Trends in Engineering and Auto Manufacturing by Prima Civitas Foundation

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 Engine Requirements

Fuel Requirements

Crops to Wheels

Evaluate Performance

Basic to Applied Research Synthesize and Characterize Fuels

Plant Science

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 Canola Methyl Ester

TDC

6° ATDC 12° ATDC

18° ATDC

Standard Diesel Fuel

TDC 18° ATDC

6° ATDC

12° ATDC

Conditions: turbocharged diesel engine CR=18:1, 0.35 bar boost, 1500 RPM, light load, and 2000 bar injection pressure.

Laser-based Combustion Diagnostics Optics

Power meter

Etalon Imaging sensor

Dye laser Nd:YAG Laser

Excimer laser

Doubling crystal

HR mirror

Fast Photodiode Spectrometer

ICCD Camera High Speed Camera

PIV laser

Heating

Biofuel Supply

Single-Cylinder Engine Fuels Comparison

Thermoelectric Materials and Systems: Fabrication at MSU

INGOT (29)

CUT HOT PRESSED PUCK

POWDER

LEGS FROM PUCK > 95% YIELD

HOT PRESSED PUCKS (34)

5 COUPLE, 13W THEOR. SKD MODULES (90)

3rd Generation Thermoelectric Modules

Numerical Simulations A block diagram showing different components of our new Lagrangian-EulerianLagrangian 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.

SpraySpray-Controlled Dump Combustor

Wall

Eulerian Cell

Fuel Injector

p2 d2

Wall dx

Fuel Droplets

p1 d1

p2 d2

â&#x20AC;˘

Monte-Carlo particles

Scalar Field (mass fractions and temperature) Droplet Field (spray)

â&#x20AC;˘ Monte Carlo Particles Liquid Fuel Droplets

Various closures for subgrid stresses

- Eulerian Grid

Gasdynamics Field

Filtered continuity and momentum equations via a generalized multi-block high-order finite difference Eulerian scheme for high Reynolds number turbulent flows in complex geometries

Chemistry

Filtered Mass Density Function (FMDF) equation via Lagrangian Monte Carlo method Ito Eq. for convection, diffusion & reaction Lagrangian 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

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.

Academic Advising

Wilson Hall

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