Ricardo Alternative Power Plant News

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Ricardo Information Services Alternative Powerplants News August 2003

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RICARDO INFORMATION SERVICES

ALTERNATIVE POWERPLANTS NEWS

AUGUST 2003

A monthly bulletindedicated to

fuel cell, hybrid electricand other alternative powerplants,

common issues, components,marketing

and industry news

byMartin Ward


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CONTENTS

Page

5. FUEL CELLS5. Fuel Cell Cars5. Buses6. Common Issues in Fuel Cells6. Fuel Cell Components7. Fuel Cell Fuel Economy7. Other Fuel Issues

10. HYBRID ELECTRIC VEHICLES10. Commercial Vehicles

10. Buses10. Common Issues in Hybrid Vehicles11. Control11. Batteries12. Fuel Consumption12. Transmissions13. Steering

14. FUEL CELL HYBRID ELECTRIC VEHICLES14. Buses

15. MILD HYBRIDS15. Cars

16. BATTERY ELECTRIC VEHICLES16. Vans

17. OTHER ALTERNATIVE POWERPLANTS17. Unconventional I.C. Engines18. HCCI

23. COMMON ISSUES IN ALTERNATIVE POWERPLANTS23. Motors for Alternative Powerplants23. Electromagnetic Compatibility23. Fuels for Alternative Powerplants24. Transmissions for Alternative Powerplants


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Notes

Alternative Powerplants News is a monthly newsletter, published by the Ricardo Information Services

Department. It summarizes the published literature on hybrid, fuel cell and other alternative powerplants,mainly for automotive applications.

Items included in this publication are based on literature received by the Ricardo Library in July. Entriesmay contain additional information on products covered in earlier editions.

Copies of the source documents may be obtained by quoting the Library reference, which appears in boldat the bottom of each article.Items not published in English may be translated by Ricardos TranslationService, on request. An additional charge would be made for these services.

Other services offered by Ricardo Information Services include:

New Engine News - A newsletter covering new and modified engines

Transmissions News - A newsletter covering new and modified transmissionsComponents News A newsletter covering i.c. componentsVehicle Engineering News A newsletter covering brakes, chassis, steering gear and other

vehicle components, themes and issuesPOWERLINK -A database containing abstracts of engine and vehicle articlesEMLEG - A database of Worldwide exhaust emission legislationForthcoming Conferences An updating service of interest to all users of our other servicesSubject Update Service A monthly round-up of POWERLINK articles on specific topics

For further details of these and other Ricardo services, please contact:

Roland Christopher, Information Manager, Ricardo Consulting EngineersTel. +44 (0)1273 794230, email: [email protected].

In the USA, please contact:

Paul Cassidy, Vice President of Business Development, Ricardo Inc.Tel. +1 (0) 734 394 3713, email: [email protected].

Any comments on this newsletter, or items for inclusion in future issues, will be gratefully received by theEditor, Martin Ward, at [email protected].

Ricardo has used reasonable endeavours to ensure that the information supplied in this service is correct.However, no responsibility or liability can be accepted for any errors or omissions. Entries in thispublication do not imply endorsement of any product or service by Ricardo.

Ricardo plc. 2003


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FUEL CELLS

Fuel Cell Cars

Honda.

Honda has developed an emission-free clean power train employing fuel cells. This power train has beenfitted in the Honda FCX fuel cell vehicle. The new power train is made up of a combined pure hydrogenfuel cell stack and Ultra capacitor system. The new power train has raised the energy efficiency of theFCX also has higher fuel economy than a HEV, and superior acceleration from a standstill to a gasolineinternal combustion engine vehicle.

See Doc.122198 pp9-12 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 29-03, EV/HEV/FCEV - Vehicle Systems, Paper 20035207.)(In Japanese.)

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General Motors.

Larry Burns, General Motors Vice President of Research, Development and Planning, makes thestatement with total assurance: "We believe that this vehicle is approaching the true reinvention of theautomobile. We would like you to drive it". The vehicle in question is GM's Hy-Wire, a by-wire-controlled,fuel-cell-powered, advanced-technology demonstrator that has no foot pedals, an aircraft-style yokeinstead of a steering wheel, and a spacious interior that takes simplicity to a new level.Covers - hydrogen, fuel-storage system, traction system, electric components, onboard reformers.Gives driving impressions.

See Doc.122057 (Automotive Engineering International, Apr 2003, pp105-108.)______

From Japan.

Toyota and Honda plan to produce about 30 fuel cell vehicles each in the coming two to three years,expanding their customer bases to Japanese and American municipal agencies and "selected" fuel cellrelated research organizations and industry members.Covers - Nissan X-Trail FCV with lithium-ion secondary battery system, Toyota RAV-4 FCV, PEM fuelstacks, Lexus LS4 30, RX330 SUV FCVS, Toyota fuel cell hybrid vehicle, Honda FCX with type 902 fuel-cell stack from Ballard.

See Doc.122072 (Automotive Engineering International, Mar 2003, pp54-56 & 58.)____________________________________________________________________________________

BusesMercedes-Benz Citaro city bus.

The first fuel cell powered Mercedes-Benz Citaro city bus has been delivered by DaimlerChrysler, in aceremony to the Lord Mayor of Madrid, Spain in early May.The 12-m long buses have a range of approximately 200 km (125 miles) and a top speed of 80 km/h (50mph) and offer capacity for up to 70 passengers, depending on individual bus operators' specifications.Ballard is supplying the 205 kWe fuel cell engines, while Calgary-based Dynetek Industries is supplyingthe on-board hydrogen fuel storage systems, in which hydrogen is stored at 350 bar (5000 psi) in roofmounted cylinders.

