engineering r&d expertise -...
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Engineering R&D Expertise
Experience:25+ years experience in developing innovative technologies in multiple industries. Particular expertise in automotive and hydraulic power systems including engine and transmissions, hybrids, fuel systems.
Proven track record of rapid design and development of new technologies with the intent of taking it to large scale production.
Expertise:- Mechanical design, solid modeling, GD&T- High bandwidth hydraulic system analysis and design- Dynamic modeling- FEA, CFD, Magnetic modeling- Dynamometer and test facility design & operation - Electronic controls- Powertrain testing- Testing and development- Systems engineering- Program management
Core Strength:Core strength is rapidly developing new technology using a combination of sophisticated analysis tools, creativity, experience and hard work.
Simulation and other virtual prototyping tools allow us to quickly and inexpensively iterate through many different designs to understand how they will function before they are built saving our clients time and money.
Multiple Industries, Same expertise: Concept to hardware
Automotive/Hydraulics O&G CleanTech Fuel injectors & systems: Diesel, NG & gasoline
High bandwidth hydraulics/solenoids
Transmission/hybridAnalysis & Design
Custom head design
Turbocharger test/development
Custom valvetrains(camless and cam based)
Actuators
Offshore drilling equipment
Natural gas gensets
Natural gas fueling skids
Self refueling engine
Anchoring system for semisubmersibles
Support equipment for land base casing operations
Algae based biodiesel
CO2 based cleaning machines
Molten salt test skids
Tidal energy harvesting
Vertical axis wind turbines
Compressed air energy storage
Clients range from start-ups to fortune 50, universities, non-profits, DOE & DOD
Czero engineers have worked on a wide range of innovative products:
Czero Projects:- High speed, low leakage valve designs- Natural gas genset skid design- Natural gas regulator skid design- Automotive engine (head, valves, piston, etc. design)- Offshore drilling equipment- Fuel injector and systems design- Bioreactor design for biodiesel feedstock from algae- Vertical axis wind turbines- Hydraulic hybrid vehicles- Outboard motors- Engine dynamometer and test facility design- Diesel and gasoline generator systems- CO2 based industrial cleaning machines- Solenoid design- Compressed Air Energy Storage- Automatic transmission valve body analysis- Advanced expander design and analysis
We have been fortunate to have some great success…..
Dr. Ellen Williams – Director of ARPAe, with Onboard Dynamics VP Jeff Witwer and CEO Rita Hansen. (2015)3 of the organizations highlighted in the display are Czero clients
2015 Awardee
2015 Awardee
2010 Awardee
Senior Staff
University of Wisconsin – Madison, Ph.D. Mechanical EngineeringUniversity of Wisconsin – Madison, M.S. Electrical EngineeringTechnische Universität Berlin – Mechanical Engineering CourseworkUniversity of Michigan – Ann Arbor, M.S. Mechanical EngineeringUniversity of Vermont – B.S. Mechanical Engineering
Guy Babbitt, PhD
Experience (28 years)- Czero, Inc – CEO; Co-Founder- Sturman Industries – Variable Valvetrain Group Leader- University of Wisconsin Engine Research Center/Powertrain Control Research Laboratory - Laboratory Manager- University of Wisconsin Fluid Power Laboratory – Research Assistant- General Motors/Saturn Corp – Project/Test engineer for automatic transmission group- University of Michigan – Lay Automotive Laboratory – Research Assistant
Expertise- Leading innovation projects- Dynamic modeling/controls
Colorado State University – B.S. Mechanical Engineering; Summa Cum Laude
Chris Turner
Experience (18 years)- Czero, Inc – VP Engineering; Co-Founder. - Sturman Industries – Lead design engineer
Expertise- CAD design- GD&T ASME Y14.5- Structural Finite Element Analysis- Electromechanical/Electrohydraulic actuation
