Trends in Engineering and Auto Manufacturing

Trends in Engineering and Auto Manufacturing

Thomas F. Wolff Associate Dean Michigan State University June 2012

Overview §  The Big Picture: What’s coming for automotive

transportation §  Research at MSU §  Educating engineers at MSU

What’s coming for the automobile?

§  How will automobile travel be different? §  The shell §  The powertrain and fuels §  Sensing §  Computing §  Civil infrastructure

The Shell

§ Composite Vehicle Research Center (CVRC) • Biomimetics • Composite Joining •  Impact resistance • Multi-function composites • Self-diagnostic composites

The Powertrain and Fuels

§ Biofuels Research § Combustion Research § Power Electronics §  Thermoelectrics § Battery technology

Fuel Crops, not Food Crops, for Renewable Energy

Fuel Requirements

Plant Science

Synthesize and

Characterize Fuels

Evaluate Performance

Engine Requirements

Crops to Wheels Basic to Applied Research

MBI: Applied Research in Bio-based Fuels

§  MBI is a MSU-affiliated not-for-profit company

§  Vision is to accelerate development and scale-up bio-based technologies

§  Cross-disciplinary with integrated labs and pilot plant

§  25 years experience

Great Lakes Bioenergy Research Center (GLBRC)

§  Five-year, $140M center funded by the Department of Energy’s Office of Basic Energy Sciences

§  Pursuing Phase II (five-years) renewal

High Load Optical Engine

Tested at Cylinder Pressures > 150 bar, Optical access: Cylinder liner, exhaust valve and piston. Goal is operation for 80 seconds @ 1500 rpm producing 1000 work cycles

Combustion Images: Bio-based Fuel Synthesized at MSU

TDC 6° ATDC 12° ATDC 18° ATDC Standard Diesel Fuel

TDC 6° ATDC 12° ATDC 18° ATDC

Conditions: turbocharged diesel engine CR=18:1, 0.35 bar boost, 1500 RPM, light load, and 2000 bar injection pressure.

Canola Methyl Ester

Laser-based Combustion Diagnostics

Biofuel Supply

Imaging sensorEtalon

Spectrometer

Heating

Nd:

YA

G L

aser

Dou

blin

g cr

ysta

lD

ye la

ser

HR mirror Power meter

PIV laser

ICCD Camera

Optics

Exc

imer

lase

r

Fast Photodiode

High Speed Camera

Single-Cylinder Engine Fuels Comparison

Thermoelectric Materials and Systems: Fabrication at MSU

13

POWDER INGOT (29) HOT PRESSED PUCKS (34)

CUT HOT PRESSED PUCK

LEGS FROM PUCK > 95% YIELD 5 COUPLE, 13W -

THEOR. SKD MODULES (90)

3rd Generation Thermoelectric Modules

Numerical Simulations

- Eulerian Grid

• Liquid Fuel Droplets

dx

dz

dy

G

d1

d2

1p 2p

SpraySpray--Controlled Controlled Dump CombustorDump Combustor

Fuel Injector

Wall

Wall

• Monte Carlo Particles Fuel

Dro

plet

s

Mon

te-C

arlo

par

ticle

s

dx

dz

dy

G

d1

d2

1p 2p

Eulerian Cell

Kinetics: (I) reduced kinetics schemes with direct ODE or ISAT solvers, and (II) flamelet library with detailed mechanisms or complex reduced schemes.Fuels: methane, propane, heptane, octane, decane, kerosene, gasoline, JP-10 and ethanol

Filtered continuity and momentum equations via a generalized multi-block high-order finite difference EulerianEulerian scheme for high Reynolds number turbulent flows in complex geometries

Various closures for subgrid stresses

Gasdynamics FieldGasdynamics Field

Scalar Field Scalar Field (mass fractions(mass fractionsand temperature)and temperature)

Filtered Mass Density Function (FMDF) equation via LagrangianLagrangian Monte Carlo method -Ito Eq. for convection, diffusion & reaction

ChemistryChemistry

Droplet Field Droplet Field (spray)(spray)

LagrangianLagrangian model for droplet equations with full mass, momentum and energy couplings between phases and a stochastic sub grid velocity model







ChemistryChemistry



- Eulerian Grid


dx

dz

dy

G

d1

d2

1p 2p


Fuel Injector

Wall

Wall


Dro

plet

s

Mon

te-C

arlo

par

ticle

s

dx

dz

dy

G

d1

d2

1p 2p

Eulerian Cell







ChemistryChemistry









ChemistryChemistry



- Eulerian Grid


dx

dz

dy

G

d1

d2

1p 2p


Fuel Injector

Wall

Wall


Dro

plet

s

Mon

te-C

arlo

par

ticle

s

dx

dz

dy

G

d1

d2

1p 2p

Eulerian Cell







ChemistryChemistry









ChemistryChemistry



A block diagram showing different components of our new Lagrangian-Eulerian-Lagrangian model for two-phase reacting turbulent flows. The interactions among the velocity field (represented by the Eulerian grid system), the chemical species (represented by the Lagrangian Monte Carlo particles), and the spray(represented by the Lagrangian droplets) are also shown.

Select Research Projects/Sponsors

§  Heavy vehicle hybrid technology – buses and three-axle+ vehicles

§  Use of advanced SiC transistors for power electric systems

§  Support from: US Army, Michigan Economic Development Corporation, US Dept of Energy Advanced Research Projects Agency – Energy, OEMs and Tier I+II suppliers, etc.

Select Research at MSU Energy Research

Wave Disk Engine

Degree Programs

Our degree programs include:""§  Applied Engineering Sciences"§  Biosystems Engineering"§  Chemical Engineering"§  Civil Engineering"§  Computer Science"§  Computer Engineering"§  Electrical Engineering"§  Environmental Engineering"§  Materials Science and Engineering"§  Mechanical Engineering"

Residential Experience

The Residential Experience is a unique experience to immerse yourself in the world of engineering. Live and learn in a collaborative and friendly environment that gets you connected early in your academic career. You can build your academic experience from a rich assortment of opportunities that will prepare you to face the technical challenges of the 21st century. ""Located in Wilson Hall.""Corporate sponsored communities.

Wilson Hall Academic Advising

Cornerstone Engineering

The Cornerstone Engineering experience seeks to provide early engineering students with a broad introduction to engineering.

Students will learn about engineering as a profession, engineering problem-solving skills and teamwork skills and the types of engineering they can major in. "Design courses are included throughout the curriculum every year."

Capstone Engineering Senior students complete a

Capstone Design Course "§  Team-based, industry-sponsored project "§  Design a solution and produce a working

prototype"§  Display and present at Design Day"

Documents

Trends in Engineering and Auto Manufacturing