Search Results (32)

The present paper proposes a novel approach for the estimation of the in-cylinder pressure and heat release in diesel engines from basic testbed measurements (i.e., brake mean effective pressure (BMEP), gross indicated mean effective pressure (IMEP360), peak firing pressure (PFP), crank angle at which 50% of fuel mass has burnt (MFB50) and exhaust gas temperature (T_exh). The method exploits a previously developed low-throughput combustion model, based on the accumulated fuel mass approach, which has been tuned by a genetic algorithm (GA) optimizer. The latter adjusts the main combustion model parameters to minimize an objective function, which depends on the prediction errors of BMEP, IMEP360, PFP, MFB50 and T_exh. Several scenarios were evaluated in which different subsets of the four previous quantities were assumed to be known from experimental activities. The proposed method is particularly useful when in-cylinder pressure traces are unavailable and only basic testbed data exist. The results show that the in-cylinder pressure and heat release profiles are estimated with a high level of accuracy, since the root mean squared error is of the order of 1–2.5 bar and 2–2.7 × 10⁻² kJ, respectively, depending on the considered scenario, while requiring a modest computational effort which is of the order of 3–6 min per test. Moreover, the low-throughput nature of the method makes it straightforward for other researchers to implement and reproduce results on different engines. The approach is also fuel-independent and can be applied to engines running on alternative/zero-carbon fuels, which are currently being extensively studied as potential ways to reduce the environmental impact of internal combustion engines. Full article

The term honk noise describes a low-frequency brake noise from approximately 400 Hz to 500 Hz which arises at extremely low speeds and low brake pressures. Manoeuvres like slowly releasing the brake at a hill or gently braking against the drag torque of an automatic gearbox lead to honk noise. Under the same conditions, we observed creep groan at about 80 Hz. It has been shown that honk noise usually occurs after or alternates with creep groan. For this reason, it is assumed that honk noise—like creep groan—is a stick–slip-induced phenomenon and therefore shows highly nonlinear behaviour. In this paper, we present an approach for explaining the onset of honk noise under stick–slip excitation. A minimal model consisting of coupled mass oscillators excited by stick–slip is investigated. The model was able to reproduce the phenomena observed in the experiments. Thus, it is suitable for explaining the mechanisms leading to honk and estimate the influence of basic parameter variations. The lessons learned are a crucial step towards more realistic finite element or multi-body simulation methods, which have high potential for saving costs in the noise, vibration, and harshness (NVH) development process of brake systems. Full article

This paper focuses on enhancing master cylinder pressure control in pressure-sensorless Electro-Hydraulic Brake (EHB) systems. A novel control strategy is developed, integrating a Piecewise Sliding Mode Controller (Piecewise-SMC) with an Extended Sliding Mode Observer (ESMO) based on a newly derived pressure–position–velocity model that accounts for rack position and velocity effects. To handle external disturbances and parameter uncertainties, the ESMO provides accurate pressure estimation. The nonlinear EHB model is approximated piecewise linearly to facilitate controller design. The proposed Piecewise-SMC regulates motor torque to achieve precise pressure tracking. Experimental validation under step-change braking conditions demonstrates that the Piecewise-SMC reduces response time by 31.8%, overshoot by 35.8%, and tracking root mean square error by 9.6% compared to traditional SMC, confirming its effectiveness and robustness for pressure-sensorless EHB applications. Full article