See Doc.122079 (Fuel Cells Bulletin, Jun 2003, p1.)


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Common Issues in Fuel Cells

Waseda University Environmental.

The objective of the present studies are to develop a new power system achieving both higher efficiencyas well as a compact and lightweight body for fuel cell vehicles which have been the focus of the world'sattention as the new type of vehicle. In this paper, the recent trends of R&D and examination of fuel cellvehicles in foreign countries are reported.Gives an overview of fuel cell vehicles from GM, DaimlerChrysler, Ford, VW, Opel and Peugeot.

See Doc.122259 (Engine Technology, Jun 2003, pp23-29.)(In Japanese.)____________________________________________________________________________________

Fuel Cell Components

Capacitors Honda.

An electric double-layer capacitor has been developed an an energy storage device for a fuel cell vehicle.Due to this packaging the unit and developments of the electrode and the electrolyte display the world'shighest level of performance for a capacitor cell, with a specific power of more than 1400W/kg and aspecific energy of 3.9Wh/kg. The new module system is equipped with a capacitor cell protection systemand cooling systems.Covers ultra capacitor.

See Doc.122198 pp5-8 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 29-03,EV/HEV/FCEV - Vehicle Systems, Paper 20035120.) (In Japanese.)

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Hydrogen Sensor - NGK Spark Plug.

A limiting current type hydrogen sensor using polymer electrolyte has been developed for hydrogenconcentration measurement in reformed gases of PEFC. The sensor output controlled by the circuitdesigned for the sensor was linearly proportional to hydrogen concentration. The model gas testsdemonstrated that the influences of coexisting gases such as H20, CO2, CH4, CH3OH temperature andpressure on the sensor output were small. In addition, fuel utilization calculated from outputs of sensorsinstalled into anode inlet and outlet well-corresponded with that calculated from cell current of a single cell.

See Doc.122191 pp1-4 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No.19-03,FC & HEV, Paper 20035076.) (In Japanese.)

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Fuel processors - University of California.

This paper focuses on a methanol fuel processor using steam reformation of methanol to generate thehydrogen required for the fuel cell stack. Since the steam reformation is an endothermic process thethermal energy required is supplied by a catalytic burner. Through the use of a model for the fuelprocessor, comprising of detailed models for the reformer, burner and CO cleanup units, we investigatethe performance of the fuel processor from the viewpoints of efficiency and transient performance. Inparticular, the model can generate results in terms of a) steady state efficiencies b) response to transientstep inputs c) efficiency and dynamics in the context of its use in a fuel cell vehicle under standard drivingcycles.

See SAE 2003-01-0810 (2003, 12pp.)


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Deionized water system - Dana Corporation and General Motors.

Deionized (DI) water is being used for humidification and cooling on some fuel cell designs. This highly

purified water is corrosive, yet the high purity is required to maintain the function and durability of the fuelcell. A study of the deionized water system was undertaken to determine the effect of various materials onwater quality, and also to determine the effect of deionized water on each material. The test setup wasdesigned to circulate fluid from a reservoir, similar to an actual application. The fluid temperature,pressure, and flow rate were controlled. The resistivity of the water was observed and recorded. Pre- andpost-testing of the water and the materials was performed. The goal is to achieve system cleanliness anddurability similar to a stainless steel system using lighter, less expensive materials. This paper describesthe test setup, test procedures, and the overall results for the eight materials tested.

See SAE 2003-01-0804 (2003, 15pp.)______

Stack seals - Dow Corning Corporation

The economic viability of PEM Fuel Cells for transportation uses requires significant reduction in the costof assembling and sealing the PEM stack. Additionally the stack sealing system or method must last thelife of the stack, and is often used to enhance the structural strength of the stack and provideperformance-enhancing functionality.This paper discusses PEM fuel cell stack sealing manufacturing and assembly methods. Methodsexamined include; die-cut gaskets, fabricated press in place, insert moulded designed profile, dispensedand other advanced sealing concepts.Advantages of silicone elastomers in PEM fuel cell stack sealing include resistance to degradation,inertness to leaching, adhesion and other silicone processing advantages.

See SAE 2003-01-0801 (2003, 9pp.)____________________________________________________________________________________

Fuel Cell Fuel EconomyJARI.

Fuel cell vehicles have been developed and demonstrated on the road in recent years, but test methodsfor fuel economy have not yet been established. The purpose of this study is to standardize simple andaccurate methods of measuring fuel economy. For study purposes, the following test methods areproposed: electric current method, pressure method, weight method and flow method. Although requiringonly a simple equipment and capable of transient measurement, electric current method is unsatisfactoryin accuracy. Pressure method and weight method proved satisfactory in accuracy; however, their systemsneed to be simplified for practical use. This paper deals with the possibility for application and relatedissues for each of these test methods.

See Doc.122191 pp5-8 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No.19-03,FC & HEV, Paper 20035073.) (In Japanese.)____________________________________________________________________________________

Other Fuel Issues

JFE Container Co.

Many automobile manufacturers have announced compressed hydrogen fuel cell vehicles in these severalyears, and many projects are promoted in Japan, US and Europe. Furthermore, the standardization of thedesign and evaluation method regarding the compressed hydrogen fuel container are examined. Thedesign requirements and the evaluation method regarding the compressed hydrogen container for fuel cellvehicles are explained.See Doc.122258 (Engine Technology, Jan 2003, pp43-45.) (In Japanese.)


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NTSEL, Gunma University and Kokushikan University.

