Ricardo Alternative Power Plant News

a
RD 03/174601.1
Unrestricted
RICARDO INFORMATION SERVICES
ALTERNATIVE POWERPLANTS NEWS
AUGUST 2003
A monthly bulletin
dedicated to
fuel cell, hybrid electric
and other alternative powerplants,
common issues, components,
marketing
and industry news
by
Martin Ward
Ricardo Information Services – Alternative Powerplants News – August 2003

a
RD 03/174601.1
Unrestricted

a
RD 03/174601.1
Unrestricted
Page 3
CONTENTS
Page
5. FUEL CELLS
5. Fuel Cell Cars
5. Buses
6. Common Issues in Fuel Cells
6. Fuel Cell Components
7. Fuel Cell Fuel Economy
7. Other Fuel Issues
10. HYBRID ELECTRIC VEHICLES

10. Commercial Vehicles
10. Buses
10. Common Issues in Hybrid Vehicles
11. Control
11. Batteries
12. Fuel Consumption
12. Transmissions
13. Steering
14. FUEL CELL HYBRID ELECTRIC VEHICLES

14. Buses
15. MILD HYBRIDS

15. Cars
16. BATTERY ELECTRIC VEHICLES

16. Vans
17. OTHER ALTERNATIVE POWERPLANTS

17. Unconventional I.C. Engines
18. HCCI
23. COMMON ISSUES IN ALTERNATIVE POWERPLANTS

23. Motors for Alternative Powerplants
23. Electromagnetic Compatibility
23. Fuels for Alternative Powerplants
24. Transmissions for Alternative Powerplants

a
RD 03/174601.1
Unrestricted
Page 4
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. Entries
may 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 bold
at the bottom of each article. Items not published in English may be translated by Ricardo’s Translation
Service, 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 transmissions
Components News – A newsletter covering i.c. components
Vehicle Engineering News – A newsletter covering brakes, chassis, steering gear and other
vehicle components, themes and issues
POWERLINK - A database containing abstracts of engine and vehicle articles
EMLEG - A database of Worldwide exhaust emission legislation
Forthcoming Conferences – An updating service of interest to all users of our other services
Subject 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 Engineers

Tel. +44 (0)1273 794230, email: RJChristopher@ricardo.com.
In the USA, please contact:
Paul Cassidy, Vice President of Business Development, Ricardo Inc.

Tel. +1 (0) 734 394 3713, email: PCassidy@ricardo-us.com.
Any comments on this newsletter, or items for inclusion in future issues, will be gratefully received by the
Editor, Martin Ward, at MLWard@ricardo.com.
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 this
publication do not imply endorsement of any product or service by Ricardo.
Ricardo plc. © 2003

a
RD 03/174601.1
Unrestricted
Page 5
FUEL CELLS
Fuel Cell Cars
Honda.
Honda has developed an emission-free clean power train employing fuel cells. This power train has been
fitted in the Honda FCX fuel cell vehicle. The new power train is made up of a combined pure hydrogen
fuel cell stack and Ultra capacitor system. The new power train has raised the energy efficiency of the
FCX also has higher fuel economy than a HEV, and superior acceleration from a standstill to a gasoline
internal 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.)
______
General Motors.
Larry Burns, General Motors Vice President of Research, Development and Planning, makes the
statement with total assurance: "We believe that this vehicle is approaching the true reinvention of the
automobile. 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 yoke
instead 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 cell
related research organizations and industry members.
Covers - Nissan X-Trail FCV with lithium-ion secondary battery system, Toyota RAV-4 FCV, PEM fuel
stacks, 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.)
____________________________________________________________________________________
Buses
Mercedes-Benz Citaro city bus.
The first fuel cell powered Mercedes-Benz Citaro city bus has been delivered by DaimlerChrysler, in a
ceremony 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 (50
mph) 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 supplying
the on-board hydrogen fuel storage systems, in which hydrogen is stored at 350 bar (5000 psi) in roof
mounted cylinders.
See Doc.122079 (Fuel Cells Bulletin, Jun 2003, p1.)