This paper presents a literature review of low-power hybrid wind–photovoltaic (PV) systems and introduces a 3 m diameter prototype rotor featuring twelve PV-coated pivoting blades stiffened by a peripheral rim. Existing solutions—foldable umbrella concepts, Darrieus rotors with PV-integrated blades, and morphing blades—are surveyed, and current gaps in simultaneous wind + PV co-generation on a single moving structure are highlighted. Key performance indicators such as power coefficient (C_p), DC ripple, cell temperature difference (ΔT), and levelised cost of energy (LCOE) are defined, and an integrated assessment methodology is proposed based on blade element momentum (BEM) and computational fluid dynamics (CFD) modelling, dynamic current–voltage (I–V) testing, and failure modes and effects analysis (FMEA) to evaluate system performance and reliability. Preliminary results point to moderate aerodynamic penalties (ΔC_p ≈ 5–8%), PV output during rotation equal to 15–25% of the nominal PV power (P_PV), and an estimated 70–75% reduction in blade–root bending moment when the peripheral ring converts each blade from a cantilever to a simply supported member, resulting in increased blade stiffness. Major challenges include the collective pitch mechanism, dynamic shading, and wear of rotating components (slip rings); however, the suggested technical measures—maximum power point tracking (MPPT), string segmentation, and redundant braking—keep performance within acceptable limits. This study concludes that the concept shows promise for distributed microgeneration, provided extensive experimental validation and IEC 61400-2-compliant standardisation are pursued. This paper has a dual scope: (i) a concise literature review relevant to low-Re flat-blade aerodynamics and ring-stiffened rotor structures and (ii) a multi-fidelity aero-structural study that culminates in a 3 m prototype proposal. We present the first evaluation of a hybrid wind–PV rotor employing untwisted flat-plate blades stiffened by a peripheral ring. Using low-Re BEM for preliminary loading, steady-state RANS-CFD (k-ω SST) for validation, and elastic FEM for sizing, we assemble a coherent load/performance dataset. After upsizing the hub pins (Ø 30 mm), ring (50 × 50 mm), and spokes (Ø 40 mm), von Mises stresses remain < 25% of the 6061-T6 yield limit and tip deflection ≤ 0.5%·R acrosscut-in (3 m s⁻¹), nominal (5 m s⁻¹), and extreme (25 m s⁻¹) cases. CFD confirms a broad efficiency plateau at λ = 2.4–2.8 for β ≈ 10° and near-zero shaft torque at β = 90°, supporting a three-step pitch schedule (20° start-up → 10° nominal → 90° storm). Cross-model deviations for C_p, torque, and pressure/force distributions remain within ± 10%. This study addresses only the rotor; off-the-shelf generator, brake, screw-pitch, and azimuth/tilt drives are intended for later integration. The results provide a low-cost manufacturable architecture and a validated baseline for full-scale testing and future transient CFD/FEM iterations. Full article

In this paper, a novel technical route, namely combining the low-pressure exhaust gas recirculation (LP-EGR) and variable compression ratio (VCR), is proposed to address the inferior fuel economy for marine dual-fuel engines of low-pressure gas injection in diesel mode. To validate the applicability of the proposed technical route, firstly, a zero-dimensional/one-dimensional (0-D/1-D) engine simulation model with a predictive combustion model DI-Pulse is established using GT-Power. Then, parametric investigations on two LP-EGR schemes, which is implemented with either a back-pressure valve (LP-EGR-BV) or a blower (LP-EGR-BL), are performed to qualitatively identify the combined impacts of exhaust gas recirculation (EGR) and compression ratio (CR) on the combustion process, turbocharging system, and nitrogen oxides (NOx)-brake specific fuel consumption (BSFC) trade-offs. Finally, an optimization strategy is formulated, and an optimization program based on response surface methodology (RSM)–particle swarm optimization (PSO) is designed with the aim of improving fuel economy while meeting Tier III and various constraint conditions. The results of the parametric investigations reveal that the two LP-EGR schemes exhibit opposite impacts on the turbocharging system. Compared with the LP-EGR-BV, the LP-EGR-BL can achieve a higher in-cylinder pressure level. NOx-BSFC trade-offs are observed for both LP-EGR schemes, and the VCR is confirmed to be a viable approach for mitigating the penalty on BSFC caused by EGR. The optimization results reveal that for LP-EGR-BV, compared with the baseline engine, the optimized BSFC decreases by 10.16%, 11.95%, 10.32%, and 9.68% at 25%, 50%, 75%, and 100% maximum continuous rating (MCR), respectively, whereas, for the LP-EGR-BL scheme, the optimized BSFC decreases by 10.11%, 11.93%, 9.93%, and 9.58%, respectively. Furthermore, the corresponding NOx emissions level improves from meeting Tier II regulations (14.4 g/kW·h) to meeting Tier III regulations (3.4 g/kW·h). It is roughly estimated that compared to the original engine, both LP-EGR schemes achieve an approximate reduction of 240 tons in annual fuel consumption and save annual fuel costs by over USD 100,000. Although similar fuel economy is obtained for both LP-EGR schemes, LP-EGR-BV is superior to LP-EGR-BL in terms of structure complexity, initial cost, maintenance cost, installation space requirement, and power consumption. The findings of this study provide meaningful theoretical supports for the implementation of the proposed technical route in real-world engines. Full article