Michigan Technological University – M.S. Mechanical EngineeringMichigan Technological University – B.S. Mechanical Engineering
Dan Pedersen, MS
Experience (23 years)- Czero, Inc.- Westport Innovations – Senior Engine Development Engineer - Combustion, Performance and Emissions- National Renewable Energy Laboratory – Task Leader ReFUEL Laboratory – Engine and Heavy Duty Chassis Dyno- Oshkosh Truck Corporation – Senior Project Engineer - Advanced Products Group- Sturman Industries – Project Leader and Development Engineer - Variable Valvetrain- Diesel Technology Co. – Performance Development Engineer – Team Lead, Development Test Lab- Cummins Engine Co. – Senior Engineer – Midrange Product and Fuel Systems Development
Expertise- Leading innovation projects- System Testing and Development
University of Michigan – Ann Arbor, M.S. Mechanical EngineeringUniversity of Michigan – Ann Arbor, B.S. Mechanical Engineering
Jeff Rogers
Experience (26 years)- Czero, Inc – Senior Mechanical Engineer- Sturman Industries – Analysis Engineer- Babcock and Wilcox Research and Development Center/McDermott Technology Inc. – Senior Engineer- University of Michigan – Thermal Fluids Laboratory – Research Assistant
Expertise- Hydraulic Modeling- Thermal/Fluid Analysis- Computational Fluid Dynamics (CFD)- Dynamic modeling- Combustion Modeling- Magnetic Modeling
University of Colorado – Colorado Springs, M.S. Mechanical EngineeringKansas State University – B.S. Electrical Engineering
Travis Johnson
Experience (16 years)- Czero, Inc. – Senior Controls Engineer- Exostrategies, Inc. – Continuous Integration Environment and Automated System Testing Lead- Sturman Industries – Senior Controls Engineer
Expertise- Automotive Controls and Communications- Embedded Development- Industrial Controls
Michigan Technological University – Houghton, MSME-EM Mechanical EngineeringUniversity of North Dakota – Grand Forks, B.S. Mechanical EngineeringUniversity of Michigan – Ann Arbor, Executive Marketing Program
Lyle Shuey, MSME
Experience (32 years)- Czero, Inc – Business Development Director- Jet Engineering – Vice President Business Development; Engineering, Corporate Strategy, Partner Management- LHP Software – Vice President Business Development and Marketing- Bright Automotive – Vice President Marketing and Sales; Founding Consultant- Maybee Associates – Partner; Marketing and Business Development consulting (included 2 year Sturman engagement)- Delphi / GM – Various Management, Engineering, Marketing, Sales Assignments (17 years)- Michigan Technological Univ. – Research Assistant; Dynamic Systems Modeling, Development, Testing
Expertise- Commercial strategy, business development, marketing and sales process execution- Breakthrough customer solution creation
Software Tools
Solid Modeling/Design
SolidWorks Premium
Autodesk Inventor
Pro/ENGINEER (PTC Creo)
AutoCAD
PhotoView 360 - Solidworks
Showcase - Autodesk Inventor
Microsoft Visio
AutoCAD P&ID
GD&T per ASME Y14.5
Analysis
Finite Element Analysis
• SolidWorks Simulation
• Autodesk A360
Czero has expertise in the following Software and tools:
Analysis (cont’d)
Computational Fluid Dynamics
• Star CD/CCM+
• Fluent
• Converge
• Autodesk A360
• Floworks
Magnetic Modeling
• Maxwell
• FEMM
Dynamic modeling
• MATLAB/Simulink/SimScape
• SolidWorks Motion Study
• PLECS
Analysis (cont’d)
Hydraulic Simulation
• MATLAB/Simulink/SimScape
• HYSAN
• GT Suite – Flow Library; Hydraulic
Amesim
GT Suite – GTPower (developing expertise)
Dymola – Modelica
Thermodynamic Analysis
• MATLAB/Simulink/SimScape
• GT Suite (developing expertise)
• EES
• Refprop (NIST)
Embedded Systems
Rapid prototyping of real time controls systems
• Simulink/Stateflow/Real Time Workshop
Embedded Systems (cont’d)
• dSPACE
• Woodward/Mototron/GAP
• National Instruments/LabVIEW
• Custom systems using Freescale MPC family microprocessors and Siemens C series microprocessors