This paper covers our investigation into a decline in fuel cell (FC) performance resulting from hydrogen

fuel containing impurities. This is a serious problem in case of adopting the methanol or gasolinereforming approach as a means of supplying fuel to FCs. The results are summarized as follows:components of the gas generated by the reformer adopting the steam reforming and auto thermalreforming approach were predicted and specific components and concentrations were identified; variousexperiments and analysis were conducted to determine the adverse effect of CO, CH4, HCHO andHCOOH poisoning on the performance of FC.Covers - proton-exchange membrane fuel cell (PEMFC).

See Doc.121930 (JSAE Review, Jan 2003, Paper No. JSAE 20034006, pp41-46.)______

Honda.

A compressed gas system previously utilized in natural gas vehicles (NGV) was utilized in the HondaFCX. Rapid filling tests of the high-pressure hydrogen tanks of both Type 3 (Aluminum liner) and Type 4(High Density Polyethylene) were carried out using compressed hydrogen gas. Type 3 tanks showedbetter performance. This result can be explained in terms of the difference in heat diffusion coefficientbetween aluminum and HDPE.

See Doc.122198 pp13-16 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 29-03, EV/HEV/FCEV - Vehicle Systems, Paper 20035208.) (In Japanese.)

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Society of Automotive Engineers of China.

As a competitor with the internal combustion engine, fuel cell has been highly regarded by carmakers

more than ever. This paper firstly evaluates the meaning of developing fuel cell from the point of view ofboth energy structure and environment protection. It also describes the current status of the fuel cell car.Secondly, the paper introduces the frame of the hydrogen supply system, equipment selection, safetymeasurement and standard for using hydrogen.

See Doc.122199 pp29-32 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 30-03, Component for EV/HEV, Paper 20035452.)

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Nissan and Nippon Oil.

The preliminary experiments for reforming of a series of gasoline components and oxygenates for fuelcells have been conducted. Aromatics and olefins showed some effects on catalysts deterioration.

Oxygenates showed better reactivity than hydrocarbons. The enhancement of reforming was observed byblending MTBE with naphtha. It has been concluded that zero-sulphur, low aromatic, low olefin and lightcomponent is most suitable as hydrocarbon-type FC fuel.

See Doc.122191 pp9-12 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No.19-03,FC & HEV, Paper 20035162.) (In Japanese.)

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McDermott Technology.

Start-up and transient response of on-board fuel processors for fuel cell vehicles continues to be asignificant challenge. McDermott Technology, Inc. under co-sponsorship of the US Department of Energyhas developed an integrated, catalytic auto thermal fuel processor for automotive applications. The fuelprocessor system is designed to deliver 50-kWe (equivalent) reformate gas suitable for use with a PEM


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fuel cell. The system design includes several features that enhance system response and serve to reducestartup time. A dynamic process simulation model of the autothermal reformer and shift vessels wasgenerated using ASPEN process simulation software. Startup and transient response tests were

conducted on the fuel processor and results compared favourably to the model predictions. Sensitivitystudies indicated that the minimum warm up time given the current design is 15 minutes which isunacceptable for automotive applications. Some simple modifications to the system, such as usingmonolith catalysts and automating the controls, could significantly reduce the warm up time.

See SAE 2003-01-0807 (2003, 7pp.)


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HYBRID ELECTRIC VEHICLES

Commercial VehiclesHino Motors.

The hybrid system for the collection and delivery light-duty truck was developed. This hybrid system hasadvanced the miniaturization lightening to make it apply to the light-duty truck to say nothing of improvingthe exhaust gas decrease and fuel cost as a chief purpose. The hybrid method adopted a parallel hybridsuitable for the light-duty truck. The ultra-thin three-phase AC induction motor/generator was put in theflywheel housing, and a small inverter of new development and a small nickel metal-hydride battery wereadopted. Consequently, exhaust gas was able to be decreased to new short-term emission regulation by50% and fuel cost was able to be improved by comparison with a conventional truck by 25% or more.

See Doc.122191 pp17-20 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No.19-03, FC & HEV, Paper 20035246.) (In Japanese.)____________________________________________________________________________________

BusesAllison Transmission.

Allison Transmissions, a division of General Motors, began development of electric drive systems in 1989by working on GMs EV1 Electric Car Programme.The Allison Electric Drives EP Parallel Hybrid Electric System has been developed for use in commercialtrucks and buses. The system has two models: the EP40, which is appropriate for 11-12m buses, and theEP50, which can operate in 18m articulated buses.The Ep System is a 600V nominal system, and has maximum output performance with an energy storagesystem of 298 kW (400 hp). Major components include: a reciprocating engine, Ev drive unit, dual powerinverter module (DPIM), system controller, Allison energy storage system.

See Book 9414 R3: p121 (MIRA New Technology 2002.)

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Sawa Fuji Electric Co, and Waseda University, Okobu Gear and Toyo Radiator.

NCB21 (Next generation City Bus) is the joint research and development meeting of the manufacturers,the government offices, and the university named above.In this paper, we performed the driving simulation in case of carrying to the city route bus of SHEV (serieshybrid electric vehicle) type. The paper evaluates the drive performance and comparison with the presentbus in the city driving modes.

See Doc.122199 pp11-16 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 30-03, Component for EV/HEV, Paper 20035154.) (In Japanese.)____________________________________________________________________________________

Common Issues in Hybrid VehiclesFiat.

This paper presents and examines Hybrid Powertrains architectures and technologies trends with a viewto enabling the mass production of hybrid vehicles in the near future (5 to 10 years).Correspondingly two families of Hybrids can be identified: hybrids with thermal engine assisted by anelectric motor, and hybrids with electric traction assisted by an engine driven electric generator.Depending on how electric motors and engines are interconnected, two basic hybrid architectures arederived: parallel hybrid (PHE) in which both electric motor and engine, through an appropriate mechanicallink, are connected to the traction wheels, series hybrid (SHE) in which only the electric motor isconnected to the traction wheels; the thermal engine drives an electric generator that supplies the electricmotor through an electrical connection.See Doc.122046 (ATA, Mar/Apr 2003, pp78-80, 82-86 & 88-89.)


