling to keep the equipment within acceptable environmental limits. These limits ensure the equipment operates reliably and within acceptable tolerances. Cooling may be supplied internally or externally to the E/E equipment case. Some E/E equipment is cooled solely by natural convection, conduction, and radiation to the surrounding environment. This document discusses specification requirements, system design considerations, component design, and system testing. It also discusses the analysis and test considerations for the thermal design of the avionic equipment. The discussion of supplementary cooling systems includes consideration of a refrigeration system. This document just covers air cooling of equipment. AIR1811 should be consulted for information on liquid cooling of equipment. Although this document is targeted at transport category airplanes, most of the material applies to other classes of aircraft with possible adaptions.
AC-9 Aircraft Environmental Systems Committee
This water separation technical report has been established to cover heavy-duty engine intake filter systems. It may also be applicable to some automotive and industrial air inlet systems where water separation is an issue.
Air Cleaner Test Code Standards Committee
In a photocatalytic air purifier system, the catalyst that cleans the air is typically titanium dioxide and it is energized by ultraviolet (UV) light. When UV light shines on the titanium dioxide, electrons (negatively charged particles inside atoms) are released at its surface. The electrons interact with water molecules (H2O) in the air, breaking them up into hydroxyl radicals (OH·), 9which are highly reactive, short-lived, uncharged forms of hydroxide ions (OH−). These small, agile hydroxyl radicals then attack bigger organic (carbon-based like virus) pollutant molecules, breaking apart their chemical bonds and turning them into harmless substances such as carbon dioxide and water. Current investigation uses the above principle to kill living organic germs, bacteria; pathogen, etc. from the cabin air in recirculation mode. A HVAC system has been developed by using a filter impregnated by titanium di-oxide (TiO2) with UV lights to improve and maintain cabin air quality. The developed system has been developed to kill virus, germs, pathogens and bacteria that typically exist in a conditioned space. The designed system can be used for conventional vehicles, EVs, ride sharing and for autonomous vehicles. Tests were conducted at a certified laboratory with MS2, a bacteriophage size of 0.027 microns. MS2 is a proxy for SARS-CoV-2, the virus that causes COVID-19 with a size of 0.125 microns. Effectiveness of the destruction rate was determined for the developed system. Detailed summary will be presented in the paper.
Mathur, Gursaran
This SAE Recommended Practice is intended for testing of external automatic brake adjusters as they are used in service, emergency, or parking brake systems for on-highway vehicle applications.
Truck and Bus Foundation Brake Committee
Enclosure-in-Chamber Setup to Achieve Near-Zero Background Concentrations for Brake Emissions Testing (SAE Paper 2020-01-1634)1278311/9/2020
Measuring brake emission continues to be a challenging non-standardized task. Extensive research is ongoing and as seen in the work in progress presented at SAE Brake Colloquium and PMP meetings. However, open items include how to achieve lower background concentration and how to design the brake enclosure. A low background concentration is essential as brake events are short and some emissions are in the range of reported background levels. Hence these emissions are difficult to distinguish from the background level. Even more critical, a high background concentration can result in a wrong particle number emissions value, either overestimated, background counted as emissions, or underestimated, background level subtracted, and low emission events no longer detected and counted. Reducing the background level to less than 100 #/cm3 appeared to be quite challenging. Applying experience in validating automotive air filters and in industrial HVAC filters, an enclosure-in-chamber setup was developed. The concept was adapted and implemented for the LINK 3900 dynamometer as for the outer chamber. The brake itself is placed in a rectangular enclosure with easy access to. Key enabler for a background level close to zero is the individual control of the inlet and outlet flow rates to this inner enclosure and an additional H13 air filter besides other (sealing) measures. The (outer) chamber of the LINK 3900 is run at negative pressure, to prevent emissions into the workplace, and the inner enclosure of the brake has a slight positive pressure to avoid particle intake through the gaps. The setup is presented in detail, including particle measurement (PM and PN) as used for measurements at LINK Limburg, Germany. This work discusses the results showing a background concentration of less than 10 #/cm3 measured with a TSI CPC 3756. This low level of background concentration is stable over the entire cycle time and has been observed for WLTP exhaust as well as the Novel braking cycle (WLTP- Brake Cycle).
