DETROIT, Feb. 25 /PRNewswire/ -- Delphi (NYSE: DPH) engineers, researchers
and scientists will reveal a glimpse at the future of automotive technology
March 4-7 at the Society of Automotive Engineers (SAE) 2002 World Congress by
presenting 37 technical papers. Delphi experts will address the future of 42-
volt, solid-oxide fuel cell and brake-by-wire systems; ways to improve fuel
economy and lower tailpipe emissions; the development of new materials; and
techniques for reducing noise, vibration and harshness, as well as helping
increase vehicle stability and safety in future vehicles.
(Photo: http://www.newscom.com/cgi-bin/prnh/20001019/DELPHIAS )
"Delphi's more than 16,000 engineers, scientists and technicians continue
to develop the latest innovations that are driving tomorrow's technology,"
said J.T. Battenberg III, Delphi chairman, CEO and president. "We are looking
forward to participating in this year's technical discussion during the SAE
World Congress to share some of our recent research findings that are sure to
shape the vehicles of the future."
In addition to this year's technical presentations, Mark Sellnau, Delphi
research scientist, will be awarded the Arch T. Colwell Merit Award for his
2001 technical paper "Cylinder-Pressure-Based Engine Control Using Pressure
Ratio Management and a Low-Cost Non-Intrusive Cylinder Pressure Sensor," which
he co-authored with General Motors' Frederic A. Matekunas, Paul A. Battiston,
Chen-Fang Chang and David R. Lancaster. This award, presented at the SAE
Honors and Convocation on Tuesday, March 5, recognizes the authors of papers
of outstanding technical or professional merit. Papers are judged primarily
for their value as new contributions to existing knowledge of mobility
engineering. Sellnau's paper discusses a low-cost engine control system that
utilizes non-intrusive cylinder pressure sensors mounted in the spark plug
boss of four-valve-per-cylinder engines and presents the cylinder pressure
sensing concept, the sensor design and the system description. The technology
can be applied to gasoline or diesel engines for improved fuel economy and
reduced emissions, and can significantly simplify the engine calibration
process.
Highlights of nine significant Delphi papers to be presented at this
year's SAE World Congress include:
"Fuel Economy Improvements in an SUV Equipped with an Integrated Starter
Generator" (Monday, March 4, at 1:30 p.m., room D0-04AB, Cobo Center)
The recent surge in gas prices has drawn attention to the lower average
fuel economy of the growing class of sport utility vehicles (SUV). Vehicle
manufacturers are looking for ways to improve the fuel economy of these
vehicles without affecting performance or utility. One possible solution is
the 42-volt integrated starter-generator (ISG). The ISG offers the ability to
reduce fuel consumption through the use of engine-off during coast-down and
idle, early torque converter lockup with torque smoothing, regenerative
braking and electrical launch assist. This paper details the fuel economy
benefits offered to SUVs with an engine stop-start function implemented with
an ISG. Dynamometer test results for an SUV equipped with a Delphi-designed
Energen-10(R) ISG are presented.
"The BRAKE Project - Centralized Versus Distributed Redundancy for Brake-
By-Wire Systems" (Monday, March 4, at 2:30 p.m., room O2-35/36, Cobo Center)
Today, many system vendors develop complete chassis systems. The
characteristics of each system are determined by both hardware and software.
This paper presents the objectives and preliminary results of the BRAKE
project - a collaborative effort of Delphi, Infineon Technologies, Volvo Car
Corporation and WindRiver. The objective of this project is to use
microelectronics technologies to design a distributed brake-by-wire system,
including: a distributed fault-tolerant system for enhanced safety, an
extension of the OSEK-based operating system for a distributed time-triggered
architecture, and an open interface between vehicle control and brake system
control.
"Fast Start-Up On-Board Gasoline Reformer for Near Zero Emissions in
Spark-Ignition Engines" (Monday, March 4, at 3:30 p.m., room W2-70, Cobo
Center)
The Ultra-Low-Emission Vehicle (ULEV) II standards proposed for 2004
introduction in California include a Super-ULEV (SULEV) standard. Gasoline-
fueled vehicles that robustly meet SULEV standards over their useful lives
offer a significant step toward eliminating the automobile as a source of
regulated pollutants. Developing SULEVs can significantly reduce an OEM's
fleet average non-methane organic gas (NMOG) emissions. This paper describes
recent progress in Delphi's program to develop a gasoline-fueled vehicle with
an on-board reformer to provide near-zero tailpipe emissions and shows results
from an engine linked to an experimental, fast start-up reformer. The authors
present both performance data for the reformer as well as engine emissions and
performance results. Program results continue to show an on-board reforming
system to be an attractive option for providing near-zero tailpipe emissions
to meet low emission standards.