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ControlNissan.

We propose a new hybrid electric vehicle (HEV) control system using car navigation information. This

system controls the charge and discharge of the battery according to the traffic condition and roadinclination information along the route proposed by the car navigation system. The fuel consumptioneffectiveness of the proposed control system has been confirmed using actual traffic and road conditiondata.

See Doc.122198 pp1-4 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 29-03,EV/HEV/FCEV - Vehicle Systems, Paper 20035175.) (In Japanese.)

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Ricardo.

The authors have been investigating energy management using algorithms that continuously optimiseenergy flows of vehicle powertrain. These are functions of performance demands, battery state of charge,

emissions requirements and system efficiency. I gains in efficiency become possible from flexibility inengine operating point through the operation of electric drive and intelligent use of ancillary systems.I authors have applied this approach during development of the I-MoGen mild hybrid diesel vehicle. Inthis paper they extend this approach to Diesel Particulate Filter regeneration strategies and further toinclude integration with telematics systems.Covers V-SIM simulation library.

See Doc.122199 pp17-22 or Listing 1570 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003,Session No. 30-03, Component for EV/HEV, Paper 20035002.)

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JATCO.

JATCO is developing an electric hybrid drive system called an integrated hybrid automatic transmission(IHAT). In the IHAT system, an internal combustion engine, a motor-generator and an automatictransmission without a torque converter are connected to the three members of a planetary gearset. TheIHAT is similar to an integrated starter generator (ISG) system, but is shorter in length and provides betterfuel economy.This paper describes the structure and functions of the IHAT and explains the control system used tomaintain smooth driveability.Covers automatic engine start-stop, creep capability, vehicle start-off, fuel economy improvementobtained with IHAT, power performance obtained with IHAT, IHAT jerkiness problem and its resolution.

See Book 9417 OC:A4B: pp55-60 (Global Powertrain Congress 2002 - Advanced Transmission,Drivetrain Systems, Sep 2002, Volume 21.)____________________________________________________________________________________

BatteriesNissan and National Defense Academy.

Proposes an innovative estimation method for internal states of a rechargeable battery as follows. First,describes the charge-discharge characteristic of a lithium-ion battery as a linear parameter varying (LPV)model, and then applied an up-to-dated adaptive-digital-filter theory to it. Estimated varying internal statesof a battery (open voltage, internal resistance, time constant, and so on) recursively. Finally thesecalculated states enabled us to estimate the state of charge (SOC), and the dischargeable or acceptablepower accurately, which are necessary to fully utilize the battery power on the vehicle.Covers hybrid vehicle, adaptive control.(In Japanese.)See Doc.122199 pp5-10 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 30-03, Component for EV/HEV, Paper 20035031.) (In Japanese.)


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Toyota and Denso.

Have developed a high performance lithium-ion battery for vehicles. The newly developed battery was

applied to the Toyota Intelligent Idling Stop System set up to Vitz Intelligent Package. Prominent featuresof the battery are high output power density at a lower temperature and good cycle/storage performances,which are achieved by improvement of various materials and structures. This paper describes R&Dconcepts and specifications of the battery.Covers - idling stop, hybrid vehicle.

See Doc.122191 pp21-23 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No.19-03, FC & HEV, Paper 20035104.) (In Japanese.)____________________________________________________________________________________

Fuel Consumption

National Traffic Safety and Environment Laboratory and Gunma University.

To realize energy-saving vehicles, this paper examines heavy duty hybrid vehicle fuel consumption andthe impacts of power train components parameters. Both series and parallel power train systems arediscussed. The energy flow among the engine, motor, battery and system efficiency are analyzed usingfull vehicle simulation. Different configuration, hybridization, control strategy, regeneration ratio andrunning modes are compared with their impact on vehicle fuel consumption. It is found that the fueleconomy improving way and potential is different for different power train. A best fuel consumption ratioof 0.45 is obtained from simulation by parallel power train.

See Doc.122199 pp23-28 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 30-03, Component for EV/HEV, Paper 20035422.)

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Industrial Technology Research Institute and Shibau Industrial University.

Linear regression method that estimates fuel consumption without energy increase/decrease condition inrechargeable energy storage system is expected as a practical fuel consumption test method for hybridvehicles. Factors to affect the test accuracy had been studied in the last two reports, and the practical testprocedure to obtain adequate accuracy with practical short test time has been proposed in the last paper.In this report, the validity of the proposed test procedure has been verified by comparing the results of theproposed test procedure to the statistical results obtained by enough tests. Results show that the linearregression method does not always lead to suitable process to estimate the fuel without SOC change.

See Doc.122199 pp1-4 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 30-03,Component for EV/HEV, Paper 20035185.) (In Japanese.)

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TransmissionsToyota.

In June 2001, Toyota Motor Corporation developed the Toyota Hybrid Systems-CVT (THS-C) for mini-vans. A new transaxle developed for the front drive unit of the THS-C system is compact, lightweight andhighly efficient. The unit achieves excellent driving comfort with smooth speed change by CVT controland provides high-level driving power control by wet multiple disc clutches.Gives - cross section of transaxle, cross section of oil pump unit.

See Doc.121921 (JSAE Review, Jan 2003, Paper No. JSAE 20034017, pp109-116.)


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SteeringMichelin and Clemson University.

A need exists to investigate the dynamic behaviour of various steering systems for hybrid vehicles in

terms of platform steering characteristics and power consumption. In this paper, empirical and analyticalmathematical models will be presented for power (e.g. hydraulic, electric and steer by wire) rack andpinion steering units. The influence of chassis, tyre-road interface and steering system non-linearities areintroduced. Representative numerical results will be presented and discussed to investigate a vehicle'stransient response for each steering system configuration.