a
RD 03/174601.1
Unrestricted
Page 6
Common Issues in Fuel Cells
Waseda University Environmental.
The objective of the present studies are to develop a new power system achieving both higher efficiency
as well as a compact and lightweight body for fuel cell vehicles which have been the focus of the world's
attention as the new type of vehicle. In this paper, the recent trends of R&D and examination of fuel cell
vehicles 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's
highest level of performance for a capacitor cell, with a specific power of more than 1400W/kg and a
specific energy of 3.9Wh/kg. The new module system is equipped with a capacitor cell protection system
and 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.)
______
Hydrogen Sensor - NGK Spark Plug.
A limiting current type hydrogen sensor using polymer electrolyte has been developed for hydrogen
concentration measurement in reformed gases of PEFC. The sensor output controlled by the circuit
designed for the sensor was linearly proportional to hydrogen concentration. The model gas tests
demonstrated that the influences of coexisting gases such as H20, CO2, CH4, CH3OH temperature and
pressure on the sensor output were small. In addition, fuel utilization calculated from outputs of sensors
installed 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.)
______
Fuel processors - University of California.
This paper focuses on a methanol fuel processor using steam reformation of methanol to generate the
hydrogen required for the fuel cell stack. Since the steam reformation is an endothermic process the
thermal energy required is supplied by a catalytic burner. Through the use of a model for the fuel
processor, comprising of detailed models for the reformer, burner and CO cleanup units, we investigate
the performance of the fuel processor from the viewpoints of efficiency and transient performance. In
particular, the model can generate results in terms of a) steady state efficiencies b) response to transient
step inputs c) efficiency and dynamics in the context of its use in a fuel cell vehicle under standard driving
cycles.
See SAE 2003-01-0810 (2003, 12pp.)

a
RD 03/174601.1
Unrestricted
Page 7
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 fuel
cell. A study of the deionized water system was undertaken to determine the effect of various materials on
water quality, and also to determine the effect of deionized water on each material. The test setup was
designed 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- and
post-testing of the water and the materials was performed. The goal is to achieve system cleanliness and
durability similar to a stainless steel system using lighter, less expensive materials. This paper describes
the 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 cost
of assembling and sealing the PEM stack. Additionally the stack sealing system or method must last the
life of the stack, and is often used to enhance the structural strength of the stack and provide
performance-enhancing functionality.
This paper discusses PEM fuel cell stack sealing manufacturing and assembly methods. Methods
examined include; die-cut gaskets, fabricated press in place, insert moulded designed profile, dispensed
and 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 Economy

JARI.
Fuel cell vehicles have been developed and demonstrated on the road in recent years, but test methods
for fuel economy have not yet been established. The purpose of this study is to standardize simple and
accurate methods of measuring fuel economy. For study purposes, the following test methods are
proposed: electric current method, pressure method, weight method and flow method. Although requiring
only a simple equipment and capable of transient measurement, electric current method is unsatisfactory
in accuracy. Pressure method and weight method proved satisfactory in accuracy; however, their systems
need to be simplified for practical use. This paper deals with the possibility for application and related
issues for each of these test methods.
____________________________________________________________________________________
Other Fuel Issues
JFE Container Co.
Many automobile manufacturers have announced compressed hydrogen fuel cell vehicles in these several
years, and many projects are promoted in Japan, US and Europe. Furthermore, the standardization of the
design and evaluation method regarding the compressed hydrogen fuel container are examined. The
design requirements and the evaluation method regarding the compressed hydrogen container for fuel cell
vehicles are explained.
See Doc.122258 (Engine Technology, Jan 2003, pp43-45.) (In Japanese.)

