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Journal Article

Proposed Standards and Tools for Risk Analysis and Allocation of Robotic Systems to Enhance Crew Safety during Planetary Surface Exploration

2009-07-12
2009-01-2530
Several space agencies have announced plans to return humans to the Moon in the near future. The objectives of these missions include using the Moon as a stepping-stone towards crewed missions to Mars, to test advanced technology, and to further exploration of the Moon for scientific research and in-situ resource utilization. To meet these objectives, it will be necessary to establish and operate a lunar base. As a result, a wide variety of tasks that may pose a number of crew health and safety risks will need to be performed on the surface of the Moon. Therefore, to ensure sustainable human presence on the Moon and beyond, it is essential to anticipate potential risks, assess the impact of each risk, and devise mitigation strategies. To address this, a nine-week intensive investigation was performed by an international, interdisciplinary and intercultural team on how to maximize crew safety on the lunar surface through a symbiotic relationship between astronauts and robots.
Journal Article

A Fatigue Life Prediction Method of Laser Assisted Self-Piercing Rivet Joint for Magnesium Alloys

2015-04-14
2015-01-0537
Due to magnesium alloy's poor weldability, other joining techniques such as laser assisted self-piercing rivet (LSPR) are used for joining magnesium alloys. This research investigates the fatigue performance of LSPR for magnesium alloys including AZ31 and AM60. Tensile-shear and coach peel specimens for AZ31 and AM60 were fabricated and tested for understanding joint fatigue performance. A structural stress - life (S-N) method was used to develop the fatigue parameters from load-life test results. In order to validate this approach, test results from multijoint specimens were compared with the predicted fatigue results of these specimens using the structural stress method. The fatigue results predicted using the structural stress method correlate well with the test results.
Journal Article

A Practical Simulation Procedure using CFD to Predict Flow Induced Sound of a Turbocharger Compressor

2015-04-14
2015-01-0662
A turbocharger is currently widely used to boost performance of an internal combustion engine. Generally, a turbocharger consists of a compressor which typically is driven by an exhaust turbine. The compressor will influence how the low frequency engine pulsation propagates in the intake system. The compressor will also produce broad-band flow induced sound due to the turbulence flow and high frequency narrowband tonal sound which is associated with rotating blade pressures. In this paper, a practical simulation procedure based on a computational fluid dynamics (CFD) approach is developed to predict the flow induced sound of a turbocharger compressor. In the CFD model of turbocharger compressor, the unsteady, moving wheel, detached eddy simulation (DES) approach are utilized. In this manner, both the broad-band and narrow-band flow induced sound are directly resolved in the CFD computation.
Journal Article

Model-Based Control-Oriented Combustion Phasing Feedback for Fast CA50 Estimation

2015-04-14
2015-01-0868
The highly transient operational nature of passenger car engines makes cylinder pressure based feedback control of combustion phasing difficult. The problem is further complicated by cycle-to-cycle combustion variation. A method for fast and accurate differentiation of normal combustion variations and true changes in combustion phasing is addressed in this research. The proposed method combines the results of a feed forward combustion phasing prediction model and “noisy” measurements from cylinder pressure using an iterative estimation technique. A modified version of an Extended Kalman Filter (EKF) is applied to calculate optimal estimation gain according to the stochastic properties of the combustion phasing measurement at the corresponding engine operating condition. Methods to improve steady state CA50 estimation performance and adaptation to errors are further discussed in this research.
Technical Paper

Impact of CO2 Dilution on Ignition Delay Times of Full Blend Gasolines in a Rapid Compression Machine

2021-09-21
2021-01-1199
Autoignition delay times of two full blend gasoline fuels (high and low RON) were explored in a rapid compression machine. CO2 dilution by mass was introduced at 0%, 15%, and 30% levels with the O2:N2 mole ratio fixed at 1:3.76. This dilution strategy is used to represent exhaust gas recirculation (EGR) substitution in spark ignition (SI) engines by using CO2 as a surrogate for major EGR constituents(N2, CO2, H2O). Experiments were conducted over the temperature range of 650K-900K and at 10 bar and 20 bar compressed pressure conditions for equivalence ratios of (Φ =) 0.6-1.3. The full blend fuels were admitted directly into the combustion chamber for mixture preparation using the direct test chamber (DTC) approach. CO2 addition retarded the autoignition times for the fuels studied here. The retarding effect of the CO2 dilution was more pronounced in the NTC region when compared to the lower and higher temperature range.
Technical Paper

