Automotive Innovation Automotive Innovation The Science and Engineering behind Cutting-Edge Automotive Technology Patrick Hossay CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2020 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U. Government works Printed on acid-free paper International Standard Book Number-13: 978-1-138-61176-4 (Hardback) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained.
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Library of Congress Cataloging‑in‑Publication Data Names: Hossay, Patrick, 1964- author. Title: Automotive innovation : the science and engineering behind cutting-edge automotive technology / Patrick Hossay. Description: First edition. | Boca Raton, FL : CRC Press/Taylor & Francis Group, [2020] Identifiers: LCCN 2019009155 | ISBN 9781138611764 (hardback) Subjects: LCSH: Automobiles—Technological innovations—Popular works.
| Automobiles—Design and construction—Popular works. Classification: LCC TL240 .2—dc23 LC record available at https://lccn.gov/2019009155 Visit the Taylor & Francis Web site at http://www.com and the CRC Press Web site at http://www.com Contents Preface. Bringing the Fire.1 What Is Gasoline?.3 The Four Strokes.4 The Engine Comes Together. 11 Defining the Combustion Chamber.
27 Low-Temperature Combustion. The End of Compromise. 39 Advanced Digital Control.42 Variable Valve Actuation. Getting Power to the Pavement.65 What Do We Need a Drivetrain to Do?.65 Manual Transmission Coupler.
76 Automatic Transmission Coupler. 86 Continuously Variable Transmissions. 88 Differentials, AWD, and Torque Vectoring. 92 Advanced Tires and Control.
99 The Principles of the Electric Motor. 100 Making an Electric Machine. 108 Torque and Power. 112 v vi Contents Induction Motor.
113 Permanent-Magnet Machines. 124 Advanced Motor Possibilities. 131 Gas versus Electrons?. 151 Electric Car Viability.
155 Using Energy Effectively. The Electric Fuel Tank. 179 Nickel-Based Batteries. 195 General Chassis Design.
226 Bringing It All Together. The Power of Shape. 233 The Nature of Drag.234 The Power of Shape. 237 The Shape of a Car.
238 The Front of the Car. 240 Contents vii Addressing the Rear Wake. 243 Three Dimensional Flow. 257 Bringing the Body Together.
290 The Road Ahead. 295 Preface Cars have changed radically over the past few decades, and the pace of change is only accelerating. Innovations in engine design, fuel systems, digital control, advanced trans- missions, and a range of other technologies have fundamentally redefined the powertrain. And advanced electronic control systems, active chassis control, driver assistance systems, not to mention electrified drivetrains, advanced batteries, and new lightweight materials are allowing us to profoundly reimagine what is possible.
It can be tough to keep up. And that’s the point of this book. These exciting changes and innovations in automotive technology are complex, but they don’t need to be intimidating. Fundamentally, the same basic principles are at work, whether you’re looking at a Model T or a Tesla.
The laws of science and mechanical principles haven’t changed. Admittedly, the engineering particulars have become more involved, and there are a lot more of them. But, in the end, all of the technology in the most advanced vehicles can be understood in principle by anyone with a basic grasp of science and mechanics. So, think of this book as a primer, a basic survey of the new automotive landscape with an eye toward a timely orientation to the most interesting innovations and the most prom- ising technological advances out there.
One aim of this work is to provide a solid intro- ductory text for an undergraduate course. In particular, the idea is to fill the gap between a vocational-based automotive repair text and an advanced engineering text. In fact, this book grew out of an undergraduate survey course on automotive technology and design. Finding a useful text for this sort of course has always been difficult, as nearly all introduc- tory texts in automotive technology focus on vocational training for mechanics; and the only other alternative is often a technically dense engineering text, a rather intimidating introduction to the field.
This text is aimed at the midpoint: a true introductory survey of the science and engineering in automotive technology that allows a generally informed reader to develop an understanding of the principles, trends, and challenges in automotive technology and the possible directions of future developments. With this in mind, the aim is to keep this work accessible and engaging. A useful orien- tation to the field should be readable and stimulating for students, mechanics, automotive enthusiasts, and anyone else who may have an interest in cars, technology, innovation, or engineering. This stuff is really amazing, exciting, and frequently ingenious; but all-too-often, the amazing stuff is buried under layers of engineering terminology and daunting computations that can thoroughly snuff out the flame of enthusiasm in the uninitiated.
