The World's Most Fuel Efficient Vehicle: Design and Development of Pac Car II

Frontmatter
	The World’s Most Fuel Efficient Vehicle
	Weitere aktuelle vdf-Publikationen
	Impressum
	Preface
	Acknowledgments
	Introduction
	Contents
Chapter 1: Fuel economy competitions
	1.1. The philosophy behind a fuel economycompetition
		1.1.1. The basic principles
		1.1.2. The spirit of the competitions
		1.1.3. History of fuel economy races in Europe
		1.1.4. Fuel economy races around the world
		1.1.5. Technical innovation
	1.2. Measuring fuel consumption
		1.2.1. Conventional fuels
		1.2.2. Hydrogen fuel
		1.2.3. Calculating the equivalent gasoline consumption
		1.2.4. Expressing of the final result
	1.3. A brief summary of the Shell Eco-marathon rules and regulations
		1.3.1. Safety
		1.3.2. Fairness
	1.4. World records
		1.4.1. A brief history
		1.4.2. Obtaining an official world record
	1.5. The pilot
Chapter 2: Some design considerations for fueleconomy vehicles
	2.1. Defining the vehicle architecture
		2.1.1. The number of wheels
		2.1.2. The number of axles
		2.1.3. The front wheels
		2.1.4. The steer wheel(s)
		2.1.5. The drive wheel(s)
		2.1.6. The brake wheel(s)
		2.1.7. Track width, wheelbase and ground-CG distance
		2.1.8. Synthesis
	2.2. Defining the target figures of the vehicle
		2.2.1. Drag
		2.2.2. Powertrain efficiency
		2.2.3. The target characteristics of the winning vehicle
		2.2.4. Conclusion
Chapter 3: Tires
	3.1. Rolling resistance of a tire
		3.1.1. Definitions
		3.1.2. Parameters affecting the rolling resistance coefficient
		3.1.3. Measuring tire drag
	3.2. Ultra-low rolling-resistance tires on the market
		3.2.1. Michelin tires for Shell Eco-marathon vehicles
		3.2.2. Other brands
		3.2.3. Synthesis
	3.3. Relevant tire mechanics basics
		3.3.1. Road contact axis system
		3.3.2. Tire positioning-angles
		3.3.3. Tire forces and moments
		3.3.4. Total rolling resistance
		3.3.5. Coefficients of friction
	3.4. The mechanical effects of cambered wheels
		3.4.1. Lateral force
		3.4.2. Aligning moment
		3.4.3. Rolling resistance force
	3.5. Mechanical effect of toe-in angle
Chapter 4: Tire drag when cornering
	4.1. Vehicle Fixed Coordinate System
	4.2. Steady-state cornering models
		4.2.1. The uni-cycle vehicle model
		4.2.2. The bi-cycle vehicle model
		4.2.3. The tri-cycle vehicle model
		4.2.4. Comparison of the tire drag generated with the three models
	4.3. Comparison of three steering system types
		4.3.1. Analysis
		4.3.2. Results
	4.4. Tire forces and moments when cornering
	4.5. The optimization of the vehicle architecture parameters
Chapter 5: Aerodynamics
	5.1. Fundamental principles of aerodynamics forlow-drag vehicles
		5.1.1. Aerodynamic drag force
		5.1.2. The sources of aerodynamic drag
		5.1.3. Vehicle body shape
	5.2. Design process for the PAC-Car II body shape
		5.2.1. Sources of the design constraints
		5.2.2. The body shape design
	5.3. Aerodynamics of the PAC-Car II
		5.3.1. Overview
		5.3.2. Wheel fairings
		5.3.3. The sailing effect
		5.3.4. Rear-view mirrors
		5.3.5. Final improvements
		5.3.6. Conclusion
	5.4. Experimental and numerical optimization methods
		5.4.1. Experimental methods
		5.4.2. Numerical methods
	5.5. Conclusion
Chapter 6: Vehicle body structure
	6.1. The pilot’s field of vision
		6.1.1. CAD modeling
		6.1.2. The vehicle mock-up