J., Martin
Ultraviolet and Titanium Dioxide Based Photocatalysis HVAC System to Eliminate COVID-19 for Occupant�s Safety & Health in Automobiles1286711/9/2020
In a photocatalytic air purifier system, the catalyst that cleans the air is typically titanium dioxide and it is energized by ultraviolet (UV) light. UV is the short-wavelength light just beyond the blue/violet part of the electromagnetic spectrum that our eyes can detect. This shortwave-length light has much more energy than ordinary, visible light�and exactly the right amount of energy to get titanium dioxide excited. Titanium dioxide is a semiconductor that covers the filter surface. Just a thin film of titanium dioxide is required at the filter surface with a substrate. When UV light shines on the titanium dioxide, electrons (negatively charged particles inside atoms) are released at its surface. The electrons interact with water molecules (H2O) in the air, breaking them up into hydroxyl radicals (OH�), which are highly reactive, short-lived, uncharged forms of hydroxide ions (OH−). These small, agile hydroxyl radicals then attack bigger organic (carbon-based like virus) pollutant molecules, breaking apart their chemical bonds and turning them into harmless substances such as carbon dioxide and water. Current investigation uses the above principle to kill living organic germs, bacteria; pathogen,viruses etc. from the cabin air. A HVAC system has been developed by using a filter impregnated by titanium di-oxide (TiO2) with UV lights to improve and maintain cabin air quality. This system can be used for conventional vehicles with internal combustion vehicles; EVs and HEVs; vehicles with start-stop feature; and autonomous vehicles. The same concept designs can also be used for high occupancy transportation modes like taxis, buses, trains and airplanes. The author has designed and constructed a UV based photocatalysis system to kill germs, pathogens and bacteria that typically exists in a conditioned space. Tests were conducted at a certified laboratory with bacteria and virus in the conditioned space. Effectiveness of the destruction rate was determined for the developed system. Detailed summary will be presented in the paper.
Mathur, Gursaran
Enclosure-in-Chamber Setup to Achieve Near-Zero Background Concentrations for Brake Emissions Testing2020-01-163410/5/2020
Measuring brake emission continues to be a challenging non-standardized task. Extensive research is ongoing and as seen in the work in progress presented at SAE Brake Colloquium and PMP meetings. However, open items include how to achieve lower background concentration and how to design the brake enclosure. A low background concentration is essential as brake events are short and some emissions are in the range of reported background levels. Hence these emissions are difficult to distinguish from the background level. Even more critical, a high background concentration can result in a wrong particle number emissions value, either overestimated, background counted as emissions, or underestimated, background level subtracted, and low emission events no longer detected and counted. Reducing the background level to less than 100 #/cm3 appeared to be quite challenging. Applying experience in validating automotive air filters and in industrial HVAC filters, an enclosure-in-chamber setup was developed. The concept was adapted and implemented for the LINK 3900 dynamometer as for the outer chamber. The brake itself is placed in a rectangular enclosure with easy access to. Key enabler for a background level close to zero is the individual control of the inlet and outlet flow rates to this inner enclosure and an additional H13 air filter besides other (sealing) measures. The (outer) chamber of the LINK 3900 is run at negative pressure, to prevent emissions into the workplace, and the inner enclosure of the brake has a slight positive pressure to avoid particle intake through the gaps. The setup is presented in detail, including particle measurement (PM and PN) as used for measurements at LINK Limburg, Germany. This work discusses the results showing a background concentration of less than 10 #/cm3 measured with a TSI CPC 3756. This low level of background concentration is stable over the entire cycle time and has been observed for WLTP exhaust as well as the Novel braking cycle (WLTP- Brake Cycle).