Accurate vertical load measurement through intelligent tire technology is crucial for vehicle stability, handling, and safety. Existing studies have mainly focused on modeling and bench experiments, overlooking a detailed comparative analysis of real sensor performance and validation under actual driving conditions. This study addresses this gap by performing sensor comparisons and extensive real-road validation to ensure the accuracy and reliability of the proposed methods. First, finite element modeling (FEM) is used to assess the feasibility of accelerometer and strain-based sensors for vertical load prediction. High-precision bench tests quantitatively compare the performance of multiple triaxial Integrated Electronics Piezoelectric (IEPE) accelerometers and Polyvinylidene Fluoride (PVDF) sensors, identifying accelerometers as the superior choice due to their better stability and linearity. Vertical load prediction algorithms are developed using Support Vector Machine (SVM) and linear regression, considering variables like contact length, vehicle speed, and tire pressure. The algorithms are validated under real-road conditions using high-performance instruments across constant speed, acceleration, braking, and cornering, and a self-designed compact Intelligent Tire Test Unit (ITTU) is deployed for product-level implementation, confirming its effectiveness in real-world driving scenarios. The findings provide a validated framework for accurate vertical load estimation and real-time tire parameter prediction, offering practical insights for improving intelligent tire technology in dynamic driving conditions. Full article

The Digital Freight Train is expected to revolutionise the rail freight industry. A critical aspect of this transformation is real-time condition monitoring of air brake systems, which are among the leading causes of train malfunctions. To achieve this goal, advanced algorithms for air brake modelling are required. This paper introduces a computationally efficient air brake model tailored for real-time diagnostic applications. A hybrid approach, integrating both empirical data and simplified fluid-dynamic equations, has been adopted. Compared to other air brake models found in the literature, the innovative contributions of the presented model are the reduction of the number of required parameters and the estimation of the brake cylinder pressure directly from the main brake pipe pressure using a feed-forward approach. Moreover, a new approach in the evaluation of the first braking phase and the brake cylinder pressure build-up as the saturation of the brake mode is presented. The model input includes the main brake pipe pressure, the weighing valve pressure, and the brake mode, and the output includes the pressure at the brake cylinder. The air brake model has been validated using data from a previous experimental campaign. The model’s accuracy in replicating the air brake system mechanism makes it well-suited for future development of model-based algorithms designed for air brake fault detection. Full article

This paper details the conceptualization, design, topology optimization, manufacturing, and validation of a hydraulic brake caliper for Formula SAE race cars made of Scalmalloy^®, an innovative Al-Mg-Sc alloy which was never adopted before to manufacture a brake caliper. A monoblock fixed caliper with opposing pistons was developed, focusing on reducing mass for a fixed braking force. The design process began with a theoretical analysis to establish braking force and pressure requirements, followed by preliminary design and topology optimization. The caliper was then manufactured using laser powder bed fusion (LPBF). Comprehensive experimental validation, including testing with static and rotating brake discs on an inertial dynamometer, confirmed the expected caliper’s performance, with the results showing strong alignment with finite element analysis estimations. In particular, strain and displacement measurements showed excellent correlation with numerical estimates, validating the design’s accuracy and effectiveness. Full article

