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BOLTON INSTITUTE

DEPARTMENT OF ENGINEERING AND SAFETY

BENG (HONS) AUTOMOBILE ENGINEERING

SEMESTER 2 EXAMINATIONS 2003/2004

POWER TRAIN TECHNOLOGY 3

MODULE NO: ATT3012

Date: Friday 4 June 2004 Time: 9.30 am 12.40 pm

INSTRUCTIONS TO CANDIDATES: There are SIX questions on this

paper.

Answer FOUR questions.

All questions are worth 25 marks

each.

Air density = 1.2 kg/m3

g = 9.81 m/s2
Density of diesel fuel = 840 kg/m3

Graph paper is available

 Page 2 of 8

Engineering and Safety

BEng (Hons) Automobile Engineering
Semester 2 Examination 2003/2004
Power Train Technology 3
Module No. ATT3012

1. An articulated heavy truck and trailer operates at a laden mass of 38000 kg, and has
the following characteristics.

Drag coefficient = 0.7

Rolling resistance coefficient = 0.007
Frontal area = 9 m2
Tyre rolling radius = 0.6 m
Rear axle ratio = 4.1:1
Overall transmission efficiency = 0.92

The truck is powered by an 11.6 litre turbocharged diesel engine, with the torque
curve and iso-fuel consumption map as shown in Fig Q1.

a) Calculate the power required at the wheels of the truck, at 100 km/h on a
level road. (5 marks)

b) Estimate the fuel consumption of the truck at 100 km/h on a level road, in
l /100 km. Assume the truck is travelling in top gear, which has a ratio of
0.8:1. (10 marks)

c) In order to reduce the road tax payable on the truck, the operator decides to
re-licence the truck to operate at a laden mass of 32,500 kg. Calculate which
gear would give the best fuel economy at a constant speed of 80 km/h on a
level road, at the new mass.

Gear ratios are: 13.8, 9.5, 6.5, 4.6, 3.0, 2.05, 1.4, 1.0, 0.9, 0.8.
(10 marks)
Total 25 marks

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 Page 3 of 8

Engineering and Safety

BEng (Hons) Automobile Engineering
Semester 2 Examination 2003/2004
Power Train Technology 3
Module No. ATT3012

2. a) A new joint venture between British and French van manufacturers is aimed
at producing a new range of vans with a range of laden masses of 2000 kg
to 3500 kg. In order to predict the required performance of this new vehicle
range, a competitors van is being used as a benchmark, but not all of the
required information is easily available.

The company need to set a target rolling resistance coefficient, Cr, for the van
based on the following performance data for their competitor.

Acceleration from 60 km/h to 80 km/h on a level road = 8.7 s

Laden mass of van = 2760 kg
Gear ratio = 3.154:1, Axle ratio = 1:1
Body width = 2.05 m, Body height = 2.54 m
Overall transmission efficency = 0.92
Tyre rolling radius = 0.33 m
Drag coefficient = 0.39
Engine torque = 285 Nm, from 1400 rpm to 2700 rpm.

From the above information, calculate the rolling resistance coefficient of the
competitors van. (18 marks)

b) The competitors van is also tested for fuel consumption at 100 km/h on a
level road, and achieves 12 l /100 km under these conditions, in the same
gear as in part (a). Calculate the specific fuel consumption of the engine at
these conditions, in g/kWh. (7 marks)
Total 25 marks

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Engineering and Safety

BEng (Hons) Automobile Engineering
Semester 2 Examination 2003/2004
Power Train Technology 3
Module No. ATT3012

3. a) Engine manufacturers have traditionally used the Morse Test and the
Willans Line test to measure engine friction, but they have now moved to
direct measures of engine friction using i.m.e.p or indicated power methods.

Describe in detail how (i), the Willans line test, and (ii) the i.m.e.p test, are
carried out, including descriptions of instrumentation and test method details
for each test. (6 marks)

Outline in detail the advantages and disadvantages of the i.m.e.p test over
the Willans line test. (4 marks)

b) A 6-cylinder petrol engine produces a maximum power of 155 kw at a speed

of 6000 rpm. A Willans Line Test is carried out on the engine at speeds of
4000 rpm and 6000 rpm, with the results shown below:

Speed Power (kW) Fuel (kg/h) Speed Power (kW) Fuel (kg/h)
4000 rpm 80 11.4 6000 rpm 100 18
60 8.8 80 15
40 6.3 60 11.7
20 4.2 40 9.4
10 3.0 20 7.2
10 6.0

