Engine Compartment Front End Module & Snorkel Placements to Achieve Maximum Volumetric Efficiency

<div class="section abstract"><div class="htmlview paragraph">The need to control global warming by regulating automotive emission levels has led to a lot of changes in the policies of different countries globally, specifically the United States (US) and the European Union (EU). More recently, the governments have been strongly pushing the integration of Electric Vehicles (EVs) in the market to replace the conventional Internal Combustion Engine (ICE) vehicles for CO₂ emissions reduction, with the enforcement of 50% EV sales by 2030 in the US and complete 100% by 2035 in the EU for passenger cars. However, these policies are misleading by considering EVs as zero emission vehicles, as there is no such technology yet available that has zero emissions during its lifecycle. During the manufacturing phase, any vehicle produced gives out emissions, with EVs emitting even higher than the conventional ICE vehicles with their battery manufacturing. Further, during the use phase, there might be no Tank-to-Wheel emissions from the EVs due to zero tailpipe emissions, but they do have very high Well-to-Tank emissions from the electricity generation needed to recharge the batteries. On the other hand, hybridization is also a promising way for CO₂ emissions reduction. Using synthetic e-fuels, hybrids can have emission reductions much higher than using conventional fuels or even when compared to EVs on life cycle basis. Hence, in this study, we have evaluated the life cycle CO₂ emissions reduction potential with electric and e-fueled ICE vehicle as two different cases, varying their sales from 0 to 100%, according to the set EU and US targets, for the total car fleet of both the countries. The evaluation is done with 0D numerical simulations performed on GT suite, for 30 different drive cycles consisting of 10 urban, 10 sub-urban and 10 highway cases with GPS based vehicle speed information, for US as well as EU separately. Results shows that e-fueled ICE and e-fueled hybrid vehicles have greater CO₂ emissions reduction potential than EVs.</div></div>

<div class="section abstract"><div class="htmlview paragraph">This study introduces the Total Cost of Ownership per Unit Operating Time (TCOP) as a novel indicator to assess the economic impact of vehicle durability. A comprehensive analysis is conducted for fuel cell vehicles (FCVs), battery electric vehicles (BEVs), and internal combustion engine vehicles (ICEVs) in light- and heavy-duty scenarios. The results show that in HDVs, the advantages of low prices for hydrogen and electricity are fully demonstrated due to their high durability. In contrast, for LDVs, the purchase cost plays a much larger role, accounting for 68% of the total cost, indicating a significant difference between vehicles. Improving durability can significantly enhance the competitiveness of FCVs. For FCVs, increasing the durability from the current levels of 150,000 km for LDVs and 600,000 km for HDVs to 20,8500 km and 1,122,000 km, respectively, would align their TCOP with that of current ICEVs. A sensitivity analysis shows that for HDVs. The focus should be placed on improving the durability of fuel cell systems in order to reduce fuel costs over the long term, while for LDVs, the key to reducing TCOP is to reduce the manufacturing cost of the whole vehicle. By 2040, assuming that the durability of FCVs is improved to the same level as ICEVs and that the cost of fuel cells continues to fall, FCVs will be more competitive than EVs and ICEVs in terms of long-term operating costs.</div></div>

<div class="section abstract"><div class="htmlview paragraph">Thermal Management System (TMS) is equally or more important part of Battery Electric (BEV)/Hybrid Electric vehicle (HEV) than an internal combustion engine (ICE) vehicle. In an ICE vehicle, TMS ensures performance of power train/engine, after treatment/exhaust system and HVAC (Climate control) whereas it connected with safety and Range anxiety elimination additionally for the case of Electric Vehicle. Electric powertrain is not a new technology to the world but the technology is evolving in last few decades, to overcome the cost and make it commercially viable, charging infrastructural development and elimination of Range Anxiety. In last few years, Indian automotive industry has taken some major steps towards electrification journey for both passenger car and commercial vehicle. In BEVs, Battery Cooling or Battery thermal management System (BTMS or BCS) and Traction cooling system (TCS) are couple with nearly conventional HVAC circuit used in any ICE vehicle. Hence, Thermal management system (TMS = BCS+ TCS + HVAC) is become a three loop system in any BEVs. Among these, BTMS/BCS plays important role to maintain performance and safety/reliability of Li-ion Battery pack. The complex Battery Thermal management system situated in key research arena alongside battery management system (BMS) for the Electric Vehicle technology. On other hand, Traction Cooling system helps to maintain desired operation temperature of traction and EV-Power electronic components to ensure proper performance and desired life. This paper is mainly dealing with an overview of thermal management system (BTMS/BCS and TCS) of Powertrain, configurational aspects, their linkage with vehicle brain and correlation with the Performance (Range anxiety, Sate of charge [SOC], life span) and Safety/reliability parameter of Electric vehicles along with validation requirement.</div></div>

