Engine Expo USA 2017

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24, 25, 26 October 2017
The Suburban Collection Showplace, Novi, MI, USA


Open Technology Forum Program

Day 1: Tuesday 24 October

Hall A DAY 1

High-performance engines win with torsional viscous dampers

Aaron Neyman
Senior product engineer / vibration solutions manager
Vibratech TVD
USA
Learn the latest in viscous-style harmonic balancer development and how it translates to winning case scenarios in professional gas and diesel motorsports. Highlights include applying the technology to OEM production engines.

Introducing innovative concepts for connecting injectors to diesel engines

Marcel Goedecke
Senior product manager
ITT Cannon
GERMANY
Wiring of injectors for diesel engines can be a costly and time-consuming process. While working with engine manufacturers, ITT Cannon has developed concepts that help to simplify the engine assembly process. These innovative concepts lead to reduced costs, complexity and installation time, and the presentation will outline areas of research, product design and technology involved in the development of these breakthrough new solutions.

Active decompression technology enabling diesel engine improvements

Alex Freitag
Director - engineering
Robert Bosch LLC
USA
Bosch and Jacobs Vehicle Systems introduce a new technology that brings diesel engines to a new level of NVH, particularly on engine startup and shutdown. With Active Decompression Technology (ADT), the familiar engine shaking upon shutdown is significantly reduced with a bolt-on, simple solution. Starting performance is improved by reducing the required starter current and dramatically increasing cranking speed. ADT can be an enabler for effective and comfortable stop-start functionality for applications that do not use it due to these challenges. Enabling stop-start for MD and HD applications can result in significant greenhouse gas emissions reduction and fuel economy improvement.

Cumulative enabling effects of a driven turbocharger

Thomas Waldron
Executive vice president
SuperTurbo Technologies Inc
USA
The SuperTurbo is a step forward from a traditional turbocharger, with a mechanical transmission that links the turbo shaft to the engine. This enables power transfer to and from the turbo shaft that is not possible with a normal turbocharger. During transient operation, the SuperTurbo operates in supercharging mode, powering the turbo shaft to quickly provide boost. During operation at higher engine power levels, the turbine of the SuperTurbo captures more energy from the exhaust than is needed to drive the compressor, and thus operates in turbo-compound mode. This extra turbine power is transferred directly to the engine crankshaft.

Reducing combustion variation with the LHP Engine Control System

Dr Adam Jungkunz
Senior systems engineer
LHP Technology Solutions
USA
With ever-increasing regulatory requirements for improved efficiency and emissions, engine researchers need state-of-the-art tools to improve their products. LHP’s Engine Control System provides researchers with an engine control testing platform that combines high-fidelity injector waveform control with next-cycle control capabilities. The injector driver circuitry provides researchers with more precise, repeatable control of voltage and current profiles for piezoelectric and solenoid injectors, allowing shorter injection pulses for novel combustion strategies. This presentation illustrates reduced coefficients of variation of power output for short injection pulses on a GDI engine with piezoelectric injectors, only attainable using LHP’s Engine Control System.

Dynamic engine emissions and lube oil consumption

Dr Sven Krause
CEO
Lubrisense GmbH
GERMANY
Vehicle emissions are currently being discussed intensively. To reduce the emission of hydrocarbons and other combustion products, the highly dynamic process in the cylinder has to be understood. Transient driving cycles reveal unknown dynamic engine characteristics regarding lube oil emission. In combination with a QTOF-MS, additional information can be obtained. The peak distribution gives hints about the source of oil consumption.

Test requirements of the automated automobile

John Arena
Product line marketing director
Teradyne Inc
USA
The presentation will explore ADAS/ECU test components. Since their invention, automobiles have required human operators to deliver vehicle control, monitoring and emergency response. ADAS systems hold the promise of eliminating humans, delivering vehicle autonomy and real-time decision making. Modern societies accept the consequences of imperfect operators and anomalous performance. It remains to be seen to what standards society will hold the makers of ADAS as they replace human control and judgement with software and electronic equivalents. The next generation of ADAS ECU manufacturing will require extraordinary degrees of unit volume production, while delivering defect detection, process verification and measurement tolerances.

One-stop-shop solutions

Shuichiro Nakajima
Technical manager
Kyowa Industrial Co Ltd
JAPAN
Kyowa is a full-service, precision manufacturer of complex prototype components and low-volume production runs. It is known for the exceptionally high-quality production of complex prototypes, dramatically fast and flexible delivery to meet tight schedules, ultra-thin-walled components for maximum weight reduction and start-to-finish service with complete confidentiality. Whether you need one unit or 1,000, Kyowa's rapid prototyping and design process allows the company to deliver them. Kyowa has recently established American Kyowa in Detroit to work with US customers. The company is eager to work with you and learn more about your specific machining and prototyping challenges.

