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Open Technology Forum
Situated right in the heart of Engine Expo North America, the Open Technology Forum is FREE to attend and features the latest technologies, concepts, and business-related presentations from many of the world’s leading experts in powertrain design, development, manufacture, logistics, and marketing.
Topics will include: • Emissions reduction • Downsizing • Hybrid powertrains • Alternative fuels • Engine testing • Component materials and surface treatment • Super/turbocharging • Transmissions
Day 1
Tuesday 23rd OctoberModerator - Leonid Moroz, president and CEO, SoftInWay Inc, USA
10:15 -
A downsized and sequentially boosted engine concept for fuel economy
Stephen Bowyer,manager, Light-Duty Engine Design & Thermodynamics,FEV Inc, USA
FEV continually develops advanced powertrains in order to push future technologies on the basis of lower fuel consumption and improved emissions without sacrificing vehicle performance. The company has recently developed a sequential turbocharged, small-displacement, direct-injected gasoline engine to meet these goals using its state-of-the-art development tools and processes. This presentation reviews the features and performance results of the engine and identifies its role in meeting future CAFE standards.
10:40 -
North America transmission market outlook
David Petrovski,principal analyst,IHS Automotive, USA
In this presentation a North America-focused transmission market outlook will be presented. A review of technology adoption drivers will set the stage for where key transmission technologies such as CVTs, DCTs, and higher-ratio automatics are going through 2020. Then we will step into key OEMs to analyze the types of transmissions they will deploy by vehicle segment.
11:05 -
Dearman Engine: ultra-high yield thermal energy recovery system
Jeremy North,CFO,Dearman Engine Company Ltd, UK
About two-thirds of the fuel energy input to an internal combustion engine is converted into heat energy. This energy is currently rejected to the environment. The Dearman Engine offers the opportunity to convert wasted engine heat (including even the easily accessible low-grade heat from the radiator) into additional shaft power. It has the potential to do this at very high efficiency because the cycle starting temperature is very low (-196°C). Practical conversion efficiencies of radiator coolant waste heat to shaft power as high as 50% could be achievable. The presentation will cover technology background, development, and applications.
11:30 -
Development of the compact high-efficiency rotary diesel combustion engine
Dr Alexander Shkolnik,president & CEO,LiquidPiston, USA
LiquidPiston developed the High Efficiency Hybrid Cycle, which has ideal thermodynamic efficiency of 75% at moderate compression ratios (18:1). To embody this cycle, the company has been working on new engine architectures, with a focus on rotary engines. After several years of research and development, and consideration of dozens of different rotary engine architectures, the company has converged on the X engine, which will be described in detail in this talk. Aside from executing the HEHC cycle, the engine is selected for its simplicity and, most importantly, sealability. The engine has the potential to achieve 2 HP/Lb and >50% efficiency.
11:55 -
Advancements of ANSYS IC engine software and GDI engine verification
Dr Saeed Jahangirian,technical engineer,ANSYS, Inc., USA
The new IC engine tool provides fast pre-processing of various engine geometries and a state-of-the-art workflow to obtain cold flow solutions with capabilities to include spray and reactions. This presentation will reveal the latest advances and developments in ANSYS IC engine technology. Brief details on the new technology will be discussed, and areas from which the engine community can significantly benefit, such as in performing high-performance computations, will be highlighted. Computational results will be compared with detailed experiments on a GDI SI engine with a compression ratio of 12 at 1000rpm and 2000rpm. The results will provide best practices on achieving high-fidelity, robust IC engine solutions.
12:20 -
Development of the 2.0-liter Boxer engine for Subaru BRZ
Nobuo Kyotoku,manager, Engine Design Department, Subaru Engineering Division,Fuji Heavy Industries Ltd, Japan
A brand-new FA20 engine was developed exclusively to be fitted in the Subaru BRZ. The basic construction comes from FB20, a former unit developed as the Subaru’s third-generation four-cylinder naturally aspirated Boxer engine. To achieve both high horsepower and environmental friendliness, which is highly demanded for the new-generation sports car, the engine adopted technical changes such as Toyota’s D-4S system and main components changes for high engine revolution speed to produce higher output. Also the height of the intake and exhaust parts was restrained to meet the BRZ packaging.