a
RD 03/174601.1
Unrestricted
Page 8
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 gasoline
reforming 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 thermal
reforming approach were predicted and specific components and concentrations were identified; various
experiments and analysis were conducted to determine the adverse effect of CO, CH4, HCHO and
HCOOH 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 Honda
FCX. 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 showed
better performance. This result can be explained in terms of the difference in heat diffusion coefficient
between aluminum and HDPE.
03, EV/HEV/FCEV - Vehicle Systems, Paper 20035208.) (In Japanese.)
______
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 of
both 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, safety
measurement and standard for using hydrogen.
03, Component for EV/HEV, Paper 20035452.)
______
Nissan and Nippon Oil.
The preliminary experiments for reforming of a series of gasoline components and oxygenates for fuel
cells have been conducted. Aromatics and olefins showed some effects on catalysts deterioration.
Oxygenates showed better reactivity than hydrocarbons. The enhancement of reforming was observed by
blending MTBE with naphtha. It has been concluded that zero-sulphur, low aromatic, low olefin and light
component is most suitable as hydrocarbon-type FC fuel.
______
McDermott Technology.
Start-up and transient response of on-board fuel processors for fuel cell vehicles continues to be a
significant challenge. McDermott Technology, Inc. under co-sponsorship of the US Department of Energy
has developed an integrated, catalytic auto thermal fuel processor for automotive applications. The fuel
processor system is designed to deliver 50-kWe (equivalent) reformate gas suitable for use with a PEM

a
RD 03/174601.1
Unrestricted
Page 9
fuel cell. The system design includes several features that enhance system response and serve to reduce
startup time. A dynamic process simulation model of the autothermal reformer and shift vessels was
generated using ASPEN process simulation software. Startup and transient response tests were
conducted on the fuel processor and results compared favourably to the model predictions. Sensitivity
studies indicated that the minimum warm up time given the current design is 15 minutes which is
unacceptable for automotive applications. Some simple modifications to the system, such as using
monolith catalysts and automating the controls, could significantly reduce the warm up time.
See SAE 2003-01-0807 (2003, 7pp.)

a
RD 03/174601.1
Unrestricted
Page 10
HYBRID ELECTRIC VEHICLES
Commercial Vehicles
Hino Motors.
The hybrid system for the collection and delivery light-duty truck was developed. This hybrid system has
advanced the miniaturization lightening to make it apply to the light-duty truck to say nothing of improving
the exhaust gas decrease and fuel cost as a chief purpose. The hybrid method adopted a parallel hybrid
suitable for the light-duty truck. The ultra-thin three-phase AC induction motor/generator was put in the
flywheel housing, and a small inverter of new development and a small nickel metal-hydride battery were
adopted. Consequently, exhaust gas was able to be decreased to new short-term emission regulation by
50% 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.)
____________________________________________________________________________________
Buses
Allison Transmission.
Allison Transmissions, a division of General Motors, began development of electric drive systems in 1989
by working on GM’s EV1 Electric Car Programme.
The Allison Electric Drives EP Parallel Hybrid Electric System has been developed for use in commercial
trucks and buses. The system has two models: the EP40, which is appropriate for 11-12m buses, and the
EP50, which can operate in 18m articulated buses.
The Ep System is a 600V nominal system, and has maximum output performance with an energy storage
system of 298 kW (400 hp). Major components include: a reciprocating engine, Ev drive unit, dual power
inverter module (DPIM), system controller, Allison energy storage system.
See Book 9414 R3: p121 (MIRA New Technology 2002.)

______
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 (series
hybrid electric vehicle) type. The paper evaluates the drive performance and comparison with the present
bus in the city driving modes.
03, Component for EV/HEV, Paper 20035154.) (In Japanese.)
____________________________________________________________________________________
Common Issues in Hybrid Vehicles

Fiat.
This paper presents and examines Hybrid Powertrains architectures and technologies trends with a view
to 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 an
electric 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 are
derived: parallel hybrid (PHE) in which both electric motor and engine, through an appropriate mechanical
link, are connected to the traction wheels, series hybrid (SHE) in which only the electric motor is
connected to the traction wheels; the thermal engine drives an electric generator that supplies the electric
motor through an electrical connection.
See Doc.122046 (ATA, Mar/Apr 2003, pp78-80, 82-86 & 88-89.)

