Annual Report Department

2.13Automotive applications

2.13.1Dynamic engine test cell

The dynamic engine test stand creates for any given internal combustion engine the effect of a virtual drive train and a virtual driver by means of applying a real-time controlled torque to the engine crankshaft using a DC-mo­tor/generator. This dynamic torque corresponds to the torque that the engine would experience when mounted in a driving vehicle.

We currently focus our research activities on automated test cycle driving (e.g. ECE, FTP). Since this is actually a speed-tracking problem, the technology could easily be applied to state-of-the-art vehicle/engine management systems such as adaptive cruise control. A second point of interest for which the test stand will be used is the design of an optimal anticipative throttle valve controller.

The test stand can accurately drive our virtual vehicle through a prescribed driving pattern. We are able to measure instantaneous fuel consumption and emissions during the test cycle. The control program uses a combination of an advanced dynamic feed forward controller and a simple PID feedback controller on all 3 pedals (throttle, clutch and brake). The PID controller is currently being compared to a sliding mode controller.

Scientific staff: E. Van den Bulck, T. Persoons

2.13.2Study of a pulsating flow in a complex engine exhaust manifold

The design of car-engine exhaust manifolds fitted with close-coupled catalysts is a formidable task due to the complexity of the flow distribution of the alternating pulsating flows that are emitted by the engine. The modelling of these manifolds can be done with CFD. However, such simulations need to be checked with selected experimental data. This project focuses on the design of an experimental methodology for measuring the performance of close-coupled exhaust manifolds. The flow distribution is measured both for stationary operation as well as dynamic operation. To this end, both a rotating valve and a cylinder head with camshaft-driven poppet valves are used to provide the pulsating flows. The catalyst brick is carefully selected in order to make sure that the measurements downstream of the catalyst is representative for the flow that enters the catalyst. The dynamic measurements result in a time evolution of the velocity distribution, revealing the dynamic flow behaviour within one period of the pulsating flow. The time-averaged dynamic velocity distribution is found to correlate very well with the linear combination of the stationary velocity distributions. This research is the continuation of a previous project with Bosal entitled IWT/VLIET project No. 97/0375 “Reduction of pollutant emissions in traffic by applying new close-coupled catalysts” (2000-2002).

Publications and reports: 2003P08

Scientific staff: E. Van den Bulck, T. Persoons

2.14Life cycle engineering

2.14.1Development of pro-active eco-design methodologies

The increasing pressure from both the governmental and the customer’s sides forces industry to face the responsibility for the environmental impact of their products’ total life cycle. As a result, end-of-pipe pollution treatment technology has become insufficient, and focus is moving towards the integration of environmental aspects already in the design process. A methodology is being developed to support this integration in a proactive way, with special emphasis on the early, conceptual design phases. One part of the methodology is based on the systematic and structured storage and context sensitive retrieval of ecodesign knowledge (i.e. guidelines, experience,...). Another part of the methodology estimates screening LCA results based on functional requirements available early in the design process. The technique is being illustrated by examples on typical machine components.

Publications and reports: 2002PP135, 2003PP094, 2003PP095

Scientific staff: W. Dewulf, J. Duflou, P. Sas

2.14.2Life cycle engineering of manufacturing systems

In a life cycle engineering approach, material production, manufacturing, use, and end-of-life considerations are taken into account during the design phase of a product. Both economic and environmental criteria can be used to evaluate the performance of a design proposal in this respect. In this research, we develop and apply models and related methods that allow designers of manufacturing systems to analyse a design at hand from a life cycle perspective, taking into account the typical characteristics of manufacturing systems. These characteristics include, on the one hand, their complexity in terms of number and diversity of components, and, on the other hand, their long life span.

Related projects: CHASM, Growth project GRD1-2000-25828, “Ecosystems”

Scientific staff: W. Dewulf, J. Duflou

2.14.3Design for environment

The increasing pressure from both the governmental and the customers’ sides forces industry to face the responsibility for the environmental impact of their products’ total life cycle. As a result, end-of-pipe pollution treatment technology has become insufficient, and focus is moving towards the integration of environmental aspects already in the design process.

A methodology is developed to support this integration in a proactive way, with special emphasis on the early, conceptual design phases. One part of the methodology is based on the systematic and structured storage and context sensitive retrieval of ecodesign knowledge (i.e. guidelines, experience,…). Another part of the methodology estimates screening LCA results based on functional requirements available early in the design process. The technique is illustrated by examples on typical machine components.

Related projects: Refining and applying the pro-active ecodesign method 'Eco-Pas'

Publications and reports: WP2002-22, WP2003-04, WP2003-10, 03DC01

Scientific staff: W. Dewulf, J. Duflou, P. Sas

2.14.4Product recycling and reuse

Closed loop economies are proposed as a major strategy towards sustainable development. The practical implementation of a closed loop economy calls, however, for supporting tools for different actors in the product life cycle. In this respect, we investigate the needs of the car dismantling sector to enable an increased reuse of car parts. Four perspectives were identified: improved quality assurance, advanced e-commerce, intra-sector logistical co-operation and market enlargement through co-operation with other sectors. A prototype system is developed, allowing for stock management, disassembly support, as well as e-commerce using a database and a web-based interface. Moreover, new research has recently started aimed at developing innovative fasteners and corresponding tools to allow easy disassembly.

Related projects: Development of improved fastening and separation techniques in support of design for disassembly and design for recycling strategies

Publications and reports: WP2003-13

Scientific staff: W. Dewulf, J. Duflou, B. Willems

2.14.5Knowledge management

The research within the field of knowledge management contains the design and analysis of useful methods and algorithms to maximally exploit the knowledge sources of a business environment focused on research and development. The continuously growing data flows and the constant changes in staff have increased the management’s need to filter, captivate and exploit the available knowledge at a maximum yield, as probably the most valuable company asset.

By representing the present knowledge (internal documents, i.e. explicit knowledge, as well as mental, i.e. tacit knowledge - inside people’s head) in a vector space model, it is possible to apply and fine tune a number of mathematical techniques such as clustering, matching and searching algorithms. To obtain a representative image of the tacit knowledge, user profiles are applied. These profiles are dynamically updated and reflect the shifting expertise and interests of the user.

Because of the modularity of the approach, a vast amount of energy is spent on the integration of the different components. Partial solutions are made compatible and together they create a powerful knowledge system. At the same time, the incorporation of labour intensive and operating system dependent parts is avoided. The aim of the research is not to develop a commercial software system, but to focus on the identification of a robust methodology, the study of suitable algorithms and procedures, and the testing of results in real business environments.

Related projects: Mc Know: Methods and Algorithms for Knowledge Management, GBOU project

Publications and reports: WP2003-15, WP2003-14, 03EC49

Scientific staff: J. Duflou, D. Cleymans, K. Hermans, B. Vandermeulen, J. Vertommen

2.14.6Life cycle engineering of manufacturing systems

In a life cycle engineering approach, material production, manufacturing, use, and end-of-life considerations are taken into account during the design phase of a product. Both economic and environmental criteria can be used to evaluate the performance of a design proposal in this respect. In this research, we develop and apply models and related methods that allow designers of manufacturing systems to analyse a design at hand from a life cycle perspective, taking into account the typical characteristics of manufacturing systems. These characteristics include, on the one hand, their complexity in terms of number and diversity of components, and, on the other hand, their long life span.

Related projects: CHASM: coping with health, environmental and safety aspects in standards for machinery

Publications and reports: WP2003-40

Scientific staff: W. Dewulf, J. Duflou, W. Lowet