Using the graph paper provided, plot the WILLANS LINES for both speeds,
and estimate the engines friction power at 4000 rpm and 6000 rpm.
(10 marks)

c) The above engine has brake thermal efficiency of 35% at maximum power
and speed, and a Morse Test gives a friction power of 38 kW at this
condition. Comment on the reasons for the difference between this result, and
the result obtained by the WILLANS LINE method.
(5 marks)
Total 25 marks

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 Page 5 of 8

Engineering and Safety

BEng (Hons) Automobile Engineering
Semester 2 Examination 2003/2004
Power Train Technology 3
Module No. ATT3012

4. A college is to compete in an electric vehicle competition for small one-seater cars

powered by a 12 volt car battery. The aim of the competition is to complete most
laps over a fixed 1 km track over 4 hours, with 1 battery change allowed.

The track consists of a 300 m long level road, followed by a 10% uphill gradient
which is 100 m long, then followed by a 400 m long level section, and finally a 5%
descent for 200 m.

The specification of the car is as follows:

Mass (including driver and battery) = 200 kg

Width = 450 mm, Height = 800 mm
Drag coefficient = 0.4
Rolling resistance coefficient = 0.01
Maximum battery charge = 90% of full capacity
Minimum battery charge for operation = 30%
Electric motor efficiency = 0.95
Transmission efficiency = 0.98
Battery capacity = 40 Ah

a) Calculate the power output of the electric motor you would recommend to
enable the vehicle to climb the hill part of the circuit and still maintain a
suitable pace to win the competition (NB. the team aim to complete 44 laps of
the track in 4 hours, and will take 5 minutes to change batteries). (Assume
speed of 2 m/s on hill).
(10 marks)

b) The team have calculated that a minimum speed of 3.33 m/s is necessary on
the level parts of the circuit, in order to achieve 44 laps. Estimate if this is
correct in order to complete the competition using the two batteries given.
(NB no energy is consumed on the down hill section). (15 marks)
Total 25 marks

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 Page 6 of 8

Engineering and Safety

BEng (Hons) Automobile Engineering
Semester 2 Examination 2003/2004
Power Train Technology 3
Module No. ATT3012

5. a) Recent air quality measurements in the UK show a dramatic fall in the levels
of carbon monoxide (CO), hydrocarbons (HC), and oxides of nitrogen (NOx)
in the atmosphere since the introduction of EURO 1 and EURO 2 exhaust
emission regulations, which needed the fitting of exhaust catalysts to new
cars.

Outline your views on whether you think that the proposed more stringent
levels of exhaust emission control are necessary in Western Europe.
(6 marks)

b) The next level of proposed European emission regulations are regarded by

many experts as more severe than US California regulations for 2005. These
regulations introduce a combined HC+NOx limit for petrol engines, and also
introduce a further limit on carbon dioxide (CO2) emissions.

Discuss the advantages and disadvantages of the proposed new legislation

from the viewpoints of:

i) the environment
ii) the vehicle purchaser
and iii) the vehicle manufacturer (9 marks)

c) The use of continuously variable transmissions (CVTs) has been proposed to

help to meet lower exhaust emission regulations. Explain how this can be
achieved.
(4 marks)

The toroidal drive type of CVT is currently being developed for a range of
vehicle applications. With the aid of diagrams, explain how this type of
transmission operates, concentrating upon how the transmission ratio can
vary continuously, how power is transmitted through the lubricating film, and
the important properties of the lubricant which makes this a viable concept.
(6 marks)
Total 25 marks

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Engineering and Safety

BEng (Hons) Automobile Engineering
Semester 2 Examination 2003/2004
Power Train Technology 3
Module No. ATT3012

6. a) Define the meaning of the term Ra (centre-line average), using diagrams as

appropriate. Include the formula for Ra.
(4 marks)

Explain how the value of Ra is normally measured. (3 marks)

b) Derive the bearing-area curve for the surface profile outlined in diagram Q6.
In this case, each vertical division of the profile is 0.4m. (10 marks)

c) Explain the significance of the value of the surface roughness parameters Ra,
in terms of defining the type of lubrication which occurs in an engine or
gearbox. Your answer should consider boundary, mixed, elasto-
hydrodynamic and hydrodynamic modes of lubrication. Use diagrams to
explain your answers.
(8 marks)
Total 25 marks

END OF QUESTIONS

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Engineering and Safety

BEng (Hons) Automobile Engineering
Semester 2 Examination 2003f2004
Power Train Technology 3
Module No. ATT3012

FIG Q1

FIG Q6