12:45 -
Development of integrated turbocharger and engine matching software
Leonid Moroz,president and CEO,SoftInWay Inc, USA
The engine is a positive displacement device whereas the turbocharger is aerodynamic turbomachinery. These two machines have distinctly different flow characteristics, and properly sizing a turbocharger for an engine is a rather complicated process. In general, the process of matching an engine and the turbocharger is accomplished based on prior experience instead of using a reliable and robust calculation methodology, which is tedious and time-inefficient. This costly process is certainly reducible if both the engine and turbocharger could be modeled as an engineering system. Here, a tool intended to improve turbocharger engine matching processes is presented.
13:10 -
Chain cam drive efficiency optimization and comparison to belt drives
Fenton O'Shea,senior engineer,BorgWarner Morse TEC Ithaca , USA
James Sisson,senior engineer,BorgWarner Morse TEC Ithaca , USA
In response to customer push for overall engine efficiency, improvements to timing drive system efficiency have been identified and qualified. Layout geometry, system tuning, and material investigations have been included in this effort. Through the use of chain drive dynamic simulation and motored engine testing, clear evidence of the success of these design optimization strategies is shown.
13:35 -
Perfection of engine block honing on agile/flexible CNC machining centers
David Chobany,vice president,Bates Technologies LLC, USA
The presentation will inform process engineers of the latest technological advancements in honing engine block cylinder bores and powertrain components. It will highlight the precisely engineered tooling and gauging system designed to produce bores with the tightest bore size and shape tolerances, and demanding surface finish and bearing surface call-outs. It will also discuss the minimization of capital expenditures and floor-space requirements by the utilization of this advanced honing technology on agile and flexible machining platforms including horizontal and vertical machining centers. This breakthrough will also allow for the use of common control logic and spare parts as well as internal control of operation and maintenance costs.
14:00 -
The Miller and Scuderi Split-Cycle: the perfect match
Stephen Scuderi,vice president and patent attorney,Scuderi Group, USA
This presentation will explain how incorporating what is known as the Miller Cycle into the Scuderi Split-Cycle engine configuration can make it possible to achieve considerable gains in both fuel efficiency and power output.
14:25 -
OSVP: open-source vehicle project
John Burton Rogers Jr.,CEO/president,Local Motors, USA
Local Motors has pioneered a new way to integrate a wide variety of engine technologies rapidly into multiple chassis configurations. Through the use of an online open design platform local motors has significantly reduced the time and cost of design and development for a new vehicle system at low-volume (<5000 units annually).
14:50 -
ESS radial lip seal technology answers CO2 and friction reduction challenge
Dr Alexander Berdichevsky,director R&D,Freudenberg NOK Sealing Technologies, USA
The requirement to reduce CO2 emissions and improve vehicle fuel economy forces engineers to look at every source of parasitic frictional losses. Currently used sealing technologies provide a satisfactory function but introduce an unwanted effect – frictional losses, which sometimes could be quite significant. There is only so much room for the torque minimization of existing designs without degrading the sealing performance. ESS seals do not employ springs, thus reducing radial load and therefore friction. However, this leads to multiple challenges related to performance and durability. All these challenges have been successfully met with ESS sealing technology.
15:15 -
Gamma Ti alloys for turbine wheel performance optimization
Cameron May,director,GfE Materials Technology Inc, USA
Gamma titanium aluminide alloys are available commercial solutions for commercial turbocharger turbine wheel application. Pilot volumes of gamma Ti wheels are being produced and tested. Such wheels are half the weight of present nickel-based components. Weight reduction in this key propulsion subsystem provides carbon footprint reduction to the vehicle. Static vehicle weight reduction is minimal but cascading benefits of this material provide significant virtual weight reduction. A vehicle equipped with this material provides a reduced carbon footprint equal to a vehicle which must be lower in weight without Gamma Ti alloys to achieve the same footprint.
