Preliminary Conference Programme



Day 1: Tuesday 21 May

Real World Powertrain Testing

Moderator

Kevin Kelly
Senior consultant
Frost & Sullivan
UK

10:15

A holistic overview of the challenges facing the powertrain industry

Kevin Kelly
Senior consultant
Frost & Sullivan
UK
With dramatic and significant challenges facing the automotive industry, this presentation will look at the impact on the powertrain, how OEMs' powertrain technologies are changing and also how this is impacting the development process (shift in V model toward SIL, HIL tools).

10:45

Stress measurement and FEA correlation of engine crankcase for powertrain durability test

Sangwoo Cha
Senior research engineer - Powertrain Structure CAE Team
Hyundai Motor Compay
KOREA
This presentation will review how the crankcase stress and bolt fastening load response under engine dynamo testing was measured using strain gauges. These were compared using finite-element method solutions considering the engine dynamic loading, and showed good results.

11:15 - 11:45

Break

11:45

Force, torque, moment and strain measurements through complete powertrain instrumentation

Michael Castiglione
VP
Michigan Scientific
USA
A complete vehicle powertrain instrumentation can be performed in order to measure torque, moment, force, and strain within a vehicle powertrain or drivetrain. Instrumentation methods include gathering data from vehicle crankshafts, flywheels, flex plates, transmissions, drive axels, and vehicle wheels. Often, a production component can be used for instrumentation with minimal modifications, which is important for maintaining the integrity of the component and not impacting the functionality of the vehicle. Having proper instrumentation is critical for gathering precision measurements in vehicle testing and development.

12:15

Measuring gears within Microns, technique, science or religion?

Dr Marc Rosenbaum
President
Mesure-Systems3D (MS3D)
FRANCE
Gears are probably the most complex part that the large volumes mechanical industry has to produce. Performances of a gear system are also totally dependent on the quality of its overall and teeth shape geometry and surface. defects generate noise, which with the introduction of the silent electric engines become less and less bearable. To prevent this problem, gears are tolerances are extremely tight, with only a few microns, which represent a major challenge for their verification. To cope with this demand metrology vendors guarantee micron accuracy, but what is this guarantee worth? let examine it.

12:45 - 14:00

Lunch

14:00

In-cylinder combustion recordings in optical engines: why, how and what

Dr Marcus Lundgren
Head of laboratory/assistant professor
Lund University
SWEDEN
Simply put, an optical engine is a research tool with optical access to the combustion chamber. This is done by installing quartz windows and pistons in the engine. This facilitates high-speed video recordings of the combustion, and increases the depth of knowledge about how laser diagnostics can be applied to visualize the fuel spray/distribution, flow fields, soot production and oxidation, etc. Therefore, optical engines are valuable research tools for fundamental in-cylinder knowledge that also can be used as validation for CFD simulations. Learn how to decrease emissions before they enter the exhaust pipe.

14:30

Measurements of powertrain mass properties

Dr Scott Zagorski
Mechanical engineer
S-E-A Limited
USA
This presentation will review a method for measuring the complete inertia matrix: mass, center of gravity (CG) location, and all moments and products of inertia. Among other things, these quantities are useful in studying engine vibrations, calculation of the torque roll axis, and in the placement of engine mounts. Although the method was developed primarily for engines, it can be used for other automotive components such as seats, wheels and tires.

15:00 - 15:30

Break

15:30

Production ready with virtual calibration

Martin Abart
Product manager
AVL List GmbH
AUSTRIA
Considering the recent introduction of regulations adding real driving emissions and in-service-conformity as additional type approval requirements, achieving the required reductions in fuel consumption has become even more challenging. Non-standard ambient conditions (altitude, temperature) are playing an increasingly important role. In this context, the use of virtual test systems, such as the AVL Virtual Test Bed, can make the difference – optimizing the use of expensive facilities (climatic TBs), reducing engine and vehicle prototypes and accelerating the time to market with improved quality. AVL Virtual Test Bed supports the development process, ensuring 100% reproducibility of any set testing conditions.