Representing SUV as a 2D Beam Carrying Spring-Mass Systems to Compute Powertrain Bounce Mode

2021-08-31
2021-01-1116
Accurate prediction of in-vehicle powertrain bounce mode is necessary to ensure optimum responses are achieved at driver’s touch points during 4post shake or rough road shake events. But, during the early stages of vehicle development, building a detailed vehicle finite element (FE) model is not possible and often powertrain bounce modes are computed assuming the powertrain to be a stand-alone unit. Studies conducted on FE models of a large SUV with body on frame architecture showed that the stand-alone approach overestimates the powertrain bounce mode. Consequently, there is a need for a simplified version of vehicle model which can be built early on to compute powertrain modes. Previously, representing all the major components as rigid entities, simplified unibody vehicle models have been built to compute powertrain modes. But such an approach would be inaccurate here, for a vehicle with body on frame architecture due to the flexible nature of the frame (even at low frequencies).
Technical Paper

IC Engine Internal Cooling System Modelling Using 1D-CFD Methodology

2020-04-14
2020-01-1168
Internal combustion engine gets heated up due to continuous combustion of fuel. To keep engine working efficiently and prevent components damage due to very high temperature, the engine needs to be cooled down. Based on power output requirement and provision for cooling system, every engine has it’s unique cooling system. Liquid based cooling systems are majorly implemented in automobile. It’s important to keep in mind that during design phase that, cooling the engine will lower the power to fuel consumption ratio. Therefore, during lower ambient conditions, the cooling system should be able to uniformly increase the temperature of the engine components, engine oil and transmission oil. This is achieved by circulating the coolant through cooling jacket, engine oil heater and transmission oil heater, which will be heated by the combustion heat.
Technical Paper

Multitarget Evaluation of Hybrid Electric Vehicle Powertrain Architectures Considering Fuel Economy and Battery Lifetime

2020-06-30
2020-37-0015
Hybrid electric vehicle (HEV) powertrains are characterized by a complex design environment as a result of both the large number of possible layouts and the need for dedicated energy management strategies. When selecting the most suitable hybrid powertrain architecture at an early design stage of HEVs, engineers usually focus solely on fuel economy (directly linked to tailpipe emissions) and vehicle drivability performance. However, high voltage batteries are a crucial component of HEVs as well in terms of performance and cost. This paper introduces a multitarget assessment framework for HEV powertrain architectures which considers both fuel economy and battery lifetime. A multi-objective formulation of dynamic programming is initially presented as an off-line optimal HEV energy management strategy capable of predicting both fuel economy performance and battery lifetime of HEV powertrain layout options.
Technical Paper

Multi-Zone HVAC Development and Validation with Integrated Heated/Vented Seat Control

2020-04-14
2020-01-1247
Vehicle multi-zone automatic Heating, Venting and Air Conditioning (HVAC) is the advanced form of the traditional air conditioning. The advantage of multi-zone automatic HVAC is that it allows the passengers of a vehicle to set a desired temperature for their own zone within the vehicle compartment. This desired temperature is then maintained by the HVAC system, which determines how best to control the available environment data to provide optimal comfort for the passengers. To achieve overall thermal comfort of the occupants in a vehicle, multi-zone HVAC takes things a step further by adding heated steering wheel and heated/vented seats to the overall HVAC control strategy. The heating and cooling of the occupants by this integrated system is performed by complex control algorithms in form of embedded software programs and Private LIN network. This paper describes the approach and tools used to develop, simulate and validate the multi-zone integrated climate control system.
Technical Paper