		6.1.3. Improvements
	6.2. Vehicle body design process
		6.2.1. The perfect vehicle body design
		6.2.2. Vehicle perception
	6.3. Structural optimization of the body
		6.3.1. The optimization method and tools
		6.3.2. Load cases
		6.3.3. Boundary conditions
		6.3.4. Materials
		6.3.5. Meshing
	6.4. Manufacturing Process
		6.4.1. Manufacturing steps
		6.4.2. Milling the one-to-one model
		6.4.3. Laminating the mold
		6.4.4. Laminating the body sections
		6.4.5. Assembling the vehicle body sections
		6.4.6. Construction details
Chapter 7: Wheels
	7.1. Wheel bearings
		7.1.1. Choosing the wheel bearings
		7.1.2. The wheel bearings of the PAC-Car II
	7.2. The wheel criteria
		7.2.1. Aerodynamics
		7.2.2. Tubeless tire compatibility: the wheel rim profile
		7.2.3. Sandwich construction versus a free-core disc
	7.3. Design process
		7.3.1. Load cases and boundary conditions
		7.3.2. Stage one: finding the best profile
		7.3.3. Stage two: optimizing the V profile
		7.3.4. Stage three: optimizing the laminate
		7.3.5. Stage four: verifying the results
	7.4. Manufacturing process
		7.4.1. Preliminary considerations
		7.4.2. Method of manufacturing
		7.4.3. Finishing
Chapter 8: Front axle & steering system
	8.1. The front axle
		8.1.1. List of front axle specifications
		8.1.2. Design concept
		8.1.3. Construction details
	8.2. The steering system
		8.2.1. List of steering system specifications
		8.2.2. The steering mechanism
		8.2.3. Steering-transmission link
Chapter 9: Powertrain
	9.1. An overview of the PAC-Car II powertrain
	9.2. The drive motor
		9.2.1. The drive motor specifications
		9.2.2. Choosing the drive motor technology
	9.3. The drive train
		9.3.1. Determining the speed ratio
		9.3.2. One-stage or a multi-stage?
		9.3.3. The choice of the drive train technology
		9.3.4. Belts
		9.3.5. Gear pairs
	9.4. The clutch
		9.4.1. One-way and jaw clutches
		9.4.2. The openable gear pairs of PAC-Car II
	9.5. The brakes
Chapter 10: Fuel cell system
	10.1. Fuel cell fundamentals
		10.1.1. What is a fuel cell system?
		10.1.2. PEM fuel cell system: stack and cell
		10.1.3. How does a fuel cell work?
		10.1.4. The quantity of reactants and products
		10.1.5. Cell potential
		10.1.6. Cell power density
		10.1.7. Cell efficiency
		10.1.8. Fuel cell system efficiency
		10.1.9. Stack sizing
	10.2. The fuel cell system of PAC-Car II
		10.2.1. Choosing a fuel cell technology for PAC-Car II
		10.2.2. Sizing the stack
		10.2.3. Constructing the stack
		10.2.4. The hydrogen circuit
		10.2.5. The air circuit
		10.2.6. The coolant circuit
		10.2.7. The electronic systems
		10.2.8. Other components
	10.3. The control systems
		10.3.1. Subsystem control
		10.3.2. Mode control
		10.3.3. Diagnostics and safety control
		10.3.4. Operation optimization
	10.4. System results
	10.5. Conclusion
Chapter 11: Driving strategy
	11.1. The PAC-Car II model
		11.1.1. The powertrain Model
		11.1.2. The vehicle model
		11.1.3. The driving strategy model
		11.1.4. The complete model
	11.2. The driving strategy problem
		11.2.1. Formulating the optimization problem
		11.2.2. The dynamic programming algorithm
		11.2.3. The driving strategy
	11.3. Validating the strategy and race results
	11.4. Conclusion
Chapter 12: Conclusion and outlook
Backmatter
	Abbreviations
	Bibliography
	About the Authors
	Awards