16:00 - 17:00

Panel Discussion - What’s next for powertrain testing optimization

Kevin Kelly
Senior consultant
Frost & Sullivan
UK
Michael Castiglione
VP
Michigan Scientific
USA
Dr Scott Zagorski
Mechanical engineer
S-E-A Limited
USA
More panelists to follow
NA1

Day 2: Wednesday 22 May

Testing Capabilities for Emission Compliance

Moderator - To be confirmed

09:30

Transient characterization of gasoline direct-injection engines for real driving emissions

Dr Byron Mason
Senior lecturer in advanced propulsion
Loughborough University
UK
Current calibration approaches fail to consider system time-dependent behavior (dynamics); in this work, a novel method for determining the dynamic variable valve timing calibration of a downsized 1.0l SI engine is presented. The approach implements analytical, robust, multi-objective dynamic optimization to deliver improved engine performance for real-world driving. Simulation results show the dominance of both fuel and NOx objectives, with a reduction in fuel consumption and engine-out NOx emissions of up to 5% and 18% respectively. Engine experimental results confirm that NOx emissions can be significantly reduced with no detriment to fuel economy over the transient investigated.

10:00

High-precision vehicle fuel economy and emissions testing

Kevin Witney
Staff engineer - powertrain engineering division
Southwest Research Institute
USA
The ability to measure small but statistically-significant changes in exhaust emissions and fuel consumption is vital to the development of new vehicle technologies. Testing on a chassis dynamometer traditionally utilizes a human to drive the vehicle over a test cycle; however, the human introduces day-to-day test variability. Commercial robots are available that actuate a vehicle’s brake and accelerator pedals, but often employ feedback control strategies that do not improve on the test precision achievable by highly-trained human drivers. To overcome these limitations, SwRI developed the DEVCon™ automated driver system. With DEVCon, test cell computers directly control vehicle acceleration and braking. This tool facilitates highly repeatable measurements and allows for the validation of small improvements in emissions and fuel economy.

10:30 - 11:00

Break

11:00

PEMS testing experience across the automotive platform and application

Nick Molden
Founder and CEO
Emissions Analytics
UK
Our presentation will share real-world emissions test results from passenger cars. Based on our independent tests, how are the latest Euro 6d-TEMP vehicles performing in real-world conditions? Are new diesels clean enough to give diesel a future? Has WLTP improved CO2 accuracy? Are we forgetting CO2 targets – has the air quality debate clouded our thinking?

11:30

Onboard evaluation of tank-to-wheel mechanical efficiencies

Enrico Corti
Founder
Alma Automotive Srl
ITALY
The need for real driving emissions testing, and actual onboard scenarios during the calibration process, are changing the powertrain experiments approach. The presentation shows how lab-grade sensors have been placed on board a vehicle to analyze the actual performance of several components. The use of onboard sensors to measure gasoline flow, cylinder pressure and torque in several positions of the driveline allows evaluation of the global tank-to-wheel efficiency, and the engine, gearbox and differential mechanical efficiencies.

12:00

Challenges & solutions when performing lubricant approval tests on the road successfully

Speaker To be confirmed
Intertek
USA
Gaining an OEM’s approval for new lubricants typically requires an extensive validation process to demonstrate compatibility with the OEM’s powertrain components. This includes not only bench and dynamometer testing, but also road testing on actual driven vehicles on public roads. Once outside the controlled lab environment, one faces multiple technical and logistic challenges in executing a successful validation test run. This talk presents several common challenges and often-overlooked pitfalls in planning and executing long duration, mileage accumulation and engine/lubricant wear test programs. Additionally, this talk will provide some recommendation and guidance to mitigate these challenges, from pre-program planning and throughout the validation test process.

12:30 - 14:00

Lunch

International Engine of the Year 2019 Awards

15:20

Meeting the demands of RDE test and development with RDE+ advanced powertrain testing tools and techniques

Steve Whelan
Head of the emissions systems global development
Horiba MIRA
UK
Dr Phil Roberts
Principal engineer
Horiba MIRA
UK
Real driving emissions (RDE) regulations and requirements are proliferating across the world. Powertrain must now be developed to meet regulated limit values under all expected driving and environmental conditions. A road-to-rig (R2R) whole-vehicle development, calibration and verification approach known as Real Driving Emissions Plus (RDE+) is being developed at Horiba MIRA. This presentation reports the methodologies developed to achieve RDE replication (driving style, altitude and temperature). For engine and chassis dynamometer and EiL systems, a multifunction efficient Dynamic Altitude System (MEDAS) was used to cover altitude and temperature requirements. Preliminary results using MEDAS and the robot driver with the vehicle driven on the chassis dynamometer showed good correlation of vehicle performance and emissions.

