Opposed-piston proposition

68 Pages·2017·14.25 MB·English

MOBILITY
ENGINEERING
TM
AUTOMOTIVE, AEROSPACE, OFF-HIGHWAY
A quarterly publication of and
Opposed-piston proposition
Greaves Cotton and Pinnacle Engines target
3-wheeler efficiency, emissions
India’s
EV-only vision
Myth, miracle
or reality?
Motorcycle
engine
simulation
Predicting
combustion-load
engine noise

Off-highway
flywheels
Durable energy
recovery and
load-leveling
Volume 4, Issue 3
September 2017
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CONTENTS
Features
36 Opposed-piston engines: the 44 Innovations for lightweighting
powerplant of the future
AUTOMOTIVE LIGHTWEIGHTING
AUTOMOTIVE POWERTRAIN Tough U.S. fuel-economy bogies for 2021 and beyond are
driving new approaches for materials, as seen in
38 India’s dream of an all-EV fleet these examples.
by 2030: Myth, miracle, or
48 More intelligence equals more
reality?
AUTOMOTIVE PROPULSION efficiency, enhanced
functionality
OFF-HIGHWAY ELECTRONICS |
41 An approach for prediction of
HYDRAULICS
motorcycle engine noise under
Advanced electronic systems require renewed focus on
combustion load
AUTOMOTIVE architectures, processors, sensors and networks.
SIMULATION
51 Connected commercial vehicles
bring cybersecurity to the fore
Cover
SAE COMVEC PREVIEW
Connectivity, automation and electrification will drive
U.S-based Pinnacle Engine’s
vehicle development in the near future, say industry experts
opposed-piston four-stroke
attending the revamped SAE COMVEC 17 event.
engine is being developed in a
technology partnership with
Indian engine and equip-
ment-maker Greaves Cotton. A
supplemental feature on p.36
examines the advantages of
opposed-piston engine layouts.
MOBILITY ENGINEERING SEPTEMBER 2017 1
CONTENTS
Departments
4 Editorial 20 Mechatronics technology offers improvements in
As EVs emerge, internal-combustion’s finest hour? performance and efficiency OFF-HIGHWAY
MECHATRONICS
6 SAEINDIA News
22 CO buildup in vehicle cabins becoming a safety
2
6 Aerospace: Then, now and future, February at issue AUTOMOTIVE SAFETY
Bengaluru
23 Exa simulation aims to keep ADAS sensors clean
7 MANOVEGAM Aero Championship final flight round, AUTOMOTIVE SIMULATION
April at Bengaluru
25 DSD’s low-cost 12V hybrid aims for small cars
7 Industrial seminars in May at Gurgaon AUTOMOTIVE POWERTRAIN
8 ‘Tractors for Modern Forming’ lecture meeting in April 26 Kubota goes ‘big’ with first-ever 200-hp diesel
engine OFF-HIGHWAY POWERTRAIN
9 Inter-Collegiate Club Project competition, June at Pune
26 Delphi and Tula show NVH benefits from Dynamic
9 Global Manufacturing Cluster Vision 2030 at Coimbatore
Skip Fire AUTOMOTIVE POWERTRAIN
10 Annual Social 2017 at Pune
28 Model maturity assessment and certification—a
11 Automotive Forum 2017 in Chennai vision TRUCK & OFF-HIGHWAY SIMULATION
11 Drive with IoT, June at Bengaluru 30 Commercial vehicles to become the ultimate ‘sensor’
OFF-HIGHWAY ELECTRONICS
13 SAE EGA, June in Bengaluru
31 Axellent progress AUTOMOTIVE PROPULSION
13 Aero Design Challenge 2017 finals, June in Chennai
34 Low-temperature combustion ready for prime time?
15 Industry News
AUTOMOTIVE POWERTRAIN
15 Pinnacle Engines partners with India’s Greaves 54 Global Vehicles
Cotton on new opposed-piston engine
54 2018 Honda Accord drops mass, adds turbos and
15 Tata Advanced Systems delivers first CH-47F
10-speed automatic
Chinook crown, tailcone for India to Boeing
55 Nissan engineers ‘Sport’ into its hot-selling CUV
16 BharatBenz delivers 50,000th truck
56 Sleek design, powertrain advances distinguish
16 IAC expands with new engineering center in India
Volvo’s new VNL trucks
17 Technology Report
58 Mercedes-Benz reveals production version of X-Class
17 Using power-dense flywheel hybrid technology to pickup truck
cut fuel consumption of OH equipment
59 VW finally fills its SUV gap with 2018 Atlas
OFF-HIGHWAY POWERTRAIN
61 Musclecar Godzilla: Dodge Reveals 840-hp
18 Mahle tests for ‘mega knock’ in downsized boosted Challenger SRT Demon
engines AUTOMOTIVE POWERTRAIN
63 Companies Mentioned, Ad Index
19 Lockheed Martin shows big support for Metamaterial
Technologies’ smart-materials research AEROSPACE 64 Q&A
MATERIALS Dr. Xinqun Gui, manager of technology, control systems
and emissions compliance at John Deere Power
Systems, discusses advanced emissions strategies
© SAEINDIA and SAE INTERNATIONAL reserves all rights .