See Doc.121992 (I.Mech. E. Proceedings, Part D, Journal of Automobile Engineering, 2003, Vol. 217, No.D5, pp349-361.)


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FUEL CELL HYBRID ELECTRIC VEHICLES

BusesToyota.

In collaboration with HINO Motors, Ltd, Toyota Motor Corporation has developed the "FCHV-BUS2", anon-step fuel cell powered hybrid bus that runs on high-pressure hydrogen. In order to improve thevehicle efficiency, the optimal electric power distribution system between the fuel cell and the secondarybatteries was proposed in addition to the use of energy regenerated during braking. Consequently, thevehicle efficiency of FCHV-BUS2 became approximately double the performance of diesel enginepowered bus.

See Doc.122198 pp17-20 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 29-03, EV/HEV/FCEV - Vehicle Systems, Paper 20035215.) (In Japanese.)


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MILD HYBRIDS

Cars

Ford and IAV.

This paper describes the design optimisation of an Integrated Starter-Generator (ISG) powertrain for apassenger car, focusing on the development of an advanced powertrain operation strategy. Theoptimisation targets for the operation strategy are low fuel consumption and low emissions.The described method is based on offline simulations and uses Design of Experiments (DoE) tools. Thesimulations were performed with the Simulink based software Advisor, a program for longitudinal vehicledynamics simulations. In the scope of the project, Advisor was modified such that planned simulationscould be carried out automatically. DoE was used to desigh the simulation experiments, to evaluate theresults and to determine the optimal settings for the operation strategy.In the first part, the vehicle and the starter generator systems as well as the analytic operation strategy arepresented. The second part describes the optimisation of the operation strategy via DoE.The influence of two ISG systems on vehicle emissions is investigated and compared. It is shown for both

ISG systems that with heuristic control strategies, emissions reductions can be achieved by introducingengine stop/start and regenerative braking functionality.With DoE, and with assumptions on model interrelationships, only those simulation experiments wereplanned and conducted which are actually required for model estimation.Uses a DI, common rail, 1.6-litre diesel engine of power output 81 kW. Compares belt-driven andcrankshaft-mounted ISGs.

See Book:9437 BVW:A4B: pp167-184 (Haus der Technik - 2nd conference on Design of Experiments inengine development, Berlin, 2003.)


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BATTERY ELECTRIC VEHICLES

VansAzure Dynamics and Manganese Bronze.

Canadian firm Azure Dynamics Corporation and UK-based Manganese Bronze Holdings Plc, through itssubsidiary purpose-built taxi manufacturer London Taxis International (LTI), have agreed for Azure tosupply electric and hybrid electric powertrains for a new multipurpose urban delivery vehicle that will beready to deliver to customers in 2005.

See Doc.122249 (Hybrid & Electric Vehicle Progress, 1 Jun 2003, p7.)


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OTHER ALTERNATIVE POWERPLANTS

Unconventional I.C. EnginesFEV variable compression ratio.

DOE as an integral component of engine developmentDesign of Experiments is used today throughout the whole engine development. Starting from a simplephase model of the development process the application of this methodology will be demonstrated anddiscussed.Covers gas exchange simulation, gas emissions, calibration, engine optimization (1.8-litre, 4-cyl, VCRvariable injection ratio engine) engine speed, load, knock, fuel economy.

See Book:9437 BVW:A4B: pp111-118 (Haus der Technik - 2nd conference on Design of Experiments inengine development, Berlin, 2003.) (In German.)

________

University of Calgary.

The paper employs a quasi-dimensional two-zone model for the operation of SI engines when fuelled withhydrogen. In this approach, the engine combustion chamber at any instant of time during combustion isconsidered to be divided into two temporally varying zones: a burned zone and an unburned zone. Themodel incorporates a detailed chemical kinetic model scheme of 30 reaction steps and 12 species, tosimulate the oxidation reactions of hydrogen in air. A knock prediction model, developed previously for SImethane-hydrogen fuelled engine applications (Shrestha and Karim 1999(a) and 1999(b)) was extendedto consider operation on hydrogen. The effects of changes in operating conditions, including a very widerange of variations in equivalence ratio on the onset of knock and its intensity, combustion duration,power, efficiency and operational limits were investigated. The results of this predictive approach wereshown to validate well against corresponding experimental results of our own and those of others,obtained mostly in a variable compression ratio CFR engine. On this basis, the effects of changes in someof the key operational engine variables, such as compression ratio, intake temperature and spark timing

are presented and discussed. Some guidelines for superior knock free-operation of engines on hydrogenare made also. Covers - modelling SI engine performance including knock (MEPIK)

See CD ROM 143 Paper ICES2003-0548 (ASME ICE Division 2003 Spring Technical Conference,Salzburg, Austria, Session - Fuels & Combustion, 8pp.)

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Colorado State University.

The topic of this paper is the simulation of the airflow characteristics of a large bore two stroke natural gasfuelled engine. The modelling was performed with the program WAVE, a computer code developed forengine cycle simulations. The engine studied was a four cylinder Cooper GMV engine. This engine has anarticulated crankshaft connecting even and odd bank cylinders. Due to the articulation, the even bank

cylinders have different piston profiles, port profiles, and compression ratios than the odd bank cylinders.

See CD ROM 143 Paper ICES2003-0552 (ASME ICE Division 2003 Spring Technical Conference,Salzburg, Austria, Session Engine Design, 6pp.)

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Ford Motor Company and University of California-Riverside.

