A Review of advanced technologies used in automobiles

Devendra Vashist
1
, Paramjeet Singh
2

1
Professor
2
Assistant Professor (Manav Rachna International University)
Abstract
This paper highlights the the technical aspects and the working of the advanced technologies
used in the present or in the future automobiles. The technologies that are discussed in pte paper
are variable valve timing, Valvetronic Engines, New Teflon Pads pistons, Downsizing and
Turbocharging, Advanced Combustion Modes, Hybrid / Electric Vehicles, Fuel Cells, Weight
Reduction Materials, Alternative Fuels, Batteries and Energy Storage, Telematics, Drive by wire
Technology and Camless engine. All these technologies are at the various stages of development.
Their working and advantages and are discussed in the paper.
Keywords: Engine, Fuel cell, batteries, hybrid vehicles.
Introduction
The key drivers for new engine technology namely changing Customer Expectations, New
Environmental Regulations on Emissions & Noise, Increasing Fuel Costs, Availability of
Alternate Fuels, New Emerging Markets & Segments, Increasing Competition
are causing todays engineers to think in the direction of more efficient and economical
technologies. The above mentioned objective were obtained by bringing changes in the engines
or by fitting modern gadgets on the automobile that not only improves its market value by paves
ways for further improvement. Few technologies that are being recently induced or are in the
stages of development are discussed in the paper.
As an automobile engineer we have always been driven by bold imagination and focused,
disciplined action to realize the power of those dreams that would build a future car. It is part of
our DNA to realize technology's potential for positive change and to share that vision with the
world. Todays engineers, designers, and planners live years in the future, imagining a future
where cars carrying our loved ones never crash; where empty cars can be sent to pick up our
friends; and where cars dont break down, leaving us stranded. As an engineer we are looking
into the future, to a time when vehicles will no longer pollute; when they use only fuels made
from renewable sources or run on electricity. We are building technologies into vehicles so they
never get trapped in a traffic jam, can anticipate and avoid collisions, and that can safely take
over the driving for sleepy, busy or distracted drivers, that improve communications capabilities
or save fuel. These various technologies are discussed in the below given paragraphs
Variable Valve Timing
Several engine manufacturers are experimenting with systems that would allow infinite
variability in valve timing. The camshafts on some Ferrari engines are cut with a three-
dimensional profile that varies along the length of the cam lobe. At one end of the cam lobe is
the least aggressive cam profile, and at the other end is the most aggressive. The shape of the
cam smoothly blends these two profiles together. A mechanism can slide the whole camshaft
laterally so that the valve engages different parts of the cam. The shaft still spins just like a
regular camshaft, but by gradually sliding the camshaft laterally as the engine speed and load
increase, the valve timing can be optimized.
Valvetronic Engines
The Valvetronic engine is the world's first engine without a throttle butterfly. Valvetronic varies
the timing and the lift of the intake valves. The Valvetronic system has a conventional intake
cam, but it also uses a secondary eccentric shaft with a series of levers and roller followers,
activated by a stepper motor. Based on signals formerly taken mechanically from the accelerator
pedal, the stepper motor changes the phase of the eccentric cam, modifying the action of the
intake valves. Valvetronic reduces maintenance costs, improves cold start behavior, lowers
exhaust emissions, and provides a smoother running engine. Valvetronic does not need specific
fuel grades or fuel qualities because of its fine atomization of fuel. Because Valvetronic allows
the engine to breathe more freely, fuel consumption is reduced by 10%. Valvetronic minimizes
pumping loss by reducing valve lift and the amount of air entering the combustion chambers.
Compared with conventional twin-cam engines with finger followers, Valvetronic employs an
additional eccentric shaft, an electric motor and several intermediate rocker arms, which in turn
activates the opening and closing of valves. If the rocker arms push deeper, the intake valves will
have a higher lift, and vice-versa. Thus, Valvetronic has the ability to get deep, long ventilation
(large valve lift) and flat, short ventilation (short valve lift), depending on the demands placed on
the engine.
New Teflon Pads pistons:
The Cummins V28 engines have used a new technology for their pistons- they have two teflon
pads and the pistons also incorporate a cutback headland. Extensive testing in laboratory and
field has shown that the Teflon padded pistons will eliminate cylinder liner water jacket
cavitation corrosion and increase cylinder liner life and hence engine life. The cutback feature
has been found to consistently reduce oil consumption and blow bye. The advantages include:
1. Improved oil consumption
2. Increased piston and cylinder liner life
Pads are removable and interchangeable Teflon pad (piston need not be replaced since the wear
takes place only on the Teflon pads).
Variable Compression Ratio:
This technology makes use of the fact that change in the compression ratio in the cylinder
improves its performance.
Downsizing and Turbocharging
The two main areas for downsizing an internal combustion engine are thermodynamic
and mechanical. "From a thermodynamic point of view, the engine operation will move towards
higher loads, at which the engine efficiency is higher. "From the mechanical point of view, the
positive aspect lies in the reduction of the friction in the piston units, together with the reduction
of the number of cylinders."Downsized engines are lighter than conventional engines, thereby
reducing vehicle mass and the improving vehicle fuel consumption. Downsizing favors
increasing engine running speed by reducing the inertia of its moving parts, but on the other
hand, works against the intake of an acceptable mix volume by the cylinders. In petrol and diesel
vehicles, the turbocharger has a centrifugal compressor powered by a turbine that is driven by the
engines exhaust gases. Hot exhaust gases flow through the turbines wheel blades, accelerating
the turbine and driving the compressor. Turbocharging recovers the energy of the exhaust gasses
to increase the inducted charge, therefore increasing the power-to-displacement ratio. Developers
have introduced variable turbine geometry to the diesel turbocharger in which a set of
adjustable vanes in the exhaust housing control gas flow across the turbine. At low engine
speeds, turbine speed is maintained or increased by minimizing the cross-section of the vanes
inlet. "A downsized and turbocharged engine has the potential to have the same or better
performance as a non-downsized, normally aspirated engine, with the advantage of a significant
increase of fuel efficiency.[1,2] Thus, a 2.5 L petrol engine capable of delivering power of 123
kW and torque of 211 Nm can be replaced by a 2 L turbo engine. This will deliver 120 kW with
torque of 250 Nm, and therefore equivalent performance, while offering a 9% reduction in fuel
consumption.
Advanced Combustion Modes
Engineers are working to increase the efficiency of internal combustion engines by
developing several advanced combustion modes. Some of these are introduction of direct
combustion system in both petrol and diesel engine with advance version like CRDI (Common
rail diesel injection) in diesel and GDI (Gasoline direct injection) in petrol.