<div class="section abstract"><div class="htmlview paragraph">With the transition from ICE vehicles to EV’s, the dominant noise sources within the vehicle cabin have shifted from engine noise to auxiliary systems, especially HVAC systems. In conventional vehicles with internal combustion engines (ICE), engine noise tends to mask noise from auxiliary sources. However, in electric vehicles (EVs), the lack of engine noise causes these auxiliary noises, such as those from the HVAC system, to become more prominent and potentially uncomfortable for occupants. The primary objective is to understand how the absence of engine noise in EVs influences the perceived HVAC noises. The research methodology involves static and on-road evaluation of both electric and ICE vehicle having common platform, conducted under same testing conditions. The study aims to quantify and compare the acoustic characteristic differences of HVAC noise between ICEs and EVs, primarily focusing on cabin airflow noise, refrigerant flow noise, and AC compressor noise. Based on the findings, possible solutions were identified for areas where EV’s exhibit worse noise signatures compared to ICE vehicles, leading to improved acoustic comfort within the cabin. The findings can be beneficial for automotive manufacturers focusing on HVAC noise quality improvements in electric vehicles.</div></div>

<div class="section abstract"><div class="htmlview paragraph">The sound quality of automotive interiors is one of the critical factors regarding customer satisfaction. As electric vehicles (EVs) rapidly rise in popularity, the known literature on sound qualities of internal combustion engine (ICE) automotive interiors has become less relevant. Because of this, comparing and contrasting 'the sound qualities of EV and ICE vehicles is essential to have the proper foundation for studying automotive noise quality in the future. In this paper, we aim to benchmark the major differences between an EV and an ICE automobile regarding interior sound quality. This study seeks to understand basic sound engineering characteristics and how they differ between the two types of vehicles. We also analyzed the public's preferences when it comes to the two types of cars. To get as much data as possible in our time-constrained project, we tested both types of vehicles in two different environments: an uncontrolled road (Bluff Street in Flint, MI) and a controlled track (the GM Mobility Research Center - MRC - at Kettering University). We also tested three different positions in the car, including the driver's seat, passenger seat, and rear middle seat position. The interior sound was then recorded using the SQobold sound acquisition device and the HEAD acoustics Aachen HEAD as the microphone. Three recordings of every type of test were taken in order to confirm consistent and accurate results. We then compared and contrasted the data in <b>Artemis</b> SUITE<sup>TM</sup>, a sound analysis software. We determined the major differences between the cars, particularly in loudness and sharpness. The final step was jury testing, in which the subjective samples compare well with our conclusions regarding sound quality metrics.</div></div>