Lehmann, Martin J.Beck, AndreasKohn, KevinPfannkuch, SteffenKilian, AlexanderKeller, FlorianWörz, TobiasZessinger, MarcoKlein, Gunnar-Marcel
Currently automotive sector is facing bi-fold challenge of light weighting and cost reduction. As end-customer is getting more focused on total cost of ownership, it is need of time that light weighting and cost reduction goes hand in hand. Presently lightweight materials such as magnesium, aluminum & composites are used but often this impact towards cost increase. In present study, a novel approach has been followed which not only focus on light weighting but also integrate design functions of two engine systems. This paper deals with the new system design to focus on low cost, light weight, NVH friendly and low development time. In design phase, function of two engine systems i.e. engine cover and Air filter were integrated followed by structural analysis. In final phase of this project, the experimental component was developed and validated for its intended function. In this study, current sheet metal design engine cover has been converted in to Thermoplastic cover with integrated Air filter. The complete engine cover with integrated air filter design has been validated at Test bed and Vehicle level for durability, performance, leakages, NVH. At end results were analyzed and compared. Results indicates that new design is a better solution over the existing design. The study demonstrates that this novel approach of light weighting and design function integration can achieve better performance while providing substantial cost saving and weight reduction.
Gadhave, Nitin SahebraoBhargava, AashishAttarde, UtkarshaPajgade, Sachin
Currently automotive design is facing multi facet challenges such as reduction in greenhouse gases, better thermal management, and low cost solution to market, vehicle weight management etc. Considering these challenges, efforts had been taken to improve weight management of engine while optimizing the cost of it. Good ‘engine breathing’ is usually associated with efficient intake system e.g. high flow air filter, a well-designed manifold, cylinder block, cylinder head and cylinder head cover etc. However, efficient ‘crankcase breathing’ is an equally important function of any engine. Even in a new engine, the combustion pressure will inevitably pass the piston rings into the crankcase. If an engine’s breathing system should become blocked or restricted, the crankcase will pressurize causing lots of problems to the engine. Prior to 1963 most vehicle engines vented their vapors and oil deposits to atmosphere and the road surface. With increasing environmental pressures positive crankshaft ventilation was introduced whereby the crankcase vapors were drawn up into the inlet manifold and, along with the air/fuel mixture, burned up in the combustion chambers. To enable this system to work safely and efficiently the ventilation from the crankcase is controlled via a PCV valve which can be integrated with the engine cylinder head cover. A cylinder head cover, particularly for covering a cylinder head of an internal combustion engine, having a plurality of functional elements such as an oil filling connection and at least one oil separation device mounted thereon. There are different materials can be used for cylinder head cover, but we have selected plastic material for engine weight reduction. This design change was successfully introduced on light duty diesel engine with newly featured three leap cylinder head cover gasket to ensure positive sealing of engine gases and engine lubricant.
Deshpande, Shirish MadanBhargava, AashishDhalait, SahilMusani, Ameel
Fuel cell technology can play a major role in reducing transportation-related emissions, especially in heavy-duty, long-haul applications. Consequent transfer of technology from air supply systems for combustion engines to cathode air paths serves as an enabler for necessary system cost reduction. To achieve the required system lifetime, the supply of clean air is essential. Gases like NOx, SO2 and NH3 poison the catalyst, leading to increased stack degradation rates. Effective removal with functionalized activated carbons enhances the catalyst´s lifetime. Research on real-life concentrations of these contaminants under different driving patterns and road profiles enables knowledge-based design of cathode air filter elements. To prevent flooding of components like air filter, humidifier, or stack, water separators are integrated at different position inside the system. Plastic air ducts with integrated sensors and flaps required to manage the air flow connect the different functional components. Broadband silencers are applied to reduce noises inside the system, e.g. generated by the compressor. Essential components like humidifier and air-cooler can easily be incorporated into the system. In the cathode air exhaust path, an additional water separator is applied to protect turbine blades and to prevent emission of splash water from the tailpipe. The consistent transfer of technology from air supply systems for combustion engines to cathode air paths enables cost-, noise and packaging-optimized, plausible system concepts with enhanced energy efficiency.