15:40 -
Synergy of main technologies supporting downsized engine
Dr Sroka Zbigniew,academic staff,Wroclaw University of Technology, Poland
The presentation will show individual and mixed relationships between engine technologies supporting the combustion processes for downsized engine. This includes charging, variable valve timing and variable compression ratio. Some parameters and factors of operating cycles will also be plotted versus downsizing index.
*This program may be subject to change
Day 2
Wednesday 24th OctoberModerator - Alexander Berdichevsky, director R&D, Freudenberg NOK Sealing Technologies, USA
10:15 -
Low-friction coatings for highly stressed engine components
Marc van der Sommen,sales director Automotive,Ionbond, Netherlands
Due to stricter emission standards every year, engines must be more and more fuel efficient. One measure is downscaling. Due to downscaling by maintaining engine performance, the load on critical components increases enormously. In order to ensure the lifetime functioning of the component, heat treatment alone is no longer enough. Ionbond DLC coatings protect components for wear and give them low friction properties at the same time.
10:40 -
Hydrogen infrastructure to support hydrogen fuel cell vehicle deployment
Mark Schiller,VP business development,Proton OnSite, USA
Hydrogen is a powerful option to improve the environment, boost economic competitiveness, and increase energy security. It can be derived from multiple sources, such as water electrolysis, natural gas reforming, biomass, coal gasification, biological hydrogen production, and thermochemical cycles. Most of these sources are available in large amounts domestically and many are renewable. This presentation will examine the use of water electrolysis to provide hydrogen for the developing fuel cell vehicle market and its impact on the environment, economic competitiveness, and energy security. In addition, advantages of electrolysis in deployment of hydrogen fueling stations will be reviewed.
11:05 -
Use of AVTC to advanced hybrid vehicle technology
Prof Zachariah Chambers,associate professor ME,Rose-Hulman Institute of Technology, USA
The use of Advanced Vehicle Technology Competitions (AVTC) in the undergraduate curriculum has helped advance hybrid vehicle technology by creating the next generation of engineers who enter the workforce as immediate producers and rapid risers. Headline sponsored by GM and the DoE, these three-year competitions follow a vehicle development process that includes modeling and simulation, mule vehicle deployment, and vehicle verification, validation, and optimization. Students are challenged to convert a stock vehicle into a hybrid electric to decrease petroleum consumption and emissions production while maintaining performance, utility, and safety.
11:30 -
Boosting systems for highly downsized direct-injection spark-ignition engines
Tom Reedy,chief engineer – Efficient Performance,Lotus Engineering, USA
Greg Banish,technical specialist - Engine Calibration & Control,Lotus Engineering Inc., USA
The Ultraboost project seeks to develop a highly pressure-charged, downsized, spark-ignition engine that’s capable of a 35% reduction in tailpipe CO2 emissions over a naturally aspirated 5-liter V8 while maintaining performance, emissions, and transient response.
11:55 -
Electric vehicle charging technology today and tomorrow
Stuart Irwin,president,Evolution Electric Vehicle Systems, USA
Review the present status of EV charging infrastructure and vehicle battery charging power demands. Discuss the future changes and interaction with the Smart grid deployment.
12:20 -
EA211 Volkswagen’s new small engine family
Oliver Schmidt,General Manager, Engineering and Environmental Office,Volkswagen Group of America, Inc., USA
With its new engine family Volkswagen was able reduce CO2 emissions by up 20% and weight by up to 30% and adopt new technologies to the portfolio of 4 Cylinder engines. In this presentation you will see the details behind this new engine and its modularity.
