Proceedings - link.springer.com3A978-3-658-05130-3%2F… · Chairperson: Prof. Dr. Ferit Kücükay...

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Proceedings

Transcript of Proceedings - link.springer.com3A978-3-658-05130-3%2F… · Chairperson: Prof. Dr. Ferit Kücükay...

Page 1: Proceedings - link.springer.com3A978-3-658-05130-3%2F… · Chairperson: Prof. Dr. Ferit Kücükay An effective process for trackside vehicle development 125 Paolo Bortolussi, Leonardo

Proceedings

Page 2: Proceedings - link.springer.com3A978-3-658-05130-3%2F… · Chairperson: Prof. Dr. Ferit Kücükay An effective process for trackside vehicle development 125 Paolo Bortolussi, Leonardo

Ein stetig steigender Fundus an Informationen ist heute notwendig, um die immer komplexer werdende Technik heutiger Kraftfahrzeuge zu verstehen. Funktionen, Arbeitsweise, Komponenten und Systeme entwickeln sich rasant. In immer schnelleren Zyklen verbreitet sich aktuelles Wissen gerade aus Konferenzen, Tagungen und Symposien in die Fachwelt. Den raschen Zugriff auf diese Infor-mationen bietet diese Reihe Proceedings, die sich zur Aufgabe gestellt hat, das zum Verständnis topaktueller Technik rund um das Automobil erforderliche spezielle Wissen in der Systematik der Konferenzen und Tagungen zusammen zu stellen und als Buch in Springer.com wie auch elektronisch in SpringerLink und Springer für Professionals bereit zu stellen. Die Reihe wendet sich an Fahrzeug- und Motoreningenieure sowie Studie- rende, die aktuelles Fachwissen im Zusammenhang mit Fragestellungen ihres Arbeitsfeldes suchen. Professoren und Dozenten an Universitäten und Hoch-schulen mit Schwerpunkt Kraftfahrzeug- und Motorentechnik finden hier die Zusammenstellung von Veranstaltungen, die sie selber nicht besuchen konnten. Gutachtern, Forschern und Entwicklungsingenieuren in der Automobil- und Zu-lieferindustrie sowie Dienstleistern können die Proceedings wertvolle Antworten auf topaktuelle Fragen geben.

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Michael Bargende · Hans-Christian Reuss Jochen Wiedemann (Hrsg.)

14. Internationales Stuttgarter Symposium

Automobil- und Motorentechnik

Band 1

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Herausgeber

ISBN ISBN (eBook)DOI 10.1007/

Die DeutscheNationalbibliothek verzeichnet diese Publikation in der DeutschenNationalbi-bliografie; detaillierte bibliografische Daten sind im Internet über http://dnb.d-nb.de abruf-bar.

Springer Vieweg© Springer Fachmedien Wiesbaden 2014Das Werk einschließlich aller seiner Teile ist urheberrechtlich geschützt. Jede Verwertung,die nicht ausdrücklich vom Urheberrechtsgesetz zugelassen ist, bedarf der vorherigen Zu-stimmung des Verlags. Das gilt insbesondere für Vervielfältigungen, Bearbeitungen, Über-setzungen, Mikroverfilmungen und die Einspeicherung und Verarbeitung in elektronischenSystemen.

DieWiedergabe vonGebrauchsnamen,Handelsnamen,Warenbezeichnungen usw. in diesemWerk berechtigt auch ohne besondere Kennzeichnung nicht zu der Annahme, dass solcheNamen im Sinne der Warenzeichen- undMarkenschutz-Gesetzgebung als frei zu betrachtenwären und daher von jedermann benutzt werden dürften.

Gedruckt auf säurefreiem und chlorfrei gebleichtem Papier.

Umschlagbild: © [M] Peugeot

Springer Vieweg ist eine Marke von Springer DE. Springer DE ist Teil der Fachver -lagsgruppe Springer Science+Business Mediawww.springer-vieweg.de

Prof. Dr.-Ing. Michael Bargende Prof. Dr.-Ing. Hans-Christian Reuss Prof. Dr.-Ing. Jochen Wiedemann FKFS Forschungsinstitut für Kraftfahrwesen Stuttgart, Deutschland

978-3-658-05129-7 978-3-658-05130-3 978-3-658-05130-3

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V

WELCOME

Within the field of mobility, an independent turnaround in the energy policy is taking place. Environmental protection and the conservation of dwindling resources are important driving forces of this development, which represents major technological challenges for companies and research institutes. For this purpose, new technologies must be developed and existing ones improved. Accordingly, the Research Institute of Automotive Engineering and Vehicle Engines in Stuttgart is placing the14th Stuttgart International Symposium on Automotive and Engine Technology under the motto »Renewable energies and future mobility concepts«. I was very happy to assume patronage of the event.

With over 800 professional attendees, more than 110 lectures and an accompanying exhibition, the Stuttgart Symposium is considered as one of the most important discussion boards for the range of automotive and engine development in Europe. It is an excellent platform for the representatives of industry and research to discuss new ideas and to present the performance of the industry in Baden-Wuerttemberg.

With this year’s focus on the main topic the symposium will go far beyond the development of vehicles and engines. It includes both the integration of diverse transport modes and systems as well as energy efficiency control of various types of motor vehicles.

Another important objective of the Baden-Wuerttemberg state government is the resource-conserving energy production. In the field of transport alternative forms of propulsion must be developed with future technologies and corresponding IT solutions, which enable an intelligent integration and application for all road users and participants.

It is about nothing less than the future of mobility! Speed, flexibility and environmen-tal friendliness will be the main criteria. The well working cooperation between science and industry in Baden-Wuerttemberg is a key prerequisite for the develop-ment of modern mobility concepts.

My thanks go to the event organizers and promoters, whom I would like to congratulate for the extensive and exciting program of the 14th Stuttgart International Symposium of automotive and engine technology. To all indoor exhibitors, as well as visitors, I wish inspiring and productive discussions.

Winfried Kretschmann Prime Minister of the State of Baden-Wuerttemberg

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VI

RESEARCH AND DEVELOPMENT IN AUTOMOTIVE AND ENGINE TECHNOLOGY

The automotive industry is globally facing a number of challenges: The legal limita-tion of CO2 emissions, the finite nature of reserves of fossil fuels and the increasing traffic congestion in urban areas and megacities are important issues. The need for affordable mobility systems which are resource-efficient as well as sustainable and climate neutral, but which also meet high safety standards and high levels of social and political acceptance, is increasingly clear. The automotive industry is therefore in-tensively working on alternative vehicle and mobility concepts. Additionally, previous research approaches are joined more and more by concepts from the fields of electrici-ty and electronics, mechatronics, information technology and computer science. To promote research in the various areas it is important to share and unify the research results from academia and industry.

