New Car Electronics

The penetration of electronics into every aspect of car design continues day by day. In this story we take a look at some of the latest in new car technology – many of the designs will be seen in cars of the next five years.

Visteon Developments

US components manufacturer Visteon has a range of innovative technologies in development.

• Advanced Front Lighting Systems

Advanced Front Lighting Systems modify headlight output so that the beam pattern is optimized for different driving conditions such as vehicle direction and speed. Drivers automatically experience the optimized lighting distribution according to the individual driving situation, thus enhancing visibility for drivers at night.

Visteon has developed intelligent software and unique algorithms to optimize its Advanced Front Lighting System offerings. These use inputs from steering wheel, speed and axle sensors to tailor the lighting pattern according to vehicle speed and road configurations, as well as headlamp actuation. Visteon offers dynamic and static systems using Halogen, High Intensity Discharge (HID)/Xenon and Light Emitting Diode (LED) sources.

Claimed benefits include:

• Directs illumination in the direction of intended vehicle path
• Offers the potential to improve visibility of roadside objects, pedestrians and hazards
• Enables driver flexibility to activate/deactivate the system
• Provides ability to shift the low beam up for additional sight distance when the high beam is activated
• Enables longer light distribution to increase down-road visibility at far distances and wide light distribution for increased peripheral visibility at close proximity

• Ionization Control System

Ionization systems utilize the ignition coil as both an actuator for ignition and a sensor for measuring the ionization current across the spark plug gap in every cylinder to continuously monitor and interpret the quality of combustion. Visteon's Integrated Ionization Control System integrates electronics into the ignition coil. This unique solution delivers a cost-effective approach to ionization and signal-to-noise ratio comparable to an instrument grade device. The exceptional signal-to-noise ratio is essential to enabling full range inaudible knock detection and for running continuous closed loop spark control. Proprietary algorithms ensure maximum benefit is drawn from interpretation of the signal.

Claimed benefits include:

• A single system that combines knock, misfire and cylinder identification sensing with ignition coil functionality
• Full range OBD II compliance for misfire, including partial burn algorithms to avoid misdiagnosis
• Excellent signal to noise ratio and high signal bandwidth enable full range knock control (audible and inaudible)
• Continuous operation (at borderline knock) for high compression ratio engines
• Single, simplified knock and misfire calibrations
• Comprehensive ignition system diagnostics
• Reduces complexity by combining multiple sensors and signals
• Improves reliability, serviceability and warranty
• Improves engine life – achieved through the ability to set knock thresholds and elimination of stresses (piston, rings, connecting rod, etc.) caused by pre-ignition of fuel during compression stroke
• Increases torque and fuel economy
• Eliminates Noise, Vibration and Harshness (NVH) "knock" concerns when running on non-premium grade fuel
• Reduces calibration time and cost 5 to 7 percent on every powertrain / vehicle

• Integrated Starter/Generator

Visteon's SpeedStart12 is a belt-driven integrated starter generator that operates within a 12-volt electrical architecture. The system, which includes liquid-cooled power electronics and motor controls, offers improvements in fuel economy and power generation capability compared to a conventional alternator. SpeedStart12 is designed for gasoline engines up to 3.0 litres and diesel engines up to 1.8 litres. SpeedStart12 also improves power generation output (up to 3 kilowatts).

When the vehicle is stationary, the engine is turned off. When the engine needs to be turned on, SpeedStart12 restarts the engine within 0.4 seconds.

In addition to quick start-to-idle time, SpeedStart12 provides these significant claimed benefits:

• SpeedStart12 is up to 20 percent more efficient than traditional alternators
• Improves fuel economy up to 5 percent, which also reduces CO2 emissions
• Integrating the power and control electronics into the motor housing makes the single unit much easier to package and more efficient. The subsequent elimination of the starter motor and its ring gear is possible in most gasoline and some diesel applications.
• Delivers up to 3 kilowatts continuous generation (2 kilowatts during low engine RPM), opening the door for other technologies that require power
• May also allow a vehicle to qualify as a "mild" hybrid for future environmental tax initiatives

The Million Dollar Computer that Crashes all Day

Volvo Cars has commissioned one of the world’s most powerful supercomputers for simulating crashes. Using over 300 processors, its capacity is the equivalent of at least one thousand ordinary home PCs. Volvo Cars’ latest investment in doubling its virtual crash simulation capacity is a natural continuation of the company’s long-term commitment undertaken three years ago to make use of cost-effective Linux clusters.