<div class="section abstract"><div class="htmlview paragraph">An Air intake system (AIS) is a duct system which leads the airflow going into the internal combustion engine. Combustion requires oxygen, and the more oxygen is provided into the combustion process the more power it will produce. The lower the air temperature, the higher its density, and hence there is more oxygen in a unit volume. The quality of air entering engine can be measured with the air temperature.</div><div class="htmlview paragraph">AIS design and routing influence the air charge temperature (ACT) at intake manifold runners and ACT is normally measured at AIS throttle body in reality. Higher ACT lead to inefficient combustion and can lead to spark retard. Optimization of AIS designs and reduction of ACT can improve engine performance and vehicle fuel economy.</div><div class="htmlview paragraph">High ACT can be a result of two different phenomena: <ul class="list disc"><li class="list-item"><div class="htmlview paragraph">Recirculation - Hot air from the underhood environment ingested into the dirty side of the air intake system. This is the result of the AIS snorkel not being isolated or sealed from the engine compartment hot air.</div></li><li class="list-item"><div class="htmlview paragraph">Underhood temperature rise - Air inside AIS is heated by the ducts walls because it is routed through a hot underhood environment. The longer the length and larger the diameter of the air induction system, and the higher duct skin temperatures, the worse the temperature rise.</div></li></ul></div><div class="htmlview paragraph">In this paper, it is planned to simulate and study the effects of following factors on ACT with CFD using a FCA production vehicle: <ul class="list disc"><li class="list-item"><div class="htmlview paragraph">Snorkel location: snorkel sucking fresh air at side air guide or snorkel sucking underhood hot recirculation air.</div></li><li class="list-item"><div class="htmlview paragraph">Exhaust hot end at front of an east-west engine or at the rear of the engine; these two arrangements will result in different underhood air temperatures and radiation to AIS surfaces.</div></li><li class="list-item"><div class="htmlview paragraph">Heat shield effects on ACT: heat shield blocks radiation from exhaust system to AIS surfaces, and hence reduces charge air heat pick from AIS duct walls.</div></li><li class="list-item"><div class="htmlview paragraph">The effects of other measures such as cutting holes on hood or fenders to lower engine compartment air temperatures.</div></li></ul></div><div class="htmlview paragraph">Although the airflow in vehicle AIS duct is transient in nature, steady CFD simulations will be performed to study the above cases for simplification, and CFD approach will be discussed in details. Vehicle test data will be used to validate the CFD models.</div><div class="htmlview paragraph">Finally, general practices of AIS development will be discussed, and future work on this topic will be outlined.</div></div>

<div class="htmlview paragraph">The purpose of this system study was to compare the performance and fuel consumption of a pure fuel cell vehicle (<i>i.e.</i> with no battery included) with an internal combustion engine (ICE) vehicle of similar weight in different drive cycles. Both light and heavy duty vehicles are studied.</div> <div class="htmlview paragraph">For light duty vehicles, the New European drive cycle, NEDC [70/220/EEC], the FTP75 [EPA] and a Swedish driving pattern from the city of Lund [<span class="xref">Ericsson, 2000</span>] are utilised. The fuel consumption for these drive cycles was compared with ICE vehicles of similar weight, an Ibiza Stella 1.4 (year 2000) from Seat and a Volvo 960 2.5 E sedan (year 1995). For heavy duty vehicles, urban buses in this study, two drive cycles were employed, the synthetic CBD14 and the real bus route 85 from Gothenburg, Sweden.</div> <div class="htmlview paragraph">It can be concluded that marked improvements in fuel economy can be achieved for hydrogen-fuelled light and heavy duty vehicles. The fuel consumption of a small fuel cell vehicle was 50% less than the corresponding ICE vehicle in both the NEDC and the FTP75. With proper dimensioning of the system components, e.g. the engine, further reductions in fuel consumption can be achieved. The range of more than 500 km with 5 kg of hydrogen in a 345 bar fuel tank was comparable to an ICE vehicle. If the pressure is raised to 690 bar, a driving range of 600 km could be achieved. As the auxiliary system counteracts the increase in fuel cell efficiency, raising the minimum operating voltage from 0.6 to 0.75 V in a 50 kW fuel cell system, provides only a 5% reduction in fuel consumption. A fuel cell bus operated in the CBD14 and the bus route 85, compared with diesel-fuelled urban bus of similar weight, demonstrates a reduction in fuel consumption of 33 and 37 % respectively.</div>