The

14th Stuttgart International Symposium Automotive and Engine Technology

18th and19th March 2014

provides an important platform for the automotive industry. The program of the symposium was expanded from four to six parallel sessions in order to meet the increased topics as well as the very high number of excellent submissions of papers. Due to the resulting variety of topics that will be presented by leading experts in more than 110 lectures, we hope to have arranged an interesting program for you. The lecture related discussions and the accompanying exhibition offer an opportunity for further professional exchange.

We look forward to welcoming you in Stuttgart, the birthplace of the automobile and wish you enjoyable and informative days at the14th Stuttgart International Symposium.

Prof. Dr.-Ing. Michael Bargende Prof. Dr.-Ing. Hans-Christian Reuss Prof. Dr.-Ing. Jochen Wiedemann

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VII

INDEX – Volume 1

SECTION 1

INNOVATIVE VEHICLES Chairperson: Prof. Dr. Frank Gauterin

Urban EV project Visio.M – Concept highlights 1 and latest prototype test results Stefan Riederer, BMW Research and Technology

Performance and efficiency – technical solutions for 3 high-performance sports cars to achieve future CO2 limits Bernhard Bihr, Gabriele Pieraccini, Holger Hofmann, Stefanie Freudenstein, Bosch Engineering GmbH

E-generation / Key technologies for electric vehicles 19 Michael Dimitrov, Dr. Ing. h.c. F. Porsche AG

CI ENGINES – COMPONENTS Chairperson: Prof. Dr. Wolfgang Thiemann

Advanced diesel fuel injection equipment – 31 A never ending BOSCH story Jürgen Hammer, Michael Raff, Dirk Naber, Robert Bosch GmbH

Cascaded indirect integrated charge air cooling 47 for passenger car diesel engines Simon Schneider, MAHLE International GmbH; Andreas Eilemann, MAHLE Behr GmbH & Co. KG; Jürgen Stehlig, MAHLE Filtersysteme GmbH

Thermal management for a light-duty-vehicle with diesel 61 engine: Evaluation of an optimized cooling system with variable cooling components Wolfgang Wenzel, John Shutty, Jeri Tsai, BorgWarner, Inc.; Thomas Buchholz, BorgWarner Thermal Systems

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INDEX – Volume 1

VIII

BATTERIES Chairperson: Prof. Dr. Werner Tillmetz

A123 battery life simulation and validation test results 79 Jeff Kessen, Roland Jeutter, Christoph Fehrenbacher, A123 Systems

Integrated electronics for battery sensors 89 Jürgen Kernhof, Ayman Ghazi, Marko Radovic, ZMDI

Development of active Battery Management System 99 for test car and test results Dan Jiang, M. Hübner, HTW Dresden

DRIVING DYNAMICS I Chairperson: Prof. Dr. Ferit Kücükay

An effective process for trackside vehicle development 125 Paolo Bortolussi, Leonardo Pascali, Dr. Ing. h.c. F. Porsche AG; Nico Castrup, RWTH Aachen

Integrated Vehicle Dynamics Control – an optimized approach 139 for linking multiple chassis actuators Lars König, Thomas Walter, Benjamin Gutmayer, Dominik Merlein, Bosch Engineering GmbH

Integration of chassis control system networking into the vehicle 151 dynamics development process H.-C. Reuss, Jan-Hendrik Herold, University of Stuttgart; Leonardo Pascali, Dr. Ing. h.c. F. Porsche AG

ELECTRICAL POWER MANAGEMENT Chairperson: Prof. Nejila Parspour

Modular modeling of a PEM fuel cell system 167 for automotive applications Raphael Hans, ETAS GmbH; Ferdinand Panik, HS Esslingen; Hans-Christian Reuss, University of Stuttgart

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INDEX – Volume 1

IX

Photovoltaic based inverter charger 181 Martin Neuburger, University of Applied Sciences Esslingen

Range extending for electric vehicle operation in urban-regional areas 199 Jens Bachstein, Andreas Daberkow, Heilbronn University; Hans-Christian Reuss, University of Stuttgart, FKFS

PRODUCTION + DESIGN I Chairperson: Prof. Dr. Rainer Gadow

Experimental study of unstretched fiber shifting during hemming 215 processes for automotive aluminum alloys Severin Hönle, Mathias Liewald, Philipp Schmid, IFU, University of Stuttgart; Manfred Sindel, AUDI AG

Virtual production planning and dimensional accuracy prediction 227 of sheet metal components in the bodyshell work Christian Kästle, Daimler AG; Mathias Liewald, Karl Roll, University of Stuttgart

SECTION 2

ADVANCED DRIVER ASSISTANCE SYSTEMS I Chairperson: Prof. Dr. Tobias Flämig-Vetter

Ego-motion estimation in urban areas 241 Claudius Gläser, Lutz Bürkle, Frank Niewels, Robert Bosch GmbH

New working model for collaboration of OEM and supplier 255 in development of advanced driver assistance functionalities for series production Ulrich Zoelch, Claus Dorrer, Martin Krenn, Martin Peller, Peter Varadi, BMW AG; Dirk Böttcher, Jürgen Diebold, Hagen Stübing, Continental AG

An efficient environmental model for automated driving 267 Ralph Grewe, Andree Hohm, Stefan Lueke, Continental AG

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INDEX – Volume 1

X

HYBRID I Chairperson: Prof. Karl-Ernst Noreikat

Emission optimized hybrid vehicle operation with 281 thermal exhaust model Florian Kunkel, Rolf Isermann, TU Darmstadt, Institute for Automatic Control and Mechatronics

Automated process integration and design optimization of a 297 mathematics-based series-hybrid electric vehicle Johannes Friebe, Thanh-Son Dao, Maplesoft GmbH; Christine Schwarz, ISKO engineers AG

Definition and implementation of a benchmarking in order to 321 derive success factors of hybrid powertrains Albert Albers, Matthias Behrendt, Friedrich Brezger, Kevin Matros, Benedikt Steiger, IPEK – Institute of Product Engineering at Karlsruhe Institute of Technology (KIT); Heidelinde Holzer, Wolfram Bohne, BMW AG

SI ENGINES – IGNITION Chairperson: Prof. Dr. Christian Beidl

Spark plugs for modern engines: challenges and solutions 337 Igor Orlandini, Arnold Schneider, Sabrina Rathgeber, Tobias Ruf, Robert Bosch GmbH

Simultaneous spatially resolved visualization of fuel/air ratio 349 and residual gas distribution in an optically accessible SI-engine Thomas Mederer, Wolfgang Friedrich, Johannes Trost, Lars Zigan, Michael Wensing, LTT, Friedrich-Alexander-University Erlangen-Nuremberg

Potential of corona ignition on gas engines using EGR 373 and lean combustion Alexander Schenk, Georg Rixecker, Volker Brichzin, BorgWarner BERU Systems GmbH; Michael Becker, BorgWarner Inc.

