Automotive Innovation: The Science and Engineering behind Cutting-Edge Automotive Technology

323 Pages·2019·22.87 MB·\323

by  Patrick Hossay (Author)

Automotive Innovation

Automotive Innovation
The Science and Engineering behind
Cutting-Edge Automotive Technology
Patrick Hossay
CRC Press
Taylor & Francis Group
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Library of Congress Cataloging‑in‑Publication Data
Names: Hossay, Patrick, 1964- author.
Title: Automotive innovation : the science and engineering behind
cutting-edge automotive technology / Patrick Hossay.
Description: First edition. | Boca Raton, FL : CRC Press/Taylor & Francis
Group, [2020]
Identifiers: LCCN 2019009155 | ISBN 9781138611764 (hardback)
Subjects: LCSH: Automobiles—Technological innovations—Popular works. |
Automobiles—Design and construction—Popular works.
Classification: LCC TL240 .H655 2020 | DDC 629.2—dc23
LC record available at https://lccn.loc.gov/2019009155
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Contents
Preface ..............................................................................................................................................ix
Author ...........................................................................................................................................xiii
1. Bringing the Fire .....................................................................................................................1
What Is Gasoline? ....................................................................................................................2
The Engine ................................................................................................................................3
The Four Strokes ......................................................................................................................4
The Engine Comes Together ..................................................................................................8
Valve Train ..............................................................................................................................11
Defining the Combustion Chamber ....................................................................................13
Pistons .....................................................................................................................................16
The Head .................................................................................................................................19
Ignition ....................................................................................................................................23
Knocking .................................................................................................................................24
Fuel Delivery ..........................................................................................................................27
Low-Temperature Combustion ............................................................................................34
2. The End of Compromise .....................................................................................................39
Advanced Digital Control.....................................................................................................39
Sensor Technology .................................................................................................................40
Engine Control .......................................................................................................................42
Variable Valve Actuation ......................................................................................................45
Induction .................................................................................................................................52
Forced Induction ....................................................................................................................55
Compression Ratio .................................................................................................................58
3. Getting Power to the Pavement .........................................................................................65
What Do We Need a Drivetrain to Do? ..............................................................................65
Manual Transmission Coupler .............................................................................................72
Manual Transmission ............................................................................................................74
Automated Manual ................................................................................................................76
Automatic Transmission Coupler ........................................................................................80
Automatic Transmissions .....................................................................................................82
Transmission Control ............................................................................................................86
Continuously Variable Transmissions ................................................................................88
Differentials, AWD, and Torque Vectoring ........................................................................92
Advanced Tires and Control ................................................................................................96
4. Electric Machines ..................................................................................................................99
The Principles of the Electric Motor ..................................................................................100
Making an Electric Machine ..............................................................................................102
Motor Performance ..............................................................................................................108
Torque and Power ................................................................................................................110
Cooling ..................................................................................................................................112
v
vi Contents
Induction Motor ...................................................................................................................113
Permanent-Magnet Machines ............................................................................................118
Magnets .................................................................................................................................121
BLPM Control .......................................................................................................................122
Reluctance Machines ...........................................................................................................124
Advanced Motor Possibilities ............................................................................................126
5. Electrified Powertrains ......................................................................................................131
Gas versus Electrons? ..........................................................................................................131
Hybrid Drive .........................................................................................................................133
Baby Steps .............................................................................................................................135
Mild Hybrid ..........................................................................................................................137
Full Hybrid ...........................................................................................................................141
Adding a Plug .......................................................................................................................148
Power .....................................................................................................................................148
Electric Vehicle .....................................................................................................................151
Electric Car Viability ...........................................................................................................155
Using Energy Effectively ....................................................................................................160
6. The Electric Fuel Tank .......................................................................................................165
What’s a Battery? ..................................................................................................................166
Battery Performance ............................................................................................................171
Battery Management ...........................................................................................................172
Cell Balancing .......................................................................................................................175
Cooling Systems ...................................................................................................................176
Battery Chemistry ................................................................................................................179
Nickel-Based Batteries .........................................................................................................181
Lithium ..................................................................................................................................184
Future Possibilities...............................................................................................................190
7. Automotive Architecture ..................................................................................................195
General Chassis Design ......................................................................................................195
Frames ...................................................................................................................................197
Crashworthiness ..................................................................................................................200
Materials ................................................................................................................................203
Alternative Metals ...............................................................................................................210
Manufacturing Metal ..........................................................................................................216
Plastics ...................................................................................................................................218
Suspension ............................................................................................................................224
Chassis Control ....................................................................................................................226
Bringing It All Together ......................................................................................................229
Modularity ............................................................................................................................230
8. The Power of Shape ............................................................................................................233
The Nature of Drag ..............................................................................................................234
The Power of Shape .............................................................................................................235
Boundary Layer ....................................................................................................................237
The Shape of a Car ...............................................................................................................238
The Front of the Car .............................................................................................................240
Contents vii
Addressing the Rear Wake .................................................................................................243
Three Dimensional Flow ....................................................................................................247
Vortex Generators ................................................................................................................250
Lift ..........................................................................................................................................251
The Ground ...........................................................................................................................253
Wheels ...................................................................................................................................257
Bringing the Body Together ...............................................................................................259
Active Aerodynamics ..........................................................................................................261
9. Smarter Cars ........................................................................................................................265
Smarter Driving ...................................................................................................................266
Perception..............................................................................................................................272
Radar ......................................................................................................................................273
Lidar .......................................................................................................................................275
Optical ...................................................................................................................................277
Sensor Fusion .......................................................................................................................281
Driver Monitoring................................................................................................................282
Localization ..........................................................................................................................283
Mapping ................................................................................................................................286
Communication ....................................................................................................................288
Decision-Making ..................................................................................................................290
The Road Ahead ...................................................................................................................293
Index .............................................................................................................................................295

