Search Results

The present paper describes an application of non-parametric shape optimization to disc brake squeal phenomena. A main problem is defined as complex eigenvalue problem in which the real part of the complex eigenvalue causing the brake squeal is chosen as an objective cost function. The Fre´chet derivative of the objective cost function with respect to the domain variation, named as the shape derivative of the objective cost function, is evaluated using the solution of the main problem and the adjoint problem. A selection criterion of the adoptive mode number in component mode synthesis (CMS), which is used in the main problem, is presented in order to reduce the computational error in complex eigenvalue pairs. A scheme to solve the shape optimization problem is presented using an iterative algorithm based on the H1 gradient method for reshaping. For an application of the optimization method, a numerical example of a practical disc brake model is presented.

Previous studies and recent practical aerodynamic evaluations have shown that aerodynamic drag of passenger vehicles with “ground simulation” with moving ground and rotating wheels may increase in some cases and decrease in other cases relative to the fixed ground and stationary wheel conditions. Accordingly, the effects of the ground simulation on the aerodynamic drag should be deeply understood for further drag reduction. Although the previous studies demonstrated what is changed by the ground simulation, the reason for the change has not been fully understood. In this article, the effects of wheels and wheel houses attachment and those by the ground simulation with ground movement and wheel rotation on the aerodynamic drag were investigated by quantification of the underfloor flow that plays a crucially important role on the formation of vortical structure around vehicles.

This paper deals with friction under wet condition in the disk brake system of automobiles. In our previous study, the variation of friction coefficient μ was observed under wet condition. And it was experimentally found that μ becomes high when wear debris contains little moisture. Based on the result, in this paper, we propose a hypothesis that agglomerates composed of the wet wear debris induce the μ variation as the agglomerates are jammed in the gaps between the friction surfaces of a brake pad and a disk rotor. For supporting the hypothesis, firstly, we measure the friction property of the wet wear debris, and confirm that the capillary force under the pendular state is a factor contributing to the μ variation. After that, we simulate the wear debris behavior with or without the capillary force using the particle-based simulation. We prepare the simulation model for the friction surfaces which contribute to the friction force through the wear debris.

Vehicles equipped with in-wheel motors are being studied and developed as a type of electric vehicle. Since these motors are attached to the suspension, a large vertical suspension reaction force is generated during driving. Based on this mechanism, this paper describes the development of a method for independently controlling roll and pitch as well as yaw using driving force distribution control at each wheel. It also details the theoretical calculation of a method for decoupling the dynamic motions. Finally, it describes the application of these 3D dynamic motion control methods to a test vehicle and the confirmation of the performance improvement.

A new type of torque transmit coupling has recently been developed for 4WD cars, that provides a better match to ABS, is of lighter weight, and uses a simpler operating mechanism. This coupling transmits torque with a multi-disc clutch that is engaged by the pressure of high viscosity silicone oil. The rotary blade generates variably the silicone oil pressure, according to both differential speed and direction of rotation between the front and rear wheels. This coupling provides a good match between 4WD performance and four wheel Anti-lock Braking System (ABS) by a modification of the rotary blade shape. No additional devices are needed. This paper describes the characteristics of this coupling and the in-vehicle performance.

Toyota has succeeded in developing for mass production the active four-wheel steering(4WS) system using yaw rate feedback and steering angle feedforward control. The active 4WS system consists of a group of various sensors, including the newly developed yaw rate sensor, ECU, a rear wheel steering actuator that employs a stepping motor and hydraulic valve, and other hydraulic elements, which actively control the steering angle of the rear wheels. The new system ensures a good response and a high level of stabililty for quick steering wen during a high-speed drive. When the vehicle deflects due to a sudden side wind, road surface disturbance, or abrupt braking, steering is automatically corrected through the rear wheels to significantly improve forward stability. In addition, the! system prwides improved performance in making small radius turns because the rear wheels are steering up to five degrees when the front wheels are turned to a large angle.

This paper presents a technique to predict the suspension load in early design stage when a passenger car with low profile tires goes over a bump. The suspension load is simulated by using ADAHS (Automatic Dynamic Analysis of Mechanical Systems). The tire was modeled as a radial spring with non-linearity decided by test data. The simulated results of suspension load agreed with the test data. The effect of shock absorber characteristics and spring bumper stiffness on the suspension load was studied by using this simulation model. As a result, the optimum specification for suspension load reduction was taken.