a
RD 03/174601.1
Unrestricted
Page 11
Control
Nissan.
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 road
inclination information along the route proposed by the car navigation system. The fuel consumption
effectiveness of the proposed control system has been confirmed using actual traffic and road condition
data.
EV/HEV/FCEV - Vehicle Systems, Paper 20035175.) (In Japanese.)
______
Ricardo.
The authors have been investigating energy management using algorithms that continuously optimise
energy 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 in
engine 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. In
this paper they extend this approach to Diesel Particulate Filter regeneration strategies and further to
include 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.)
______
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 automatic
transmission without a torque converter are connected to the three members of a planetary gearset. The
IHAT is similar to an integrated starter generator (ISG) system, but is shorter in length and provides better
fuel economy.
This paper describes the structure and functions of the IHAT and explains the control system used to
maintain smooth driveability.
Covers automatic engine start-stop, creep capability, vehicle start-off, fuel economy improvement
obtained 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.)
____________________________________________________________________________________
Batteries
Nissan 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 states
of a battery (open voltage, internal resistance, time constant, and so on) recursively. Finally these
calculated states enabled us to estimate the state of charge (SOC), and the dischargeable or acceptable
power accurately, which are necessary to fully utilize the battery power on the vehicle.
Covers hybrid vehicle, adaptive control.
(In Japanese.)
03, Component for EV/HEV, Paper 20035031.) (In Japanese.)

a
RD 03/174601.1
Unrestricted
Page 12
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 features
of 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&D
concepts and specifications of the battery.
Covers - idling stop, hybrid vehicle.
____________________________________________________________________________________
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 and
the impacts of power train components parameters. Both series and parallel power train systems are
discussed. The energy flow among the engine, motor, battery and system efficiency are analyzed using
full vehicle simulation. Different configuration, hybridization, control strategy, regeneration ratio and
running modes are compared with their impact on vehicle fuel consumption. It is found that the fuel
economy improving way and potential is different for different power train. A best fuel consumption ratio
of 0.45 is obtained from simulation by parallel power train.
03, Component for EV/HEV, Paper 20035422.)
______
Industrial Technology Research Institute and Shibau Industrial University.
Linear regression method that estimates fuel consumption without energy increase/decrease condition in
rechargeable energy storage system is expected as a practical fuel consumption test method for hybrid
vehicles. Factors to affect the test accuracy had been studied in the last two reports, and the practical test
procedure 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 the
proposed test procedure to the statistical results obtained by enough tests. Results show that the linear
regression method does not always lead to suitable process to estimate the fuel without SOC change.
Component for EV/HEV, Paper 20035185.) (In Japanese.)
____________________________________________________________________________________
Transmissions
Toyota.
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 and
highly efficient. The unit achieves excellent driving comfort with smooth speed change by CVT control
and 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.)

a
RD 03/174601.1
Unrestricted
Page 13
Steering
Michelin 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 analytical
mathematical models will be presented for power (e.g. hydraulic, electric and steer by wire) rack and
pinion steering units. The influence of chassis, tyre-road interface and steering system non-linearities are
introduced. Representative numerical results will be presented and discussed to investigate a vehicle's
transient 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.)

a
RD 03/174601.1
Unrestricted
Page 14
FUEL CELL HYBRID ELECTRIC VEHICLES
Buses
Toyota.
In collaboration with HINO Motors, Ltd, Toyota Motor Corporation has developed the "FCHV-BUS2", a
non-step fuel cell powered hybrid bus that runs on high-pressure hydrogen. In order to improve the
vehicle efficiency, the optimal electric power distribution system between the fuel cell and the secondary
batteries was proposed in addition to the use of energy regenerated during braking. Consequently, the
vehicle efficiency of FCHV-BUS2 became approximately double the performance of diesel engine
powered bus.
03, EV/HEV/FCEV - Vehicle Systems, Paper 20035215.) (In Japanese.)

a
RD 03/174601.1
Unrestricted
Page 15
MILD HYBRIDS
Cars
Ford and IAV.
This paper describes the design optimisation of an Integrated Starter-Generator (ISG) powertrain for a
passenger car, focusing on the development of an advanced powertrain operation strategy. The
optimisation 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. The
simulations were performed with the Simulink based software Advisor, a program for longitudinal vehicle
dynamics simulations. In the scope of the project, Advisor was modified such that planned simulations
could be carried out automatically. DoE was used to desigh the simulation experiments, to evaluate the
results 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 are
presented. 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 introducing
engine stop/start and regenerative braking functionality.
With DoE, and with assumptions on model interrelationships, only those simulation experiments were
planned 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 and
crankshaft-mounted ISGs.
See Book:9437 BVW:A4B: pp167-184 (Haus der Technik - 2nd conference on Design of Experiments in
engine development, Berlin, 2003.)