Designing for 3D printing – DMLS

Joshua Parker
DMLS technician
Proto Labs
USA
This presentation will explore the different ways to take full advantage of the direct metal laser sintering (DMLS) process. We will discuss some of the design considerations, such as surface finish, internal features, stresses and support requirements. Knowing how to work around some of these limitations will open up many new design opportunities. We will also explore how DMLS can be used as a solution for low-volume production parts.

Method for testing moments of inertia of an engine

Dr Dale Andreatta
Mechanical engineer
SEA Ltd
USA
The presentation provides an overview and video demonstration of a simple device to measure the center of gravity, three moments and three products of inertia of objects such as engines. It can test any rigid object in the weight range of 200-700 lb, and up to a 4ft cube. The device has reasonable hardware costs, is easy and quick to use, and provides accurate results. Software guides the testing process and performs the calculations.

Day 2: Wednesday 25 October

Hall A DAY 2

CANalytics CAN interface software

Todd VanGilder
Vice president
Wineman Technology
USA
The new CANalytics platform from Wineman Technology makes all the benefits of CAN accessible in one cohesive application with a CAN interface as a standalone executable. R&D or ATE engineers can develop custom applications through a fully featured interface, and use that interface to integrate automated processes. CANalytics will work with a variety of CAN hardware, reducing overall test system cost. It currently supports NI-XNET and Advanced Vehicle Technologies AVT-853 hardware. Benefits include: supports import/export of .DBC files; includes a LabVIEW API; simulates an ECU; views all CAN traffic on a specific bus; automation through any scripting language that serializes/de-serializes JSON.

Advanced gasoline engine technologies to achieve diesel-like fuel efficiency

Paul Freeland
Principal engineer
Cosworth Limited
UK
Legislation on CO2 emissions had encouraged a reliance on diesel vehicles to achieve fleet average targets. However, air-quality issues and real-world driving legislation are forcing a review, and the potential of diesel engines to reduce CO2 is now considerably reduced. This requires that gasoline engines continue to be developed to their ultimate efficiency potential. This presentation shows methods whereby gasoline engines can rival the fuel efficiency of diesel engines. It details the development of a 2.0 liter GDI engine delivering 105kW/liter, yet capable of less than 300g/kW.h BSFC at 2000/2.0bar BMEP using series-production technologies.

Quick and reliable efficiency motor mapping and analysis

Michael Hoyer
Applications/marketing engineer
HBM Test and Measurement
USA
Maximizing the efficiency of electric motors is vital to increasing the range and capabilities of an electric vehicle and thus considerably improving its marketability and sales. Many test labs have multiple pieces of measurement equipment from different suppliers to help test and characterize electric motors. Although these systems appear to work, they often have high levels of complexity and function much more slowly than an optimized system. This presentation proposes a ‘single-box solution’ specifically designed for ultimate electric motor testing, allowing for quick efficiency motor mapping and reliable motor analysis, and resulting in major increases in productivity, capability and R&D.

HIL solutions today for powertrains of tomorrow

Dan White
Chief engineer
LHP Engineering Solutions
USA
The new hardware-in-the-loop test platform from LHP Technology Solutions reduces the risk associated with the rapid pace of technology advancement by building upon an open architecture platform combined with years of automotive engineering experience. Powertrain HIL test systems present unique requirements for real-time control due to the angle domain processing and signal conditioning challenges for simulating advanced sensors and actuators. This presentation will examine how LHP Technology Solutions solves these problems using National Instruments hardware, LHP signal conditioning, LabVIEW FPGA and Simulink engine models to create a fully automated powertrain HIL test system.

Thermally conductive compression rings offer potential for emission reductions  

Dr David Krus
Director of business development
Materion Performance Alloys
USA
The most straightforward path to greater fuel efficiency and/or reduced emissions is to downsize a boosted internal combustion engine. To maintain engine performance, specific output must be increased while downsizing. High thermal conductivity compression rings made of copper-based alloys can be used to extend the combustion system operating limits by improving the combustion regime and ultimately reducing brake-specific fuel consumption.

Next-generation, high specific output engines with direct water injection

Naag Piduru
Senior engineer CFD/CAE
Nostrum Energy LLC
USA
Water injection has gained relevance in recent years as an enabler for increased performance achieved by controlling end of compression temperatures, and thereby knock onset. Nostrum's patented colliding jet injectors rely on jet-to-jet collision as opposed to tradition air shear break-up. This method improves atomization and considerably reduces liquid lengths, thus avoiding liner and intake port impingement, as well as minimizing water consumption. Future generations of high BMEP engines will benefit greatly from direct water injection. Nostrum will present latest developments, CFD and practical applications of its colliding jet direct injector.