Figure 1 Gasoline direct injection (engine
section)
(1 Piston, 2 Intake valve, 3 Ignition coil and
spark plug, 4 Exhaust valve, 5 High-pressure
fuel injector, 6 Fuel rail)




Figure 2 Working principle of HCCI Engine

Another mode is called (homogeneous charge compression ignition) HCCI. All vehicle
manufacturers are developing Homogenous Charge Compression Ignition (HCCI) engines that
use spark ignition for heavy load operation but in light load can ignite a lean mixture throughout
a cylinder without a spark. The "homogenous charge" is a uniform mix of air, fuel and up to 70
percent of the already-burned exhaust gas. Compression stroke brings the mixture to a controlled
self-ignition state -- no need for a spark. Because of the uniform mix in the cylinder, there's no
hot flame front, and the mixture burns almost instantaneously and completely throughout the
cylinder. So there aren't any "hot spots" to produce engine knocking. The engine requires spark
plugs for starting and heavy loads, but in HCCI mode, it improves fuel economy about 10 to15
percent--close to a diesel. It does require a "designer" gasoline, perhaps a synthetic gasoline. [3,
4, 5]
Hybrid / Electric Vehicles
Hybrid vehicles are quipped with both combustion and electric engines. Especially,
electric engine is designed to operate efficiently at constant speed. These vehicles are currently
in production. The path to electrification/hybridization includes a full range of technologies
including light electrification, traditional and plug-in hybrids, battery-electric vehicles, and
extended-range electric vehicles [6]. Electric Vehicles (EV) run on 100 percent electricity to
provide gas- and emission-free driving. This technology holds great potential, especially for use
in smaller vehicles running at lower speeds for short distances, in highly populated urban areas.

Figure 3 Drive trains in hybrid vehicles
Table 1 Degree of hybridization
step Technology Degree of hybridization
1 Avoiding energy losses during idling by shutting off the
combustion engine.
Mild HEV (e.g. Honda Civic)

2 Recuperating energy from regenerative braking. Mild HEV (e.g. Honda Civic)
3 Using the battery energy to assist the engine and enable
downsizing the engine
Mild HEV (e.g. Honda Civic)

4 Running the combustion engine at its maximum load,
where the engine efficiency maximizes.
Full HEV (e.g. Toyota Prius)
5 Driving without the combustion engine running Full HEV (e.g. Toyota Prius)
6 Enlarging the battery pack and recharging it with energy
from a wall plug
PHEV (in development)