Programming
• C, C++, C #, Silverlight, Visual Basic, FORTRAN
• MATLAB Coder/Simulink Coder
Communication Protocols
• J1939,J1857,Modbus, XCP,CCP
Instrumentation and data acquisition systems
• National Instruments/LabVIEW
• Measurement Computing
• Custom designed systems
Embedded Systems (cont’d)
SCADA
• Allen Bradley AC800M PLC
• Woodward Micronet and Atlas
Data processing and presentation
MATLAB
JMP
National Instruments DIAdem
Excel
Mathcad
PowerPoint
Project and Program Management
Microsoft Project
Asana
Fuel Injection
High pressure intensified
Unit pumps
Common rail
Accumulator Pump Systems
Gasoline port injection
Gasoline direct injection
Multiple fuel systems
Medium pressure natural gas
Variable Valve Actuation
Electrohydraulic based camless
Electromechanical based camless
Cam based variable valve actuation
Valve deactivation
Related automotive experience
Hydraulics
Steering Systems
Lubrication systems
Mobile hydraulics
Industrial hydraulics
Digital pump controls
High speed valves
Vehicle Technology
Hydraulic hybrids
Vehicle drive cycle analysis
Electric vehicle simulation
Engine / Vehicle testing
Automatic transmissions
Example Projects
Solenoid Valve Design & Analysis (Czero semi automated optimization)
Data imported into
magnetic analysis
software. Force
maps created for
each case
Performance metrics automatically
plotted and rated allowing various
trades to be quickly identified
Magnetic data files used in
simulation for each case to
see how the actuator AND
system perform
Detail CAD DesignGenerate large number
of solid models from file
of parameters
automatically
Fluid Forces and
Internal LossesStructural AnalysisIteration as
needed to get
final design
Test
500-1000 design iterations day.
Optimal designs arrived at very quickly saving time and money
Natural Gas Genset – Cleansheet Design- Cummins QSK60 (1.45 MW)
- Runs off bottled gas
- 30’ ISO container, fully contained
- Czero designed, Cummins built and
qualified.
- Currently being tested by Bright Rail
Energy
Czero worked with Cummins and did
design of container and all support
systems except controls (cooling,
exhaust, etc).
Czero’s work with Bright Rail Energy and Bright Storage Technologies
Bright Energy Storage Technologies & Bright Rail Energy
- Started by augmenting their small engineering team (2011)
- Czero still doing work for both companies and is currently on projects with them
- Czero acted as virtual engineering team at first, and worked with them as they brought majority of work in house
- Multiple patent applications filed
Picture of the genset being tested.
Natural Gas Fuel Skid
Fuel Inlet Conditions:- Gas temperature: -30°C to 40°C
- Gas pressure: 300psi to 3,250psi
Fuel Outlet Requirement:- Fuel Flow: 2,210SCFH to 14,500SCFH
(idle to full load)
- Fuel Pressure: 4.8psi to 6psi
- Fuel temperature: 5°C to 50°C
Clean sheet design by Czero.
Currently being tested with
good success
CO2 Nexus
- Designed and built first double door commercial laundry system (2011)
- CO2Nexus successfully tested with Aramark at their facility
- Patagonia now funding CO2Nexus
- Czero still doing work for CO2Nexus and currently on project for them
- Czero acted as virtual engineering team at first, they are bringing more in house
- Multiple patent applications filed
CO2 Based Cleaning Machines
Czero concepted and
designed the first barrier
system for CO2Nexus. Have
done several more designs for
them.
Custom system Drive Assembly for CO2Nexus
Czero designed a lower cost, higher
reliability drive system for their dry
cleaning machines.
Dual mode engine – for onboard natural gas refueling
Engine operates normally or can be reconfigured on
fly to have some cylinders act as compressor to allow
onboard refueling
Phase one tested successfully, now working on phase
two with DOE.
Custom Valve Deactivation System for ARAPe
Custom valve deactivation system designed and built by
Czero. Parts now being tested.