No part of this publication and/or website may be reproduced, stored in a retrieval system or
transmitted in any form without prior written permission of the Publisher. Permission is only deemed
valid if approval is in writing. SAEINDIA and SAE International buys all rights to contributions, text and
images, unless previously agreed to in writing.In case of Address/addressee not found return to SAE
INDIA, No 1/17Ceebros Arcade, 3rd Cross, Kasturba Nagar, Chennai -600 020. Telefax: 91-44-2441-1904,
Phone: [phone].
2 SEPTEMBER 2017 MOBILITY ENGINEERING
ME Altair Ad 0917.qxp_Mobility FP 7/5/17 4:13 PM Page 1
EDITORIAL
EDITORIAL
Bill Visnic
Editorial Director
[email protected]
Asit K. Barma
SAEINDIA Editor As EVs emerge, internal-combustion’s finest hour?
C. V. Raman
ED, MSIL
[email protected] I find it not without irony that at the time the OP engine design presents many potential
Arun Jaura auto industry is consumed with interest and in- advantages, including substantial improve-
Project Director, Michelin
[email protected] vestment in battery electric vehicles (EVs), the ments in thermal efficiency, reduced parts
Bala Bharadvaj technology presumably being “displaced”—the count and lower emissions. Not coincidentally,
MD, Boeing R & T
[email protected] internal-combustion engine—might be reaching on the cover of this issue you’ll find the new
Mathew Abraham its most promising stage of development. OP-engine design that Greaves Cotton and the
Sr. GM, Mahindra
[email protected] During this seminal period of automotive U.S.’s Pinnacle Engines said can propel India’s
Dr. Venkat Srinivas technology disruption, both EV propulsion and three-wheelers to BS VI emissions compliance
Vice President & Head -
Engineering & Product IC powertrains are indeed competing, if you (see p. 15 for those details).
Development, Mahindra & will. Some argue that it really isn’t a competi- Meanwhile, just as this issue of Mobility
Mahindra Truck and Bus Division
[email protected] tion at all: the 100-year-old IC engine has a Engineering was created, Mazda announced it
Lindsay Brooke mature and easy to volume-build design, is will introduce a sparkless compression-ignition
Editor-in-Chief
[email protected] inexpensive to build and its efficiency, if not gasoline engine for production vehicles in 2019.
Ryan Gehm remarkable, certainly isn’t shameful anymore. Gasoline compression-ignition has been a pow-
Associate Editor
[email protected] Toyota, Honda and others have mass-produced ertrain development aspiration for more than a
Jennifer Shuttleworth gasoline engines in affordable vehicles that decade because the technology presents the
Associate Editor
[email protected] now are turning into work as much as 40% of opportunity to match or surpass diesel-engine
Lisa Arrigo their fuel’s energy. efficiency without the emissions liabilities die-
Custom Electronic
Products Editor But IC engines generate tailpipe emissions. sels can’t seem to overcome.
[email protected] And as vast as the improvements in engine General Motors, Hyundai and others have
Contributors emissions-reduction have been, EVs present the had documented gasoline compression-ignition
Kami Buchholz advantage—albeit perceived—of having zero development programs, but until Mazda’s
Detroit Editor
emissions. Factor in the recent controversy sur- announcement that its so-called Skyactive-X
Stuart Birch
European Editor rounding many automakers’ manipulation— engines will be available in 2019 would make it
Jack Yamaguchi deliberate or alleged—of diesel emissions and the first company to make the technology com-
Asia Editor
cities around the world are ginning up legisla- mercially available. More importantly in terms
Steven Ashley
Dan Carney tion to outlaw diesels or IC engines in favor of of the EV-versus-IC tussle, Mazda claims a
Terry Costlow
Richard Gardner “zero-emission” EVs. Skyactive-X engine’s well-to-wheels emissions
John Kendall
Bruce Morey Two excellent feature stories in this issue are better than an EV when factoring the emis-
Linda Trego
Paul Weissler almost precisely demarcate the extremes of the sions of the central source of electricity an EV
EV-versus-IC conversation—and why the attempt needs for charging.
