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Automobiles of the future will be forced to travel further on a tank of fuel while discharging lower levels of pollutants. Currently, the United States uses in excess of 18 million barrels of petroleum per day. Sixty-six percent is used in the transportation of people and goods. Highway vehicles currently account for just under two-thirds of the nation's gasoline consumption, and about one-third of the total United States energy usage [1] while contributing a significant amount to the annual U.S. air pollutant burden. In 1997, 57.5% of the carbon monoxide, 29.8% of the nitrogen oxides, 27.2% of the volatile organic compounds, and 23.8% of the carbon dioxide came from highway vehicles [2] The U.S. government has supported R&D pertinent to highway vehicles since the early 1960's, to mitigate these problems.

In the increasingly complex and expensive arena of motor sport, data acquisition has become an essential tool of today's race engineer. With the limited budget and testing time available to most Formula SAE teams, a more effective data acquisition system, compared to off the shelf models, is needed. Therefore, a wireless data acquisition system was created to help improve the performance of the University of Calgary Formula SAE racecar. Our objective was to design and build a system that enabled the team to test and measure the vehicle performance in real-time. This live system will allow any race team to analyze the data prior to the car entering the pits allowing for appropriate modifications to be made at this time. This greatly reduces the number of pit stops and track time required to arrive at the optimum setup. The system has also been used as a driver aid.

A challenge of the maintenance engineering is to detect future failures and the wear in machine components without interrupting its operation. Doing it in a cheap and simple way is even more challenging. With this purpose, the present study collected the debris expelled in the exhaust pipe of an engine through an innovative device built in the Tribology Study Group of UFRN. It was tested a 5 HP stationary diesel engine working under constant load over 150 hours (non-continuous). The morphology and chemicals compounds of the debris collected by the device were analyzed using Scanning Electrons Microscope (SEM) and Energy Dispersive Spectroscopy (EDS), respectively. After the 150 hours of testing, the engine was disassembled and visually inspected. Photos were taken to identify the wear mechanisms present on the piston skirt, piston head, cylinder head and valves. After that, was made a correlation between the collected debris and the wear mechanisms observed in the piston.

During development of electronic products, several measurements are performed to ensure the electromagnetic disturbances are in such levels permitted by costumer requirements. Normally these tests are performed in certified laboratories. This usually causes high impact on timing plan and development costs. In order to reduce the time and cost involved on pre-compliance EMC tests, a Transverse Electromagnetic (TEM) cell was used as a tool for fast analysis of proposed design solutions during development of a brushless motor controller. The TEM was used as an Antenna to measure the electromagnetic disturbances (magnetic field) generated by the EUT (Equipment Under Test). A mathematical correlation between the voltage measured using the Antenna (TEM) and results found in a Certified Laboratory are compared and presented.

The reduction in the cost of drawing tools is of major importance in the production of small and medium series of shaped steel components. Usinor has therefore engaged studies of potential alternative materials for the manufacture of these tools. The solutions envisaged involve the elimination of metal machining operations, which currently represent more than 50 % of fabrication costs. However, because of the constraints associated with stamping, particularly as regards the mechanical strength and wear resistance of the tool surfaces, the studies have revealed of the need to conserve a metallic material at the tool surface. A new tool fabrication technique is therefore proposed, consisting of first electroforming a metallic skin and then casting the remainder using a hydraulic concrete.

Interactive driving simulation is attractive for a variety of applications, including screening, training and licensing, due to considerations of safety, control and repeatability. However, widespread dissemination of these applications will require modest cost simulator systems. Low cost simulation is possible given the application of PC level technology, which is capable of providing reasonable fidelity in visual, auditory and control feel cuing. This paper describes a PC based simulation with high fidelity vehicle dynamics, which provides an easily programmable visual data base and performance measurement system, and good fidelity auditory and steering torque feel cuing. This simulation has been used in a variety of applications including screening truck drivers for the effects of fatigue, research on real time monitoring for driver drowsiness and measurement of the interference effect of in-vehicle IVHS tasks on driving performance.

