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Application Examples

ACR Co., Ltd.
- Applying CFD (Computational Fluid Dynamics) to improve the efficiency of turbochargers for extended-range electric vehicles (EREVs)
- Streamlining production using 3D metal printing

ACR has proficient technical capabilities in vehicle exhaust catalytic converters. They are currently developing micro diesel engines for EREVs (extended-range electric vehicles). Software Cradle’s SC/Tetra CFD software plays an important role in the micro engine development process.

Fig 1: ACR EXCAT and ACR DPF

ACR has high technical capabilities in developing emission control devices for trucks and other diesel powered vehicles. PM (particulate matter) emission control devices for diesel engines can be categorized in two ways. DPF (diesel particulate filter) literally burns the collected PM. In contrast, oxidation catalysts, such as platinum, can be used to remove the PM using oxidation reactions. ACR PMR is a PM control device for vehicles, which meets regulation standards for eight regions in Japan. ACR also produces ACR-EXCAT, a catalytic PM control device, for vehicles that produce low PM levels (Fig 1). ACR NXPR, is a NOx and PM control device, that is a very popular product.

Picture 1: Mr. Keiji Kishishita
Executive Engineer, ACR

While ACR traditionally manufactures a variety of catalytic equipment, honeycombs, and filters, they also manufacture the ACR-NHBL52 which is a portable home power source that is designed to lower peak power usage and provide back-up power in emergency conditions. Equipped with a broad range of skills and tools, ACR conducts evaluations for their own products, and also offers evaluation services for other companies as well.

ACR's most recent interests involve development of small engines to extend EV (electric vehicle) range. Mr. Keiji Kishishita, the Executive Engineer at ACR (Picture 1), manages the overall EREV project on developing auxiliary engines and turbocharger systems.

Better Software and Technical Support: ACR Revisits CFD

Despite rising demand, environmentally friendly EVs are not capable of traveling long distances compared to traditional internal combustion (IC) powered vehicles. However, EREVs can be made to travel farther by using an auxiliary engine for power generation. By using an auxiliary engine to power a generator that recharges the EV batteries, range is extended by making normal stops at the fueling station. With an EREV system, power to the driving wheels is always supplied by the electric motor. This is how the EREV is fundamentally different from the PHEVs (plug-in hybrid electric vehicles). In PHEVs, both the IC engine and the electric motor can be used to power the vehicle. This makes PHEVs more complicated, costly, and not strictly an EV in the purest sense.


ACR uses a single cylinder design for the EREV engine generator for light weight and to maintain low costs. The demand for EREVs is especially high for delivery firms, where fuel consumption is high due to heavy cargo and substantial stop and go driving. In addition, delivery vehicles travel long distances. Delivery vehicles must be in service as much as possible so drivers can use their time efficiently. Delivery firms cannot realistically convert to an all EV fleet because the fleet would be largely unavailable when the EV batteries are being charged. This is an ideal application where auxiliary engine power generator in EREVs can be useful. An EREV delivery fleet would encourage further uses of EVs in the transportation sector.

Fig 2: Components of an EV micro diesel power generator  

ACR's EREV development project is sponsored by the NEDO (New Energy and Industrial Technology Development Organization) in Japan. The success of this three-year test program has proved that auxiliary engine EV technology has great potential in promoting increased EV usage. ACR hopes to implement the engine in EREVs in three years (Fig 2).

Developing a small auxiliary engine for EREVs presents significant design challenges. These include the pulsation caused by large loads. Also power limitations caused by using low displacement engines prompted ACR to investigate turbocharging to increase engine power. During this time, ACR introduced a thermal fluid analysis tool to help them develop a new turbocharger. Mr. Hiroshi Matsuoka, ACR CEO and President, suggested using computational simulation as a design tool because of growing confidence in the simulation tools which had largely improved in recent years.

Mr. Kishishita and his team initially used a CFD tool developed by a foreign company, but did not implement the tool into their design process, because it was too difficult to operate. Mr. Matsuoka suggested using software with strong local support which would enable them to resolve problems quickly. They selected SC/Tetra.
 

​​*All product and service names mentioned are registered trademarks or trademarks of their respective companies.
*Contents and specifications of products are as of January 1, 2015 and subject to change without notice. We shall not be held liable for any errors in figures and pictures, or any typographical errors in this brochure.

Company Details






 

ACR Co., Ltd.
Founded 2004
Businesses Development and manufacturing of vehicle exhaust filters
Consultation services for diesel engine exhaust treatment devices
Head Office Yamato-shi, Kanagawa, Japan
URL http://www.acr-ltd.jp/

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