1. Thomas Gerlach, MSc, Dipl.-Ing. – Automotive Engineering Consulting
With more than 20 years of experiences in the automotive industry I can
assist clients to achieve targets to be successful with their future products in
the international market environment.
I offer comprehensive experiences in:
•Emissions (e.g. BS VI in 2020, India) and Fuel Economy Improvement
•Engine Performance Enhancement
•Engine Calibration
•Engine Testing, Data collection, Analyses and Interpretation
•Fuel Systems development
•EMS and Control strategy development
•Combustion development
•Variety of Engine Applications and fuels (2-stroke, 4-stroke, rotary, UAV, etc)

2. Contact
Thomas Gerlach – Automotive Engineering Consulting
Mobile: +61 (0) 42 629 0069
Email : tgerlach.consulting@gmail.com
skype: tgerlach.consulting@gmail.com
Dec 13, 2016
2
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

3. • Strong engineering and scientific background in terms of problem analysis and solving
• Background in transportation technology and design
• Sound knowledge of technologies based on alternate & renewable fuels and its potential as
a possible future energy source
• Excellent knowledge of combustion engines, power generation and related engineering
areas
• Strong background and hand-on experience in technologies related to energy efficiency &
emissions
• Wide range of experiences with state of the art advanced engine & control system
development
• Development and implementation of new EMS control strategies
General Engineering
Dec 13, 2016
3
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

4. Team Management
• Supervising staff in order to ensure best possible utilisation of all team members based
on their individual strengths and capabilities
• Planning and co-ordination of available resources
• Conducting of internal performance reviews with team members
• Conduction team meetings with aim to form a strong sense of team spirit
• Dealing with difficulties inside the team and improving performance of team members
by means of face to face conversations
• Providing mentorship to junior staff
• Strengthening specific skills and motivation of team member and staff
Dec 13, 2016
4
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

5. Project Management 1/2
• Managing, executing and controlling all aspects of project activities of a wide range of
projects with a number of international partners and customers off-site as well as on-site
• Highly developed ability to highlight possible projects risks and consequently consider risks
mitigation plans at an early stage of the program
• Establishment of strong customer liaison and regular reporting to ensure best achievable
customers satisfaction
• Planning and communication of project status reporting, project risk and risk mitigation plans
internally as well as externally
• Communication with external and internal stakeholders and customers throughout the
project to ensure the customer is regularly updated with project status
Dec 13, 2016
5
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

6. Project Management 2/2
• Developing status material and leading of customer conference calls or meetings
• Managing project budget and resources to ensure completion of project on time and within
budget
• Preparing detailed reports and presentations for internal and external communication of all
project related issues
• Preparation, issuing and presentation of proposals for customer program requests
• Conducting program sales process with potential new customers
• Execution and support of business development processes in order to expand customer
portfolio
Dec 13, 2016
6
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

7. Combustion development
• Gasoline homogenous combustion (Lambda=1)
• Gasoline lean-stratified combustion
• Direct Injection – CNG, high performance demonstrator engine
• Paper SAE 2011-01-0923
• Dual fuel combustion with LNG + Diesel (pilot diesel)
• Converted fleet of trucks (C15 engine) to LNG/Diesel dual fuel
• HCCI/CAI combustion
• Demonstrated on SCRE with Orbital Air Assist and Conti Piezo HPDI
• Paper SAE 2008-01-0035 presented at SEA Show, 2008, Detroit
• 2-stroke high performance engine combustion development with direct injection
• European motorbike manufactures, 2 prototypes presented
Dec 13, 2016
7
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

8. Engine Applications 1/2
• Single cylinder research engine (SCRE)
• Automotive SCRE 0.4 liter (CAI, Piezo HPDI, Orbital Air Assist)
• Heavy Duty SCRE 1.7 liter (Dual Fuel, CNG DI, Ethanol DI, Piezo HPDI, CI, SI)
• Heavy duty engines (Cummins, Caterpillar, Guascor)
• Diesel (mechanical, Unit injector, Common rail)
• Dual fuel (LNG/Diesel)
• 100% Ethanol conversion, SI
• Methanol/DME
• Automotive engines (BMW, Audi, VW, OEM India, China)
• Natural aspirated
• Turbo-charged (incl. CNG)
Dec 13, 2016
8
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