Hydrogen Internal Combustion Engine (H2ICE) powered vehicles have been considered a low emission,low cost, practical method to help establish a hydrogen fueling infrastructure. However, the naturallyaspirated H2ICE operating lean has performance issues requiring either increased displacement orinduction boost to have comparable power to the modern gasoline powered IC engine. Ford ScientificResearch Laboratory has continued its H2ICE system investigation, conducting dynamometer engine-boosting experiments utilizing a 2.0 L Zetec engine (with compression ratios of 14.5:1 and 12.5:1), and a


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2.3 L Duratec HE-4 engine (with a compression ratio of 12.2:1) with boosted manifold air pressure up to200 kPa. Test data of brake torque and exhaust emissions are reported at various boost pressures.Results of a detailed NOx study, conducted at University of California Riverside, with EGR and

aftertreatment for a naturally aspirated 2.0 L Zetec engine are also reported. The trade off between enginecompression ratio and thermal efficiency, power density, and NOx emission control strategy is discussed.

See SAE 2003-01-0631 (2003, 13pp.)____________________________________________________________________________________

HCCINagoya Institute of Technology.

Ignition characteristics of natural-gas oriented gaseous fuels, which can be simply represented by ignitiondelays of the fuel/oxidizer mixtures, were examined precisely by using a rapid compression machine asthe first step. For the non-cool-flame generating methane, n-butane mixed with it as a supplementary fuelacts as a more intense ignition promoter than methane or propane, even though its octane rating is similar

and almost as high as the commercial gasoline. Lean fuel/air mixtures with various fuel/fuel ratiosbetween methane and n-butane were supplied to a premixed compression-ignition engine (i.e.homogeneous charge compression ignition engine, HCCI) with or without supplementary gaseousformaldehyde induction as an ignition control additive as the second step. In the no additive case themethane and butane function as the two fuels in the high/low octane two-fuel premixed compression-ignition operation we proposed previously as another ignition control procedure. The formaldehydeaddition to the methane/butane/air mixtures has given the engine desired and stable ignition timingscontrollable by the amount of formaldehyde to be added, almost independent on the fuel/fuel ratiosbetween methane and butane. The efficacy of formaldehyde has been confirmed as an ignition controlmedium for the piston-compression ignition of hydrocarbon/air mixtures.

See CD ROM 144 pp31-48 (3rd Dessau Gas Engine conference, Dessau, Germany, May 2003.)______

RWTH and FEV.

Cyclic variations in the combustion process of gas enginesDescribes the nature and causes of cycle-by-cycle variations in gas engines, in terms of knock andmisfires. Control solutions are explored.Covers - ignition, combustion, open combustion chambers, HCCI, divided chambers, lean/richcombustion, pilot ignition.Uses a combination of these measures depending on engine function and operating conditions.Recommendations are given.

See CD ROM 144 pp49-64 (3rd Dessau Gas Engine conference, Dessau, Germany, May 2003.)(In German.)

______

Volvo Car Corporation and Chalmers University of Technolog.

Operating an engine in homogeneous charge compression ignition (HCCI) mode requires the air fuelmixture to be very lean or highly diluted with residuals. This is in order to slow the kinetics down and toavoid too rapid heat release. Consequently, the operational window for the engine in HCCI mode is not thesame as for the engine operating in spark ignited (SI) mode. Homogeneous charge compression ignitionengine mode, in this study, is accomplished by trapping residual mass using variable valve timing.This study reports the development of a mode change strategy for a single cylinder camless engine, andits successful implementation in a camless multi-cylinder engine. It was found that the operation in the firstcouple of cycles following a mode change deviate markedly from the steady state operation in the newmode, therefore the control parameters during the change have to be optimized. The influence of the

residual mass fraction and the intake valve closing as control parameters are investigated. Both single


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cylinder and multi cylinder mode changes from un-throttled SI combustion (generated with early intakevalve closing) to HCCI combustion (generated with negative valve overlap) and vice versa wereinvestigated.

See SAE 2003-01-0753 (2003, 9pp.)______

Tianjin University.

This paper presents a compound combustion technology of Premixed Combustion and Lean DiffusionCombustion for realizing the concept of HCCI combustion in a DI diesel engine. The premixedcombustion is achieved by the technology of multi-pulse fuel injection. The start of pulse injection,injection-pulse number, injection period of each pulse and the dwell time between the injection pulses arecontrolled. The objective of controlling the pulse injection is to limit the spray penetration of the pulseinjection so that the fuel will not impinge on the cylinder liner, and to enhance the mixing rate of each fuelparcel by promoting the disturbance to the fuel parcels. The last or main injection pulse is set around

TDC. A flash mixing technology is developed from the development of a so-called BUMP combustionchamber, which is designed with some special bump rings. The combustion of fuel injected in the maininjection proceeds under the effect of the BUMP combustion chamber at much higher air/fuel mixing ratethan does in a conventional DI diesel engine, which leads to lean diffusion combustion. The effects ofmulti-pulse injection and BUMP combustion chamber on auto-ignition, rate of heat release and engineemissions are discussed.

See SAE 2003-01-0741 (2003, 12pp.)______

Lund Institute of Technology.

This paper discusses the effects of cooled EGR on a turbocharged multi cylinder HCCI engine. A six

cylinder, 12 litre, Scania D12 truck engine is modified for HCCI operation. It is fitted with port fuel injectionof ethanol and n-heptane and cylinder pressure sensors for closed loop combustion control. The effects ofEGR are studied in different operating regimes of the engine.In this case the effects of EGR on boost and combustion duration and phasing are of primary interest. It isshown that CO, HC and NOx emissions in most cases all improve with EGR compared to lean burn.Combustion efficiency, which is computed based on exhaust gas analysis, increases with EGR due tolower emissions of CO and HC.