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INDEX – Volume 1

XI

DRIVING DYNAMICS II Chairperson: Prof. Dr. Oliver Sawodny

Improvement of collision avoidance systems by using a 389 propulsion system for advanced brake performance Sven Knecht, Jens Neubeck, Jochen Wiedemann, FKFS

Design of a decision maker for an evasive or braking maneuver 401 for collision avoidance Carlo Ackermann, R. Isermann, Institute of Automatic Control and Mechatronics, TU Darmstadt; Sukki Min, Changwon Kim, Hyundai Motor Company

FVV PROJECTS Chairperson: Dr. Karl Kollmann

Characterization of gasoline biofuels regarding 417 combustion anomalies Marco Günther, Bastian Morcinkowski, Florian Kremer, Stefan Pischinger, RWTH Aachen University

In-cylinder causes of particle emissions on DISI engines 435 Helge Dageförde, Heiko Kubach, Thomas Koch, IFKM, Karlsruhe Institute of Technology (KIT); Ulrich Spicher, MOT GmbH

Particle number measurement techniques: 461 PMP particle number counting methodology, PMP-HD measurement system comparison Thomas Maier, Georg Wachtmeister, LVK, TU Munich

PRODUCTION + DESIGN II Chairperson: Prof. Dr. Thomas Maier

Investigation on the tribological behavior of thermally sprayed 477 cylinder liner coatings Andrei Manzat, Rainer Gadow, IFKB, University of Stuttgart

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INDEX – Volume 1

XII

Chances and risks when using high strength steel sheets 493 in structural parts of modern car bodies M. Liewald, S. Wagner, R. Radonjic, University of Stuttgart, Institute for Metal Forming Technology (IFU)

Competitive fiber reinforced composite materials for increased 509 service temperature usable in exhaust systems Patrick Weichand, Rainer Gadow, IFKB, IMTCCC, University of Stuttgart

SECTION 3

VEHICLE DESIGN Chairperson: Prof. Dr. Lutz Eckstein

Aerodynamics development of road and racing cars – 521 similarities and differences Jörg Müller, Jan Monchaux, AUDI AG

The role of aerodynamics at Mercedes Benz 533 Teddy Woll, Daimler AG

Potentials of virtual chassis development 535 Andreas Wagner, AUDI AG

EMISSIONS I Chairperson: Prof. Dr. Georg Wachtmeister

Advanced systems and trends for powertrain emission measurement 549 Kozo Ishida, Masayuki Adachi, Hiroshi Nakamura, HORIBA, Ltd.

Reduction of engine-out emission and fuel consumption by variable 565 EGR distribution in diesel and multi fuel engines Yunyu Hu, Thomas Körfer, Thorsten Schnorbus, FEV GmbH; Michele Miccio, FEV Italy S.r.l.; Joschka Schaub, RWTH Aachen

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INDEX – Volume 1

XIII

Regeneration control of a LNT via a dynamic NOx-Sensor 581 Bernhard Breitegger, Albert Beichtbuchner, AVL List GmbH; Christian Doppler, Virtual Vehicle Research Center GmbH; Muammer Kilinc, Continental Automotive GmbH; Klaus Hadl, TU Graz

Impact of engine combustion on the reactivity of diesel soot 597 from commercial vehicle engines Sven Lindner, Alexander Massner, Uwe Gärtner, Daimler AG; Thomas Koch, Institute for Reciprocating Engines, Karlsruhe Institute of Technology (KIT)

POWER SUPPLY NETWORK Chairperson: Prof. Dr. Klaus Dietmayer

Online thermal monitoring for power semiconductors in 611 power electronics of electric and hybrid electric vehicles Manuel Warwel, Gerd Wittler, University of Applied Sciences Esslingen; Michèle Hirsch, Robert Bosch GmbH; Hans-Christian Reuss, Institute for Internal Combustion Engines and Automotive Engineering, University of Stuttgart

Control concept for the electrical integration of 627 thermoelectric generators into a vehicle power supply Jan Hendrik Carstens, Clemens Gühmann, TU Berlin

Breakthrough of an electrically driven air-conditioning 643 compressor due to 48V? Jan Ackermann, T. Steinmetz, C. Brinkkötter, IAV GmbH; S. Hertel, Consulting4Drive; D. Kettner, A/C Innovations GmbH

48V at Mercedes-Benz – options for further applications 645 Michael Timmann, Martin Renz, Daimler AG

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INDEX – Volume 1

XIV

SECTION 4

ENERGETIC EFFICIENCY Chairperson: Prof. Dr. Horst E. Friedrich

Pre-development validation of an engine mounted 665 encapsulation approach on SUV vehicle as ‘Eco-Innovation’ by means of EU Regulation 725/2011 D. Petley, W. Jansen, B. Wicksteed, Jaguar Land Rover Cars Ltd; D. Caprioli, T. Bürgin, Autoneum Management AG

Efficient truck cabin cooling with waste heat 681 during driving and parking Dirk Neumeister, R. Burk, L. Ludwig, A. Wiebelt, MAHLE Behr GmbH & Co. KG

Sensitivity analysis on factors influencing the overall 683 rolling resistance of commercial vehicles Werner Krantz, Jens Neubeck, Jochen Wiedemann, IVK/FKFS, University of Stuttgart

Evaluation of the energy demand for air conditioning 705 by means of weather and mobility data A. Basler, F. Freese, P. Megyesi, M. Roth, Dr. Ing. h.c. F. Porsche AG; F. Gauterin, FAST, Karlsruhe Institute of Technology (KIT)