a
RD 03/174601.1
Unrestricted
Page 16
BATTERY ELECTRIC VEHICLES
Vans
Azure Dynamics and Manganese Bronze.
Canadian firm Azure Dynamics Corporation and UK-based Manganese Bronze Holdings Plc, through its
subsidiary purpose-built taxi manufacturer London Taxis International (LTI), have agreed for Azure to
supply electric and hybrid electric powertrains for a new multipurpose urban delivery vehicle that will be
ready to deliver to customers in 2005.
See Doc.122249 (Hybrid & Electric Vehicle Progress, 1 Jun 2003, p7.)

a
RD 03/174601.1
Unrestricted
Page 17
OTHER ALTERNATIVE POWERPLANTS
Unconventional I.C. Engines

FEV variable compression ratio.
DOE as an integral component of engine development

Design of Experiments is used today throughout the whole engine development. Starting from a simple
phase model of the development process the application of this methodology will be demonstrated and
discussed.
Covers gas exchange simulation, gas emissions, calibration, engine optimization (1.8-litre, 4-cyl, VCR
variable 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 in
engine 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 with
hydrogen. In this approach, the engine combustion chamber at any instant of time during combustion is
considered to be divided into two temporally varying zones: a burned zone and an unburned zone. The
model incorporates a detailed chemical kinetic model scheme of 30 reaction steps and 12 species, to
simulate the oxidation reactions of hydrogen in air. A knock prediction model, developed previously for SI
methane-hydrogen fuelled engine applications (Shrestha and Karim 1999(a) and 1999(b)) was extended
to consider operation on hydrogen. The effects of changes in operating conditions, including a very wide
range 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 were
shown 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 some
of 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 hydrogen
are 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.)
_______
Colorado State University.
The topic of this paper is the simulation of the airflow characteristics of a large bore two stroke natural gas
fuelled engine. The modelling was performed with the program WAVE, a computer code developed for
engine cycle simulations. The engine studied was a four cylinder Cooper GMV engine. This engine has an
articulated 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.)
______
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 naturally
aspirated H2ICE operating lean has performance issues requiring either increased displacement or
induction boost to have comparable power to the modern gasoline powered IC engine. Ford Scientific
Research 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

a
RD 03/174601.1
Unrestricted
Page 18
2.3 L Duratec HE-4 engine (with a compression ratio of 12.2:1) with boosted manifold air pressure up to
200 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 engine
compression ratio and thermal efficiency, power density, and NOx emission control strategy is discussed.
See SAE 2003-01-0631 (2003, 13pp.)

____________________________________________________________________________________
HCCI
Nagoya Institute of Technology.
Ignition characteristics of natural-gas oriented gaseous fuels, which can be simply represented by ignition
delays of the fuel/oxidizer mixtures, were examined precisely by using a rapid compression machine as
the first step. For the non-cool-flame generating methane, n-butane mixed with it as a supplementary fuel
acts 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 ratios
between methane and n-butane were supplied to a premixed compression-ignition engine (i.e.
homogeneous charge compression ignition engine, HCCI) with or without supplementary gaseous
formaldehyde induction as an ignition control additive as the second step. In the no additive case the
methane 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 formaldehyde
addition to the methane/butane/air mixtures has given the engine desired and stable ignition timings
controllable by the amount of formaldehyde to be added, almost independent on the fuel/fuel ratios
between methane and butane. The efficacy of formaldehyde has been confirmed as an ignition control
medium 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 engines