DESIGN
to legislate any single solution is likely to fail. Mazda may steal the thunder from
Lois Erlacher
Creative Director On page 38, a trio of powertrain engineers mega-supplier Delphi, which is assiduously
Ray Carlson from Hindujatech provide an incisive and fair- working to create its own viable production sys-
Associate Art Director minded analysis of what would be required for tem, called GDCI (gasoline direct-injection com-
India to reach EV sales and market-share mile- pression-ignition). Delphi claims GDCI engines
SALES &
stones in the coming future. And while they will be capable of achieving 42% thermal effi-
MARKETING
don’t directly discuss the emissions “profile” of ciency, meet the U.S.’s most-rigorous emissions
G. Vijayan
SAEINDIA EVs when compared with today’s IC engines, standards and do so on regular-grade unleaded
No.1/17, Ceebros Arcade
they do point out that to supply a large quan- gasoline; those details and more can be found
3rd Cross Kasturba Nagar
Chennai tity of EVs with sufficient charging energy, India starting on p. 34.
India 600 020
(T) 91-44-24411904 would require scores of new utility-scale pow- As EVs to many appear to be the way for-
(E) [email protected]
erplants. Unless they are nuclear, the power- ward, it’s fascinating to see such intense con-
plants would burn some kind of fossil fuel and current development in IC-engine innovation.
create emissions. I’m pleased you’ll find many of the latest devel-
Meanwhile, the story immediately preceding opments pertinent to this high-stakes contest in
on page 36 details the promising work that’s this issue of Mobility Engineering.
underway on opposed-piston IC engines. The Bill Visnic, Editorial Director
4 SEPTEMBER 2017 MOBILITY ENGINEERING
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SAEINDIA
SAEINDIA
BOARD OF DIRECTORS
Dr. R.K. Malhotra
President
News
Dr. Aravind S. Bharadwaj
Immediate Past President
Dr. Bala Bharadvaj
Sr. Vice President & Chairman,
Finance Board & Aerospace Board
Mrs. Rashmi Urdwareshe
Aerospace: Then, now and future, February Vice President & Chairperson,
Membership Board
Mr. I.V. Rao
at Bengaluru
Vice President & Chairman,
Engineering Education Board
Mr. Sanjay Deshpande
Dignitaries lighting
Secretary
the lamp.
Dr. G. Nagarajan
Treasurer & Vice Chairman,
Engineering Education Board
Prof. Prakash Joshi
Joint Secretary
Dr. Arunkumar Sampath
Vice President & Chairman, Automotive
Board & Vice Chairman, Finance Board
Mr. N. Balasubramanian
Chairman, Meetings and
Exposition Board
Mr. P. Panda
Vice Chairman, Meetings and
Exposition Board
Mr. Nitin Agarwal
Chairman, Off-Highway Board
Com. Rakesh B. Verma
Vice Chairman, Off-Highway Board
Mr. Prakash Sardesai
Chairman, Professional Development
Programs Board
Dr. R. Venugopal
Vice Chairman, Professional
Development Programs Board
The SAEINDIA Aerospace Board successful- MD, Altair India; Mr. Michael Jones, APAC
Mr. Balraj Bhanot
ly convened a high-profile marque event in Business Director, Eaton; Mr. Sundaresh Chairman, Development Board
February in Bangalore. It was well-posi- Shankaran, AVP, Head of Core Engineering Dr. K.P. Murthy
Vice Chairman, Development Board
tioned in February between the highly suc- Infosys; Mr. J. Munirathnam, Chairman –
Ms. Pamela Tikku
cessful launch of the interceptor missile in SAEIBS; Mr. Damodaran Subramaniam, Sr. VP, Chairman, Section Board
Odisha and the inauguration of Aero India Safran Engineering; Mr. Ravi Shankar Mysore, Mr. Sanjay Nibhandhe
Vice Chairman, Section Board
in Bangalore. Head of Engineering, UTAS; Mr. Ravindra
Mr. S. Radhakrishnan
The theme Aerospace & Defense Then, Nuguri, CDO, L&T Technology Services; Mr. G Vice Chairman, Membership Board
Now and Future attempted to provide a per- VV Ravikumar, AVP Advanced Manufacturing Representing SAE
spective of evolution and way forward. The Infosys; Mr. Vasanth Kini, MD, Titanium International
event theme tracked perfectly with knowl- Industries; Mr. Anand Joshi, Head of Dr. David L. Schutt
Chief Executive Officer
edge contributions from very experienced Engineering, Eaton; and Mr. Parvez Alam,
Mr. Murli M. Iyer