Cars can be really exiting; a book on them should be too. So, this book will be useful for students of automotive engineering and technology that need an orientation to the field. This book should also be useful to a seasoned automotive technician trying to stay on top of a rapidly changing field, or a newly minted mechanic who needs a general orientation to the near future of the automobile, and even an auto- motive enthusiast who just wants to better understand how recent technological changes come together. With luck this text will inspire budding engineers and maybe even motivate a few mechanics and gear heads to dig deeper, continue to explore the field, and perhaps even choose to take the next step and select a career that allows them to contribute to redefin- ing the future of the automobile.
This is truly a golden age in automotive design, a time ix x Preface when the future seems up for grabs, and a new possibilities have become not just feasible but likely. Remember, this book is intended as a primer. You don’t need a deep background in automotive technology to keep up. But a basic understanding of science and the funda- mentals of mechanics won’t hurt.
Each topic and each chapter begin at the beginning, the basic principles that underpin the technology. Subsequently, the chapters move on to the ideas and engineering that define some of the most exciting innovations in the field; and in the end, each chapter addresses some of the most promising advances for the near future. In sum, the chapters offer a basic lay of the land, an orientation to the technology that is reshaping that field and plenty of real-world examples of remarkable automotive innovations. Since the idea is to keep this book accessible, approachable, and short, this text has defined limits.
It is fundamentally about cars, the current cars on the road now, and the likely changes that will define the cars on the road tomorrow. It’s not about the automotive industry more generally, or the future of transportation infrastructure, manu- facturing, or policy. Nor is it a detailed examination of research in science or engineer- ing. So, automotive-related innovations that could one day reshape vehicles by remaking transportation infrastructure, such as alternative fuels, fuel cells, or intelligent transpor- tation systems (ITS), are interesting, but that’s really not what this book is about.
Likewise, this is a primer; so, for a complete presentation of the advanced engineering techniques and computations needed to design these systems, you’ll need to look elsewhere. In short, both the scope and depth of this text are intentionally focused. This is an introductory survey of contemporary automotive innovations for readers with a basic mechanical and science background. With all of this in mind, this book addresses four principle areas: first, the technology of the combustion-based automobile on the road now and in the near future, addressed in the first three chapters; second, the technology of the electrified drivetrain that’s increas- ingly present now and very likely to become dominant in the near future, addressed in the subsequent three chapters; third, innovations in chassis and body design, which are covered in Chapters 7 and 8; and lastly, a basic introduction to the sensor and navigation technology that enables advanced driver assistance systems and the possibilities for self- driving cars, addressed in the final chapter.
So, within this broad framework, Chapter 1 begins with the basics of the internal com- bustion engine and quickly moves on to review recent innovations in ignition manage- ment, advanced fuel delivery, combustion chamber design, and moves through to the basic principles of advanced low-temperature combustion possibilities and ingenious new engine designs. Chapter 2 then builds on this foundation with an examination of the digital control technology that has redefined the internal combustion engine, from vari- able valve timing and lift to variable intakes, as well as promising developments in more advanced active control mechanisms that enable precise on the fly changes in just about every aspect of the engine, defying the tradeoffs and limits engineers once faced when designing automotive engines. Chapter 3 then connects these technologies to the road by examining the rest of the powertrain, beginning with the basic principles of gearing and moving through to advanced innovations in transmission design including continuously variable transmissions, automatic manual transmission, dual-clutch systems, torque vec- toring, and even advances in future tire design, where the rubber literally meets the road. This then paves the way for an exploration of electrification of the drivetrain.
Chapter 4 begins with a general introduction to electric motors and their performance advantages and challenges, with a particular focus on brushless DC and induction AC motors and control Preface xi technology. It ends with an introduction to some of the more promising advances in motor design that may represent the electric machines of future automobiles. Chapter 5 examines the electrified powertrain, beginning with hybrid vehicle engineering, discussing varying hybrid drive architectures as well as the nature of regenerative braking and recent energy recovery innovations. It also explores electric vehicle technology, and the challenges and possibilities for future EVs.
Energy storage technology is examined in Chapter 6, from basic battery science to promising developments in advanced battery chemistry and design. The subsequent two chapters explore advanced vehicle design beyond the powertrain, beginning with a basic discussion of vehicle structure and handling and moving onto advanced suspension, active chassis control, new materials, and crashworthiness. Vehicle aerodynamics is examined in Chapter 8, again beginning with basic concepts of airflow and bluff bodies and moving onto an examination of recent applications such as air curtains, active shutters, ground effect management, and other advanced aerodynamic innovations. The last chapter examines advanced driver assistance systems.