Research into alternative CO2-neutral fuels is in full swing in HAN Automotive’s research lab. A number of Automotive students are helping out as part of their internship. Who are these students and what part of the research have they been working on?

From left to right Automotive students Melchior, Robin, Stijn, Ilias and Dave

The transition from internal combustion engines to electric is not proceeding at the pace previously predicted. This is due to a lack of raw materials for the batteries and permanent magnets needed for high-efficiency electric motors. Moreover, our electricity grid is not sufficient to charge so many electric cars.

For this reason, the focus is on alternative fuels, preferably CO2-neutral. Synthetic methanol is an example of this.

In HAN Automotive’s lab, plenty of hands-on research is being done on this. There, PR & marketing communication specialist Erik Rijpstra met lecturer-researcher Erik Kemkers, who helps students get started. The lecturer-researcher told that HAN Automotive students Melchior, Robin, Stijn, Ilias and Dave are doing their internship assignment here and collaborating on this research. In a nice orderly little classroom!

Different exhaust gas composition

Erik Kemkers explains that using new fuels means a different exhaust gas composition, which also requires modifications to the exhaust gas aftertreatment system. “The necessary complex exhaust gas measuring equipment has to be calibrated every (measuring) day.”

Ilias is from Cyprus, who deliberately chose the Netherlands to study. “He hesitated between 3 schools/colleges, but the passion for cars was the deciding factor. Ilias’ task is to design and build an automated and mobile calibration setup ( ≤ 500kg !!!). This fits with his specialization Structural Design (SD),” Erik explains.

Testing fuel cells and batteries

HAN Automotive has a facility for testing fuel cells (hydrogen) and batteries. Erik: “We can dynamically charge and discharge batteries with this set-up. Our customers (partners) also want to know what the batteries do under non-laboratory conditions. The test room has a small climate chamber to investigate the behavior of batteries at low(er) temperatures.”

“The most recent customer request made us realize that modifications to the test facility are needed and that there is still a lack of knowledge among the users of the facility. Trainee Robin will work to solve this. He will look into what the customer needs, what modifications to the test setup are needed, drafting test procedures for the main types of batteries and act as an intermediary between specialists in this field and us.”

Measuring systems

Meanwhile, the CI (Compressed Ignition) and SI (Spark Ignition) modules have been merged into 1 module. For the less technical reader, these are diesel and petrol. This calls for a new practical. At the end of 2022, BOCHANE handed over a brand new Renault Clio Hybrid to Automotive. Melchior and Stijn will investigate what systems are in this car, how these systems are controlled and what needs to be measured to make this control behavior visible to the students.

“The practical with this wonderful car is going to happen on our new power test bench,” Erik says with some pride. “Stijn and Melchior are going to find out whether all the required readings are available through the vehicle’s diagnostic socket, or whether measuring instruments need to be added.”

Engine test stand

HAN Automotive has a number of engine test stands ranging from 50cc to 11200cc. “These setups are used for education and research. The 50cc engine is tuned during a practical (as part of a project) to meet the requirements of the (virtual) customer. Besides the now available means of tuning the block (water injection, turbo simulation, chiptuning et cetera), more variants should be sought.”

“Another practical gives students an overview of what energy flows in the internal combustion engine and how large they are. Determining the internal friction losses (using the Willans line method) sometimes goes well, but sometimes not at all. Student Dave tackles the above issues, among others, as part of his internship. Dave’s specialisation is Power Train (PT).”

Source and photography: HAN Automotive, Erik Kemkers