Harenbrock, MichaelKorn, AlexanderWeber, AndreasHallbauer, Eva
A Study on NVH Performance Improvement of TPE Air Intake Hose Based on Optimization of Design and Material2019-01-14916/5/2019
Environmental and fuel economy regulations (Eu 6d and WLTP RDE) on automobiles have been tightened recently. To counter this regulation, the global automobile industry is focusing on weight reduction, fuel efficient turbo charger, cooled EGR, thermal management, low friction and so on. However, the high-speed turbocharger makes turbulence, and resulting in airflow noise. This noise is transmitted indoor through the air intake system, which adversely affects the vehicle's competitiveness. Therefore, for turbo engine, it is essential to reduce the noise of the air intake system. The air intake system consists of air cleaner, air filter, air intake hose and air duct. The air flow noise of turbo-engine is mainly the emission noise emitted from the walls of air intake system. And the transfer path of turbo noise is in order of air intake hose, air cleaner and air duct. Therefore, it is effective to reduce the noise of the air intake hose located at the beginning of noise transfer path. In the past, rubber hoses with vibration and acoustic insulation were mainly used to reduce the emission noise of air intake hose, but these can’t be recyclable and have high density (heavy). To overcome these shortcomings, TPE hoses are being applied, which are lighter, more competitive, durable and recyclable than rubber hoses. However, the air intake hoses with thin bellows and rigid TPE material have less noise attenuation performance than rubber hoses, so need to be improved noise insulation performance. This paper describes how to improve the NVH performance by optimizing the bellows design of air intake hose related to mass (m) and stiffness (k) and developing high damping material (c).
Jung, HyunsooJin, JungkookPark, Jong MinJin, Yong Sun (Steven)Han, Won HeeKim, YounghaeGu, Yu
Filter Element Robustness Strategy for Mud Ingestion2019-01-09164/2/2019
Air filter elements have been around since the dawn of automotive development. The function of an air induction system and the filter element in particular is to remove particulates such as dust, soot, and relatively minor contaminants from the air flow. This protects the engine, turbocharger, and other components from wear. However, sometimes severe duty cycles may cause large amounts of dust, mud, and water to enter the air induction system (AIS). This can cause filter degradation and even rupture or deformation, leading to highly increased engine and turbocharger wear. One example of this extreme loading is the tar sands region of Alberta, Canada, where trucks can accumulate over 1000 pounds of mud on a vehicle during normal usage over a few weeks’ time. Significant amounts of this mud also get ingested into the AIS. This study attempts to analyze different aspects of filter design to increase robustness to severe usage, particularly mud. Different aspects studied are filter element structure, filter element media, inlet location, and inlet blocking. Traditional ISO 5011 tests would not replicate the mud aspect that was sometimes seen in the field. To get a repeatable laboratory measurement, the authors developed a new mud cycle for testing that alternates a water spray and normal ISO 5011dust injection to accumulate mud on filter elements until rupture or deformation, causing a bypass. This test showed similar results of deformation as was seen in Alberta. Using this testing process, various filter elements with varying design attributes such as media type, filter element sizes etc. are tested and compared. This study compares different filter elements and comes up with a relation between the different filter design attributes and mud testing performance. Knowing the design factors that play a significant role in affecting the performance would help to design better, mud enduring filter elements in the future. Concurrently, virtual simulations are performed on a couple of filter elements with significantly different design and inlet area to help compare the flow dynamics of mud and water particles. Flow simulation studies also validate the obtained testing results and aid in providing more design recommendations.
Emley, John L.Shrevatsan, VenkatesanNichols, Jon
Design, Simulation & Optimization of an Air Intake System to Reduce Induction Noise2019-26-01911/9/2019
Air intake system (AIS) plays a major role in reducing the noise level in passenger car compartment, which has become an important requirement due to increasing customer expectation for better in cab noise. The ideal air intake system design should have minimum possible noise at snorkel entry point which ultimately contributes in cabin noise. There are different techniques that are implemented for an air intake system noise reduction e.g. choosing proper location of air entry suction point in engine bay compartment, suitable design for air filter box (volume), duct designs etc. Further design improvement are possible with an addition of tuned resonators in the system. An addition of resonator have major effect seen in reducing air induction noise and to meet target Sound Pressure Levels (SPL). But at the same time, selecting the correct type of resonator, its position & volume, frequency/s band at which resonator is tuned are important parameters. The work presented here describes and compares the simulation results (GT POWER) with the measured SPL levels at different rpm range with different resonator types for Utility Vehicle (UV) as below, a Air intake system without resonator. b Multi-band resonator: resonator tuned for larger range of frequency band and requires more packaging volume. c Helmholtz resonator: resonator tuned for single frequency (for certain rpm at which peak observed) & requires less packaging volume. Based on the correlation developed between simulation and test results, the simulation models are useful for further refinement and proper selection of final optimum hardware. These simulation models are also further useful for future programs at design stage itself.