0 10 20 30 40 50-7
-6
-5
-4
-3
-2
-1
0
1
Positio
n (
mm
)
Time (ms)
Valve Position, Stage 1 Intake: Vary Orifice
0.5 mm2
1 mm2
1.5 mm2
2 mm2
2.5 mm2
3 mm2
3.5 mm2
4 mm2
4.5 mm2
5 mm2
5.5 mm2
6 mm2
10 15 20 25 30 35 40
-1.5
-1
-0.5
0
0.5
1
Velo
city (
m/s
)
Time (ms)
Valve Velocity, Stage 1 Intake: Vary Orifice
0.5 mm2
1 mm2
1.5 mm2
2 mm2
2.5 mm2
3 mm2
3.5 mm2
4 mm2
4.5 mm2
5 mm2
5.5 mm2
6 mm2
Phase II of dual mode required novel check valve/actuator
365 366 367 368 369 370 371 372
0
0.2
0.4
0.6
0.8
1
Pla
te P
ositio
n (
mm
)
Time (ms)
Plate Position
0.5N/mm
1N/mm
3N/mm
5N/mm
Traditional check
Czero does dynamic modeling, CFD, FEA,
etc. to ensure design will work as intended.
Custom head with valve deactivation for dual mode engine
New head to interface with existing Ford hardware
design by Czero. Currently being tested with good
success
Component Mass (g)Quantity/
Dynamic FactorMoving Mass
Valve 22.0 1 22.0
Snubber Piston 3.8 1 3.8
Top Washer 0.8 1 0.8
Bottom Washer 0.8 1 0.8
Top Sleeve 1.0 1 1.0
Bottom Sleeve 2.7 1 2.7
Spring 1.0 0.33 0.3
Spring Perch 3.7 1 3.7
Set Screw 0.3 1 0.3
35.4TOTAL
Length of contact for stem top (for viscous friction and annular leakage) = 4.89mm (‘B’)
Length of contact for stem bottom, through hard stop (for viscous friction and annular leakage) = 10.51mm (‘A’)
Length of contact for hard stop (for annular leakage) = 6.14mm (‘D’)
Length of contact for stem, through guide (for viscous friction) = 8.59mm (‘G’)
Total Moving Mass
Clearances
4 locations of annular leakage accounted for in model:• Top hydraulic volume to ambient (clearance ‘B’)
• Bottom hydraulic volume to ambient (clearance ‘D’)
• Bottom hydraulic volume to ambient (clearance ‘A’)
• Top and bottom volume to flow passage volume while damping (clearance ‘C’)
4 locations of viscous friction, and 1 location of coulomb friction:
• Coulomb: Stem seal
• Viscous: stem top (‘B’)
• Viscous: stem to guide (‘D’)
• Viscous: stem to hardstop (‘A’)
• Viscous: piston (‘C’)
Dual mode engine (cont’d)Geometric Tolerance
Sensitivity
Czero performs extensive stack calculations to ensure that
the product will work under all conditions.
Onboard Dynamics
- Did design and analysis of first system for OSU (2012)
- DOE increased funding from $700k to $1M based on progress
- DOE awarded follow on funding of $3.8M, just delivered second prototype system. Continue to work on project
- Czero acting as virtual engineering team
- Multiple patent applications filed
The ARPAe Project Goes to the White House
Dr. Ellen Williams – Director of ARPAe, with Onboard Dynamics VP Jeff Witwer and CEO Rita Hansen. (2015)
Alage bioreactors for Solix Biofuels / Solix Biosystems
Czero work with Solix Biosystems
- Started by augmenting their small engineering team (2007)
- Took on Engineering Director role and helped fill out engineering team
- Executed on project and helped secure A and B series funding
- Czero still doing work for Solix Biosystems and is currently on project
- Czero acted as virtual engineering team at first, they are bringing more in house
- Multiple patent applications filed
Pilot scale bioreactor designed by Czero
Solix AGS 4000 portable
bioreactor and support
equipment designed by Czero
(Formerly Solix)
Hydraulic Hybrid – Gen III (Czero internal project)Complete design by Czero:
- ~5 months concept to operational
- Leveraged existing components
- Tested in class 6 truck
- 2 years operation with only minor seal leak
- Excellent condition on teardown
Hydraulic Hybrid – Gen III
Pictures of the GEN III installed into truck and tested
Hydraulic Hybrid - GEN II: Drop in Replacement
GEN II designed to address the high cost of installation in retrofit cases.