SOFTWARE PROCESSES Chairperson: Prof. Dr. Karl-Ludwig Krieger

ISO 26262 for large SW Models 721 Heiko Doerr, Ingo Stuermer, Model Engineering Solutions GmbH

ODX process from the perspective of an automotive supplier 727 Dietmar Natterer, Thomas Ströbele, Franz Krauss, ZF Friedrichshafen AG

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INDEX – Volume 1

XV

From SULEV EAT Concept to ECU software 739 Wei Han, Daniel Heß, Olaf Friedrichs, Patrick Stracke, Frank Bunar, Stefan Schirmer, IAV GmbH

Powertrain co-simulation on top of standards 755 Christoph Störmer, Christoph Malz, Corina Mitrohin, Ghizlane Tibba, ETAS GmbH

RAILWAY VEHICLES Chairperson: Prof. Dieter Bögle

Future diesel engines for rail applications – efficient and low-emission 771 Andreas Wegmann, Thorsten Fuchs, Voith Turbo GmbH & Co. KG

DynoTrain – vehicle reaction – track quality – 783 contact geometry in realtime Thomas Kolbe, R. Kratochwille, DB Systemtechnik GmbH

Road/Rail trucks – very special rail vehicles 785 Joachim Feuchter, ZWEIWEG International GmbH & Co. KG

The new light rail vehicle DT8.12 for Stuttgart 795 Matthias Jost, Stadler Pankow GmbH

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XVI

SPEAKERS, CHAIRPERSONS – Volume 1 Carlo Ackermann rtm, TU Darmstadt

Jan Ackermann IAV GmbH

Dr. Masayuki Adachi HORIBA, Ltd.

Jens Bachstein Hochschule Heilbronn

Prof. Dr. Michael Bargende FKFS/IVK, University of Stuttgart

Alexander Basler Dr. Ing. h.c. F. Porsche AG

Prof. Dr. Christian Beidl vkm, TU Darmstadt

Bernhard Bihr Bosch Engineering GmbH

Jean-Michel Billig Renault SAS

Prof. Dieter Bögle Paolo Bortolussi Dr. Ing. h.c. F. Porsche AG

Bernhard Breitegger AVL List GmbH

Thomas Buchholz BorgWarner Cooling Systems GmbH

Thomas Bürgin Autoneum Management AG

Jan Handrik Carstens TU Berlin

Andreas Daberkow Hochschule Heilbronn

Helge Dageförde FKM, Karlsruher Institut für Technologie (KIT)

Dr. Volkmar Denner Robert Bosch GmbH

Prof. Dr. Klaus Dietmayer Universität Ulm

Michael Dimitrov Dr. Ing. h.c. F. Porsche AG

Dr. Heiko Dörr Model Engineering Solutions

Prof. Dr. Lutz Eckstein ika, RWTH Aachen

Christoph Fehrenbacher A123Systems GmbH

Joachim Feuchter ZWEIWEG International GmbH & Co. KG

Prof. Dr. Tobias Flämig-Vetter Duale Hochschule BW Stuttgart

Dr. Johannes Friebe Maplesoft GmbH

Prof. Dr. Horst E. Friedrich DLR e. V.

Olaf Friedrichs IAV GmbH

Prof. Dr. Rainer Gadow IFKB, Universität Stuttgart

Prof. Dr. Frank Gauterin FAST, Karlsruher Institut für Technologie

Dr. Claudius Gläser Robert Bosch GmbH

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SPEAKERS, CHAIRPERSONS – Volume 1

XVII

Ralph Grewe Continental

Marco Günther RWTH Aachen University

Prof. Dr. Jürgen Hammer Robert Bosch GmbH

Raphael Hans ETAS GmbH

Jan-Hendrik Herold FKFS

Severin Hönle IFU, Universität Stuttgart

Dan Jiang HTW Dresden

Matthias Jost Stadler Pankow GmbH

Christian Kästle Daimler AG

Dr. Jürgen Kernhof ZMDI

Sven Knecht FKFS

Thomas Kolbe DB Systemtechnik GmbH

Dr. Karl Kollmann Dr. Lars König Bosch Engineering GmbH

Dr. Werner Krantz IVK, Universität Stuttgart

Prof. Dr. Karl-Ludwig Krieger ITEM, Universität Bremen

Prof. Dr. Ferit Kücükay IfF, TU Braunschweig

Florian Kunkel IAT, TU Darmstadt

Sven Lindner Daimler AG

Thomas Maier LVK, TU München

Prof. Dr. Thomas Maier IKTD, Universtität Stuttgart

Andrei Manzat IFKB, Universität Stuttgart

Kevin Matros IPEK, KIT

Thomas Mederer LTT, Friedrich-Alexander-Universität Erlangen-Nürnberg

Dr. Corina Mitrohin ETAS GmbH

Dr. Jörg Müller AUDI AG

Dietmar Natterer ZF Friedrichshafen AG

Prof. Martin Neuburger Hochschule Esslingen

Dr. Dirk Neumeister MAHLE Behr GmbH & Co. KG

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SPEAKERS, CHAIRPERSONS – Volume 1

XVIII

Prof. Karl-Ernst Noreikat NorCon

Dr. Igor Orlandini Robert Bosch GmbH

Prof. Nejila Parspour IEW, Universität Stuttgart

Dean Petley Jaguar Land Rover Cars Ltd

Prof. Dr. Wolfram Ressel Universität Stuttgart

Prof. Dr. Hans-Christian Reuss FKFS/IVK, Universität Stuttgart

Dr. Stefan Riederer BMW Forschung und Technik

Dr. Georg Rixecker BorgWarner BERU Systems GmbH

Prof. Dr. Oliver Sawodny ISYS, Universität Stuttgart

Dr. Simon Schneider MAHLE Behr GmbH & Co. KG

Dr. Thorsten Schnorbus FEV GmbH

Christine Schwarz ISKO engineers AG

Prof. Dr. Wolfgang Thiemann HSU Hamburg

Prof. Dr. Werner Tillmetz Zentrum für Sonnenenergie- und Wasserstoff-Forschung BW

Michael Timmann Daimler AG

Prof. Dr. Georg Wachtmeister LVK, TU München

Dr. Andreas Wagner AUDI AG

Stefan Wagner University of Stuttgart, Institute for Metal Forming Technology (IFU)