The price of this vehicle is approximately 30~40 percent more than a comparable conventional
vehicle, but it is projected that the extra cost will be regained over its life time. A petrol engine in
a conventional car has an average engine efficiency of 17%-20% under normal driving
conditions. Most of the energy in the fuel is lost as heat and a smaller part as engine friction.
However, of the remaining energy out from the engine approximately 10%-12% is lost during
idling and another 20%-30% is lost when braking. In conclusion, only 12%-14% of the energy
supplied as fuel is actually used to move the car forward. HEVs can deal with some of these
energy losses using different kinds of technologies designed to harness and utilize lost energy.
Figure 1 shows degrees ranging from mild HEV, to full HEV and PHEV refer to the
technologies used and, in general, increased degrees of fuel efficiency.
Fuel Cell Technology
A fuel cell works as an electrochemical cell by combining hydrogen and oxygen without
combustion to generate electricity. A series of load cells requires drainage after prolonged use.
Fuel cell will produce electricity if the fuel remains forever.
The mechanism of energy generation is explained under.
Inside a cell a fuel hydrogen is passed over a negatively
charged charged pole, or anode, where electrons are
stripped off through catalytic action. The hydrogen ions
that result then flow through the conducting substance
(known as electrolyte) towards a positively charged pole or
cathode. The electron flow produces an electric current.
Fig 4 Fuel Cells
The hydrogen ions are left to combine at the cathode with oxygen, producing heat and water. The
oxygen needed for the reaction is usually taken directly from the air around the fuel cell. Ethanol,
methanol and hydrogen are the main sources of fuel for the production of electricity from fuel
cells. The electricity generated drives the car. Fuel cell technology allows vehicles to run on
alternative fuels. Alternative fuels burns cleaner as compared to the conventional fuels. Fuel cells
are getting smaller in size and can be introduced into the engine without compromising
performance. Ethanol is the best choice for alternative fuels because of its natural properties.[6]