Patil, UjwalRahane, Dnyanesh
The range of test conditions on the dynamometer shall be sufficient to determine the primary operating characteristics corresponding to the full range of vehicle operations. The characteristics to be determined are: a Torque ratio versus speed ratio and output speed b Input speed versus speed ratio and output speed c Efficiency versus speed ratio and output speed d Capacity factor versus speed ratio and output speed e Input torque versus input speed NOTE: For more information about these characteristics and the design of hydrodynamic drives, refer to “Design Practices: Passenger Car Automatic Transmissions,” SAE Advances in Engineering, AE-18 (Third Ed.) or AE-29 (Fourth Ed.).
Automatic Transmission and Transaxle Committee
This SAE Aerospace Recommended Practice (ARP) provides recommended practices for cleaning aircraft oxygen equipment such as tubing, pieces, parts (including regulator and valve parts), cylinders and ground-based equipment that may be used to support aircraft oxygen systems. This revision introduces a cleanliness coding scheme that can be referenced as a requirement, and/or referenced to identify compliance to meeting such a requirement. These methods may apply to gaseous and liquid oxygen equipment. This document specifies work area details, methods to select suitable cleaning agents, cleaning methods, test methods to verify cleanliness level, and methods of packaging the components and parts after cleaning. Technicians designated to clean oxygen equipment must be qualified and trained to clean oxygen equipment. This ARP is applicable to metallic and non-metallic parts.
A-10 Aircraft Oxygen Equipment Committee
This SAE Aerospace Recommended Practice (ARP) contains guidelines and recommendations for subsonic airplane air conditioning systems and components, including requirements, design philosophy, testing and ambient conditions. The airplane air conditioning system comprises that arrangement of equipment, controls and indicators that supply and distribute air to the occupied compartments for ventilation, pressurization, and temperature and moisture control. The principal features of the system are: a A supply of outside air with independent control valve(s). b A means for heating c A means for cooling (air or vapor cycle units and heat exchangers) d A means for removing excess moisture from the air supply e A ventilation subsystem f A temperature control subsystem g A pressure control subsystem Other system components for treating cabin air such as filtration and humidification are included, as are the ancillary functions of equipment cooling and cargo compartment conditioning. The interface with the major associated system, the pneumatic system (Chapter 36 of ATA 100) is at the inlet of the air conditioning shutoff valves. This boundary definition aligns with that in the ATA 100 Specification.
AC-9 Aircraft Environmental Systems Committee
This SAE Aerospace Information Report (AIR) covers airbone particulate contaminants that may be present in commercial aircraft cabin air during operation. Discussions cover sources of contaminants, methods of control and design recommendations. Air quality, ventilation requirements and standards are also discussed.
AC-9 Aircraft Environmental Systems Committee
This specification covers standard requirements for reciprocating aircraft engines.
E-25 General Standards for Aerospace and Propulsion Systems
This SAE Aerospace Recommended Practice (ARP) outlines the basic general design requirements for ground support equipment used in the civil air transport industry. It is intended to assist in standardizing requirements for various configurations of equipment. For procurement of equipment, sections of this document should be specified with due consideration of the functional and environmental requirements of the equipment, and to the relative cost of satisfying those requirements.
AGE-3 Aircraft Ground Support Equipment Committee
The purpose of this SAE Recommended Practice is to establish a testing procedure to determine the performance capability of heavy duty vehicle cooling systems to meet Original Equipment Manufacturer or end user thermal specifications to ensure long term reliable vehilcle operations. The recommendations from the present document are intended for heavy-duty vehicles including, but is not limited to, on- and off-highway trucks, buses, cranes, drill rigs, construction, forestry and agricultural machines.