Manuel Warwel Hochschule Esslingen

Andreas Wegmann Voith Turbo GmbH & Co. KG

Patrick Weichand IFKB, Universität Stuttgart

Prof. Dr. Jochen Wiedemann FKFS/IVK, University of Stuttgart

Felix Wittmeier FKFS

Dr. Teddy Woll Daimler AG

Dr. Ulrich Zoelch BMW Group

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Proceedings

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Ein stetig steigender Fundus an Informationen ist heute notwendig, um die immer komplexer werdende Technik heutiger Kraftfahrzeuge zu verstehen. Funktionen, Arbeitsweise, Komponenten und Systeme entwickeln sich rasant. In immer schnelleren Zyklen verbreitet sich aktuelles Wissen gerade aus Konferenzen, Tagungen und Symposien in die Fachwelt. Den raschen Zugriff auf diese Infor-mationen bietet diese Reihe Proceedings, die sich zur Aufgabe gestellt hat, das zum Verständnis topaktueller Technik rund um das Automobil erforderliche spezielle Wissen in der Systematik der Konferenzen und Tagungen zusammen zu stellen und als Buch in Springer.com wie auch elektronisch in SpringerLink und Springer für Professionals bereit zu stellen. Die Reihe wendet sich an Fahrzeug- und Motoreningenieure sowie Studie- rende, die aktuelles Fachwissen im Zusammenhang mit Fragestellungen ihres Arbeitsfeldes suchen. Professoren und Dozenten an Universitäten und Hoch-schulen mit Schwerpunkt Kraftfahrzeug- und Motorentechnik finden hier die Zusammenstellung von Veranstaltungen, die sie selber nicht besuchen konnten. Gutachtern, Forschern und Entwicklungsingenieuren in der Automobil- und Zu-lieferindustrie sowie Dienstleistern können die Proceedings wertvolle Antworten auf topaktuelle Fragen geben.

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Michael Bargende · Hans-Christian Reuss Jochen Wiedemann (Hrsg.)

14. Internationales Stuttgarter Symposium

Automobil- und Motorentechnik

Band 2

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Herausgeber

ISBN ISBN (eBook)DOI 10.1007/

Die DeutscheNationalbibliothek verzeichnet diese Publikation in der DeutschenNationalbi-bliografie; detaillierte bibliografische Daten sind im Internet über http://dnb.d-nb.de abruf-bar.

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Prof. Dr.-Ing. Michael Bargende Prof. Dr.-Ing. Hans-Christian Reuss Prof. Dr.-Ing. Jochen Wiedemann FKFS Forschungsinstitut für Kraftfahrwesen Stuttgart, Deutschland

978-3-658-05129-7 978-3-658-05130-3 978-3-658-05130-3

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V

WELCOME

Within the field of mobility, an independent turnaround in the energy policy is taking place. Environmental protection and the conservation of dwindling resources are important driving forces of this development, which represents major technological challenges for companies and research institutes. For this purpose, new technologies must be developed and existing ones improved. Accordingly, the Research Institute of Automotive Engineering and Vehicle Engines in Stuttgart is placing the14th Stuttgart International Symposium on Automotive and Engine Technology under the motto »Renewable energies and future mobility concepts«. I was very happy to assume patronage of the event.

With over 800 professional attendees, more than 110 lectures and an accompanying exhibition, the Stuttgart Symposium is considered as one of the most important discussion boards for the range of automotive and engine development in Europe. It is an excellent platform for the representatives of industry and research to discuss new ideas and to present the performance of the industry in Baden-Wuerttemberg.

With this year’s focus on the main topic the symposium will go far beyond the development of vehicles and engines. It includes both the integration of diverse transport modes and systems as well as energy efficiency control of various types of motor vehicles.

Another important objective of the Baden-Wuerttemberg state government is the resource-conserving energy production. In the field of transport alternative forms of propulsion must be developed with future technologies and corresponding IT solutions, which enable an intelligent integration and application for all road users and participants.

It is about nothing less than the future of mobility! Speed, flexibility and environmen-tal friendliness will be the main criteria. The well working cooperation between science and industry in Baden-Wuerttemberg is a key prerequisite for the develop-ment of modern mobility concepts.

My thanks go to the event organizers and promoters, whom I would like to congratulate for the extensive and exciting program of the 14th Stuttgart International Symposium of automotive and engine technology. To all indoor exhibitors, as well as visitors, I wish inspiring and productive discussions.

Winfried Kretschmann Prime Minister of the State of Baden-Wuerttemberg

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VI

RESEARCH AND DEVELOPMENT IN AUTOMOTIVE AND ENGINE TECHNOLOGY

The automotive industry is globally facing a number of challenges: The legal limita-tion of CO2 emissions, the finite nature of reserves of fossil fuels and the increasing traffic congestion in urban areas and megacities are important issues. The need for affordable mobility systems which are resource-efficient as well as sustainable and climate neutral, but which also meet high safety standards and high levels of social and political acceptance, is increasingly clear. The automotive industry is therefore in-tensively working on alternative vehicle and mobility concepts. Additionally, previous research approaches are joined more and more by concepts from the fields of electrici-ty and electronics, mechatronics, information technology and computer science. To promote research in the various areas it is important to share and unify the research results from academia and industry.

The

14th Stuttgart International Symposium Automotive and Engine Technology

18th and19th March 2014

provides an important platform for the automotive industry. The program of the symposium was expanded from four to six parallel sessions in order to meet the increased topics as well as the very high number of excellent submissions of papers. Due to the resulting variety of topics that will be presented by leading experts in more than 110 lectures, we hope to have arranged an interesting program for you. The lecture related discussions and the accompanying exhibition offer an opportunity for further professional exchange.

We look forward to welcoming you in Stuttgart, the birthplace of the automobile and wish you enjoyable and informative days at the14th Stuttgart International Symposium.