9. Engine Applications 2/2
• 2-stroke UAV engines
• Single cylinder and boxer
• Rotary UAV engines
• Single rotor
• General purpose engines
• Diesel mechanical injection (with applied supercharger)
Dec 13, 2016
9
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

10. Fuel Systems 1/2
• Sound knowledge of fuel systems
• Intake manifold injection (EFI)
• Direct injection solenoid (HPDI)
• Direct injection piezo (HPDI piezo)
• Direct injection Orbital Air Assist
• Direct injection CNG
• Diesel fuel injection (mechanical, unit injector, common rail )
• Injector benchmarking
• Fuel metering tests
• Fuel injection event variation tests
• Fuel droplet size measurement (MALVERN particle-sizer)
• Fuel spray high speed imaging (LAVISION high speed camera)
Dec 13, 2016
10
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

11. Fuel Systems 2/2
• Injector positioning and installation
• Positioning of injector in manifold
• Positioning of injector in combustion chamber relative to spark plug positions
• Fuel Injector layout/design
• Sound knowledge of features and requirements (incl. direct injectors)
• Fuel system layout and design
• fuel lines, regulators, damper, return, fuel pump
• Layout for special application fuel pumps (e.g. ethanol fuel system)
• Reduction of pulsations
Dec 13, 2016
11
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

12. Engine Testing
• Expert knowledge in operating all kinds of engines test cells (incl. PUMA)
• Engine test cell layout
• Engine installation and setup
• Temperature measurement
• Pressure measurement
• High Speed Cylinder Pressure measurement
• Pressure transducer installation and signal conversion
• High speed crankshaft encoder
• Fuel flow measuring
• Data collection
• ASAP, PUMA
• Data post-processing
Dec 13, 2016
12
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

13. Fuels
• Sound knowledge and hand-on experiences with
• Gasoline
• Diesel
• CNG / LNG
• Ethanol
• Methanol/DME
• Dual Fuel
• LNG/Diesel
• Heavy Fuels for UAV applications
• JP8
• JP5
• Avgas
Dec 13, 2016
13
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

14. Emissions Reduction
• Sound knowledge of current and future emission regulations
• Understanding of technologies available for achieving emissions regulations
• General exhaust behaviour of 4- and 2-stroke engines
• Operating principles of exhaust after treatment Systems (SI - engine, DI – engine)
• Impact of combustion on emissions
• Homogeneous combustion emissions treatment
• Lean stratified combustion emissions treatment
• Emission reduction technologies
• 3-way-catalyst,
• NOx-trap (regeneration, aging),
• DPF
• Secondary air
• EGR
Dec 13, 2016
14
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

15. Calibration and Control Strategies
• Engine calibration tools
• INCA, Matlab, Uniplot, CCP
• Dual fuel heavy duty engine calibration
• Performance and fuel split emissions, AFR (NG, Diesel)
• SI Heavy duty engine conversion to 100 % Ethanol ( Brazilian blend)
• Performance development
• Fuel consumption
• Turbo charger selection
• Engine start
• Automotive engine calibration
• VW and BMW gasoline direct injection (solenoid, piezo HPDI)
• Emission development
• CNG DI natural aspirated and turbo charged
• UAV engine (pistons, rotary)
• Engine start, idle, altitude performance development
Dec 13, 2016
15
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

16. Control Strategies
• Development of relevant control strategies for EMS (engine management systems)
• Fuel injection (fuel quantity and timing)
• Emission reduction
• Engine performance
• Ambient conditions adaptation
• Engine start, warm-up etc.
Dec 13, 2016
16
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting

17. Data Analyses and Interpretation
• Collection of relevant data from engine test cell and or vehicle testing
• Analysis and display of relevant data required for desired task
• Data processing and handling using tools:
• ETAS equipment
• Uniplot
• Matlab
• Excel
• Interpretation of data with respect to performance, efficiency
• Combustion performance analysis based on high speed cylinder pressure data
Dec 13, 2016
17
Thomas Gerlach, MSc, Dipl.-Ing. - Consulting