Cooling Systems Standards Committee
Many general purpose engines, such as the ones used in construction machines, operate in environments with excessive amounts of airborne dust, and are thereby equipped with a cyclone air cleaner so that they can remove as much dust from contaminated air streams in the engine. However, the compact general purpose engine is mainly a single-cylinder type, and the intake flow pulsates. Since the centrifugal action of the cyclone air cleaner under the intake pulsation changes according to the pulsation, it is difficult to enhance the dust separation performance. In this study, we aimed to determine a cyclone air cleaner factor with high purification performance even under the intake pulsation conditions of a general purpose engine. We have designed an ideal geometry for the cyclone air cleaner, which centrifugally separates dust during inhaling and discharges the centrifuged dust using positive pressure due to pulsation. A numerical calculation of the flow under the intake pulsation of this cyclone air cleaner was carried out, and the separation and discharge functions were analyzed. Accordingly, it was confirmed that although the swirling speed inside the cyclone air cleaner depended on pulsation, it demonstrated purification performance even under an intake pulsation by the dust discharge function. We have also found a method to operate the discharge function at the instant when the separation function is the strongest.
Takahashi, HirotoShinohara, Toshiki
Today, 99% of the two wheelers in India operate with carburetor based fuel delivery system. But with implementation of Bharath Stage VI emission norms, compliance to emission limits along with monitoring of components in the system that contributes towards tail pipe emissions would be challenging. With the introduction of the OBD II (On-Board Diagnostics) and emission durability, mass migration to electronically controlled fuel delivery system is very much expected. The new emission norms also call for precise metering of the injected fuel and therefore demands extended calibration effort. The calibration of engine management system starts with the generation of pre-calibration dataset capable of operating the engine at all operating points followed by base calibration of the main parameters such as air charge estimation, fuel injection quantity, injection timing and ignition angles relative to the piston position. Finally, the vehicle calibration is executed keeping drivability and compliance to legislative norms as prime requirements. The quality of the pre-calibration data and base calibration decides the number of iterations required to arrive at the final dataset that meets the emission targets. Currently, the pre-calibration data is ported from datasets belonging to engines of similar displacement calibrated before; as a result of which the data do not fit well at all engine operation points. This paper elucidates a model based approach that generates pre-calibration dataset closest in match to the dataset obtained after base calibration at engine dynamometer using limited measurement logs from the engine. This is achieved through modelling the system using identified geometrical information of the engine, intake and exhaust systems and then introducing the physics of engine operation into it. Using the geometrical information, MATLAB based models are built to calculate the critical parameters like pressure drop across air filter, resonant frequency of the Helmholtz resonator in the intake path, throttle and valve flow coefficients and friction torque. The output of these individual MATLAB models are then fed into a predictive model that estimates the combustion parameters. These in turn serve as inputs to a one dimensional engine model built in GT Suite which then predicts the air charge entering the cylinder, optimum ignition angles, brake torque and exhaust gas temperature at the manifold. A case study was done with a 200cc air cooled engine as reference, for which the outcome of the GT Suite model is compared against the actual calibration dataset. The model is found to predict the air-charge at an accuracy of 85%, optimum ignition angles within ± 4.5° CA, brake torque at 85% accuracy and exhaust temperatures within ±20° C.
Palackal, Rose Mary SimonKartha, Balagovind NandakumarRamachandran, KarthikeyanVijaykumar, SrikanthReddemreddy, Pramod
On-engine surge detection could help in reducing the safety margin towards surge, thus allowing higher boost pressures and ultimately low-end torque. In this paper, experimental data from a truck turbocharger compressor mounted on the engine is investigated. A short period of compressor surge is provoked through a sudden, large drop in engine load. The compressor housing is equipped with knock accelerometers. Different signal treatments are evaluated for their suitability with respect to on-engine surge detection: the signal root mean square, the power spectral density in the surge frequency band, the recently proposed Hurst exponent, and a closely related concept optimized to detect changes in the underlying scaling behavior of the signal. For validation purposes, a judgement by the test cell operator by visual observation of the air filter vibrations and audible noises, as well as inlet temperature increase, are also used to diagnose surge. The four signal treatments are compared with respect to their reliability as surge indicator and the time delay between surge onset and indication. Results show that the signal power in the surge frequency band has reasonably good properties as surge indicator. The normal Hurst exponent is problematic, since periodic vibrations from engine firing dominate the scaling behavior. Root mean square and the above mentioned scaling exponent do not measure vibrations caused by surge directly, but rather the reduction in housing vibrations due to the engine load drop. Nevertheless, it was found to be possible to design an indicator that gives good results based on the change in scaling behavior.