Preface
Cars have changed radically over the past few decades, and the pace of change is only
accelerating. Innovations in engine design, fuel systems, digital control, advanced trans-
missions, and a range of other technologies have fundamentally redefined the powertrain.
And advanced electronic control systems, active chassis control, driver assistance systems,
not to mention electrified drivetrains, advanced batteries, and new lightweight materials
are allowing us to profoundly reimagine what is possible. It can be tough to keep up. And
that’s the point of this book.
These exciting changes and innovations in automotive technology are complex, but
they don’t need to be intimidating. Fundamentally, the same basic principles are at work,
whether you’re looking at a Model T or a Tesla. The laws of science and mechanical
principles haven’t changed. Admittedly, the engineering particulars have become more
involved, and there are a lot more of them. But, in the end, all of the technology in the most
advanced vehicles can be understood in principle by anyone with a basic grasp of science
and mechanics.
So, think of this book as a primer, a basic survey of the new automotive landscape with
an eye toward a timely orientation to the most interesting innovations and the most prom-
ising technological advances out there. One aim of this work is to provide a solid intro-
ductory text for an undergraduate course. In particular, the idea is to fill the gap between
a vocational-based automotive repair text and an advanced engineering text. In fact, this
book grew out of an undergraduate survey course on automotive technology and design.
Finding a useful text for this sort of course has always been difficult, as nearly all introduc-
tory texts in automotive technology focus on vocational training for mechanics; and the
only other alternative is often a technically dense engineering text, a rather intimidating
introduction to the field. This text is aimed at the midpoint: a true introductory survey of
the science and engineering in automotive technology that allows a generally informed
reader to develop an understanding of the principles, trends, and challenges in automotive
technology and the possible directions of future developments.
With this in mind, the aim is to keep this work accessible and engaging. A useful orien-
tation to the field should be readable and stimulating for students, mechanics, automotive
enthusiasts, and anyone else who may have an interest in cars, technology, innovation,
or engineering. This stuff is really amazing, exciting, and frequently ingenious; but
all-too-often, the amazing stuff is buried under layers of engineering terminology and
daunting computations that can thoroughly snuff out the flame of enthusiasm in the
uninitiated. Cars can be really exiting; a book on them should be too.
So, this book will be useful for students of automotive engineering and technology that
need an orientation to the field. This book should also be useful to a seasoned automotive
technician trying to stay on top of a rapidly changing field, or a newly minted mechanic
who needs a general orientation to the near future of the automobile, and even an auto-
motive enthusiast who just wants to better understand how recent technological changes
come together.
With luck this text will inspire budding engineers and maybe even motivate a few
mechanics and gear heads to dig deeper, continue to explore the field, and perhaps even
choose to take the next step and select a career that allows them to contribute to redefin-
ing the future of the automobile. This is truly a golden age in automotive design, a time
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