In the era of low cost product, enormous pressure to keep product development cost and time as low as possible. Durability verification and validation always consume big amount of product development cost and time. This paper gives low cost and quick, durability virtual verification which can be tested by running vehicle on track to check correlation. In this low cost durability verification, maximum stress levels on Frame and Cabin are generated analytically at all hot spot location based on finite element inertia relief analysis. Basic input load data is acquired by running proto type vehicle on track. Mathematical loading spectrum (Range Vs Cycle-Cumulative frequency distribution) for track is evaluated from acquired data. Stress spectrums are generated analytically for all hot spot locations based on mathematical load spectrum. Analytically component S-N curve for frame, cabin components with different slops [1,2] is generated based on material ultimate tensile stress values.

This paper presents the FEV low cost EV platform intended to provide a modular and scalable platform for 2 and 3 wheelers that is robust and meets the desired performance characteristics. To enable this, we use a dedicated vehicle control unit (VCU) that is running FEV’s matured model library called PERSIST. The platform makes use of the inherent advantage of being a small scale vehicle that can be used with lower sized components or reduced set of components without compromising on safety. The electric vehicle platform will have modularly developed components and associated software and hardware with standardized interfaces. The electric power train includes support for standardized lithium ion batteries and a low cost vehicle control unit. This is required to not only safe guard the system overall but also be able to optimize the driving range, enhance drivability and to provide the driver with a more stable and secure interface for operating the vehicle.

The Brazilian automotive market is growing, vehicle sales ranked in the 4th. global position only behind China, United States and Japan; more than 40% of Brazilian production are entry level vehicles. The use of air conditioning systems in those basic vehicles are increasing due to being also considered as a safety device, besides its original thermal comfort function. Since 2008 a partnership between Inmetro, CONPET and Petrobras established the adoption of an “energy seal” ranking of vehicles in respect to their fuel consumption; the newly introduced tax regime: Inovar-Auto establishes less taxation to more efficient vehicles. This and other environmental concerns are demanding the reduction of CO2 emissions. Due to cost restrictions, the A/C systems installed in those vehicles, in most of the cases, are too simple and inefficient.

The adoption of the newly developed self-standing grid construction allows a more flexible layout of the electrodes and location of the grids, while reducing the number of grid leads. These improvements make it possible to minimize the lead pitch and to increase the flexibility of the lead out position. For example, the leads of the new clip-on type displays will allow them to be condensed on one side of the display, while in the case of the ordinary Vacuum Fluorescent Displays (VFDs) the leads are located on both the top and the bottom. By connecting flat cables to the minimized leads, a clip-on VFD was successfully developed, which is excellent in terms of mounting flexibility, circuit maintenance, system cost and function. The manufacturing process and features of the clip-on VFD will be described later.

A two pedal drive device has been developped, using a standard dry clutch, an electric motor as an actuator and a microprocessor control. With the help of a compensator spring, a low power, low inertia motor with a fast response can be used. The control characteristic is basically a centrifugal law, with several modifications. Several sensors input information into the microprocessor and compensate for manufacturing tolerances and lining wear. The Electronic Clutch Control has been fitted to different cars and has given optimal results. It can be used in conjunction with manual transmissions, CVTs or other types of transmissions.

The cost of fuel control systems for small gas turbine engines is quite high and could be significantly reduced by simplifying the fuel metering system and bringing it under electronic control. Such an attempt has been made regarding the popular Bendix DP-F2 fuel control unit (FCU). Presently, the DP-F2 FCU is using a metering valve with a complex profile head, being moved in a calibrated orifice using double bellows operated by the compressor pressure. The differential pressure across the metering valve is controlled by a bypass valve fitted with a diaphragm which moves a shaped plunger inside a multi-orifice barrel. It is proposed to use a pressure balanced metering valve with a plunger moved in a slitted barrel by a stepper motor, which is changing the valve flow area according to the engine compressor pressure signal.

In the past, In-Circuit Emulations of single chip microcontrollers were accomplished by expensive emulators with elaborate development computers as drivers. This is no longer true with intelligent hardware design and the introduction of the Personal Computer (PC). This paper discusses two emulation tools for the MCS-96 family of 16-bit microcontrollers using a PC as it's host computer and minimal hardware design for almost a nonintrusive emulation tool for under $500.