The present study aimed to enhance the efficiency and efficacy of the Al/Cu joint production process implemented by the company VEMID Ltd., Jagodina, Serbia, by attaining sound joints within a very short welding time. For this purpose, the present study aimed at investigating the accuracy and the quality of the continuous drive friction welding (CDFW) process, as well as the optimum combination of CDFW parameters with highest joint efficiency in terms of investigated properties. The accuracy was estimated through an analysis of temperature–time curves recorded during CDFW using an infrared camera. The quality was evaluated through an investigation of the properties of Al/Cu joints produced using different friction (66.7, 88.9, and 133.3 MPa) and forging (88.9, 222.2, and 355.6 MPa) pressures and a constant total welding time (4 s) and rotational speed (2100 rpm). Thermal imaging with an infrared camera demonstrated that the actual total welding time was 15% longer compared to the nominal value. This was attributed to the slow pressure response of the pneumatic brake system. The relative changes in the maximum surface temperature (T_MS) during the CDFW process corresponded to changes in welding pressures, indicating the potential of the thermal imaging method for monitoring and assessing this process. A preliminary investigation demonstrated that Al/Cu joints produced using welding pressures less than 88.9 MPa often displayed the presence of non-joined micro-regions at the Al/Cu interface and a significant thickness of interfacial Al₂Cu (up to 1 µm). However, when friction pressure was set at 66.7 MPa, an increase in the forging pressure to 222.2 MPa eliminated the presence of non-joined micro-regions and reduced the thickness of Al₂Cu to 0.5 µm on the average level. These Al/Cu joints achieved the highest joint efficiencies in terms of strength (100%) and ductility (61%). They exhibited an electrical conductivity higher than 92% of the theoretical value. A further increase in any welding pressure produced similar or deteriorated properties, accompanied by an increase in the consumption of raw materials and energy. Such turn of events was counterproductive to the original goal of increasing the efficiency and efficacy of the CDFW process. Full article

The gasification of residues into syngas offers a versatile gaseous fuel that can be used to produce heat and power in various applications. However, the application of syngas in engines presents several challenges due to the changes in its composition. Such variations can significantly alter the optimal operational conditions of the engines that are fueled with syngas, resulting in combustion instability, high engine variability, and misfires. In this context, this work presents an experimental investigation conducted on a port-fuel injection spark-ignition optical research engine using three different syngas mixtures, with a particular focus on the effects of CO/H₂ and diluent ratios. A comparative analysis is made against methane, considered as the baseline fuel. The in-cylinder pressure and related parameters are examined as indicators of combustion behavior. Additionally, 2D cycle-resolved digital visualization is employed to trace flame front propagation. Custom image processing techniques are applied to estimate flame speed, displacement, and morphological parameters. The engine runs at a constant speed (900 rpm) and with full throttle like stationary engine applications. The excess air–fuel ratios vary from 1.0 to 1.4 by adjusting the injection time and the spark timing according to the maximum brake torque of the baseline fuel. A thermodynamic analysis revealed notable trends in in-cylinder pressure traces, indicative of differences in combustion evolution and peak pressures among the syngas mixtures and methane. Moreover, the study quantified parameters such as the mass fraction burned, combustion stability (COVIMEP), and fuel conversion efficiency. The analysis provided insights into flame morphology, propagation speed, and distortion under varying conditions, shedding light on the influence of fuel composition and air dilution. Overall, the results contribute to advancing the understanding of syngas combustion behavior in SI engines and hold implications for optimizing engine performance and developing numerical models. Full article

Fine particles from vehicles occur in a range of particulate matter (PM) sizes and influence the roadside atmosphere. The contribution of fine dust from automobiles to road pollution has reportedly been extremely high. Researchers have estimated that non-exhaust fine dust originating from brakes, tires, clutches, and road surface wear rate is increasing. Several studies have shown that brake pads account for a significant proportion of non-exhaust emissions. In this study, a friction test using vehicle brake pads was carried out with a friction tester to reveal the harmfulness of brake pad particles by the driver’s driving habits. Conditions were made considering the pressure, vehicle speed, and temperature and assuming the amount of deceleration of the vehicle. Particle collection devices were used to analyze the concentration of number and the mass distribution of particles produced in the experiment, with a range from 6 nm to 7.3 μm to gauge the toxicity of particles. The results showed that the number concentration of fine particles tended to increase linearly with changes in vehicle deceleration (braking energy) in the particle diameter region around 0.75–7.3 μm. The number concentration of fine particles tended to increase exponentially in the particle diameter region around 71–120 nm. The rapid occurrence of ultrafine particles in nanometers varied depending on the test conditions. Full article

