In response to the continuous pressure for cost reduction in manufacturing and the need to comply with diverse global regulations, the tools used in engine research and development are constantly evolving and becoming more sophisticated. From prototype demonstrations to advanced analytics, a wide range of suppliers are working tirelessly to push the boundaries of this field.
The image above presents a detailed schematic of an oil mist spray flame in a compression ignition engine, simulated using high-performance computing and TFM tools. It clearly illustrates distinct high-temperature and low-temperature zones, showcasing the complexity of combustion processes.
Michael Franke, Director of Light Diesel and Commercial Engines at FEV, remarked that "for commercial vehicle engine designers, it's currently a very exciting time." With the implementation of the US Tier4 Final emission standards, developers must now meet regulatory requirements within shorter design cycles. Franke noted that while optimizing products according to these standards is an opportunity, the focus has shifted toward long-term goals such as meeting end-user needs and competing effectively in the market.
However, this technological advancement also brings challenges, especially in the small engine sector. "The engine industry has always been highly cost-sensitive," Franke explained. "Many foreign manufacturers are entering or attempting to enter the US market with low-cost products." He added that China and India have started implementing stringent emission standards like National VI and Bharat-VI, which are progressing rapidly. These new players can meet EPA Tier4 Final off-highway equipment emission standards through technological applications, making compliance less of a barrier in the US and European markets.
The upcoming Stage V standard will introduce further challenges, particularly for engines over 37 kW. While the Euro 5 standard regulates particulate matter in exhaust, the US standard does not. Franke predicts that engine manufacturers may need to rely on particulate filters to meet these new requirements. However, the limited space in off-highway vehicles makes installing a particulate filter difficult, potentially requiring SCR (Selective Catalytic Reduction) coating filters. For engines up to 37 kW, achieving the latest HC + NOx emission requirements under Euro 5 may involve EGR (Exhaust Gas Recirculation) and DOC (Diesel Oxidation Catalyst) filters.
Combining multiple technologies can help address compliance issues, but the effectiveness depends on the specific technologies used. Franke emphasized that the future automotive industry will demand modular engine architectures, allowing manufacturers to easily integrate electrified components while keeping core engine parts consistent. To support this, FEV has introduced a patented ITES system that integrates turbo compounding, electrification, and pressurization technologies seamlessly. This modular approach enables cost optimization through high component sharing across various applications.
With the miniaturization of engines, FEV’s IITE system has demonstrated the ability to improve fuel economy in road vehicles by over 15%. The company is currently exploring its application in off-highway vehicles as well.
Thaddaeus Delebinski, Head of Diesel Systems Business Unit at IAV, agrees that "modular architecture in engine design is essential." The off-highway sector faces even greater challenges due to the variety of equipment types, varying regulations, and differing fuel usage. Natural gas is gaining importance, yet there are still few natural gas-powered machines on the market. Without maximizing component sharing, production costs for small batches can spiral out of control. Therefore, modular design is crucial for meeting diverse market needs.
IAV employs a model-based development methodology that reduces testing and verification efforts, minimizing reliance on expensive resources like high-altitude calibration or virtual emission cycles. The company has also integrated simulation tools such as Velodyn for Com Apps, which can be combined with GT Power and Amesim for testing up to 1.5 MW of power.
Delebinski highlighted IAV’s expertise in emissions control, OBD, and predictive diagnostics. He explained that the company works closely with off-highway customers to understand post-processing and diagnostic features throughout a device’s lifecycle. Additionally, IAV helps customers achieve electrification, improving fuel efficiency and providing enhanced security and diagnostics.
Data plays a vital role in modern engineering, and access to rich, real-time data allows for faster testing and verification. As real-world testing expands from road vehicles to off-highway equipment, data collection becomes even more critical, opening up new opportunities.
IAV has extensive test benches, ranging from component testing to heavy-duty engines up to 1.5 MW, along with portable measuring systems for vehicles and machinery.
Jonathan Dutton, Director of Transportation and Mobile Travel at Dassault Systèmes, emphasized that assessing total cost of ownership requires considering multiple factors. Dassault Systèmes provides multidisciplinary R&D tools applicable to both road and off-highway vehicles, though with some differences in specific requirements. For example, while road vehicles require smooth load output, off-highway vehicles like excavators experience rapid load changes. Despite these differences, many tools can be shared between the two sectors.
Dassault Systèmes’ tools cover four main areas: multidisciplinary physics simulation, optimization based on Design of Experiments, hybrid system simulations, and systems engineering that links engine requirements to design throughout the product lifecycle. The company’s 3DExperience platform aims to mimic user experiences, enabling engineers to better understand engine needs through CAD, mechanical simulation, control, and system modeling.