Hydraulic Hybrid - Gen II
Modification to Allison transmission only required new case and
oil pump housing. Other custom made components resulted in
elimination of the torque converter and split torque hybrid
operation. (only design work done to prints, not manufactured)
(Patented)
Test Rig for 800C Molten SaltsCzero designed a test skid for 800C molten salts for
NREL as a subcontractor to SpringsFab.
Malt processing skidCzero designed a skid for
processing malt for K-malt. The
skid is now in use.
Compressed Air Energy Storage (CAES)– Analysis for Client
Crankshaft Torque Analysis
PV diagram for all four stages
0 30 60 90 120 150 180 210 240 270 300 330 3600
2000
4000
6000
Forc
e, (N
)
Force Cam to Pushrod
0 30 60 90 120 150 180 210 240 270 300 330 3600
500
1000
1500
Forc
e, (N
)
Force Bridge to Valve - must stay positive
0 30 60 90 120 150 180 210 240 270 300 330 3600
2
4
6
Cylin
de
rP
ressu
re (
bar)
0 30 60 90 120 150 180 210 240 270 300 330 3600
5
10
15
Crank Angle (deg)
Pop
pe
t F
low
Are
a (
cm
2)
LP
HP
Valvetrain forces
Czero performed thermodynamic
simulations with mechanical
simulations to ensure that the cycle
was going to achieve the required
round trip efficiency and that the
stresses would be within allowable
limits
We found it was not possible to produce the valve lift with the exact duration required (very short duration, with high lift), so performed trade studies to assess the thermodynamic efficiency with various valve profile traces, comparing both lift and duration for different profiles shapes.
CAES Trade study AnalysisDouble-harmonic
durations
lift 70 75 80 85 90 95 100
8 85.4 87.7 88.1 87.5 86.0 83.7 81.0
9 86.7 88.7 88.9 88.1 86.5 84.2 81.4
10 87.7 89.4 89.4 88.5 86.7 84.3 81.4
11 88.5 89.8 89.7 88.6 86.7 84.2 81.2
12 89.0 90.1 89.9 88.6 86.6 84.0 80.9
6th order polynomial
durations
lift 70 75 80 85 90 95 100
8 87.4 89.3 89.5 88.7 87.0 84.7 81.9
9 88.6 90.2 90.2 89.2 87.4 85.0 82.1
10 89.5 90.8 90.6 89.4 87.6 85.1 82.1
11 90.1 91.2 90.8 89.5 87.5 84.9 81.8
12 90.6 91.4 90.9 89.5 87.3 84.6 81.4
Double-dwell, mod sine, dwell = 10
durations
lift 70 75 80 85 90 95 100
8 90.1 91.3 91.0 89.8 87.9 85.4 82.4
9 91.0 91.9 91.4 90.1 88.1 85.4 82.4
10 91.6 92.2 91.7 90.2 88.0 85.3 82.1
11 91.9 92.4 91.7 90.1 87.8 85.0 81.7
12 92.2 92.5 91.6 89.9 87.5 84.6 81.1
Compressor Efficiency
Poppet Valve Flow Study for compressor – Lift Optimization
Czero performs detailed trade studies enabling data driven
selection of architectures and operating parameters within
complex design space. This gets you to the best solution quickly
saving time and money
CAES Analysis – Iterating/optimization via modelingMultiple iterations were performed to hone in on an optimized solution
Final cam traces provided lower thermodynamic efficiency than hoped for, but favored a design with high confidence of durability
Efficiency sweep
CAES test system
Fuel injection design/analysis/modeling – SAE Paper
Czero engineers do high fidelity hydraulic modeling such as this injector model
Off shore oil drilling/production
Simple hydraulic test skid for O&G
customer designed and built by Czero.
Czero is developing large skids and system for
use in offshore oil drilling for O&G customer