Kerres, BertrandCronhjort, AndreasMihaescu, MihaiStenlaas, Ola
Paccar has announced a new 12-speed automated transmission (AT) and column-mounted shifter to improve fuel economy and driver ergonomics in Peterbilt and Kenworth models in North America beginning in October. The transmission and shifter were jointly developed to provide a superior shifting experience while reducing weight. “The Paccar Transmission offers best-in-class performance, reliability and low cost of operation,” said Kyle Quinn, Peterbilt general manager and Paccar senior vice president. “With the availability of this innovative transmission, the proven MX-13 engine and the efficient Paccar Axle, the Peterbilt Models 579 and 567 can now be spec'd with the industry's most advanced proprietary drivetrain.”
Borst, Matthew
This SAE Aerospace Information Report (AIR) is intended as a guide toward standardization of descriptions and specifications of fluid contamination products.
AE-5B Aircraft and Engine Fuel and Lubricant Sys Components
This publication will be limited to a discussion of liquid and particulate contaminants which enter the aircraft through the environmental control system (ECS). Gaseous contaminants such as ozone, fuel vapors, sulphates, etc., are not covered in this AIR. It will cover all contamination sources which interface with ECS, and the effects of this contamination on equipment. Methods of control will be limited to the equipment and interfacing ducting which normally falls within the responsibility of the ECS designer.
AC-9 Aircraft Environmental Systems Committee
Passive, tuned acoustic absorbers, such as Helmholtz resonators (HR) and quarter-wave tubes, are commonly used solutions for abating the low-frequency tonal noise in air induction systems. Since absorption at multiple frequencies is required, multiple absorbers tuned to different frequencies are commonly used. Typically, the large size and multiple numbers of these devices under the hood is a packaging challenge. Also, the lack of acoustic damping narrows their effective bandwidth and creates undesirable side lobes. Active noise control could address all of the above-mentioned issues. Most active noise control systems use feedforward adaptive algorithms as their controllers. These complex algorithms need fast, powerful digital signal processors to run. To ensure the convergence of the adaptation algorithm, the rate of adaptation should be made slow. This might lower the effectiveness of the controller during the transients, e.g., a fast run up of the engine in an induction or exhaust noise control application. An alternative to the feedforward active noise cancellation is feedback-based active noise control. Feedback noise control strategies are more straightforward and computationally less demanding than adaptive feedforward schemes and thus can be programmed in less expensive micro-controllers rather than digital signal processors. Contrary to feedforward scheme where the microphone and speaker are located upstream of the air filter and thus subject to the environmental elements, in proposed feedback scheme, they are placed downstream of the engine air filter and are well protected. An active feedback noise control system is developed for an air induction system and its effectiveness demonstrated in a laboratory set up. A number of 2nd order filters programmed in a microcontroller were used to control the engine noise at multiples tones. The effectiveness of the actively controlled system matched or exceeded that of the traditional induction system with multiple passive acoustic absorbers.
Kashani, RezaJayakumar, Karthik S.Bugli, NevilleLapp, Jeff
A simulation approach to predict the amount of snow which is penetrating into the air filter of the vehicle’s engine is important for the automotive industry. The objective of our work was to predict the snow ingress based on an Eulerian/Lagrangian approach within a commercial CFD-software and to compare the simulation results to measurements in order to confirm our simulation approach. An additional objective was to use the simulation approach to improve the air intake system of an automobile. The measurements were performed on two test sites. On the one hand we made measurements on a natural test area in Sweden to reproduce real driving scenarios and thereby confirm our simulation approach. On the other hand the simulation results of the improved air intake system were compared to measurements, which were carried out in a climatic wind tunnel in Stuttgart. An estimation of the snow particle size and the snow mass flux on the two test sites was measured by a Snow Particle Counter (SPC). Our investigation shows that an Eulerian/Lagrangian approach can be used to predict the snow ingress. By using snow properties from the test sites as well as from literature, we observed a good agreement between the simulation results and the experiments. Our results also show that it is possible to improve the air intake system by using an Eulerian/Lagrangian framework. However, there are limitations due to the model applied for the particle-wall interactions and due to the fact that the snow particle density and especially the snow particle shape are not known from the test area.
Huber, ChristophWeigand, BernhardReister, HeinrichBinner, Thomas
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