The company has been using a supercomputer since development of the Volvo 850 commenced in 1987. At that time, high-capacity computers were introduced to perform flow, panel pressing and crash simulation calculations.

The aim throughout has been to develop sufficient capacity to enable the simulation engineers to input test data before going home in the evening so that they have the results the following morning. These can be reviewed together with the design engineers during the day, enabling fresh input data to be prepared for that night. This basically enables work to be carried out around the clock.

The main purpose of the new supercomputer is not to make the calculation process faster, but to enable more and much more advanced calculations to be performed in parallel. If necessary, all of the computing power can be used to perform a single calculation, which can thus be completed in a very short time.

At present, the supercomputer can run a virtual crash text in five hours compared with three days ten years ago, while today’s mathematical models are ten times bigger (in other words, more accurate) than at that time.

The new supercomputer consists of 151 nodes (IBM eServers 325), each consisting of two CPUs, making a total of 302 AMD Opteron processors. The measured capacity is 1.3 TFlops (peak), making the Volvo Cars installation one of the fastest Linux clusters in the automotive industry.

New Components for Large Hybrid Vehicles

Denso Corporation has developed new components for hybrid vehicles: a high voltage battery-monitoring unit; a DC-DC converter, and an electric compressor for air conditioning systems. All are smaller and lighter than conventional hybrid components. The components are used in the Japanese market Toyota Harrier hybrid and Kluger hybrid vehicles, and the United States model Lexus RX400h and Toyota Highlander hybrids.

• Battery-Monitoring Unit

The new battery-monitoring unit monitors the main high voltage battery's condition including voltage, current and temperature, which traditionally were performed by the battery ECU. The battery-monitoring unit was designed separately from the hybrid control computer, because the battery-monitoring unit needs to be installed close to the main battery.

• DC-DC Converter

Denso's newly developed DC-DC converter (which charges the conventional 12V battery) is approximately 10 percent smaller than a conventional DC-DC converter, but has increased output current from 100 amperes to 120 amperes. Denso achieved the increased output current by adopting a new circuit control technology to reduce energy loss in the DC-DC converter. To handle the increased output current, Denso improved the converter's power elements by changing the mounting method from soldering to welding. Customized integrated circuits reduce the area of the converter's circuit board by approximately 40 percent, contributing to the 10 percent converter size reduction.

• Electric Air Con Compressor

The electric compressor, jointly developed with Toyota Industries Corporation, is the first in the world to incorporate an inverter that drives the built-in motor. This structure reduces the compressor size by approximately 60 percent compared with a conventional electric compressor and inverter. Denso miniaturized the inverter by using simplified circuits and a higher-density mounting with three-dimensional wirings.

It is difficult to integrate the conventional compressor and inverter, because a conventional hybrid car’s inverter is cooled by the engine's coolant system. To solve this problem, Denso developed a new cooling method using air conditioning refrigerant in the compressor, allowing the integration of the electric compressor and the inverter. Denso's unique segment conductor wiring method, which was developed for alternators in 2000, reduced the size of the built-in motor.

Electronically Controlled Thermostat

The new THEMIS (THErmal Management Intelligent System) valve developed by Valeo manages cooling system liquid flows between the engine, radiator and heating loop to optimize powertrain performance while also enhancing in-cabin thermal comfort. The four-way electronic water valve replaces the passive wax thermostat found in conventional car engine cooling systems.

It enables the engine temperature to rise more quickly, shortening the cold running phases that cause most pollution and reduce engine component life. The valve also optimizes and stabilizes the engine temperature according to different driving and engine load conditions, so minimizing fuel consumption (petrol or diesel) and pollutant emissions. If it is combined with an electric circulating pump, the THEMIS valve manages the liquid flow in the heating loop to maintain thermal comfort in the cabin even after the engine has been switched off.

The electronic controller of the THEMIS valve monitors and optimizes the coolant flow by opening each of its outlets as required. To be more precise, the valve contains one inlet and three outlets that can be opened to feed-in or bypass the radiator, heater core and engine. For an optimal service life, the valve is actuated by a brushless motor and is equipped with contactless absolute position sensors that combine high durability with accuracy.

This innovative device offers many advantages, including significantly reduced pollutant emissions (10-20% CO2, and 10% HC), fuel savings (2-3%), higher engine efficiency, improved engine durability and reliability and enhanced thermal comfort in the cabin after engine stop.

The THEMIS valve will be fitted to production vehicles from 2007 onwards.