12:45 -
Lubricious ceramic coatings for linerless Al and Mg engine bores
Dr Xueyuan Nie,professor,University of Windsor, Canada
The auto maker is striking to minimize engine friction lose and weight. Reducing the friction of cylinder bore and piston assemblies is a great deal for advanced engine development in fuel economy and low emission. The presentation will report on a lubricious ceramic coating as a unique material alternative method to currently used bore materials including cast-iron liner, Alusil and PTWA coatings for weight or friction reduction. Compared with existing bore surface technologies, the lubricious coating on A356 Al and AJ62 Mg cylinder bores was shown to have an ultra-low coefficient of friction during tribo tests, particularly at high load conditions.
13:10 -
Efficient software techniques for mandatory vehicle onboard diagnostics implementation
Dwight Hansell,VP Business Development,Pi Innovo, USA
The presentation will describe software and techniques that enable systems developers implementing mandatory OBD to focus on fault detection algorithms without having to develop fault handling interfaces. The complexity of this task has grown rapidly over the years, with successive legislative requirements for the management of onboard diagnostics data. The continuing developments in hybrid and alternative fuels powertrain technologies translate directly into considerable engineering effort to implement OBD-compliant systems. The OBD Infrastructure software platform recently released by Pi Innovo can significantly reduce the effort required to meet diagnostics requirements and scan tool communication protocols based on CARB, EPA, and EURO standards.
13:35 -
Shedding light on light
Patrick McGowan,VP business development,Performance Assembly Solutions, USA
Shedding Light on Light gives a historical perspective on MMCs in the automotive and defense marketplace, outlining previous misgivings and how science worked through the issues with assistance from major universities to render a far superior product to Boeing, NASA and beyond.
14:00 -
Liquid gaskets help to enable light-weighting initiatives
Matthew Boback,Senior Application Engineer,Henkel Corporation, USA
As vehicles move to reduce the overall weight in an effort to improve fuel economy and reduce overall costs, plastic components are being introduced to replace traditional metal substrates. With improved adhesion properties of liquid formed-in-place gasket sealants, plastic oil pans can now be sealed with methods long used on metal substrates. This process reduces the overall weight and cost of the engine, giving manufacturers increased flexibility in design.
14:25 -
Low-voltage hybridization for affordable fuel economy and driveability
Nicholas Pascoe,chief executive officer,Controlled Power Technologies Ltd, UK
This presentation considers the development of low-voltage (<60V) modular hybridization solutions, evolving from stop-start systems at 12V to low-cost mild hybrid systems at 48V, to achieve improved fuel economy and driveability from conventional powertrains. Recent focus has been on extending the performance envelope at 48V of CPT’s SpeedStart product, a belt-driven integrated starter generator, for transient recuperation and torque assist, with careful attention to thermal management of the electronics and windings. The status of CPT’s TIGERS product, an exhaust gas-driven turbine generator, is also discussed.
14:50 -
A new era in batteries: Polymer Lithium Sulphur
Dr Mark Crittenden,customer brand manager,OXIS Energy, UK
We have developed a new battery electrochemistry called Polymer Lithium Sulphur. The technology has a number of key advantages over existing technologies, including superior specific energy and excellent safety levels.
15:15 -
Successful case study: metal to plastic conversion of throttle bodies
Michael Kole,president,Pinnacle Sales LLC, USA
Since 2003 Helvoet has been engaged in the advancement of materials in engine technology, specifically for use in replacement of machined aluminum housings. After nine years and over 10 million components Helvoet will present the advancements in this technology, including the major improvements in materials, process, quality, and costs. Included will be the successes and challenges, as well as lessons learned and a roadmap for the future. This is a case study from development through delivery, highlighting the advantages of metal to plastic conversion for any and all components within the engine and powertrain system.
15:40 -
An experience of selection of engine for new assembly unit
Vijaya Bhaskar Sirimalla,director,UBE Automotive Limited, India
The selection process for a new engine is crucial. This paper outlines a conceptual approach to the selection of an automotive engine for a new assembly line, to be established when several alternative models are available.