CAE Cooling Module Noise and Vibration Prediction Methodology and Challenges

2020-04-14
2020-01-1262
In the NVH domain, the cooling module is an important subsystem in ground vehicles. Recently, with the development of small high output turbocharged internal combustion (IC) engines, cooling module noise and vibration has become more challenging. Furthermore, with plug-in hybrid electric vehicle (PHEV), in some cases the cooling fan could be operational while the IC engine is not running. This poses a significant challenge for cabin noise enhancement. Small turbocharged IC engines typically require higher cooling capacity resulting in larger fan size designs with higher speed. Accurate prediction of the unbalance loads generated by cooling fan and loads transferred to the body are critical for the Noise Vibration and Harshness (NVH) performance of the vehicle. If the NVH risk of cooling module operation is not well quantified and addressed early in the program, attempts to find solutions in post launch stage could be very expensive and not as effective.
Technical Paper

A DFSS Approach Study on the Effects of Vehicle Cabin Properties on HVAC System’s Cool Down Performance Using 1D Simulation

2020-04-14
2020-01-1258
Due to the increase in heat wave across the globe, maintaining the thermal comfort of passengers in a vehicle is becoming a challenge. Considering global warming, there is a need to shift towards greener refrigerants which in itself causes a marginal degradation in the Heating Ventilation and Air Conditioning (HVAC) system performance. Also the emission norms and regulations demanding for a smaller engine if not for a hybrid or electric vehicle, there is a need for optimally designing the HVAC system since it is directly related with the efficiency of the vehicle and also plays a vital role in the customer comfort. Hence maintaining the comfort level of the passengers needs further exploration and challenging rather than optimizing the HVAC system alone in the competitive market. Conventionally for given system where we need sufficient cooling, the capacity of the components can be increased in order to meet the customer comfort.
Technical Paper

Novel CAE CV Joint Modeling Method for Driveline Half-Shaft at Idle Condition

2020-04-14
2020-01-1265
Idle shake is an important NVH attribute. Vehicles with good NVH characteristics are designed to perform excellent in IDLE and SHAKE conditions. Typically, tactile vibrations at idle are measured at the driver seat and steering wheel. Vibrations caused by engine excitation at idle are passed through several paths to the body structure. The dominant paths being the engine mounts and the half-shafts, either one of them or both can be a major factor influencing the perceived idle vibration in a vehicle. In the past, modeling the half-shafts accurately has been a challenge and often time has been ignored because of modeling complexity. This has led to idle CAE predictions not correlating with test data. The aim of this paper is to describe a finite element modeling method of half-shaft to predict idle vibrations levels.
Technical Paper

Advanced Novel Method to Simplify the Detailed Half-Shaft Model and Rapid Model Development

2020-04-14
2020-01-1274
It has been previously shown that a detailed representation of the half-shaft correlates with test data. Developed detailed half-shaft models have shown improvement in capturing the half-shaft path at vehicle idle condition. Since the detailed half-shaft model needs to capture many components and requires detailed solid geometry for each component represented, full CAD model from half-shaft supplier or part scanning is required. Furthermore, despite the availability of CAD geometry, the detailed half-shaft will require solid meshing of the CV joints, the shaft, linearized springs and manual creation of the complex coordinate systems for orientation of contact points. This paper proposes an automated method to reduce the half-shaft model to a semi-elastic rigid body elements model with linearized spring components. The simplified model reduces the modeling time by eliminating solid meshing of components and automating complex coordinate system development without losing accuracy.
Technical Paper

Virtual Method for Electronic Stop-Start Simulation & VDV Prediction Using Modified Discrete Signal Processing for Short Time Signals

2020-04-14
2020-01-1270
Electronic Stop-Start (ESS) system automatically stops and restarts the engine to save energy, improve fuel economy and reduce emissions when the vehicle is stationary during traffic lights, traffic jams etc. The stop and start events cause unwanted vibrations at the seat track which induce discomfort to the driver and passengers in the vehicle. These events are very short duration events, usually taking less than a second. Time domain analysis can help in simulating this event but it is difficult to see modal interactions and root cause issues. Modal transient analysis also poses a limitation on defining frequency dependent stiffness and damping for multiple mounts. This leads to inaccuracy in capturing mount behavior at different frequencies. Most efficient way to simulate this event would be by frequency response analysis using modal superposition method.
Technical Paper