Selective Interrupt and Control (SIC) with RPECS

Logan Smith
Research engineer
Southwest Research Institute
USA
By leveraging its open control and data acquisition system, RPECS, SwRI has successfully demonstrated the ability to manipulate stock ECU control of engine actuators. RPECS sits between the ECU and the sensors and actuators, and normally passes signals through directly. The test engineer is able to command offsets or other control calibration changes, to investigate off-stock performance. This has been applied to injectors, ignition, cam phase, GDI fuel pumps, and more.

Recent advances in residual stress x-ray diffraction

Taylor Thompson
Application scientist
Proto Manufacturing
USA
The residual stress present in manufactured components can have a severe impact on fatigue life, distortion, stress corrosion cracking, crack initiation and propagation. Residual stress is introduced in nearly every step of the manufacturing process. Particularly, failure-critical locations often have known levels of residual stress that must be adhered to for quality compliance. X-ray diffraction (XRD) is commonly used to measure residual stress, being both quantitative and non-destructive. Recent advances have allowed XRD to become an extremely flexible and accurate method of stress characterization, allowing access to measurement locations in the complex part geometries found in engine components.

Oil debris monitoring in engine testing applications

Simon Wilson
Product manager
Gastops Ltd
CANADA
For many years the automotive industry has introduced oil debris monitoring sensors into research, endurance and some production test applications. Applications range from passenger vehicles, to off-highway vehicles and motorsports. The presentation will provide an overview of the technology, how it works, how it is applied, the history of its development, and how it has become critical test equipment in automotive testing applications.

Day 3: Thursday 26 October

Hall A DAY 3

Engine oil aeration – simple test method for lubricant formulations

Ricardo Hein
Director
Conexo Inc
USA
Oil aeration in engines causes malfunction of hydraulically driven components, promotes oil degradation and deposits, and affects oil film formation. Measuring different lubricants for their natural aeration characteristic shows a variety air entrainment levels in the same oil classification. This testing gives OEMs an opportunity to scan oils for the aeration properties before an actual engine aeration test. The goal is to understand what proportion of the oil aeration is contributed by the oil formulation and the oil condition versus how much oil aeration is contributed by the engine design.

Port water injectors with spray targeted colliding jet technology

Vijay Dangwal
Research and development engineer
Nostrum Energy LLC
USA
Given recent product applications by BMW and Porsche, water injection has established itself as a viable option for controlling knock onset in highly boosted engines. However, with 10 times the liquid length of iso-octane, a conventional air shear injector is challenged to atomize water without impingement or excessive droplet size. Colliding jet technology is effective in reducing liquid length and droplet size. These benefits result in reductions in water consumption, mitigation of hardware risks and expansion of the knock mitigation range. Nostrum will present practical applications of its port water injectors with spray targeting and split gamma sprays.

Benchmarking engines in today’s changing industry

Christian Fusik
Business Development, the Americas
A2Mac1
USA
A2MAC1 has been the world’s foremost supplier of benchmarking data, services and software for more than 20 years. It presently has teardown facilities in France, United States, China, India and Thailand. Its current customers include the majority of global automotive OEMs, a multitude of Tier 1 and 2 suppliers and other leading manufacturers of construction, farm and transportation equipment. The A2Mac1 software platform is the foundation for more than a few of our automotive OEM customers as well as several off-highway and aerospace OEs. Our global database provides users with a centralized location to view, compare and store all their benchmarking data and is available 24/7 online. Navigation of the database is intuitive with simple, yet highly effective tools. This presentation will reveal the many benefits of using the A2Mac1 platform as the basis for all your benchmarking needs.

Hot Gas Transient Reactor for simulating exhaust of diesel engines

Scott Eakle
Principal engineer
Southwest Research Institute
USA
FOCAS Hot Gas Transient Reactor (HGTR) is a computer-controlled, multi-fueled, burner-based continuous-flow reactor designed to duplicate the lean exhaust conditions produced by light-duty to line-haul size truck engines. HGTR is an entirely transient reactor capable of evaluating full-size catalysts. Unlike typical small core gas reactor benches, which use bottled gas to simulate exhaust conditions, HGTR produces a continuous exhaust flow through combustion of fuels and compounds, producing an exhaust gas composition that duplicates the gaseous species observed from a diesel engine. The reactor was designed to accommodate full-size catalyst systems and to replicate user-based programmable cycles.

Simplifying test system and test lab management with TestTracker

Roy Krans
Product group manager
Wineman Technology Inc
USA
This presentation discusses how, in today’s PC-dominated, data-heavy testing environment, getting a handle on your organization's test systems is paramount to maximizing your company’s investment. Modern test systems handle a multitude of configurations, system settings and test files while generating gigabytes of raw data, results and reports. Without an overall strategy for generating and managing all of this information, many of the benefits of these technologically advanced systems can be lost. Throughout the presentation we will examine these challenges and discuss how WTI's TestTracker software solves them.
Please Note: This conference programme may be subject to change

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Future Show: Engine Expo North America 2018, 23-25 October 2018, Halls A,B & C, Suburban Collection Showplace, Novi, Michigan, USA
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