The shock absorber of suspension has two important basic functions. One is to control vehicle attitude changes when steering and when accelerating and decelerating, and the other is to dampen forces transmitted from the road by its damping effect, thus softening shocks. The characteristics of these two demands in performance, driving stability and riding comfort, conflict with each other but are selected from the concept of a car and from coaching by users. Namely, someone puts stress on driving stability and the other puts stress on riding comfort. Electronics have advanced in recent years and the use of electronic absorber control systems in order to achieve both driving stability and riding comfort has become widespread first of all in Japanese vehicles and also in European and American vehicles. Toyota first developed its TEMS (TOYOTA ELECTRONIC MODULATED SUSPENSION) in 1983 (1) and since then many improvements have been added.

Tire treadwear is a very complicated phenomenon that is influenced by various factors. Any quantitative treadwear estimating method applicable to tires on a vehicle has not yet been established. In this study the effects of acting force to the tire and tire attitude (dynamic wheel alignment) upon treadwear were made clear experimentally by taking notice of the fact that they are only the factors directly influencing tire treadwear provided that a tire and a road surface are determined. Furthermore, on the assumption that treadwear will increase linearly, an examination was made to find a method of estimating treadwear of tires on any vehicle in any running condition by using above-mentioned effects for the values of tire-acting force and dynamic wheel alignment calculated from the vehicle particular and running condition.

An unprecedented phenomenon that achieves high NOx conversion was found over an NSR catalyst. This phenomenon occurs when continuous short cycle injections of hydrocarbons (HCs) are supplied at a predetermined concentration in lean conditions. Furthermore, this phenomenon has a wider range of applicability for different catalyst temperatures (up to 800 degrees Celsius) and SVs, and for extending thermal and sulfur durability than a conventional NOx storage and reduction system. This paper analyzes the reaction mechanism and concludes it to be highly active HC-deNOx by intermediates generated from adsorbed NOx over the base catalysts and HCs partially oxidized by oscillated HC injection. Subsequently, a high performance deNOx system named Di-Air (diesel NOx aftertreatment by adsorbed intermediate reductants) was demonstrated that applies this concept to high speed driving cycles.

This paper describes the application of a life prediction method for stainless steel exhaust manifolds. Examination of the exhaust manifold cracks indicated that many of the failures could be attributed to out-of-phase thermal fatigue due to compressive strains that occur at high temperatures. Therefore, the plastic strain range was used as the crack initiation criteria. In addition, the comparison of the calculated thermal fatigue stress-strain hysteresis to the experimental hysteresis made it clear that it was essential to use the stress-strain data that was obtained through tensile and compression testing by keeping the test specimens at the maximum temperature of the thermal fatigue test mode. A finite element crack prediction method was developed using the aforementioned material data and good results were obtained.

A new ABS and Traction control system (TRAC system) has been developed and put into mass production in a new model LEXUS LS400. The TRAC system controls Sub-Throttle Valve and brake hydraulic pressure independently for left and right wheels. To realize the ABS and TRAC system,it is necessary for the Electronic Control Unit (ECU) to process complex algorithm and high speed calculation. The ABS and TRAC ECU for LEXUS LS400 is constructed by 3 TOYOTA custom 8-bit single chip microcomputers. Each CPU performs wheel speed calculation,ABS control and TRAC control,sharing the common data through high speed serial communication. This paper describes the function of each CPU,the method of CPU communication and fail safe function in the ECU.

We adopted the active hydropneumatic suspension and the dual-mode 4WS system for the 1989 Toyota CELICA. The active control suspension system detects the vehicle state with various sensors to control the oil pressure in the hydraulic cylinder with the linear pressure control valve; controlling attitude, ride comfort, stability & controllability and three-level vehicle height. The 4WS system continuously changes the steering angle ratio between the front and rear wheel according to the vehicle speed, decreasing the minimum turning radius at a low speed by 0.5 m and improving the controllability at a medium speed and the stability at a high speed. In addition, we further improved the performance of each system by integrally controlling the active control suspension system and the 4WS system. Thus, we succeeded in improving the total performance of vehicle dynamics by adding ABS to these systems to control the vertical, lateral and longitudinal accelerations.