See SAE 2003-01-0743 (2003, 19pp, 34 refs.)______

Hokkaido University.

Direct injection of various ignition suppressors, including water, methanol, ethanol, 1-propanol, hydrogen,and methane, was implemented to control ignition timing and expand the operating range in an HCCIengine with induced DME as the main fuel. Ultra-low NOx and smokeless combustion was realized over awide operating range. The reaction suppressors reduced the rate of low-temperature oxidation andconsequently delayed the onset of high-temperature oxidation. Analysis of the chemical kinetics showed areduction of OH radical in the premixed charge with the suppressors. Among the ignition suppressors,alcohols had a greater impact on OH radical reduction resulting in stronger ignition suppression. Althoughwater injection caused a greater lowering of the temperature, which also suppressed ignition, the strongchemical effect of radical reduction with methanol injection resulted in the larger impact on suppression ofoxidation reaction rates.

See SAE 2003-01-0746 (2003, 14pp.)


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SCANIA and KTH.

Homogeneous Charge Compression Ignition, HCCI, has the attractive feature of low particulate and low

NOx emission combined with high efficiency. The principle is a combination of an Otto and a Dieselengine in that a premixed charge is ignited by the compression heat.One of the main challenges with the HCCI combustion system is to control the combustion timing/phasingfor varying load and external conditions. A method to achieve this on a cycle-by-cycle basis is to vary thevalve timing based on a feedback signal from the combustion timing of previous cycles.A combined engine and control simulation is performed.The results show that combustion phasing successfully can be controlled by aid of variable valve timingduring varying external conditions. Engine tests describing the control performance achieved in initialexperiments are reported. Net Indicated Mean Effective Pressure, net IMEP, of up to 5.6 bar has beentested. The work described forms the basis for further studies of HCCIcontrol.

See SAE 2003-01-0748 (2003, 16pp.)

______

AVL.

Two compression ignition/combustion models were studied for gasoline HCCI engine auto ignition andcombustion with 3D CFD code FIRE. The calculation results were validated with the experimental dataobtained in a single cylinder HCCI research engine under various operating conditions. Detailed chemicalreaction model showed good agreement with the experiment. In addition, a reduced chemical reactionmechanics model demonstrated its potential for practical engineering purpose such as investigating theimpact of valve timing strategies on HCCI engine characteristics with a modern 4 valve engine. CoversCHEMKIN, SENKIN, AVL CIS (Compression Spark Ignition).

See Doc.122231 pp13-17 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 44-

03, Basic Technologies for Controlled Gasoline, Paper 20035137.) (In Japanese.)_______

The high potential of Controlled Auto Ignition with gasoline engines - to combine excellent fuel economywith extremely low engine-out emissions - is already known from various basic research approaches. Thereal challenge, however, is the practical application under real world operating conditions and typicalproduction constraints. The Controlled Auto Ignition System AVL CSI was designed in view of minimumchanges to existing production engines, large volume production feasibility and cost effectiveness. Whilekeeping the fuel economy benefit of lean unthrottled operation, the CSI reduces by a partially variablevalve train and a cylinder pressure controlled EMS the NOx engine out emission towards such anextended, that future emission limits will be met even without DeNOx catalyst. Covers stratified chargeengine, HCCI, variable valve timing optimization, engine control, combustion control, AVL CSI(Compression and Spark Ignition, EHVA (Electro Hydraulic Valve Actuation). (In Japanese.)

See Doc.122232 pp11-15 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 45-03, Applications of Advanced Gasoline Combustion, Paper 20035121.)

______Chiba University.

A production two-stroke schnurle-type gasoline engine was modified to enable compression ignition byboth port fuel injection and in-cylinder direct injection. Using this device, examination of compressionignition operation conditions and engine performance tests were carried out. As a result, direct injectionwas found superior to port injection in exhaust gas emissions and fuel efficiency, and some interestingcombustion characteristics, such as shorter combustion period in higher engine speed were also found.

See Doc.122232 pp17-20 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No. 45-

03, Applications of Advanced Gasoline Combustion, Paper 20035212.) (In Japanese.)


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University of Wisconsin-Madison.

Bulk gas temperature in an HCCI engine was measured using a novel optical sensing technique. A

wavelength-agile absorption sensor using a fibre-coupled LED was used to measure the in-cylinder gastemperature. H2O absorption spectra spanning 1380-1420 nm were recorded once every 63 s using thissensor. The gas temperature was inferred from a least-squares fit of the integrated absorbance areas ofH2O absorption features in this spectral region to those from simulated spectra. The primary source of theH2O was the humidity in the intake air. Measurements were made during the compression and earlyportion of the combustion phase of an n-heptane fueled HCCI engine. The measured pressure-temperature history was compared to kinetic calculations of the ignition delay, and showed the traversal ofthe negative temperature coefficient regime.Covers Wavelength-agile absorption spectroscopy of water vapour.

See SAE 2003-01-0744 (2003, 11pp.)______

Brunel University.

The effects of Air/Fuel (A/F) ratios and Exhaust Gas Re-Circulation (EGR) rates on Homogeneous ChargeCompression Ignition (HCCI) combustion of n-heptane have been experimentally investigated. Theexperiments were carried out in a single-cylinder, 4-stroke and variable compression-ratio engineequipped with a port fuel injector. Investigations concentrate on the HCCI combustion of n-heptane atdifferent A/F ratios, EGR rates and their effects on knock limit, engine load, combustion variability, andengine-out emissions such as NOx, CO, and unburned HC. Variations of auto-ignition timings andcombustion durations in the two-stage combustion process are analyzed in detail. Results show that HCCIcombustion with a diesel type fuel can be implemented at room temperature with a conventional dieselengine compression-ratio. However, its knock limit occurs at very high A/F ratios, although high EGR ratescan be tolerated. It was also found that auto-ignition timings or start time of both the low- and high-temperature combustion stages of diesel HCCI combustion are very sensitive to EGR rates. But

combustion durations dominantly depend on the A/F ratios. Since the combustion temperature is very low,NOx emissions is at near zero ppm level among all attainable operating regions. However, HC and COemissions are high and increase with incomplete combustion caused by misfire.