Describes the nature and causes of cycle-by-cycle variations in gas engines, in terms of knock and
misfires. Control solutions are explored.
Covers - ignition, combustion, open combustion chambers, HCCI, divided chambers, lean/rich
combustion, 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 fuel
mixture to be very lean or highly diluted with residuals. This is in order to slow the kinetics down and to
avoid too rapid heat release. Consequently, the operational window for the engine in HCCI mode is not the
same as for the engine operating in spark ignited (SI) mode. Homogeneous charge compression ignition
engine 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, and
its successful implementation in a camless multi-cylinder engine. It was found that the operation in the first
couple of cycles following a mode change deviate markedly from the steady state operation in the new
mode, 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

a
RD 03/174601.1
Unrestricted
Page 19
cylinder and multi cylinder mode changes from un-throttled SI combustion (generated with early intake
valve closing) to HCCI combustion (generated with negative valve overlap) and vice versa were
investigated.
See SAE 2003-01-0753 (2003, 9pp.)

______
Tianjin University.
This paper presents a compound combustion technology of Premixed Combustion and “Lean Diffusion
Combustion” for realizing the concept of HCCI combustion in a DI diesel engine. The premixed
combustion 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 are
controlled. The objective of controlling the pulse injection is to limit the spray penetration of the pulse
injection so that the fuel will not impinge on the cylinder liner, and to enhance the mixing rate of each fuel
parcel 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 combustion
chamber, which is designed with some special bump rings. The combustion of fuel injected in the main
injection proceeds under the effect of the BUMP combustion chamber at much higher air/fuel mixing rate
than does in a conventional DI diesel engine, which leads to “lean diffusion combustion”. The effects of
multi-pulse injection and BUMP combustion chamber on auto-ignition, rate of heat release and engine
emissions 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 injection
of ethanol and n-heptane and cylinder pressure sensors for closed loop combustion control. The effects of
EGR 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 is
shown 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 to
lower 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 HCCI
engine with induced DME as the main fuel. Ultra-low NOx and smokeless combustion was realized over a
wide operating range. The reaction suppressors reduced the rate of low-temperature oxidation and
consequently delayed the onset of high-temperature oxidation. Analysis of the chemical kinetics showed a
reduction 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. Although
water injection caused a greater lowering of the temperature, which also suppressed ignition, the strong
chemical effect of radical reduction with methanol injection resulted in the larger impact on suppression of
oxidation reaction rates.
See SAE 2003-01-0746 (2003, 14pp.)

a
RD 03/174601.1
Unrestricted
Page 20
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 Diesel
engine 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/phasing
for varying load and external conditions. A method to achieve this on a cycle-by-cycle basis is to vary the
valve 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 timing
during varying external conditions. Engine tests describing the control performance achieved in initial
experiments are reported. Net Indicated Mean Effective Pressure, net IMEP, of up to 5.6 bar has been
tested. The work described forms the basis for further studies of HCCI
control.
See SAE 2003-01-0748 (2003, 16pp.)

______
AVL.
Two compression ignition/combustion models were studied for gasoline HCCI engine auto ignition and
combustion with 3D CFD code FIRE. The calculation results were validated with the experimental data
obtained in a single cylinder HCCI research engine under various operating conditions. Detailed chemical
reaction model showed good agreement with the experiment. In addition, a reduced chemical reaction
mechanics model demonstrated its potential for practical engineering purpose such as investigating the
impact of valve timing strategies on HCCI engine characteristics with a modern 4 valve engine. Covers
CHEMKIN, SENKIN, AVL CIS (Compression Spark Ignition).
03, Basic Technologies for Controlled Gasoline, Paper 20035137.) (In Japanese.)
_______
The high potential of Controlled Auto Ignition with gasoline engines - to combine excellent fuel economy
with extremely low engine-out emissions - is already known from various basic research approaches. The
real challenge, however, is the practical application under real world operating conditions and typical
production constraints. The Controlled Auto Ignition System AVL CSI was designed in view of minimum
changes to existing production engines, large volume production feasibility and cost effectiveness. While
keeping the fuel economy benefit of lean unthrottled operation, the CSI reduces by a partially variable
valve train and a cylinder pressure controlled EMS the NOx engine out emission towards such an
extended, that future emission limits will be met even without DeNOx catalyst. Covers stratified charge
engine, HCCI, variable valve timing optimization, engine control, combustion control, AVL CSI
(Compression and Spark Ignition, EHVA (Electro Hydraulic Valve Actuation). (In Japanese.)
03, Applications of Advanced Gasoline Combustion, Paper 20035121.)
______
Chiba University.
A production two-stroke schnurle-type gasoline engine was modified to enable compression ignition by
both port fuel injection and in-cylinder direct injection. Using this device, examination of compression
ignition operation conditions and engine performance tests were carried out. As a result, direct injection
was found superior to port injection in exhaust gas emissions and fuel efficiency, and some interesting
combustion characteristics, such as shorter combustion period in higher engine speed were also found.
03, Applications of Advanced Gasoline Combustion, Paper 20035212.) (In Japanese.)

