Opposed-Piston Proposition Greaves Cotton and Pinnacle Engines Target 3-Wheeler Efficiency, Emissions India’S EV-Only Vision Myth, Miracle Or Reality?
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MOBILITY ENGINEERINGTM AUTOMOTIVE, AEROSPACE, OFF-HIGHWAY A quarterly publication of and Opposed-piston proposition Greaves Cotton and Pinnacle Engines target 3-wheeler efficiency, emissions India’s EV-only vision Myth, miracle or reality? Motorcycle engine simulation Predicting combustion-load engine noise Off-highway flywheels Durable energy recovery and load-leveling Volume 4, Issue 3 September 2017 ME AR Ad 0917.qxp_Mobility FP 8/1/17 5:00 PM Page 1 AR…The Force Behind The Field AR’s High Intensity Radiated Fields (HIRF) Equipment Designed To Meet Tomorrow’s Needs Inherent danger associated with High Intensity Radiated Fields (HIRF) is becoming increasingly evident with the growing complexity of military and aircraft systems. Sources of HIRF include high power radars, weapons, and naturally occurring environmental conditions. Unprotected equipment can fail with potentially devastating results. 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In India, contact Complus Systems at www.complus.in or call 91-80-416-83883 ISO 9001:2008 We don’t just build great products. Certified We build great products that last. rf/microwave instrumentation www.arworld.us Download the AR RF/Microwave Mobile App: www.arworld.us/arApp Other divisions: modular rf U receiver systems U ar europe ar Copyright © 2017 AR. The orange stripe on AR products is USA +1-215-723-8181. Reg. U.S. Pat. & TM. Off. CONTENTS Features 36 Opposed-piston engines: the 44 Innovations for lightweighting powerplant of the future AUTOMOTIVE LIGHTWEIGHTING AUTOMOTIVE POWERTRAIN Tough U.S. fuel-economy bogies for 2021 and beyond are driving new approaches for materials, as seen in 38 India’s dream of an all-EV fleet these examples. by 2030: Myth, miracle, or 48 More intelligence equals more reality? AUTOMOTIVE PROPULSION efficiency, enhanced functionality OFF-HIGHWAY ELECTRONICS | 41 An approach for prediction of HYDRAULICS motorcycle engine noise under Advanced electronic systems require renewed focus on combustion load AUTOMOTIVE architectures, processors, sensors and networks. SIMULATION 51 Connected commercial vehicles bring cybersecurity to the fore Cover SAE COMVEC PREVIEW Connectivity, automation and electrification will drive U.S-based Pinnacle Engine’s vehicle development in the near future, say industry experts opposed-piston four-stroke attending the revamped SAE COMVEC 17 event. engine is being developed in a technology partnership with Indian engine and equip- ment-maker Greaves Cotton. A supplemental feature on p.36 examines the advantages of opposed-piston engine layouts. MOBILITY ENGINEERING SEPTEMBER 2017 1 CONTENTS Departments 4 Editorial 20 Mechatronics technology offers improvements in As EVs emerge, internal-combustion’s finest hour? performance and efficiency OFF-HIGHWAY MECHATRONICS 6 SAEINDIA News 22 CO2 buildup in vehicle cabins becoming a safety 6 Aerospace: Then, now and future, February at issue AUTOMOTIVE SAFETY Bengaluru 23 Exa simulation aims to keep ADAS sensors clean 7 MANOVEGAM Aero Championship final flight round, AUTOMOTIVE SIMULATION April at Bengaluru 25 DSD’s low-cost 12V hybrid aims for small cars 7 Industrial seminars in May at Gurgaon AUTOMOTIVE POWERTRAIN 8 ‘Tractors for Modern Forming’ lecture meeting in April 26 Kubota goes ‘big’ with first-ever 200-hp diesel engine OFF-HIGHWAY POWERTRAIN 9 Inter-Collegiate Club Project competition, June at Pune 26 Delphi and Tula show NVH benefits from Dynamic 9 Global Manufacturing Cluster Vision 2030 at Coimbatore Skip Fire AUTOMOTIVE POWERTRAIN 10 Annual Social 2017 at Pune 28 Model maturity assessment and certification—a 11 Automotive Forum 2017 in Chennai vision TRUCK & OFF-HIGHWAY SIMULATION 11 Drive with IoT, June at Bengaluru 30 Commercial vehicles to become the ultimate ‘sensor’ 13 SAE EGA, June in Bengaluru OFF-HIGHWAY ELECTRONICS 13 Aero Design Challenge 2017 finals, June in Chennai 31 Axellent progress AUTOMOTIVE PROPULSION 34 Low-temperature combustion ready for prime time? 15 Industry News AUTOMOTIVE POWERTRAIN 15 Pinnacle Engines partners with India’s Greaves Cotton on new opposed-piston engine 54 Global Vehicles 54 2018 Honda Accord drops mass, adds turbos and 15 Tata Advanced Systems