As many countries transition to electric vehicles (EVs) to reduce tailpipe emissions from internal combustion engine vehicles (ICEVs), both vehicle types continue to generate non-exhaust particulate matter (PM), including tire wear, brake wear, road surface wear, and particularly road dust resuspension. Among these, road dust resuspension is a major contributor to non-exhaust PM. While factors such as vehicle weight and drivetrain configuration have been extensively studied in fleet-level research, direct comparisons between ICEVs and EVs of the same model have not been explored. This study investigates the effects of drivetrain, vehicle weight, and payload on road dust resuspension emissions from ICEV and EV models. Two experimental approaches were employed: (1) acceleration from 0 to 60 km/h, and (2) a simulated real-world driving cycle (RDC). Each test was conducted under both light and heavy payload conditions. The results show that the EV consistently emitted more PM than the ICEV during both acceleration and RDC tests, based on factory-standard vehicle weights. Under identical vehicle weight conditions, the EV demonstrated higher PM resuspension levels, likely due to its higher torque and more immediate power delivery, which increases friction between the tires and the road, particularly during rapid acceleration. Both vehicle types exhibited significant increases in PM emissions under heavy payload conditions. These findings underscore the importance of addressing non-exhaust emissions from EVs, particularly road dust resuspension, and highlight the need for further research into mitigation strategies, such as vehicle lightweighting.

Well-to-wheel greenhouse gas emissions of electric versus combustion vehicles from 2018 to 2030 in the US

The Aerospace Corporation, in support of the Department of Energy (DOE) Electric Vehicle Project, has undertaken two activities related to defining the possible characteristics of the mid-1980s electric passenger car. The first activity, an investigation of the potential performance and cost characteristics through computer modeling, was supported by the Argonne National Laboratory, General Research Corporation, Jet Propulsion Laboratory, Lawrence Livermore National Laboratory, and NASA/Lewis Research Center. That investigation was restricted to a 4-passenger, all-electric car similar to the DOE Electric Test Vehicle-One (ETV-1) developed by the General Electric Company and the Chrysler Corporation. The study effort was completed in February 1981. The second effort currently underway is an electric vehicle (EV) applications research study that is part of a government/industry collaborative effort. Based on the computer modeling results, the state of technology for the mid-1980s, 4-passenger electric car could achieve an urban driving range of 80 to 100 miles with acceleration competitive with a comparable-size, diesel-powered car. Top speeds and ramp accelerations compatible with highway driving also appear achievable. These conclusions assume that the batteries being developed through DOE funding--improved lead-acid, zinc/nickel oxide, iron/nickel oxide, and zinc/chloride--will achieve their currently established performance goals in mass production. The purchase price of a 4-passenger electric car with a 100-mile range is projected to be at least 50 percent higher than that of a comparable internal combustion engine (ICE) vehicle. However, life-cycle costs for a 4-passenger, 100-mile-range car are predicted to range from slightly lower to moderately higher than those of a comparable ICE vehicle depending on petroleum costs and the cost and cycle life of the batteries. The eventual cost and performance of the mid-1980s electric car will be influenced greatly by the trade-offs associated with battery weight and cost versus vehicle payload and range requirements. In general, cost and performance results tend to indicate the desirability of pursuing the development of a 2-passenger car and/or a less than 100-mile-range car if the market for these types of vehicles appears sufficiently attractive. For the second effort, The Aerospace Corporation will subcontract an electric vehicle applications research study to identify the vehicle attributes most likely to influence consumer purchasing decisions. The Statement of Work for this study was prepared by a Steering Committee composed of representatives of the major domestic automobile manufacturers, the EV supply industry, the electric utility industry, and other interested organizations. As part of this effort, it was necessary to define the characteristics of the mid-1980s electric car and its expected competition in that time frame. Vehicle characteristics were selected based on a consensus of the Steering Committee members. The projected characteristics of the baseline electric car defined by the Steering Committee agree quite closely with those predicted in the modeling work mentioned earlier. For the conduct of the study, it has been predicted that the baseline electric car will achieve a 75-mile range, accelerate somewhat more slowly than a comparable ICE vehicle, and perform satisfactorily on highways. The monthly ownership and operation cost (at current gasoline prices) and purchase price are estimated to be 30 and 50 percent higher, respectively. Assuming a more optimistic battery purchase price and replacement rate, the vehicle monthly cost is predicted to be equal to that of a comparable-size ICE vehicle. Competitive vehicles in the mid-1980s are assumed to be powered by gasoline, diesel, or an alternative fuel such as methanol. The fuel economy of these vehicles in urban driving is estimated to be 40 to 50 mpg, and the acceleration is projected to be similar to or somewhat slower than today's ICE vehicle. It is anticipated that the results of the applications study will help focus future DOE and industry research and development efforts on those areas that will most satisfy consumer needs.