a
RD 03/174601.1
Unrestricted
Page 21
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 gas
temperature. H2O absorption spectra spanning 1380-1420 nm were recorded once every 63 µs using this
sensor. The gas temperature was inferred from a least-squares fit of the integrated absorbance areas of
H2O absorption features in this spectral region to those from simulated spectra. The primary source of the
H2O was the humidity in the intake air. Measurements were made during the compression and early
portion 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 of
the 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 Charge
Compression Ignition (HCCI) combustion of n-heptane have been experimentally investigated. The
experiments were carried out in a single-cylinder, 4-stroke and variable compression-ratio engine
equipped with a port fuel injector. Investigations concentrate on the HCCI combustion of n-heptane at
different A/F ratios, EGR rates and their effects on knock limit, engine load, combustion variability, and
engine-out emissions such as NOx, CO, and unburned HC. Variations of auto-ignition timings and
combustion durations in the two-stage combustion process are analyzed in detail. Results show that HCCI
combustion with a diesel type fuel can be implemented at room temperature with a conventional diesel
engine compression-ratio. However, its knock limit occurs at very high A/F ratios, although high EGR rates
can 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 CO
emissions 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 injection
and negative valve overlap for exhaust gas retention was examined. The fuel was injected directly into the
residual in-cylinder gas during the negative valve overlap interval for the purpose of reforming it by using
the 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 in
the case of compression stroke injection. Injection timing during the negative valve overlap was found to
be an important parameter that affects the HCCI region width. The injection timing also had the most
suitable 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 and
HC emissions (and the associated combustion inefficiencies) at low-loads. Engine performance and
emissions 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

a
RD 03/174601.1
Unrestricted
Page 22
comparison of fully premixed and GDI (gasoline-type direct injection) fueling. The experiments were
conducted in a single-cylinder engine (0.98 litres) using iso-octane as the fuel. Comparative computations
were 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 charge
inhomogeneities.
See SAE 2003-01-0752 (2003, 25pp, 40 refs.)

a
RD 03/174601.1
Unrestricted
Page 23
COMMON ISSUES IN ALTERNATIVE POWERPLANTS
Motors for Alternative Powerplants
Aisin.
We have developed permanent magnet assisted synchronous reluctance motor (NynR motor) using
inexpensive permanent magnet (ferrite magnet) for a drive motor of an electric vehicle (EV) or a hybrid
electric vehicle (HEV). The objective of this development is to reduce the motor cost by utilizing
reluctance torque without using expensive magnet (NdFeB magnet). We confirmed the developed motor
is applicable by the test result when the motor performance is adapted to the system specification with
high speed. Such motor design and evaluation results are shown in this paper. Further, we also
introduced the comparison with a switched reluctance motor (SR Motor) which we have been developing
separately.
____________________________________________________________________________________
Electromagnetic Compatibility
MIRA.
Current European legislative electromagnetic emissions requirements, described in the automotive EMC
directive 95/54/EC, are based on broadband quasipeak and narrowband average emissions as measured
using an antenna at a fixed point relative to the vehicle.
A programme of measurements was therefore conducted on a small set of representative electric vehicles
in order to quantify the emissions of such vehicles, and to investigate the associated practical
measurement issues.
A number of representative alternative powertrain vehicles were selected for test, including: two different
electric 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 Powerplants