Weight Reduction Materials
Advanced materials are essential for boosting the fuel economy of modern automobiles
while maintaining safety and performance. Because it takes less energy to accelerate a lighter
object than a heavier one, lightweight materials offer great potential for increasing vehicle
efficiency. Replacing cast iron and traditional steel components with lightweight materials such
as high-strength steel, magnesium (Mg) alloys, aluminum (Al) alloys, carbon fiber, and polymer
composites can directly reduce the weight of a vehicle's body and chassis by up to 50 percent and
therefore reduce a vehicle's fuel consumption. A 10% reduction in vehicle weight can result in a
6%-8% fuel economy improvement. By using lightweight structural materials, cars can carry
additional advanced emission control systems, safety devices, and integrated electronic systems
without increasing the overall weight of the vehicle. While any vehicle can use lightweight
materials, they are especially important for hybrid electric, plug-in hybrid electric and electric
vehicles. Using lightweight materials in these vehicles can offset the weight of power systems
such as batteries and electric motors, improving the efficiency and increasing their all-electric
range. Alternatively, the use of lightweight materials could result in needing a smaller and lower
cost battery while keeping the all-electric range of plug-in vehicles constant.[7,8,9]
Alternative Fuels
The alternative fuels being tested at present are Liquefied Petroleum Gas (LPG),
Compressed Natural Gas (CNG), Liquefied Natural Gas (LNG), Methanol, Ethanol, Hydrogen,
etc. These are designed to reduce emission and release fewer green house gas emissions.
However, the effectiveness of some of these technologies are still controversial due to its limited
availability and its performance on pollution reduction, so the technologies are mainly applied in
niche market such as buses and service vehicles.[10]
Batteries and Energy Storage
Since conventional batteries are too heavy, fleeting, costly, and most seriously, limited in
capacity, In order to expand battery operating range and reduce costs, some researchers are
designing and testing new battery chemistries and subsystems. Advanced chemistries could
allow batteries to operate through greater temperature extremes, last longer, and reduce weight
and cost. Other efforts are being made to reduce the cost of the ancillary systems, such as
cooling, to further reduce the total cost of the battery system. [6,11] Companies such as EEStor,
A123 Systems and Altair Nanotechnologies could soon be building batteries capable of powering
a car for 300 to 400 miles. (As an added benefit, they might need only minutes to recharge.)
42 Volt Systems
Perhaps the most intriguing development that is well underway will be the coming of the
42-Volt Electrical Systems in passenger cars and trucks. This dramatic change will be required to
support not only the increasing appetite for more consumer electronics in vehicles, but also some
dramatically different systems than weve ever encountered before. Look for changes to
currently mechanically driven systems to become electrical. This includes air conditioning
systems, water pumps, and even alternators. There will also be further inroads of electrically
controlled components such as steering and suspension systems and further proliferation of
conveniences such as heated windshields, seating, zone heating & AC, and the European
movement toward start- stop engines. There are even projects in place for the implementation
of heated catalysts to further reduce vehicle emissions. Conversion of many of these historically
Mechanical systems will allow for further vehicle weight reduction and increased fuel
efficiency as well as provide highly desirable and profitable consumer features. All these
developments will force the conversion to 42-Volt electrical systems in the very near future.
[12,13,14]
Telematics
Most experts predict a continuing merging of information and telecommunications
technology into the global automotive industry. Technologies such as GPS and increasing in-
vehicle entertainment options will drive dramatic changes in the driving environment. Virtually
all vehicle manufacturers are embracing these technologies, but it will be very difficult for any
one to establish a truly sustainable competitive advantage in this area. In any event, the increased
use of electronics in these devices will have both direct and indirect impact on adhesive and
sealant suppliers and technology. [15]
Drive by wire Technology
Each year the Vehicle gets just a little bit more refined as new technology replaces old. It
started with Luxuries like Key Start, then Hydraulic Brakes and continues today with Climate
Controlled Air Conditioning, Cruise Control, and Electronic Fuel Injection and now drive by
Wire.
Like so many of today's technologies, Drive by Wire is primarily a response to tightening
emission standards. As with fuel injection and integrated engine controllers, Drive by Wire
systems improve engine efficiency while cutting vehicle emissions. They do this by replacing
clunky and inaccurate mechanical systems with highly advanced and precise electronic sensors.
Drive-by-wire, DbW, by-wire, or x-by-wire technology in the automotive industry
replaces the traditional mechanical control systems with electronic control systems using
electromechanical actuator and human- machine interfaces such as pedal and steering feel
emulators. Conventional cars mainly use hydraulic and mechanical technology to conduct
operations, including acceleration, braking steering, etc. These same basic vehicles operations,
and although the systems are powerful, they can be overly complex, inefficient and conducive to
wear and tear over the years. But over the years, manufacturers and outside researchers and
inventors have been integrating computers and electronics into modern cars. If drivers could
simply get accustomed to the idea, drive-by-wire systems have the potential to increase comfort,
functionality and safety during the drive. Computers and sensors would analyze commands and
instruct vehicles on exactly what to do. And by- wire systems have an environmental angle, too,
since the technology could improve fuel economy and reduce or improve engine emissions.
There are several different types of drive-by-wire systems, which is why its sometimes
referred to generally as x-by-wire. Here are a few of the main by-wire systems:
Throttle-by-wire Throttle-by-wire, or accelerate-by-wire, was the first type of drive-
by-wire system introduced. These systems use a pedal unit and an engine management system.
The pedal uses sensors that measure how much or how little the driver moves the accelerator,
and the sensors send that information to the engine management system. The engine
management system is a computer that, among other tasks, determines how much fuel is
required, and it provides this input to an actuator a device that converts energy into
mechanical motion. The pedal could be the same pedal drivers have become accustomed to using
today, an easy-to-reach pad placed near the foot thats pressed down in order to accelerate the
car. The same operation could also be incorporated into a joystick or videogame-like controller,
which would get rid of the need for a foot pedal completely. Of course, this would require
drivers to use their hands for acceleration, braking and steering.
Brake-by-wire There are actually two types of brake-by-wire systems. Hydraulic, or
wet, brake-by-wire uses additional hydraulic parts to create pressure on the brakes. Electric, or
dry, brake-by-wire, on the other hand, simply uses an electric motor and no hydraulic brake
fluid.
Steer-by-wire Sensors detect the movements of the steering wheel and send
information to a microprocessor. The computer then sends commands to actuators on the axles,
which turn according to the drivers directions.[14]
Camless engine
In a camless engine, electromechanical actuators (a set of electromagnets), placed
directly on the valves, replace the camshaft. This technology makes it possible to optimize the
circulation of gases in the engine both for intake and exhaust, and to deploy operating modes that
improve fuel consumption, clean exhaust technology and performance. In a traditional engine,
the opening and closing of the valves is commanded by the camshaft. During its rotation, the
cams push the valves. Although this process is effective and has been in use since the invention
of the four-stroke engine, it nonetheless has its limits. The periods of valve lift are conditioned
by the geometrical profile of the cams, which is fixed no matter how the engine is operating.
This mechanical system is therefore a compromise that takes account of the different conditions
of engine running, a difficult trade-off between fuel consumption, performance and clean
running. To better adapt the intake and gas exhaust phases, there are now systems that make it
possible to deliver a level of clean engine technology acceptable to the market such as the
camshaft angle variator, which permits a level of flexibility by varying the angle of the entire
camshaft. However, the different specific properties of air intake and gas exhaust processes in
the engine require better flexibility for each cylinder, even each valve, if performance is to
continue to improve. The camless system offers all this.
Conclusion
Different future technologies were studies and there benefits were presented along with
their working. Once these technologies become fully functional it will not only make the
travelling part of human comfortable but also reduce our dependence on conventional fuels. It
has been observed that these technologies are also environment and user friendly.
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