See SAE 2003-01-0747 (2003, 17pp.)______

Nissan Motor.

A gasoline-fueled homogeneous charge compression ignition (HCCI) engine with both direct fuel injectionand negative valve overlap for exhaust gas retention was examined. The fuel was injected directly into theresidual in-cylinder gas during the negative valve overlap interval for the purpose of reforming it by usingthe high temperature resulting from exhaust gas recompression. With this injection strategy, the HCCI

combustion region was expanded dramatically without any increase in NOx emissions which were seen inthe case of compression stroke injection. Injection timing during the negative valve overlap was found tobe an important parameter that affects the HCCI region width. The injection timing also had the mostsuitable value in each engine load for the best fuel consumption.

See SAE 2003-01-0749 (2003, 11pp.)______

Sandia National Laboratories.

A combined experimental and modeling study has been conducted to investigate the sources of CO andHC emissions (and the associated combustion inefficiencies) at low-loads. Engine performance andemissions were evaluated as fueling was reduced from knocking conditions to very low loads for a variety

of operating conditions, including: various intake temperatures, engine speeds, compression ratios, and a


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comparison of fully premixed and GDI (gasoline-type direct injection) fueling. The experiments wereconducted in a single-cylinder engine (0.98 litres) using iso-octane as the fuel. Comparative computationswere made using a single-zone model with the full chemistry mechanisms for iso-octane, to determine the

expected behavior of the bulk-gases for the limiting case of no heat transfer, crevices, or chargeinhomogeneities.

See SAE 2003-01-0752 (2003, 25pp, 40 refs.)


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COMMON ISSUES IN ALTERNATIVE POWERPLANTS

Motors for Alternative Powerplants

Aisin.

We have developed permanent magnet assisted synchronous reluctance motor (NynR motor) usinginexpensive permanent magnet (ferrite magnet) for a drive motor of an electric vehicle (EV) or a hybridelectric vehicle (HEV). The objective of this development is to reduce the motor cost by utilizingreluctance torque without using expensive magnet (NdFeB magnet). We confirmed the developed motoris applicable by the test result when the motor performance is adapted to the system specification withhigh speed. Such motor design and evaluation results are shown in this paper. Further, we alsointroduced the comparison with a switched reluctance motor (SR Motor) which we have been developingseparately.

See Doc.122191 pp13-16 (JSAE 2003 Annual Congress, Yokohama, Japan, May 2003, Session No.19-03, FC & HEV, Paper 20035136.) (In Japanese.)

____________________________________________________________________________________

Electromagnetic CompatibilityMIRA.

Current European legislative electromagnetic emissions requirements, described in the automotive EMCdirective 95/54/EC, are based on broadband quasipeak and narrowband average emissions as measuredusing an antenna at a fixed point relative to the vehicle.A programme of measurements was therefore conducted on a small set of representative electric vehiclesin order to quantify the emissions of such vehicles, and to investigate the associated practicalmeasurement issues.A number of representative alternative powertrain vehicles were selected for test, including: two differentelectric vehicles; two different hybrid electric vehicles, a fuel cell van, an electric bus, and electric step-

through motorcycle.

See Book 9414 R3: pp209-210 & 212 (MIRA New Technology 2002.)____________________________________________________________________________________

Fuels for Alternative PowerplantsBP.

Gives an overview of winners to the BP GreenFleet awards and includes details of all entrants.Ricardo won a certificate of Innovative Excellence for the i-MoGen hybrid project.

See Doc.121994 (Abbey Publishing, 2003, 74pp.)______

Bosch.

Gasoline and diesel engines will remain the dominant power sources in passenger cars for a long time with a market share above 95 percent until 2015, and still holding 85 percent by 2025. This was theforecast presented by Bernd Bohr, member of the Board of Management of Robert Bosch GmbH, at aninternational automotive press briefing recently held by the Stuttgart-based automotive supplier.But how do internal combustion engines compare with fuel-cell drives? Bohr answered this question byconsidering the whole degree of efficiency from well to wheel. The fuel cell is admittedly extremely efficientengine specific, but the provision of the required hydrogen is extremely complicated. This makes theoverall degree of efficiency only slightly higher than that of the diesel engine. Bohr did a cost-benefitanalysis of the fuel cell again in direct comparison to classic drives. For a compact car to reduceemission of carbon dioxide by one percent, diesel and gasoline engines require additional costs of aboutone percent. For a hybrid drive, the ratio is twice as much and for the fuel cell, it comes to about four times


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that amount.

See Electronic Document 2576. (Downloaded from the Internet, Bosch website, Jun 2003, press

release, PI 4182 My/Li, 2pp.)____________________________________________________________________________________

Transmissions for Alternative PowerplantsYokohama University.

This paper describes design principle and performance of a newly developed bi-directional traction drivereducer with clutch function for an electric-motor power train. Configuration of the reducer is similar to aplanetary type, but the loading through the wedge roller mechanism is quite different from the conventionaltype. The wedge roller controls not only the Hertzian pressure of the traction contact in proportion totransmitting torque, but the free running of output shaft by retracting itself from the orbit.

See Doc.121959 (Transactions of the JSAE, Apr 2003, Paper 20034184, pp67-71.) (In Japanese.)

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