"Cold Starting Performance of a 42-Volt Integrated Starter Generator
System" (Tuesday, March 5, at 3:30 p.m., room D2-15, Cobo Center)
Over the next several years, vehicle manufacturers will begin to use a 42-
volt-based system to integrate the starter and generator into one unit known
as an integrated starter-generator (ISG). The ISG, its associated electronics
and battery pack form a system that has the ability to perform torque
smoothing of the driveline, electrical launch assist, regenerative braking,
high power generation, engine stop/start and other features. One of the
important tasks to be performed by the ISG is starting the internal combustion
engine under extremely low temperature conditions. Cold starting requirements
have a great influence on the design of any ISG system. This paper examines
how the cold starting requirements affected the design of the Delphi Energen-
10(R) ISG system. Test results performed at -29 degrees C for the cranking of
a gasoline 4.0-liter, V-6 powertrain are presented. A discussion of the
electric motor control strategy used during the cold starting events with an
ISG system is also included.
"Solid-Oxide Fuel Cell Auxiliary Power Unit - A Development Update"
(Tuesday, March 5, at 10:30 a.m., room M2-29, Cobo Center)
Delphi and BMW were successful in demonstrating an Auxiliary Power Unit
(APU) based on solid-oxide fuel cell (SOFC) technology in February 2001. An
SOFC APU generates power using hydrogen and carbon monoxide reformed from
fuels such as gasoline, diesel, or natural gas. This paper describes Delphi's
most recent activities in the development of a second-generation APU. This
development has been targeted toward resolving the fundamental issues with the
following key subsystems: fuel-cell stack, fuel reformers, and energy and
thermal management. Major focus has also been directed at system integration
challenges to make a more robust and efficient product.
"Optimization of a Modular Cockpit Cross-Car Beam for Crashworthiness"
(Wednesday, March 6, at 10 a.m., room W1-55, Cobo Center)
Modularization is demanded more each day by OEMs because it minimizes
production cost, reduces development time and improves quality while enhancing
performance. A cockpit module is a complex subsystem that houses components
such as driver and passenger air bags, knee bolsters, steering column,
instrument cluster, heating and cooling systems, and an entertainment system.
These components are either partially or fully supported by the cross-car
beam. This subsystem should be quiet while in operation. The cross-car beam
should be designed in such a way that it withstands the high dynamic loads
induced during a crash event. Virtual build of vehicles, using math-based
engineering tools such as finite element modeling, is replacing the costly,
time-consuming hardware builds during the developmental phase. Optimal design
of the beam will minimize the mass and hence reduce the cost of the module.
This paper presents a numerical optimization of a modular cockpit cross-car
beam for crashworthiness subjected to loads induced due to a side-impact using
a commercial code (LS-OPT) that uses an optimization algorithm based on
statistical methods.
"Influence of Vehicle Chassis Systems on Vehicle Propensity To Maneuver-
Induced Rollovers" (Wednesday, March 6, at 3 p.m., room D0-03CD, Cobo Center)
With growing popularity among consumers of vehicles with high centers of
gravity, evaluation of rollover propensity of these vehicles becomes an issue
of increasing importance. This paper evaluates the effects of active chassis
systems on vehicle propensity to roll over caused by aggressive handling
maneuvers. The results of simulations demonstrate that an uncontrolled
vehicle rolls over in tested maneuvers when the steering angle is sufficiently
large. Active chassis control systems significantly increase rollover
stability - either the vehicle cannot be rolled over regardless of the
magnitude of the steering angle, or the amplitude of the steering angle
necessary to roll over the vehicle is markedly increased.
"Thermoplastic Elastomer Intumescent Fire Shield" (Thursday, March 7, at
4 p.m., room D0-03AB, Cobo Center)
The intumescent material described in this paper expands under high heat
or fire conditions to form an insulating sponge. The material -- a blend of
high-density polyethylene and chlorinated polyethylene -- is processed using
normal plastic techniques. Tensile properties, heat aging, fluid aging, and
thermal properties have been evaluated and are presented. Fire testing using
a 1000 degrees C Bunsen burner as a source, showed that the material does not
drip or burn through, even after 30 minutes of exposure. Prototype fire
shields made of the intumescent material have been tested on fuel tanks,
bulkheads, and wheel well covers. In all cases the intumescent material
provided excellent protection. Similar applications are identified for
airplanes, motorcycles, industrial and residential buildings. The material is
recyclable and can be made from recycled polymers.
"Emerging Substrate Technologies for Harsh-Environment Automotive
Electronics Applications" (Thursday, March 7, at 10:30 a.m., room D2-13/14,
Cobo Center)
The requirements for harsh environment (e.g. on-engine, on- or in-
transmission) electronic controllers in automotive applications have been
growing increasingly stringent. Along with the environmental concerns come
the challenges of meeting overall size constraints required of increasingly
complex controllers by utilizing finer features and geometries. Electronic
substrate technologists have evolved to meet the challenge posed by the
performance, size and cost requirements. This paper deals with two primary
interconnection substrate technologies that are poised to meet the challenge:
1) organic laminate based high-performance printed wiring boards and 2)
ceramic based substrates.
For more information about Delphi, please visit Delphi's Virtual PressRoom
at http://www.delphi.com/vpr .
SOURCE Delphi Automotive Systems
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