Prof. Dr.-Ing. Michael Bargende Prof. Dr.-Ing. Hans-Christian Reuss Prof. Dr.-Ing. Jochen Wiedemann

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VII

INDEX – Volume 2

SECTION 1

E-MOBILITY Chairperson: Prof. Johann Tomforde

Electric vehicles the solution for the future? 1 Gerhard Hettich, EAST Consulting Engineering for Automotive Systems and Technologies

The electrification of the power train makes it possible – 15 Realization of electric concept vehicles as a source of innovations Marco Rohe, Schaeffler Engineering GmbH

918 Spyder - Concept of a super sports car for the future 27 Frank-Steffen Walliser, Dr. Ing. h.c. F. Porsche AG

DRIVING COMFORT Chairperson: Prof. Dr. Stefan Böttinger

Consistent assessment of chassis relevant ride comfort 41 on roads and test rigs Markus Eisenbarth, G. Boisdequin, Dr. Ing. h.c. F. Porsche AG F. Gauterin, FAST, Karlsruhe Institute of Technology (KIT)

Requirements for the disturbance response of steering and 55 suspension systems based on vehicle targets Martin Münster, M. Lehner, BMW AG; D. Rixen, TU München

Approach for determination of objective characteristic parameters 73 to predict vehicle vibrations caused by powertrain Rui Cai, R. Spengler, C. Olfens, Daimler AG; A. Albers, M. Behrendt, IPEK, Karlsruhe Institute of Technology (KIT)

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INDEX – Volume 2

VIII

EMISSIONS II Chairperson: Prof. Dr. Thomas Koch

Exhaust gas treatment with compact DEF mixing section 87 and SCR coated DPF for future emission standards Tobias Ohrnberger, C. Becker, Bosch Emission Systems GmbH; H. Härle, Robert Bosch GmbH

Comparison of pressure and air-assisted atomizers for 105 Urea-SCR injection in diesel engine exhaust Alexander Spiteri, P. Dimopoulos Eggenschwiler, Y. Liao, EMPA Swiss Federal Laboratories for Materials Science and Technology

Effect of biofuels on particle emissions from compression 117 and spark ignition engines Bianca Maria Vaglieco, E. Mancaruso, S. Di Iorio, P. Sementa, Istituto Motori – CNR

ALTERNATIVE POWERTRAIN + SMALL ENGINES Chairperson: Prof. Dr. Cornel Stan

Experimental study of the in-engine variability of 133 a free piston linear alternator Alexander Heron, H. E. Friedrich, F. Kock, F. Rinderknecht, J. Haag, DLR e. V.

Split-crankshaft engine: concept for a combustion engine 147 with a two-piece disengageable crankshaft Johannes Bergmaier, G. Wachtmeister, LVK, TU München; P. Fischer, H. Pflaum, K. Stahl, FZG, TU München

Potential of fuel injection in two-stroke engines 165 for hand-held power tools Armin Kölmel, T. Gegg, S. Meyer, ANDREAS STIHL AG & Co. KG; A. Trattner, Stephan Schmidt, R. Kirchberger, H. Eichlseder, TU Graz

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INDEX – Volume 2

IX

REIFEN Chairperson: Dr. Andreas Wagner

The new Hohenheim tyre model 181 Paul Witzel, S. Böttinger, University of Hohenheim

Utilization of customer-relevant driving behavior for reliable friction 197 potential estimation by scaling nonlinear tyre models Hans-Martin Kroll, FTM, TU München; B. Buschardt, AUDI AG; K. Schmidt, Audi AG; M. Lienkamp, FTM, TU München

Reference testing method for rolling resistance tire evaluation 213 Jakub Vidner, Kistler Automotive GmbH; F. Masera, BiA Italy; O. Chabut, Kistler France SASU

SPITZENCLUSTER

Chairperson: Franz Loogen

Project BIPoLplus - wireless electric vehicle charging with 22kW 225 Karlheinz Baier, Daimler AG; M. Scholz, P3 automotive GmbH; A. Kilic, P. Schumann, Robert Bosch GmbH; P. Behrendt, Porsche AG; Y.Girardey, IPT Technology GmbH; K. Knaisch, KIT; D. Martinovic, University of Stuttgart; E. Melo, W. Schnurbusch, IPT Technology GmbH; G. Walker, EnBW AG

ELISE – a telematic data gateway for electric vehicles 243 Thomas Kotschenreuther, A. Rupalla, RA Consulting GmbH

Epromo: Cluster project to research on process modular 253 manufacturing assembly and testing concepts for the production of electrical traction motors Günther Heidmann, teamtechnik Maschinen und Anlagen GmbH

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INDEX – Volume 2

X

SECTION 2

SI ENGINES Chairperson: Prof. Dr. Stefan Pischinger

Gasoline engine – Fit for the future powertrain 255 Stefan Kampmann, R. Busch, A. Christ, Robert Bosch GmbH

BlueDirect – the technology for a globalised market 269 Anton Waltner, F. Altenschmidt, A. Kaden, R. Kemmler Daimler AG

The Porsche 918 Spyder high-performance combustion engine 285 Roland Sargenti, C. Hauck, W. Buck, J. Burckhardt, M. Gickeleiter, D.-G. Steinhauser, H. Kristen, Dr. Ing. h.c. F. Porsche AG

The Volkswagen WRC Engine 299 Donatus Wichelhaus, Volkswagen Motorsport GmbH

HYBRID II Chairperson: Prof. em. Dr. Günter Hohenberg

Approach of a method for functional evaluation of hybrid drivetrains 301 Jörg-Michael Birkhold, J. Kerner, L. Spiegel, I. Stache, Dr. Ing. h.c. F. Porsche AG; A. Albers, IPEK, Karlsruhe Institute für Technology (KIT)

Analysis of the optimum drive-line configuration for a compact-class 313 passenger car for differing usage patterns Marco Warth, M. Bassett, J. Hall, B. Mahr, MAHLE Powertrain Ltd.

Research on the fuel-efficiency of parallel hybrid vehicles as 329 a basis for the design of rule-based operating strategies Daniel Görke, IVK, University of Stuttgart; M. Bargende, FKFS/IVK, University of Stuttgart; U. Keller, N. Ruzicka, S. Schmiedler, Daimler AG

Co-simulation and »control-orientated« modeling in 351 the development of a hydraulic hybrid system Agostino Gambarotta, P. Casoli, N. Pompini, L. Riccò, University of Parma

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INDEX – Volume 2

XI

AERODYNAMICS I Chairperson: Dr. Teddy Woll

Electrical wind tunnel external balance system 371 Tomokazu Oyama, T. Ichige, A. Inoue, A & D Company Limited J. Bredenbeck, A & D Europe GmbH

Prospects of experimental aerodynamics 387 Andreas Dillmann, DLR, Institute for Aerodynamics and Fluid Engineering