With the progress of super computers in recent years, a number of studies on “Computational Fluid Dynamics” (CFD) have been carried out, and various schemes for Navier-Stokes equations have been presented. Similar methods have also been applied to automotive engineering - aerodynamics, for exampre - in order to determine flow phenomena. In this paper, the application of numerical simulations to the flow cavitation that occurs in some part of orifices in the vehicle hydraulic system, will be discussed. Authors have developed a CFD program for the clarification of flow phenomena in such orifices. Using the relationship between calculated results and measured results of noise levels in such orifices, a new method for estimation of the occurrence of flow cavitation has also been developed. As a result, a new orifice configuration capable of preventing the cavitation has been designed.

Grip feeling is an important facet in vehicle dynamics evaluation from a driver satisfaction and enjoyment standpoint. To improve grip feeling, we analyzed the subjective comments from test driver's about grip feeling and an evaluated human sensitivity to lateral motion. As a result, we found that drivers evaluate transient grip feeling according to the magnitude of lateral jerk. Next, we analyzed what vehicle parameters affect lateral jerk by using theoretical equations. As a result, we found that cornering power is an important parameter, especially the cornering power of rear tires as they can be create larger lateral jerk than can front tires.

A full vehicle multi-body dynamic (MBD) model with suspension control system is developed for fatigue life prediction under rough road condition. The model consists of tires, a trimmed body, heavy attached parts, powertrain, suspension, joints, and a driver model, and includes a suspension control system that varies characteristics of the suspension according to the rough road inputs. For tires, a commercial MBD tire model is employed with identifiable parameters. The models are simulated to run on the optically measured road surface of the proving ground. Apart from the trimmed body, several important heavy attached parts are modeled separately, that represent dynamic behavior that induces complex body input load. These parts, along with suspension and powertrain systems are connected to the body using nonlinear elements such as joints, springs, and dampers. Contact conditions are used to represent mount bushing, hood lock, stopper rubber, etc.

The finite element method (FEM) is effective for analyzing brake squeal phenomena. Although FEM analysis can be used to easily obtain squeal frequencies and complex vibration modes, it is difficult to identify how to modify brake structure design or contact conditions between components. Therefore, this study deals with a practical design method using sensitivity analysis to reduce brake squeal, which is capable of optimizing both the structure of components and contact conditions. A series of analysis processes that consist of modal reduction, complex eigenvalue analysis, sensitivity analysis and optimization analysis is shown and some application results are described using disk brake systems.

In recent years, there has been a growing need for excellent automobile safety. The number of vehicle with active safety systems such as ABS, Brake Assist and VSC (Vehicle Stability Control) is dramatically increasing. A current brake control systems tend to generate activating noise and uncomfortable brake pedal feeling, which they have to restrain its positive use during ordinary braking. To improve this point, a new brake control system has been developed. This paper introduces the configuration, functions and effects of the system. The new hydraulic modulator adopts a gear pump (trochoid pump) and linear solenoid valves. This allows the modulator to be controlled silently and smoothly. As a result, it becomes possible to apply hydraulic pressure in the normal operating range at any time and a high level of performance is realized. Several new benefits were added to the current control system.

Authors have developed an apparatus which measures the piston temperature using electromagnetic induction. The characteristics of this apparatus are as follows; 1 Applicable to 6 points per cylinder and all cylinders 2 Capable of measuring while the engine is running from start to 6000r/min full-load operation 3 Wide measuring range; from -30 to 400 °C 4 High accuracy; ±2.5 °C 5 Quick and easy setup 6 High durability This technology contributes to realizing the best balance of piston reliability and matching of combustion conditions. In this report, authors analyzed its influences upon piston temperature when the ignition timing,the oil/water temperature or the oil flow from piston jet were changed, respectively.

Reducing disk brake squeal, especially low frequency disk brake squeal (1-5kHz), is an important technical issue in vehicles. The disk brake squeal mechanism has been shown in many papers (1), (2), (3), (4), (5), (6), (7), (8) and (9). Recently, the disk brake squeal comes to be simulated by Finite Element Analysis (FEA) for disk brake design (10), (11), (12), (13), (14), (15), (16), (17), (18) and (19). Though FEA is useful, it is sometimes difficult to modify in large when the prototype of disk brake system has been designed. First Order Analysis gives design concepts, which should be done before FEA. This paper shows First Order Analysis of low frequency disk brake squeal. The equation of motion is shown in 4 degrees of freedom model. In this equation the generalized force matrix is composed of the variations of pressure and friction force between each brake pad and brake disk. The generalized force matrix is arranged with a symmetric matrix and an anti-symmetric matrix.