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European car manufacturers, setmakers and research institutes have been working for the last decade on Adaptive Frontlighting Systems (AFS). Due to the fact, that an AFS is no longer a single part of the car, it will have to be regarded in systems context with sensor and control devices resulting in a rising complexity. In order to help the engineer in developing an AFS, the software-tool AFSim has been programmed providing functions to swivel and to dim the light-distribution of a headlight on a freely programmable road with curves. The software package AFSim has been recently expanded with further functions facing the range of a headlight.

Spherical, aspherical Fresnel lenses and pillow lenses have an extensive use in rear lamp design. These systems, using refraction or TIR (Total Internal Reflection), allow to control the geometrical spread and the photometry of the luminous flux. A transparent system guarantees a homogeneous and uniform light distribution, attractive appearance, lower costs and reduced overall dimensions. Nevertheless a simple lens system hasn't enough efficiency in collecting luminous flux. Generally the solid angle subtended by lens is small and to improve the optical efficiency, designers use reflectors. TIR reflectors are transparent segmented surfaces, which match the traditional lens performances with high efficiency and new style. This paper discusses the principles, features and performances of TIR reflectors. It also presents the new software developed to design these systems, showing the achieved results.

A method for predicting body deformation during operation, which cannot be measured by conventional methods, has been developed. The method creates a body model based on the characteristics extracted by modal analysis of the results of a vibration testing of an actual vehicle. The model is combined with a suspension model, using multibody dynamics software, and body deformation calculations are performed. In this paper, the influence of body deformation on vehicle controllability and stability is studied and the usefulness of the method is verified.

The present work is the continuation of the research activity developed by the same authors in last years about the use of recent technologies (Artificial Neural Networks) for the set up of “software redundancy” modules to be implemented On Board for the use in Diagnostic Systems. In the present work, a system based on Artificial Neural Networks models for automotive engines Fault Diagnosis and Isolation purposes is set-up and analysed. Four sensors/actuators (throttle valve, rotational speed, torque and intake manifold pressure) are considered, and the respective acquired data are used to train and test four ANN modules correlating the different quantities. An FDI scheme is presented which generates fault codes sequences by suitably treating the primary residuals, obtained by comparing experimental data with the calculated ones by the ANN modules. The robust fault isolation capabilities of the proposed FDI system are presented and discussed.

Automotive Information Systems, Inc., which operates an automotive repair hotline, has developed a software application to make its technicians’ expertise available in an automated, interactive form. This system, Auto Fix, is based on Bayes Theorem, which models problems based on probability, and an extensive automotive database. Auto Fix delivers solutions to users via an easy-to-use Web-based user interface. This paper addresses the issues of user definition, team staffing, technology selection, knowledge authoring and data integration; it also offers observations on challenges and successes met in the development process.

With the revolutionary advances in computing power and software technology, the future trend of integrating design and CFD analysis software package to realize an automated design optimization has been explored in this study. The integrated process of UG, ICEMCFD, and FLUENT was accomplished using iSIGHT for vehicle Aero/Thermal applications. Process integration, CFD solution strategy, optimization algorithm and the practicality for real world problem of this process have been studied, and will be discussed in this paper. As an example of this application, the results of an underhood thermal design will be presented. The advantage of systematical and rapid design exploration is demonstrated by using this integrated process. It also shows the great potential of computer based design automation in vehicle Aero/Thermal development.

Velocity profiles for air flowing under a vehicle body are determined by analyzing videotapes of neutrally buoyant soap bubbles using motion analysis software and equipment. What had heretofore been primarily a qualitative flow visualization technique has been extended to provide quantitative data. The light sources, cameras, and bubble generator, mounted on the vehicle, are powered by the vehicle's electrical system, making it possible to compare underbody velocities measured in a wind tunnel with those over the road. Results are presented for a heavy-duty 4×4 pickup truck at speeds up to 25m/s (55 mph). The velocity profiles in the tunnel and on the road were quite similar.

To shorten the term of automobile development, recently the numerical experimental systems are focused as the compensation methods of real experimentations. These systems are based on the accurate modeling method, and simulate actual motions of mechanism sufficiently accurate to predict the results of actual experimentation and to be the alternative of it. The automobile mechanisms involve various nonlinierity in its motion because of its complex mechanic structure, fluid existence and thermo utilization nature. Therefore the modeling method applied to automobile mechanism is particularly required the accuracy on nonlinear action. There were mainly two modeling method well known. One is the Bondgraph method which simulate energy flow of dynamic system. As the all physical phenomenon is recognized as embodiment of energy behavior, this method is to be excellent in accuracy as calculation of physical phenomenon.

The paper presents a communication architecture for distributed embedded computer systems that require to transmit safety-critical real-time data - which must not be delayed - on the same bus as non-critical data. Such non-critical data can come from sources like sensors and event-based traffic, typically for on-demand diagnosis. This architecture utilizes the communication protocols TTP/C and TTP/A, and a software layer in the distributed nodes, to provide a fault-tolerant platform for reliable yet flexible communication over a multiplex bus.

This paper presents a commercial off-the-shelf (COTS) approach to the automated generation of safety critical software for a distributed control system. The tool suite presented supports Honeywell's next generation Modular Aerospace Controls (MAC) architecture that facilitates fault tolerant distributed engine control utilizing intelligent components connected with TTP/C. This paper describes the integration of tool chains from two commercial vendors, the BEACON™ tool chain from Applied Dynamics International (ADI) and the TTP support tool chain from Time Triggered Technology (TTTech). The integration of these tool chains yields a powerful end-to-end systems-to-software environment that enables a fully automated approach to the development of distributed embedded software and its verification data.