The goal is to reduce engineering costs and deliver higher-quality designs that meet performance, operating, and manufacturing cost targets. Dutton stated that simulation technology helps minimize the number of prototypes required.
By correlating simulation results with actual test data, AVL identified cracks in the bridge between the exhaust and intake valves.
The impact of new emission requirements on engine architecture is significant, demanding greater attention. Michael DeJack, Senior Technical Expert at AVL, provided an example of how to address low-cycle fatigue. Using commercial tools and in-house expertise, AVL tackled the challenge of thermomechanical fatigue, which arises from repeated heating and cooling of the engine. This type of fatigue places higher demands on cylinder head materials, requiring trade-offs between strength and thermal conductivity.
To solve these issues, AVL utilized Abaqus nonlinear finite element simulation software, paired with the Z-Mat tool for advanced material modeling. The company developed a library of material models and damage models to simulate failure due to thermomechanical fatigue.
AVL has created numerous iCAE toolboxes around Abaqus and other commercial tools, forming a knowledge base that includes workflows, material data, scripts, and analysis results. Tools like AVL’s Fire CFD and Excite Dynamic are part of this comprehensive resource.
Dassault Systèmes’ V6 engine solution uses RFLP models to understand products from an integrated systems engineering perspective. Its real-time interactive capabilities provide traceability for simulations, showing the full system, requirements, logical architecture, and functional architecture.
Direct combustion simulation offers breakthroughs in understanding fuel injection and in-cylinder combustion, which significantly affect emissions and fuel economy. Dr. Sibendu Som of ANL noted that simulating these details generates massive computational loads, making ANL’s supercomputing center a key resource for engine developers.
ANL partners with truck and locomotive engine customers, helping them develop optimized injector thermal barrier coatings using advanced heat transfer and precision injection models. Another challenge is understanding the chemical kinetics of in-cylinder combustion, which involves hundreds of reactions. Engineers typically use simplified model fuels with 70–80 components instead of real fuels with thousands of components. However, ANL’s Tabulated Flamelet Model (TFM) improves soot behavior modeling and explores low-temperature combustion characteristics.
Som mentioned that with the latest technology, developers can spend up to 20% of their calculation time modeling real fuels with up to 5,000 chemical compositions, leading to significant breakthroughs in fuel simulation.
Real-time fuel consumption measurement is critical, especially for off-highway vehicles, where high fuel consumption causes issues like EGR cooler fouling and particulate filter soot accumulation. Robert Dolan of IAV explained that the FOCAS system uses mass spectrometry to measure oil content in any gas, offering a more accurate alternative to traditional methods. Unlike the old "drying and weighing" technique, FOCAS provides real-time data, reducing measurement time from weeks to days and offering deeper insights into transient conditions.
FOCAS is being tested in real-world conditions, with IAV currently working on a proof of concept with a client.
USB Charger Socket
Function description
The socket is ordinary converter,with
two output 5V2A power USB power supply at the same time,can be very
convenient in use electrical appliances and recharge the equipment at
the same time,such as digital products like Iphone Ipad,MP3,MP4 etc.The
charge apply to full range of international AC output,no-load power
consumption less than 0.3W,with short circuit,overload,over-voltage
protection,can be convenient for your life and save more energy
Timer Control Time Adgustment
1.Press the power switch 1 time,the 1HOUR LED will light on.The Timer into ON mode,USB and control socket output ON .
2.Continuously press the power switch
the LED light on,the Countdown mode and LED light on will cycle change
from 1HR,2HR,4HR,6HR,8HR,10HR.
3.Choose you need countdown time
mode,the mode LED will lighto on,start countdown until countdown time
finish,the control output and USB change to OFF
4.Then the countdown is start,The Time indicate LED will from high to low auto change until Countdown finish off.
Failure analysis:
1.check whether the power supply connection is good
2.check whether the USB cable is loosen
Warning Note:
1.Use indoor and dry location ONLY
2.The load max does not exceed 15A 3600W
3.This product does not convert voltage please do not miss use DO NOT exceed the maximum loading of 3600 Watts 15A
4.Always have earth connection for safety reason
5.If in doubt please consult with a qualified electrician
USB Charger Socket, Fast Charge USB Wall Socket, USB Plug Socket, USB Socket Charger, Socket USB charger
NINGBO COWELL ELECTRONICS & TECHNOLOGY CO., LTD , https://www.cowellsockets.com