A Case Study on Reducing the Fuel Pulse Noise from Gasoline Engine Injectors

2020-04-14
2020-01-1276
There are many noise sources from the vehicle fuel system to generate noise inside a vehicle. Among them, the pressure pulsation due to the rapid opening and closing of gasoline engine injectors can cause undesirable fuel pulse noise. As the pressure pulsation propagates in the fuel supply line toward to rear end of the vehicle, the pressure energy is transferred from fuel lines to the vehicle underbody through clips and into the passenger compartment. It is crucial to attenuate the pressure pulsation inside the fuel line to reduce the fuel pulse noise. In this paper, a case study on developing an effective countermeasure to reduce the objectionable fuel pulse noise of a V8 gasoline injection system at engine idle condition is presented. First, the interior noise of a prototype vehicle was tested and the objectionable fuel pulse noise is exhibited. The problem frequency ranges of the pulse noise were identified.
Technical Paper

A Comparison of Componentization Constructs for Supporting Modularity in Simulink

2020-04-14
2020-01-1290
The Model-Based Development (MBD) paradigm is widely used for embedded controls development, with the MathWorks Simulink modelling environment being extensively used in the automotive industry. As production-scale Simulink models are typically large and complex, there exists a need to decompose them properly in order to facilitate their maintainability, understandability, and evolution. MathWorks recommends the use of three constructs for model “componentization” or decomposition: the Subsystem, Library, and Model Reference. However, a recently added construct introduced in Simulink R2014b, the Simulink Function, can also be used for this purpose, while also supporting information hiding due to the construct’s ability to be scoped and encapsulate data.
Technical Paper

CAE Modeling Static and Fatigue Performance of Short Glass Fiber Reinforced Polypropylene Coupons and Components

2020-04-14
2020-01-1309
One approach of reducing weight of vehicles is using composite materials, and short glass fiber reinforced polypropylene is one of most popular composite materials. To more accurately predict durability performance of structures made of this kind of composite material, static and fatigue performance of coupons and components made of a short glass fiber reinforced polypropylene has been physically studied. CAE simulations have been conducted accordingly. This paper described details of CAE model setup, procedures, analysis results and correlations to test results for static, fiber orientation flow and fatigue of coupons and a battery tray component. The material configurations include fiber orientations (0, 20 and 90 degrees), and mean stress effect (R = -1.0, -0.5, -0.2, 0.1 and 0.4). The battery tray component samples experience block cycle loading with loading ratio of R = -0.3 and 0.3. The CAE predictions have reasonable correlations to the test results.
Technical Paper

Pedestrian Head Impact, Automated Post Simulation Results Aggregation, Visualization and Analysis Using d3VIEW

2020-04-14
2020-01-1330
Euro NCAP Pedestrian head impact protocol mandates the reduction of head injuries, measured using head injury criteria (HIC). Virtual tools driven design comprises of simulating the impact on the hood and post processing the results. Due to the high number of impact points, engineers spend a significant portion of their time in manual data management, processing, visualization and score calculation. Moreover, due to large volume of data transfer from these simulations, engineers face data bandwidth issues particularly when the data is in different geographical locations. This deters the focus of the engineer from engineering and also delays the product development process. This paper describes the development of an automated method using d3VIEW that significantly improves the efficiency and eliminates the data volume difficulties there by reducing the product development time while providing a higher level of simulation results visualization.
Technical Paper

A Vehicle Level Transient Thermal Analysis of Automotive Fuel Tanks

2020-04-14
2020-01-1342
Maintaining the fuel temperature and fuel system components below certain values is an important design objective. Predicting these temperatures is therefore one of the key parts of the vehicle’s thermal management process. One of the physical processes affecting fuel tank temperature is fuel vaporization, which is controlled by the vapor pressure in the tank, fuel composition and fuel temperature. Models are developed to enable the computation of the fuel temperature, fuel vaporization rate in the tank, fuel temperatures along the fuel supply lines, and follow its path to the charcoal canister and into the engine intake. For diesel fuel systems where a fuel return line is used to return excess fluid back to the fuel tank, an energy balance will be considered to calculate the heat added from the high-pressure pump and vehicle under-hood and underbody.
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