<div class="section abstract"><div class="htmlview paragraph">Today, most vehicles in developing countries are equipped with air conditioning systems that work with Hydro-Fluoro-Carbons (HFC) based refrigerants. These refrigerants are potential greenhouse gases with a high global warming potential (GWP) that adversely impact the environment. Without the rapid phasedown of HFCs under the Kigali Amendment to the Montreal Protocol and other actions, Earth will soon pass climate tipping points that will be irreversible within human time dimensions. Up to half of national HFC use and emissions are for the manufacture and service of mobile air conditioning (MAC). Vehicle manufacturers supplying markets in non-Article 5 Parties have transitioned from HFC-134a (ozone-safe, GWP = 1400; TFA emissions) to Hydro-Fluoro-Olefin, HFO-1234yf (ozone-safe, GWP < 1; TFA emissions) due to comparable thermodynamic properties. However, the transition towards the phasing down of HFCs across all sectors is just beginning for Article 5 markets. Patents on R-1234yf will soon expire, just as scarcity is likely to drive the price of R-134a to historic highs.</div><div class="htmlview paragraph">This work consists of two case studies, specific to an Internal Combustion Engine (ICE) and an Electric Vehicle (EV). Two different refrigeration system architectures are examined. Both the shortlisted vehicles have different and complex AC system architectures. Complex AC system architectures are selected in this study with the objective of understanding and deploying the learnings in vehicles with less complex and simpler AC system architectures. The ICE vehicle selected for the study has a dual AC configuration with two cooling points (front and rear), using DX architecture. In the EV, an architecture similar to that of the ICE vehicle is deployed for cabin cooling, but unlike the ICE vehicle, it has a secondary coolant-based loop provisioned for battery thermal management. For this study, the baseline HFC-134a refrigerant is replaced by a ‘drop-in’ alternate low-GWP HFO-1234yf refrigerant in both vehicles.</div><div class="htmlview paragraph">This study focuses on cooling performance evaluation with existing HFC refrigerant and proposed HFO refrigerant for both AC system architectures, gap identification, and proposing common and unique solutions for bridging the performance gaps.</div></div>

<div class="section abstract"><div class="htmlview paragraph">Electric vehicles (EVs) present a distinct set of challenges in noise, vibration, and harshness (NVH) compared to traditional internal combustion engine (ICE) vehicles. As EVs operate with significantly reduced engine noise, other sources of noise, such as motor whine, power electronics, and road and wind noise, become more noticeable. This review paper explores the key NVH issues faced by EVs, including high-frequency tonal noise from electric motors, gear meshing, and vibrations. Additionally, it examines recent advancements and trends in NVH mitigation techniques, such as active noise control, improved material insulation, and advanced vibration isolation systems. Furthermore, this paper discusses the role of computational tools, simulation technologies, and testing methodologies in predicting and addressing NVH concerns in EVs. By providing an in-depth analysis of the challenges and the latest innovations, this review aims to contribute to the ongoing development of quieter and more refined EVs.</div><div class="htmlview paragraph">EVs pose unique challenges in the realm of noise, vibration, and harshness (NVH) that differ from those encountered in traditional internal combustion engine (ICE) vehicles. With the significant reduction in engine noise in EVs, other noise sources—such as motor whine, power electronics, and road and wind noise—become more prominent. This review paper delves into the primary NVH challenges associated with EVs, including the high-frequency tonal noise produced by electric motors, gear meshing, and vibration issues. It also explores the latest advancements and trends in NVH mitigation techniques, such as active noise control, enhanced material insulation, and advanced vibration isolation systems. Additionally, the paper highlights the role of computational tools, simulation technologies, and testing methodologies in predicting and addressing NVH challenges in EVs. Through a comprehensive analysis of these challenges and innovations, this review aims to support the ongoing efforts to develop quieter and more refined EVs</div></div>