918 Spyder – the aerodynamic triathlete 389 Christian del Gaizo, H. Maier, M. Roll, Dr. Ing. h.c. F. Porsche AG

ELECTRONIC ARCHITECTURE Chairperson: Prof. Dr. Clemens Gühmann

Real-time metrics for automotive ethernet architectures 405 Kai Richter, J.Diemer, S. Schliecker, Symtavision GmbH

High data rates and short latencies for future vehicle networks – 421 Have conventional microcontroller concepts reached their limits? Burkhard Triess, ETAS GmbH

What CAN FD offers for automotive networking 431 Harald Eisele, Adam Opel AG; K. P. Orlando, General Motors

Localizing minor damages in cars by means of structure-borne 449 sound analysis Andre Kneifel, J. Harmstorf, S. Gontscharov, K.- L. Krieger, ITEM, University of Bremen; K. H. Baumgärtel, Hella Fahrzeugkomponenten GmbH

SIMULATION + ANALYSIS I Chairperson: Prof. Dr. Roland Baar

Constraints of the combustion process for a supercharged 463 DISI-engine for applications in motorsports Christian Pötsch, R. Kudicke, G. Wachtmeister, LVK, TU München; D. Wichelhaus, Volkswagen Motorsport GmbH

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INDEX – Volume 2

XII

Multi-component modeling of liquid fuel for an improved 485 analysis of fuel-dependent processes Marlene Wentsch, A. Perrone, M. Chiodi, FKFS; M. Bargende, FKFS/IVK, University of Stuttgart; D. Wichelhaus, Volkswagen Motorsport GmbH

Lumped-parameter modeling and analysis of automotive waste heat 503 recovery systems based on an organic rankine cycle Marcello Canova, The Ohio State University; A. Gambarotta, M. Crialesi Esposito, University of Parma; K. Laboe, M. Zajac, Chrysler Group LLC

Lean stratified turbocharged gasoline engines to meet emissions 519 and fuel economy targets in 2018 Richard Osborne, C. Rouaud, J. Andersson , K. Pendlebury, M. Keenan, Ricardo UK; T. Hametner, Ricardo Deutschland; D. Walters, J. P. Bowen, Cardiff University

VEHICLE ACOUSTICS Chairperson: Dr. Detlef Schulze-Fehrenbach

Identification and definition of acoustic relevant limit values 533 for electric vehicles Jan Fischer, A. Albers, M. Behrendt, IPEK, Karlsruhe Institute of Technology (KIT); D. Lieske, Daimler AG

Comparison of vehicle rolling noise on the test bench and on the road 549 Michael Krämer, P. Brandstätt, Fraunhofer Institute for Building Physics, Stuttgart; B. Boškovi , Stuttgart University of Applied Sciences

Wind noise testing at the full scale aeroacoustic wind tunnel 563 of Shanghai Automotive Wind Tunnel Center Yinzhi He, Z. Yang, Y. Wang, Shanghai Automotive Wind Tunnel Center

Active versus passive sound systems for air intake system 573 Matthias Alex, B. Huurdeman, Mann+Hummel

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INDEX – Volume 2

XIII

SECTION 3

CI ENGINES Chairperson: Prof. Dr. Peter Eilts

With Diesel into the age of super ultra low emission vehicles 595 Dirk Samuelsen, J. Gerhardt, H. Lüders, S. Scherer, M. Strobel, Robert Bosch GmbH

Combination of electrically heated catalytic converter 623 and SCR@DPF for challenging V-TDI projects Henning Lörch, Stefan Möhn, U. Weiss, J. Haas, AUDI AG

Diesel engine and aftertreatment strategies to meet 637 real driving emissions legislation Roscoe Sellers, A. Ward, Ricardo UK; T. Hametner, Ricardo Deutschland GmbH

VEHICLE CONCEPTS Chairperson: Prof. Dr. Thomas Vietor

DLR@UniST – Synergies emerging from integrating four 653 individual electric drives in a lightweight chassis controlled by intelligent driving strategies Andreas Höfer, H. Friedrich, A. Schumann, V. Bosch, DLR e. V.; A. Wiesebrock, IVK, University of Stuttgart

Analysis of new freedoms in future vehicle interiors 669 Theodoros Tzivanopoulos, J. Stieg, Volkswagen Group Research Wolfsburg; P. Krasteva, T. Vietor, IK, TU Braunschweig

Analysis of Chinese market demands concerning chassis attributes 683 Felix Schröder, Audi China; A. Wagner, AUDI AG

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INDEX – Volume 2

XIV

AERODYNAMICS II Chairperson: Prof. Dr. Andreas Dillmann

Optimization of climatic wind tunnel operation by analyzing 699 influences of relative humidity on the temperatures of vehicle components Andrea Nati, BMW Group; C. Hornreich, C. J. Kähler, Institute of Fluid Mechanics and Aerodynamics, Universität der Bundeswehr München

On-road aerodynamic efficiency under realistic transient wind conditions 715 Ales Alajbegovic, B. Duncan, J. Gargoloff, Exa Corporation

Numerical aeroacoustics at Mercedes Benz – progress and challenges 731 Volker Schwarz, Daimler AG

SECTION 4

ADVANCED DRIVER ASSISTANCE SYSTEMS II Chairperson: Prof. Dr. Klaus Müller-Glaser

ECODyNIS »Ensured Electro-Mobility and Effective 733 CO2-Reduction by Dynamical Navigation in Settlements using Traffic Information via Digital Radio« Gert Siegle, ECODyNIS-Konsortium

Robust traction control coordinated with driver intention 747 Chi Jin, Z. Yu, L. Xiong, Y. Chen, Tongji University

Automatic cruise control for electric vehicles – Statistical 759 consumption and driver acceptance analysis in a representative test person study on public roads Andreas Freuer, M. Grimm, FKFS; H.-C. Reuss, FKFS/IVK, University of Stuttgart

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INDEX – Volume 2

XV

SIMULATION + ANALYSIS II Chairperson: Prof. Dr. Helmut Eichlseder

Model-based calibration of engine controller using automated transient 781 design of experiment Nils Tietze, Bosch Engineering GmbH; U. Konigorski, TU Darmstadt; C. Fleck, D. Nguyen-Tuong, Robert Bosch GmbH/Corporate Research

TRSim Air Path – A library to simulate the air path of any diesel engine 801 Christian Bessai, F. Cornelius, D. Heß, P. M. Isaac Delso, IAV GmbH

Simulation of diesel engine emissions by coupling 1-D with 821 data-based models Thorsten Huber, T. Kruse, ETAS GmbH; G. Cornetti, Robert Bosch GmbH