BP.
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 the
forecast presented by Bernd Bohr, member of the Board of Management of Robert Bosch GmbH, at an
international 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 by
considering the whole degree of efficiency from well to wheel. The fuel cell is admittedly extremely efficient
“engine specific”, but the provision of the required hydrogen is extremely complicated. This makes the
overall degree of efficiency only slightly higher than that of the diesel engine. Bohr did a cost-benefit
analysis of the fuel cell – again in direct comparison to classic drives. For a compact car to reduce
emission of carbon dioxide by one percent, diesel and gasoline engines require additional costs of about
one percent. For a hybrid drive, the ratio is twice as much and for the fuel cell, it comes to about four times

a
RD 03/174601.1
Unrestricted
Page 24
that amount.
See Electronic Document 2576. (Downloaded from the Internet, Bosch website, Jun 2003, press
release, PI 4182 My/Li, 2pp.)
____________________________________________________________________________________
Transmissions for Alternative Powerplants

Yokohama University.
This paper describes design principle and performance of a newly developed bi-directional traction drive
reducer with clutch function for an electric-motor power train. Configuration of the reducer is similar to a
planetary type, but the loading through the wedge roller mechanism is quite different from the conventional
type. The wedge roller controls not only the Hertzian pressure of the traction contact in proportion to
transmitting 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.)

Ricardo Alternative Power Plant News

Загружено:

Сведения о документе

Исходное описание:

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Ricardo Alternative Power Plant News

Загружено:

Авторское право:

Доступные форматы

a

RICARDO INFORMATION SERVICES

ALTERNATIVE POWERPLANTS NEWS

Ricardo Information Services – Alternative Powerplants News – August 2003

Ricardo Information Services – Alternative Powerplants News – August 2003

10. HYBRID ELECTRIC VEHICLES

14. FUEL CELL HYBRID ELECTRIC VEHICLES

15. MILD HYBRIDS

16. BATTERY ELECTRIC VEHICLES

17. OTHER ALTERNATIVE POWERPLANTS

23. COMMON ISSUES IN ALTERNATIVE POWERPLANTS

Ricardo Information Services – Alternative Powerplants News – August 2003

Other services offered by Ricardo Information Services include:

New Engine News - A newsletter covering new and modified engines

Roland Christopher, Information Manager, Ricardo Consulting Engineers

In the USA, please contact:

Paul Cassidy, Vice President of Business Development, Ricardo Inc.

Ricardo plc. © 2003

Ricardo Information Services – Alternative Powerplants News – August 2003

Fuel Cell Cars

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

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

Ricardo Information Services – Alternative Powerplants News – August 2003

Waseda University Environmental.

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

Fuel Cell Components

Hydrogen Sensor - NGK Spark Plug.

Fuel processors - University of California.

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

Ricardo Information Services – Alternative Powerplants News – August 2003

Deionized water system - Dana Corporation and General Motors.

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

Stack seals - Dow Corning Corporation

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

Fuel Cell Fuel Economy

Other Fuel Issues

JFE Container Co.

Ricardo Information Services – Alternative Powerplants News – August 2003

NTSEL, Gunma University and Kokushikan University.

Society of Automotive Engineers of China.

Nissan and Nippon Oil.

Ricardo Information Services – Alternative Powerplants News – August 2003

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

Ricardo Information Services – Alternative Powerplants News – August 2003

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

Common Issues in Hybrid Vehicles

Ricardo Information Services – Alternative Powerplants News – August 2003

Ricardo Information Services – Alternative Powerplants News – August 2003

Toyota and Denso.

National Traffic Safety and Environment Laboratory and Gunma University.

Industrial Technology Research Institute and Shibau Industrial University.

Ricardo Information Services – Alternative Powerplants News – August 2003

Ricardo Information Services – Alternative Powerplants News – August 2003

Ricardo Information Services – Alternative Powerplants News – August 2003

Ricardo Information Services – Alternative Powerplants News – August 2003

Ricardo Information Services – Alternative Powerplants News – August 2003

Unconventional I.C. Engines

DOE as an integral component of engine development

Colorado State University.

Ford Motor Company and University of California-Riverside.

Ricardo Information Services – Alternative Powerplants News – August 2003

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

RWTH and FEV.