<div class="section abstract"><div class="htmlview paragraph">This research investigates the energy savings achieved through eco-driving controls in connected and automated vehicles (CAVs), with a specific focus on the influence of powertrain characteristics. Eco-driving strategies have emerged as a promising approach to enhance efficiency and reduce environmental impact in CAVs. However, uncertainty remains about how the optimal strategy developed for a specific CAV applies to CAVs with different powertrain technologies, particularly concerning energy aspects. To address this gap, on-track demonstrations were conducted using a Chrysler Pacifica CAV equipped with an internal combustion engine (ICE), advanced sensors, and vehicle-to-infrastructure (V2I) communication systems, compared with another CAV, a previously studied Chevrolet Bolt electric vehicle (EV) equipped with an electric motor and battery. The implemented control is a universal speed planner that solves the eco-driving optimal-control problem within a receding-horizon framework, utilizing V2I communications for signal phase and timing information. The controller calculates accelerator and brake pedal positions using the vehicle’s state and real-time environmental information. Both the Pacifica, target vehicle, and the Bolt, EV, are equipped with a drive-by-wire system. The experiments encompass five road scenarios repeated three times, covering a 3.7-km track with various stop signs, traffic signals, and speed limits. Three control calibrations are employed to represent human-driver-like, non-connected automated, and V2I-connected driving. First and foremost, the results demonstrate functional eco-driving controls with no extreme acceleration or traffic law violations in the Pacifica (ICE vehicle). Energy savings of up to 6% without connectivity and up to 22% with V2I connectivity are achieved in the ICE vehicle as well. Additionally, a comparison is made between an ICE vehicle and an EV to analyze the energy-saving impacts of eco-driving controls across different powertrain characteristics. In conclusion, this study emphasizes the significance of correlating powertrain design with controls and eco-driving strategies during the development of CAVs.</div></div>

<div class="section abstract"><div class="htmlview paragraph">Electric vehicles (EVs) are considered as zero emission vehicles because of no exhaust emissions (tailpipe emission). But electric power generation contributes in the well to wheel emissions. Hence, Electric vehicle cannot be regarded as completely pollution free. In Internal Combustion Engine (ICE) based vehicles, the pollution is from both the tailpipe (exhaust pipe) and from the well to wheel (extraction of the gasoline in this case). Tailpipe emissions are taken in compliance with Bharat stage emission standards. Standard emissions of CO<sub>2</sub>, NOx, PM and CH from refineries, during extraction of fuel (gasoline/diesel), are considered for well to wheel emissions. In this work a comparative study of tailpipe and well to wheel emissions from EVs and ICE vehicles is carried out. Three vehicle categories namely; Heavy Duty Vehicles, Passenger cars and 2 wheelers and four major pollutants, namely; CO<sub>2</sub>, NOx, PM and CH (hydrocarbons) are taken into consideration. It has been found out that there has been continuous rise in emissions in terms of tonnes of CO<sub>2</sub> eq/MWh up to the year 2012-13, but it became constant for following years. This was mainly due to increase in renewable energy sources for electricity generation. After calculating the emissions/km for different vehicle categories it has been concluded that over all emissions from ICE vehicles are still much more as compared to their counter parts in EVs.</div></div>

PurposeTo model and analyze the dynamic response of an electric vehicle (EV) suspension system and compare it with a conventional internal combustion engine (ICE) vehicle, focusing on passenger comfort and safety.Design/methodology/approachBoth vehicles are modeled as quarter car (two DOF for EV) and half car (four DOF for EV and five DOF for ICE). The analysis includes vehicle–road and vehicle–bridge interaction dynamics using MATLAB Simulink and the Runge–Kutta method, incorporating various road profiles and disturbances.FindingsThe EV’s suspension system outperforms the ICE vehicle in ride comfort and road holding across various conditions, with better responses to road disturbances and reduced peak overshoot. These results highlight the advantages of EV designs in enhancing overall vehicle dynamics.Originality/valueThis study makes several novel contributions, including the mathematical modeling of a half-car model for an ICE vehicle that incorporates secondary unbalanced forces of the engine. It also explores a complex vehicle–bridge interaction system, considering both road roughness and sinusoidal bumps. Furthermore, it compares the dynamic responses of an equivalent EV model traversing this complex bridge, with a conventional ICE vehicle, providing new insights into the distinct characteristics of EV suspensions.