Fast and precise pressure control for an electropneumatic brake system is essential for ensuring the safe operation of trains. However, the nonlinearity and uncertainties of the system make controller design challenging. This paper proposes a prescribed performance control method integrating an extended state observer to address this issue. A thermodynamical model of the brake cylinder is first built based on the pneumatic characteristics of the braking system, considering multiple modes, coupling effects, and input saturation. Then, an extended state observer is designed to estimate model uncertainty due to temperature variation and disturbances and to achieve online compensation of the model. A feedback control law with a specified prescribed performance function is developed based on the updated thermodynamic model to guarantee the transient and steady-state performance of the pressure control. A parameter adaptive method is also utilized to handle input saturation. The observer’s bounded convergence and stability analysis of the closed-loop control system is given using the Lyapunov theory. Compared experimental results are provided to verify the effectiveness of the proposed method. Full article

In 2019, the Centers for Disease Control and Prevention estimated that 329,000 Americans were injured in cycling-related incidents. Since the first bicycle brake in 1817, there has been an individual brake lever for decelerating each wheel, while on cars, there has been a single control lever for decelerating multiple wheels since 1921. To perform an emergency stop on a bicycle, the rider must proportion hand pressure on each brake lever and simultaneously vary hand pressure throughout the duration of the maneuver to match the variations of normal force on each tire. Only highly skilled riders, with years of training and practice, can correctly proportion brake pressure to maximize available traction and thus minimize stopping distances. The objective of this study is to simulate and prototype a hydraulic, single-lever bicycle brake system, integrating front and rear brake proportioning, which minimizes stopping distance compared to dual-lever simulations. A design is developed to address the brake proportioning issue. Based on the simulations and physical model, the prototype proportioning valve decreased simulated stopping distances up to 18%. Exploring a range of bike types and scenarios, stopping distances were decreased between 13% and 26%. Simulating an ideal proportioning valve, stopping distances were further decreased between 4% and 40%. These results show that there can be an advantage to brake proportioning technologies in bicycles. Full article

Tyre wet skid resistance greatly affects vehicle safety, and it is dependent on the frictional behaviour at the tyre–road interface; however, the currently available numerical models, using the finite element method, either neglect the road roughness or obtain the rightness using expensive computed tomography scans, rendering them inefficient and complex. This study aims to present an estimation method of rubber slides on a rough road, to study tyre wet skid resistance. A three-dimensional rough road model was established, using the harmonic superposition method; the sealing effect of the water film on a wet road was modelled in terms of the pseudo-hydrodynamic bearing effect; the contact pressure, hysteresis friction, and water film hydrodynamic lift force were calculated. Subsequently, a friction model was established that accounted for the road surface morphology, tyre properties, sliding speed, and contact pressure. The accuracy of the friction model was experimentally validated, using the published experimental results. The friction model was then adopted, to conduct a study of the wet skid resistance of a 205/55R16 tyre with two different tread patterns. The simulation results were consistent with the experimental results of braking distance on a wet road. Finally, the effects of road roughness, tread rubber, load, and inflation pressure on wet skid resistance were carried out and analysed. The works in this paper have important significance and practical value for the development of high-performance tyres. Full article

The integrated braking control system (IBC) has become one of the most popular brake-by-wire (BBW) solutions due to its compactness and versatility. Accurate monitoring of wheel cylinder pressure in real time is the basis for brake pressure control, and pressure estimation is a low-cost and reliable method. However, the IBC is an electromechanical hydraulic coupling system that has significant nonlinear behaviors; moreover, vehicle dynamics also have a critical impact on the accuracy of pressure estimation. To solve this problem, this paper proposes a novel adaptive extended Kalman filter (EKF) approach that combines a hydraulic model and a single-wheel model. This novel strategy has better estimation than the hydraulic model when the pressure is accurately estimated by the single-wheel model, while when the single-wheel model is not accurate, the EKF degrades to the hydraulic model. Finally, vehicle experimental data under high- and low-mu braking are collected. The pressure estimation error of the EKF is within 0.4 MPa in the low-mu road and 2 MPa in the high-mu road. It is proven that the proposed pressure estimation strategy is highly effective. Full article