*This program may be subject to change
Day 3
Thursday 25th OctoberModerator - Paul Fricker, business development manager, Grainger and Worrall Ltd, UK
10:15 -
Casting and casting processes for 2015 onward
Paul Fricker,business development manager,Grainger and Worrall Ltd, UK
Synopsis to follow
10:40 -
Developing drivetrain robustness for small engine testing
Marek Tatur,director of operations,FEV Inc, USA
The downsizing efforts result in engines with lower displacement as well as lower number of cylinders. To account for the torsional effects, FEV employs a multi-body system modeling approach through which base engine information is used to determine optimized drivetrain setups. All mechanical elements in the setup are analyzed based on their torsional behavior. Bending and axial vibration are considered in the analysis as well. The presentation will include a thorough description of all methods and algorithms used to determine the vital output parameters. Examples of optimized engine-dynamometer setups will be presented and discussed.
11:05 -
Rapid prototyping of castings, expensive gadget or real engineering tool?
Thomas Becker,president,ACTech North America Inc, USA
Compare the costs of using the latest rapid prototyping technology in the development phase with the costs of using a more traditional approach. The focus will be on the rapid prototyping process for cast and machined engine parts.
11:30 -
DASY X-Engine – a new engine configuration for practical applications
Matthew Diggs,Engineer Consultant,, USA
Double-Acting Scotch Yoke X-Engine - a set of patent-pending technologies make this configuration feasible. For 4-stroke diesel applications – including stationary power, marine, military vehicles, aircraft and automotive – the DASY X-Engine is superior to V-engine and in-line engine configurations for fuel economy, performance, NVH, package size, weight, durability and cost.
11:55 -
Improving engine development with next-cycle control
Gary Parente,product manager,National Instruments, USA
FPGA technology in conjunction with real-time processing power provides the means to deterministically acquire engine parameters, target desired combustion conditions, and adjust engine input parameters between, and in some cases during, every combustion event in an engine. Using FPGA technology and COTS products, a custom engine control unit (ECU) can be built that allows for feedback from in-cylinder sensors and next-cycle and same-cycle control of every combustion event.
12:20 -
Coatings for fuel cell and super low-friction application
Guenter Franz Eitzinger,chief engineer,High Tech Coatings GmbH, Austria
Coating of components is a key technology for the efficiency and durability of most PEM fuel cell applications. We have recently developed modified carbon-based coatings and also nitride coatings for bipolar plates. Those coatings are the basis of a reliable and economic fuel cell. The performance of low-friction coatings is strongly influenced by the substrate, oil additives or distinct environmental conditions. Knowing these interactions, one is able to systematically tailor the tribological properties of the overall system. This strategy is presented using several examples, such as recently developed amorphous high-temperature DLC coatings with nanoparticles.
12:45 -
The Hitchiner casting process for GDI fuel-rail applications
Mark Nigro,sales & marketing manager,Hitchiner Manufacturing Co Inc, USA
Hitchiner's counter-gravity investment casting technology is uniquely suited to casting near net shape fuel-rail components in stainless steel for GDI applications. The high-pressure fuel environment necessitates a casting process that can deliver superior metallurgical integrity and that is highly repeatable in a production environment. Hitchiner has worked closely with fuel system suppliers to develop a process that meets the technical requirements for GDI applications in the most cost-effective way.
13:10 -
Patternless sand casting via additive manufacturing
Terrence Senish,general manager,ExOne LLC - Midwest, USA
How lightweight complex sand castings can be produced through additive manufacturing
*This program may be subject to change
INTRODUCING THE ADVANCED POWERTRAIN CONCEPTS & TECHNOLOGY ZONE
Engine Expo North America 2013 will accommodate a brand new zone, called The Advanced Powertrain Concepts & Technology Zone, which will feature pioneering technologies dedicated to improving fuel economy, increasing performance and reducing emissions. Ground-breaking concepts & technologies designed to optimise automotive powertrains including flex fuel, biofuel, weight reduction, advanced materials and more will feature in this exciting new show area.
Expo Venue for 2013
46100 Grand River,
Novi, MI 48374
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