delivers first CH-47F 10-speed automatic Chinook crown, tailcone for India to Boeing 55 Nissan engineers ‘Sport’ into its hot-selling CUV 16 BharatBenz delivers 50,000th truck 56 Sleek design, powertrain advances distinguish 16 IAC expands with new engineering center in India Volvo’s new VNL trucks 17 Technology Report 58 Mercedes-Benz reveals production version of X-Class 17 Using power-dense flywheel hybrid technology to pickup truck cut fuel consumption of OH equipment 59 VW finally fills its SUV gap with 2018 Atlas OFF-HIGHWAY POWERTRAIN 61 Musclecar Godzilla: Dodge Reveals 840-hp 18 Mahle tests for ‘mega knock’ in downsized boosted Challenger SRT Demon engines AUTOMOTIVE POWERTRAIN 19 Lockheed Martin shows big support for Metamaterial 63 Companies Mentioned, Ad Index Technologies’ smart-materials research AEROSPACE 64 Q&A MATERIALS Dr. Xinqun Gui, manager of technology, control systems and emissions compliance at John Deere Power Systems, discusses advanced emissions strategies © SAEINDIA and SAE INTERNATIONAL reserves all rights . No part of this publication and/or website may be reproduced, stored in a retrieval system or transmitted in any form without prior written permission of the Publisher. Permission is only deemed valid if approval is in writing. SAEINDIA and SAE International buys all rights to contributions, text and images, unless previously agreed to in writing.In case of Address/addressee not found return to SAE INDIA, No 1/17Ceebros Arcade, 3rd Cross, Kasturba Nagar, Chennai -600 020. Telefax: 91-44-2441-1904, Phone: 91-44-4215 2280. 2 SEPTEMBER 2017 MOBILITY ENGINEERING ME Altair Ad 0917.qxp_Mobility FP 7/5/17 4:13 PM Page 1 EDITORIAL EDITORIAL Bill Visnic Editorial Director [email protected] Asit K. Barma SAEINDIA Editor C. V. Raman As EVs emerge, internal-combustion’s finest hour? ED, MSIL [email protected] I find it not without irony that at the time the OP engine design presents many potential Arun Jaura Project Director, Michelin auto industry is consumed with interest and in- advantages, including substantial improve- [email protected] vestment in battery electric vehicles (EVs), the ments in thermal efficiency, reduced parts Bala Bharadvaj MD, Boeing R & T technology presumably being “displaced”—the count and lower emissions. Not coincidentally, [email protected] internal-combustion engine—might be reaching on the cover of this issue you’ll find the new Mathew Abraham its most promising stage of development. Sr. GM, Mahindra OP-engine design that Greaves Cotton and the [email protected] During this seminal period of automotive U.S.’s Pinnacle Engines said can propel India’s Dr. Venkat Srinivas technology disruption, both EV propulsion and three-wheelers to BS VI emissions compliance Vice President & Head - Engineering & Product IC powertrains are indeed competing, if you (see p. 15 for those details). Development, Mahindra & Mahindra Truck and Bus Division will. Some argue that it really isn’t a competi- Meanwhile, just as this issue of Mobility [email protected] tion at all: the 100-year-old IC engine has a Engineering was created, Mazda announced it Lindsay Brooke Editor-in-Chief mature and easy to volume-build design, is will introduce a sparkless compression-ignition [email protected] inexpensive to build and its efficiency, if not gasoline engine for production vehicles in 2019. Ryan Gehm Associate Editor remarkable, certainly isn’t shameful anymore. Gasoline compression-ignition has been a pow- [email protected] Toyota, Honda and others have mass-produced ertrain development aspiration for more than a Jennifer Shuttleworth gasoline engines in affordable vehicles that decade because the technology presents the Associate Editor [email protected] now are turning into work as much as 40% of opportunity to match or surpass diesel-engine Lisa Arrigo their fuel’s energy. efficiency without the emissions liabilities die- Custom Electronic Products Editor But IC engines generate tailpipe emissions. sels can’t seem to overcome. [email protected] And as vast as the improvements in engine General Motors, Hyundai and others have Contributors emissions-reduction have been, EVs present the had documented gasoline compression-ignition Kami Buchholz Detroit Editor advantage—albeit perceived—of having zero development programs, but until Mazda’s Stuart Birch emissions. Factor in the recent controversy sur- announcement