Engine Monitoring System (EMOS) plays a crucial role towards engine safety and monitoring for low cost commercial vehicles not equipped with a full-fledged Engine Management System (EMS). The EMOS system mainly focuses on monitoring of coolant temperature, alternator belt failure, and lubrication oil pressure and coolant level indication This paper describes various engineering design considerations for balancing the application requirements with implementation costs. It also highlights some common pit-falls in detecting alternator failures leading to nuisance trips as well as system design considerations involved in matching the gauge indication accuracy with the coolant high temperature trip point. The system designer needs to take into account, difference between alternator belt slippage versus total belt failure condition and implement different control strategies accordingly.

The conception of new engines as well as the further development of those already existing, is influenced to an ever accelerating extent by the aspects of cost, besides the need for driveability, fuel economy and ecological conservation. For an independent engine manufacturer it is especially important to be able to offer products that, considering the competition in terms of performance, fuel consumption, exhaust emissions and noise levels, have favourable price ranges. The growing need for environmental preservation, in particular, has forced the introduction of normaly more expensive technology such as new injection and turbocharging systems. In relation to the criteria involved in minimising the production costs, this results in a conflict of objectives.

A low cost fault tolerant and redundant multiplex wiring system specifically designed for automotive applications is described in this paper. Although there are many multiplex wiring systems are being used to simplify the car wiring harness, but very few are low cost, fault tolerant and redundant at the same time. Most of the system address mainly the protocol and software issues and neglected the reliability of the multiplex wiring system. This paper addresses the fault tolerant and redundancy of the system and use hardware based integrated circuit to convert from parallel to serial at the transmitter side and serial to parallel at the receiver side.

Power-supply forms a key hardware block for every automotive ECU. Apart from delivering robust and reliable logic supply voltages it is also burdened with many auxiliary tasks like transient protection, good EMI/EMC performance, Power-hold function, Analog Sensor supply voltage etc. It also needs to meet all automotive norms including short to battery/ground etc. This paper discusses low cost implementation techniques which maximize the value delivered to the vehicle application at minimal cost. Innovative techniques are described for combining sensor and logic supplies wherever applicable. Hurdles faced during such circuit optimization are clearly explained along with the solutions adopted to overcome hurdles yet meeting automotive test norms. A novel low cost concept which combines transient protection as well as power-hold function (without using the conventional relay based technique) further adds value to the end application.

The application of hybridization technology is now widely regarded as a significant step forward to reduce fuel consumption and hence CO₂ emissions for ground vehicles. Many programs and much research has been done on these technologies in the automotive market, however little work has been done in the very cost sensitive market sector of the small motorcycle. This paper introduces and discusses the application of a low-cost hybrid technology to small motorcycles and scooters, and reviews some of the initial trade-offs through the use of a new hybrid simulation model developed at Cranfield University. The study being presented assessed the existing Energy Storage Systems (ESS) in the market. This list was reduced, omitting options which posed a clear safety or cost risk, or solutions which would disproportionally increased the Gross Vehicle Weight (GVW). Also omitted were storage options which could not be production ready in the near term, 3 - 5 years.

Integration of vehicle system components provides important cost and weight reductions, valuable space savings, etc. while maintaining reliability and performance. Clear Vision Safety is enhanced by combining the major components and functions of a vehicle windshield washer system. This new system integrates hot fluid windshield cleaning with the wiper motor and washer pump, which is adapted to the wiper linkage assembly. The components of the hot fluid windshield cleaning system (heating elements and advanced electronics) are combined with a unique motor with gearing capable of both 1) high torque output for driving the windshield wiper linkage, and 2) high speed output for pumping hot fluid onto the windshield. Motor and pump drive requirements and features are efficiently integrated into one electronic circuit for improved reliability and significant cost reduction.

A production calibrated GTDI 1.6L Ford Fusion was used to demonstrate low HC, CO, NOx, PM (particulate mass), and PN (particulate number) emissions using advanced catalyst technologies with newly developed high porosity substrates and coated GPFs (gasoline particulate filters). The exhaust system consisted of 1.2 liters of TWC (three way catalyst) in the close-coupled position, and 1.6L of coated GPF in the underfloor position. The catalysts were engine-aged on a dynamometer to simulate 150K miles of road aging. Results indicate that ULEV70 emissions can be achieved at ∼$40 of PGM, while also demonstrating PM tailpipe performance far below the proposed California Air Resources Board (CARB) LEV III limit of 1 mg/mi. Along with PM and PN analysis, exhaust system backpressure is also presented with various GPF designs.