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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
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
- 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
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
- 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
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
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"