15:50

Fast transient emissions from light-duty and heavy-duty vehicles

Dr Mark Peckham
Senior director
Cambustion Ltd
UK
Fast emissions analyzers with millisecond response times have been used to measure simultaneous engine-out and tailpipe emissions during real-world driving. The results, correlated with engine and GPS data, reveal the causes of the short but significant spikes of emissions that occur during real-world driving, aggravated by stop/start, bus stops, traffic intersections and speed calming. The combination of fast response and accurate GPS allows for the positioning of urban air quality 'hot spots' with centimeter accuracy.

16:20 - 17:00

Panel Discussion - Meeting RDE and WLTP requirements and beyond

Jon Andersson
Global technical expert, Emissions Measurements and Standards
Ricardo UK Ltd
UK
Nick Molden
Founder and CEO
Emissions Analytics
UK
Dr Mark Peckham
Senior director
Cambustion Ltd
UK
More panelists to follow
NA1

Day 3: Thursday 23 May

Measuring Diverse Powertrain Technologies

Moderator

Dr Marc Rosenbaum
President
Mesure-Systems3D (MS3D)
FRANCE

09:30

Digital twins – flexible real-time integration in test facilities

Dr Felix Pfister
Business development powertrain
IPG Automotive GmbH
GERMANY
The automotive industry is currently being disrupted by digital-twin technology, which also has the potential to reshape how our testbed infrastructure works today. Dyno rig-mounted ICEs can, for example, be subjected to fully immersive experiences, such as RDE test drives, by interacting with the virtual space of a digital-twin vehicle and the environment in real time. The presentation will show and discuss how virtual components are flexibly integrated into such a robustly engineered mixed-reality test environment. Digital twins are the core factor in leveraging component testbeds to testbeds for system-driven development and testing.

10:00

System design and experimental verification of an electric drive unit (EDU)

Phil Bradshaw
Test and development engineer
Drive System Design Ltd
UK
This presentation will discuss a novel process for the design of an EDU for a case study vehicle, creating load cases based on real-world drive cycles and undertaking in-house testing for durability verification. With extensive expertise in electric drivetrain design and testing, DSD will detail its bespoke test cycles, as well as the simulation tools it has developed to optimize the inverter, motor and transmission. The best-practice durability processes adopted by DSD will then be presented to give a complete design-to-test cycle.

10:30

Precision measurement of valve travel and rotation in fired engines

Dr Rolf Slatter
CEO
Sensitec GmbH
GERMANY
The new VTMS (Valve Travel Measurement System) solution from Sensitec, based on giant magnetoresistive (GMR) sensors, allows the optimization of valvetrain dynamics in fired engines. Differences between ideal and real valve travel can be assessed together with real valve timing. This provides for the first time complete information about the gas exchange, as well as the vibrational behavior of the valvetrain, all at a significantly lower price than laser-vibrometer-based systems. The GMR sensors incorporate a small rare earth bias magnet and use a fine-toothed structure on the valve shaft as a measurement scale.

11:00 - 11:30

Break

11:30

Testing of an electric propulsion system for an autonomous vehicle

Patrick Vikari
Senior technical expert
Hofer Powertrain
GERMANY
Autonomous driving will change the development processes of the future. Predictable driving strategy will influence the load cycle and can provide more reliable simulation data for calculation of housing, gears, shafts and bearings. Changing use cases to public transportation offers the potential of optimized maintenance strategies. Onboard measurement systems with multiple sensors will lead to an increase in availability and reliability. Testing strategies must adapt to these new requirements and need to be optimized for automated and efficient validation plans.

12:00

High dynamic maneuver testing in hub-coupled dynamometers

Christian Engström
CEO
Rototest
SWEDEN
The presentation will showcase what to expect when taking the road maneuvers to the lab. It will address challenges such as load transfer, hybrid mode-change, variable road conditions and simulation environments.

12:30 - 13:30

Panel Discussion - Lowering emissions by using more efficient and accurate measurement, testing techniques and technologies

This will be a joint panel discussion held with The Path to Euro 7 Conference audience
Dr Marc Rosenbaum
President
Mesure-Systems3D (MS3D)
FRANCE
Dr Felix Pfister
Business development powertrain
IPG Automotive GmbH
GERMANY
Petrica Dulgheru
Senior emissions engineer
Bosal Emission Control Systems
BELGIUM
More panelists to follow
NA1
Please Note: This conference programme may be subject to change

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