leaders like Mr. Ashok Baweja Former COO, UCAL-JAP. Executive Advisor-Global Affairs
Office of the Chief Executive Officer
Chairman HAL and Head – Quest Global The audience comprised several A&D
Defense; Dr. Bala Bharadwaj, MD, Boeing S&T industry leaders and nearly half of the audi- Presented by SAEINDIA
Media, Communications and
and Vice Chair SAEINDIA; Mr. Hitendu ence was young aerospace professionals
Publications Committee
Chaudhry Ex HAL and TAAL; Mr. David who represent the future. The topics cov-
Dr. Sudhir Gupte
Bradley, ED, Assystems; Ms. Karla Wallace, ered by the speakers and panelists were Chairman
ED, UTAS; Mr. Mikael Erdos, Head – Overview of Aerospace Industry by Mr. Asit Kumar Barma
Vice Chairman
Engineering, Airbus India; Mr. Pavan Kumar Assystems, Innovation in Aircraft Systems
Mr. Vasanth Kini
integration with six sub-topics: Integrated Member
Mr. Dhananjayan
Propulsion, Electric Architecture, Intelligent
Member
Systems, Advanced Materials, Advance Dr. Vijaykanthan Damodaran
Member
Manufacturing and Advanced Methods by
Mr. Deepak Sawkar
UTAS; Industry 4.0 for Aerospace by Infosys; Member
Make in India by Quest Global Defense; Mr. Jitendra Malhotra
Member
Indian Engineering Experience by Airbus; Dr. S. Selvi
Learnings from APAC/China experience over Member
Mr. T. Bharathiraja
10 years by Eaton; Operating Centers in Member
India by Altair Engineering; and SAEINDIA Ms. Swati Milind Athavale
Member
Aerospace Board and SAEINDIA Bangalore
Mr. Manohar K. Chaudhari
Section updates. There was extensive net- Member
working between the speakers, panelists, Mr. Rajesh Kumar
Member
board members and the audience during the Mr. Saravanan Natarajan
lunch and tea breaks and the event received Member
Dr. M.K. Ravishankar
Mr. Munirathnam presenting the memento. considerable positive feedback. Member
6 SEPTEMBER 2017 MOBILITY ENGINEERING
SAEINDIA
News
MANOVEGAM Aero Championship final flight round,
April at Bengaluru
Lamp lighting by the dignitaries. Event dignitaries.
MANOVEGAM 2017 was inaugurated flight round. The virtual round was con- first prize in the regular class and PESIT-
during the October, 2016 networking ducted in March and the flight round Bengaluru south campus won the first
dinner with SAE International President was conducted in April at Siddaganga prize in the micro class. Dr. Bala
Mr. Cuneyt Oge, SAEINDIA Aerospace Institute of Technology (SIT), Tumkuru, Bhardwaj, MD, Boeing India Engineering
committee members and SAEINDIA Karnataka. The MANOVEGAM Flight & Technology Center, served the vale-
Bengaluru section managing commit- round was inaugurated by Dr. Sree dictory function and as a chief guest
tee members at Bengaluru. The compe- Sivakumara Swamigalu, Founder, Sri presented the awards to the winning
tition was in two different categories, Siddaganga Education Society and teams. And the four teams’ members
Regular class and Micro class. Regular Prasanth Sakhamuri, MD, Hind High won internship opportunities in top
class is a glow-engine competition, Vacuum Company Pvt. Ltd. aerospace companies.
with the purpose of developing the A total of 29 teams comprised of 261 The entire event was well-orches-
fundamental understanding of flight. undergraduate and graduate students trated by the Convener Mr. Damodaran
Micro class is an all-electric competition from different parts of INDIA partici- Subramaniam – managing director
to balance the tradeoff between two pated in the event. The competition was Safran aerospace engineering service
potentially conflicting requirements— judged by a panel of eminent personali- followed by organizer and logo designer
carrying the highest-possible payload ties from Safran Engineering Services, Mr. Purushotham, Mr. Sathyakanth
while simultaneously pursuing the low- Assystem, Airbus, Rolls Royce, UTAS, Thagyarajan, Mr. Shanshanth, Mr. Rakesh
est empty weight. UCAL-JAP Super fly hobby, Javaji M D.R. and Ms. Jyothi of SAEIBS with their
The competition consists of two dif- Consulting, HCL, GE, and CEMILAC. outstanding contribution for achieving
ferent phases: the virtual round and a Viva Institute of Technology won the grand success to this event.