The airflow around a detailed car underbody has been simulated using a commercial CFD software. Moving ground and rotating-wheel boundary conditions were applied in order to allow comparisons of Cd and dCd values with experimental data from a wind tunnel fitted with moving ground facilities. The calculated Cd and dCd figures compared very well with the available experimental results. Four configurations were tested and the maximum difference between experimental and numerical Cd values was 0.009. The individual contribution of different parts of the vehicle to the total drag was calculated and is discussed in this paper. This paper also describes in detail the numerical technique used to perform the computations.

To help our customers to design their parts, USINOR Research Center, with the collaboration of DOVAL, develop HYDROPUNCH, a finite element software to estimate quickly the difficulties of hydroformed parts without taking into account the process parameters. HYDROPUNCH is based on a simplified computing method, which provides the evaluation of the geometrical difficulties of the prebent and hydroformed tubes as soon as the product design stage and which may help the tool design office for the definition of the hydroforming process. The interest of this method, the speed of execution and several functionalities will be illustrated by different examples.

This paper proposes a new approach towards achieving a totally simulation-based software development process for electronic control units (ECU) in automotive applications. It introduces a tool-based methodology to support the system software designer right from inception through the chain by bridging the main steps of software development, i.e. “Simulation/Automatic Code Generation”, “Compilation” and “Measurement & Calibration”. The coherent linkage of these steps to each other by means of flexible open interfaces (conform with ASAM-MCD [1] and OSEK [2]) is addressed in this paper.

A new algorithm for injection control has been designed, enabling small, consistent, pilot injection quantities. The control scheme described in this paper is adaptable and software tunable. It enjoys advantages including the ability to compensate for both manufacturing tolerances and operating conditions such as pressure, temperature and injection timing. In bench and dynamometer testing on Sturman Industries' DHOS (Digital Hydraulic Operating System) diesel injector the algorithm has proven its effectiveness for decreasing the minimum stable injection quantity. This data is presented along with results showing improved repeatability at large injection quantities and stable multiple injection sequences. The approach thus provides both improved performance and tremendous flexibility for the injection sequence.

This paper describes an environment for the development of production Engine Management Systems (EMS). This includes a formal framework and modeling methodology. The environment is based on using Simulink/Stateflow for developing a control system executable specification and a plant model. This allows for simulations of the system to be performed at the engineer's desk, which is identical performance with production software. We provide the details for incorporating production legacy code into the Simulink/Stateflow control system. The system includes a multi-rate, and event driven operating system. This system is developed to facilitate new algorithm development and automated software testing. Based on Simulink/Stateflow this specification will be suitable for use with commercial automatic code generation tools.

In the future, one of the main goals in transforming the Army is the process of moving away from the use of paper maps and grease pencils into more embedded and computer orientated forms of command and control. There are currently many weapons platforms trying to achieve this function; however, each platform is developing their own solution that meet individual needs. The Army as a whole needs to standardize on a single path forward to ensure that all systems can use to communicate across the digitized battlefield. Therefore, each platform will have a “common picture”, and software reuse will be promoted across the Army.

Elkhart Industrial Division of Amcast Industrial Corporation uses a patented process called FORMCAST™, to produce near-net shaped automotive components with superior mechanical properties. The very high pressure generated in the complex forming cavity necessitates a need for an inserted tool design to reduce stresses. Previously, at SAE 1998, the usefulness of using a general purpose FEA software was demonstrated using an inserted tooling simulated in 2D. The extension of this technique to 3D is quite demanding but today's computers and software make such a simulation possible and helps in the development of advanced processes without building numerous prototype dies. This paper is intended to demonstrate that by using a 3D case study simulation of tooling for a Miniblock, which is a car air-conditioner component that the simulation to actual results will correlate.

In this paper we explore the system requirements and specifications of an affordable traffic alerting system that pertains mainly to traffic exceptions as incidents, construction, and warnings. It is feasible to implement such a system since the infrastructure needed to rapidly detect the occurrence of incidents is available on most highways. Our concern here is with the rapid dissemination of incident information to the affected commuters. We review our proposed traffic alerting service, and then focus on the RDS technology as an affordable medium for disseminating incidents information. We design a software application suited for a traffic center, investigate the different Open Data Application (ODA) requirements of the RDS radio, and propose an RDS transmission group structure that will carry a specific incident information reliably under the RDS limited bandwidth constraint.

Under the brand name “Communiport,” Delphi has been introducing many new products into the mobile multi media infotainment market. To date, each of these products have been uniquely designed with software tailored to the specific application. To meet the rapid time to market requirements, to develop the myriad of new products while keeping development resources to a minimum, to maximize reuse, and to establish an open architecture demanded by our customers, DDES is developing an open computing platform (OCP) for its next generation “Communiport” products. This paper describes the OCP, from both a hardware and software perspective; how we got there and where we are heading. Included for reference is an analysis of eleven systems from various customers. The heart of the OCP is the Hitachi SH-4 computer and companion IC, the QSSL QNX Neutrino operating system, the Win CE operating system, and the Hewlett-Packard Chai Java Virtual Machine.

In terms of modern technical systems, the automotive sector is characterized by escalating complexity and functionality requirements. The development of embedded control systems has to meet highest demands regarding process-, time- and cost-optimization. Hence, the efficiency of software development becomes a crucial competitive advantage. Systems design engineers need effective tools and methods to achieve exemplary speed and productivity within the development phase. To obtain such tools and methods, semiconductor manufacturers and tool manufacturers must work closely together. Within the joint efforts of ETAS and Infineon, the software tool suite ASCET-SD was enhanced to generate efficient C code for Infineon's TriCore architecture mapped on ETAS's real-time operating system ERCOSEK. The processor interface to application & calibration tools was realized using the ETK probe based on a JTAG/Nexus link at very high bandwidth.