DRIVERTRAIN TESTING Chairperson: Prof. Dr. Bernhard Geringer

The chassis dynamometer as a real world driving environment 835 Till Weber, C. Beidl, Institute for Internal Combustion Engines and Powertrain Systems; T. Düser, AVL Zöllner GmbH; C. Gietzelt, TÜV Hessen

Model-based load change reaction optimization using 857 vehicle drivetrain test beds Julien Pillas, F. Kirschbaum, R. Jakobi, A. Gebhardt, F. Uphaus, Daimler AG

Control of an engine test-bench via hardware-software-co-simulation 869 Josef Zehetner, M. Benedikt, Virtual Vehicle Research Center; M. Wierse, Porsche AG; H. Kokal, M. Paulweber, AVL List GmbH; G. Stettinger, Alpen-Adria-Universität Klagenfurt; B. Toye, Porsche Gmb

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XVI

SPEAKERS, CHAIRPERSONS – Volume 2 Dr. Ales Alajbegovic Exa Corporation

Matthias Alex Mann+Hummel GmbH

Prof. Dr. Roland Baar TU Berlin

Karlheinz Baier Daimler AG

Prof. Dr. Michael Bargende FKFS/IVK, University of Stuttgart

Johannes Bergmaier lvk, TU München

Christian Bessai IAV GmbH

Dr. Jörg-Michael Birkhold Dr. Ing. h.c. F. Porsche AG

Prof. Dr. Stefan Böttinger University of Hohenheim

Rui Cai Daimler AG

Marcello Canova The Ohio State University

Christian del Gaizo Dr. Ing. h.c. F. Porsche AG

Jonas Diemer Symtavision GmbH

Prof. Dr. Andreas Dillmann DLR, Institute for Aerodynamics and Flow Technology

Prof. Dr. Helmut Eichlseder IVT, TU Graz

Prof. Dr. Peter Eilts ivb, TU Braunschweig

Harald Eisele Adam Opel AG

Markus Eisenbarth Dr. Ing. h.c. F. Porsche AG

Jan Fischer IPEK, Karlsruhe Institute of Technology (KIT)

Andreas Freuer FKFS

Prof. Agostino Gambarotta University of Parma

Prof. Dr. Bernhard Geringer ifa, TU Wien

Daniel Görke IVK, University of Stuttgart

Prof. Dr. Clemens Gühmann TU Berlin

Prof. Dr. Lino Guzzella ETH Zürich

Dr. Yinzhi He Shanghai Automotive Wind Tunnel Center

Günther Heidmann teamtechnik Maschinen und Anlagen GmbH

Alexander Heron DLR e. V.

Prof. Dr. Gerhard Hettich EAST Consulting Engineering for Automotive Systems and Technologies

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SPEAKERS, CHAIRPERSONS – Volume 2

XVII

Andreas Höfer DLR e. V.

Prof. em. Dr. Günter Hohenberg IVD Prof. Hohenberg GmbH

Thorsten Huber ETAS GmbH

Margret Hucko SPIEGEL ONLINE GmbH

Chi Jin Tongji University

Dr. Stefan Kampmann Robert Bosch GmbH

Andre Kneifel ITEM, University of Bremen

Prof. Dr. Thomas Koch IFKM, Karlsruhe Institute of Technology (KIT)

Prof. Dr. Herbert Kohler Daimler AG

Dr. Armin Kölmel ANDREAS STIHL AG & Co. KG

Thomas Kotschenreuther RA Consulting GmbH

Silke Krebs Ministerin im Staatsministerium Baden-Württemberg

Michael Krämer Stuttgart University of Applied Sciences

Hans-Martin Kroll FTM, TU München

Franz Loogen e-mobil BW GmbH

Helmfried Meinel Ministerialdirektor im Ministerium für Umwelt, Klima und Energiewirtschaft Baden-Württemberg

Prof. Dr. Klaus Müller-Glaser ITIV, Karlsruhe Institute of Technology (KIT)

Martin Münster BMW AG

Andrea Nati BMW AG

Dr. Tobias Ohrnberger Bosch Emission Systems GmbH

Dr. Richard Osborne Ricardo UK

Tomokazu Oyama A&D Europe GmbH

Julien Pillas Daimler AG

Prof. Dr. Stefan Pischinger VKA, RWTH Aachen University

Christian Pötsch lvk, TU Munich

Brigit Priemer auto motor und sport

Prof. Dr. Hans-Christian Reuss FKFS/IVK, University of Stuttgart

Marco Rohe Schaeffler Engineering GmbH

Dirk Samuelsen Robert Bosch GmbH

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SPEAKERS, CHAIRPERSONS – Volume 2

XVIII

Dr. Roland Sargenti Dr. Ing. h.c. F. Porsche AG

Felix Schröder AUDI AG

Dr. Detlef Schulze-Fehrenbach Daimler AG

Dr. Volker Schwarz Daimler AG

Roscoe Sellers Ricardo UK

Prof. Dr. Gert Siegle ECODyNIS-Konsortium

Alexander Spiteri Empa, Swiss Federal Laboratories for Materials Science and Technology

Prof. Dr. Cornel Stan Research and Transfer Centre e.V. at the West Saxon University of Applied Sciences of Zwickau

Nils Tietze Bosch Engineering GmbH

Prof. Johann Tomforde Competence & Design Center for Mobility Innovations

Burkhard Triess ETAS GmbH

Theodoros Tzivanopoulos Volkswagen Konzernforschung – Volkswagen Group Research Wolfsburg

Bianca Maria Vaglieco Istituto Motori – CNR

Jakub Vidner Kistler Automotive GmbH

Prof. Dr. Thomas Vietor ikt, TU Braunschweig

Dr. Frank-Steffen Walliser Dr. Ing. h. c. F. Porsche AG

Anton Waltner Daimler AG

Dr. Wolfgang Warnecke Deutsche Shell Holding GmbH

Dr. Marco Warth MAHLE Powertrain Ltd.

Till Weber vkm, TU Darmstadt

Marlene Wentsch FKFS

Dr. Donatus Wichelhaus Volkswagen Motorsport GmbH

Prof. Dr. Jochen Wiedemann FKFS/IVK, University of Stuttgart

Paul Witzel University of Hohenheim

Dr. Teddy Woll Daimler AG

Dr. Josef Zehetner Virtual Vehicle Research Center