Industrial seminars in May at Gurgaon
Two seminars organized in association with Siemens, “Finite
Element Analysis (FEA) for the Automotive Industry using
Simcenter” and “Bharat Stage VI – How it impacts Testing,
Instrumentation and Development,” were organized in associ-
ation with AVL by SAEINDIA Northern Section (SAEINS) in
May at Gurgaon.
For the “Finite Element Analysis (FEA) for the Automotive
Industry using Simcenter,” seminar, the welcome address was
given by Mr. Ajay Pandey of Siemens and the inaugural
address—along with a brief on SAEINS activities—was given
by Mr. Sunil Malhotra, Vice Chairman (seminars and confer-
ences). The seminar gave insight on the impact of Finite
Element Analysis (FEA) for Automotive Industry using Mr. Rakesh Sood presenting the memento.
MOBILITY ENGINEERING SEPTEMBER 2017 7
SAEINDIA
News
Simcenter in the mobility sector and detailed how the soft-
ware delivers unmatched modeling realism and computational
performance. The software is designed to help predict real
product behavior and put 3D simulation on the critical path
for complex product development.
The speakers included Mr. Kamanasish Biswas, Mr. Geetanand
Kedilaya and Mr. Khushpreet Singh; the three have a combined
experience of 30-plus years. They presented the salient features
and advantages of Simcenter for mobility experts. The seminar
saw participation from cross-section of industries and three
Colleges. The valedictory address was given by Mr. P Panda – Sr.
Vice Chairman SAENIS. Mr. Rakesh Sood – Vice Chairman
The seminar group.
Student Activities SAENIS, also was present.
Bharat Stage VI – How it impacts Testing, Instrumentation
and Development, was presented to offer insight on the impact Paquereau, GM, Engine and Vehicle Development, AVL India;
of BS VI on testing instrumentation and development in the Mr. Alexander Painsi - BDM, Emission Instrumentation, AVL
mobility sector. A brief on SAEINS activities was given by Mr. Graz; Mr. Marco Schoeggl – BDM, In-Vehicle Measurement, AVL
Anup Kacker, ED, SAEINS. It was followed by expert talk by Graz; Mr. Franz Murr – BDM, Combustion Measurement, AVL
team of experts from AVL namely Mr. Michael Muehloegger, Graz; and Mr. Peter Domjan - Group Product Manager,
Global Business Unit Manager, Measurement & Instrumentation Consumption Measurement, AVL Graz.
Products, AVL Graz; Mr. Manoj Kusumba, HOD, Diesel The seminar had participation from cross-section of industries
Development, PTE/DED, AVL India; Mr. Jean Baptiste and five colleges and saw total participation of 65 attendees.
‘Tractors for Modern Forming’ lecture meeting in April
The SAEISS Erode Division organized its Engineering and Technology. Dr. E. improving the development of farming
fifth lecture meeting on ‘‘Tractors for Rajasekar, Secretary, SAEISS and at TAFE research institute. Modern
Modern Forming” in April at Vellalar Professor, IRTT, Erode, detailed the forming methods, which now are typical
College of Engineering and Technology, SAEINDIA and SAEISS activities and industry practice, also were discussed.
Erode, together with the Collegiate Club welcomed the participants of the lec- The trends in the Indian agriculture sec-
at the venue opening by Mr. S. Sriraman, ture meeting. tor and its various developments also
Chairman SAEISS. Dr. Jayaraman, Dr. P. Navaneethakrishnan, Chairman, were discussed.
Principal of Vellalar College of SAEISS-Erode Division, introduced the Dr. M. Easwaramoorthy, Secretary
Engineering and Technology, presented speaker to the participants and handed SAEISS Erode Division, delivered the
a salvai to him. over the session for his lecture. Mr. S. vote of thanks. Dr. R. Kumaravelan,
Mr. S. Sriraman presented the Sriraman started his lecture by explain- HOD/Mechanical Engineering, Vellalar
SAEINDIA Collegiate Club certificate to ing the topic of the day, “Tractors for College of Engineering and Technology
Mr. S. D. Chandrasekar, Secretary and Modern Forming,” which detailed vari- presented the memento to Mr. S.
Correspondent of Vellalar College of ous activities undertaken by TAFE for Sriraman as a token of gratitude.
Lighting the kuthuvilaku by Mr. S. Sriraman, Chairman, SAEISS Handing over the SAEINDIA Collegiate Club Certificate by Mr. S.
and Senior Vice President, TAFE, Chennai. Sriraman and Dr. P. Navaneethakrishnan.
8 SEPTEMBER 2017 MOBILITY ENGINEERING