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The main objective of the combined control unit is to develop a cost effective and optimal control system that manage the proper torque distribution and minimize the loss of communication delay caused by individual inter-controller cooperative control. The control systems of the Hybrid Electric Vehicle (HEV) are more complicated than conventional vehicle. The major difference of HEV has Power Electronics (PE) system. The control systems of PE-part in the HEV are consisted with Hybrid Control Unit (HCU), Motor Control Unit (MCU) and Battery Management System (BMS) individually. In this study, the controllers of PE system are combined into one PCB (1Board-1Micom). Vehicle-testing and dynamometer-testing results confirm that the combined control unit achieves approximately 45% cost and 47% weight reduction compare to the non-combined (Individual controllers) same hybrid vehicle.

Over the past decade, there have been many efforts to generate engine sound inside the cabin either in reducing way or in enhancing way. To reduce the engine noise, the passive way, such as sound absorption or sound insulation, was widely used but it has a limitation on its reduction performance. In recent days, with the development of signal processing technology, ANC (Active Noise Control) is been used to reduce the engine noise inside the cabin. On the other hand, technologies such as ASD (Active Sound Design) and ESG (Engine Sound Generator) have been used to generate the engine sound inside the vehicle. In the last ISNVH, Hyundai Motor Company newly introduced ESEV (Engine Sound by Engine Vibration) technology. This paper describes the ESEV Plus Minus that uses engine vibration to not only enhance the certain engine order components but reduce the other components at the same time. Consequently, this technology would produce a much more diverse engine sound.

Periodically, engine block-bearing cap structure is subject to the mixed bearing load from combustion and inertia mass of crank. Recently, due to the trend of lightness, cast steel is replaced with aluminum in the material of gasoline engine block. And, the load acting on the main bearing cap is rapidly rising due to the increase of engine power. Therefore, in the development stage, fretting fatigue failures frequently occurred on the block face contacted with the bearing cap. Fretting is a kind of wear which is occurred by micro relative movement. Even though various researches have been made to investigate fretting fatigue failure with FEA approaches, they are not enough to evaluate the phenomenon. In this study, the new CAE method simulating the fretting fatigue failure on the engine block face is developed and the mechanism of the fretting fatigue on the engine block is investigated.

At present, the assembling order of COWL is decided according to the design of the Vehicle’s A pillar outer. Therefore when the factory layout changes, extensive costs are needed according to the changes of the A pillar outer design. Thus, this study was carried out to develop a new COWL structure that is able to determine the layout of the factory without changing the design of the A pillar outer. In addition, by adjusting the DFSS tool to COWL, the direction of the material and thickness of COWL was studied to optimize the dynamic stiffness of the body structure and pedestrian protection performance. Based on this study, the optimization of the OPEN COWL is presented.

Recently electric and electronic devices in vehicle have been rapidly increasing. Because the dynamic characteristics of these systems are too much complicated, it is getting very difficult to predict the change of electrical energy accurately. Especially, since the lead-acid battery has a fast aging process, managing the electrical energy in vehicle becomes more difficult. This paper shows the electrical energy simulator, which consists of a battery, an alternator and various electrical devices. In particular, proposed aging battery model was implemented using a finite element method (FEM) based on electrochemical approach. And the thermal characteristic of alternator is also focused on getting reliable performance. Finally, we validated the electrical energy simulator including this battery model on the actual conditions in vehicle.

Transient control for EV/HEV mode change takes an important role in the system of the parallel HEV, which consists of internal combustion engine (ICE), electric motor (EM), integrated starter & generator (ISG), battery, automatic transmission and clutch (that replaces the torque converter), not only ICE/EM control but also clutch engagement control are the key of it. To improve the mode change performance, this study proposes clutch slip control methods. Method 1. focuses on the open loop clutch pressure control so as to adjust target clutch transfer torque. The main idea of Method 2. is to control the clutch pressure in order to achieve the desired speed difference(Method 2-1) from each side of clutch when motor speed is faster than engine idle speed and keep target engine speed(Method 2-2) when motor speed is slower than engine idle speed. This paper defines control sequence which is scheduling the behavior of powertrain components as well.

The purpose of this paper is to identify and reduce the suspension rattle noise. First, the characteristics of the rattle noise are analyzed experimentally in the time and frequency domain. It was found that the rattle noise and vibration at shock absorber mounting point are strongly correlated. Second, the sensitivity analysis of design parameters is performed using a half car model in ADAMS. The result of the simulation model is verified by comparison with test. Finally, the influence of design parameters for the rattle noise is investigated. The study shows that the shock absorber mounting bushing is the most sensitive parameter to affect the suspension rattle noise. This paper shows how the suspension rattle noise can be improved.

The LNT(Lean NOx Trap) system has been developed for NOx reduction to meet Tier2Bin5 by using 2.2ℓ-diesel engine which was recently introduced by Hyundai Kia Motor company. The compression ratio was adjusted to 15.5 and the trim size of the turbine was reduced to increase EGR rates. During the FTP75 mode test, the engine out NOx was reduced by about 30% compared to the standard engine. The rich mode combustion was developed for the wide operating range despite of the low compression ratio. It was accomplished by adjusting air and FIE system, mainly by increasing post2 injection quantity. The A/F (Air-to-Fuel) ratio was controlled by additional post2 injection quantity. The neutral transition between lean mode and rich mode combustion was completed. The noise and torque change could not be recognized by the drivers during the transition of combustion mode (lean-to-rich or rich-to-lean). The transition procedure was finished within about 1sec for the whole operating range.

A low pressure exhaust gas recirculation system (LP EGR system) enables the expansion of the EGR operating area than that of the widely used high pressure EGR system. As a result, fuel consumption and emissions can be improved. In order to meet the EU 5 emissions regulations, an exhaust throttle LP EGR system was used. The EU5 vehicles developed using this system have greater merits than other vehicles. However, because the exhaust throttle LP EGR valve is installed adjacent to the after-treatment system, the material of the LP EGR valve itself must be stainless steel in order to withstand the thermal stress, consequently, the cost is increased. Therefore, in order to achieve cost rationalization for EU6 vehicles, an intake throttle LP EGR system is developed and applied to replace the exhaust throttle LP EGR system. In order to apply the intake throttle LP EGR system, the EGR valve is installed in front of the turbo charger compressor.

Studies in the EU and the USA found higher deformation and occupant injuries in frontal crashes when the vehicle was loaded outboard (frontal crashes with a small overlap). Due to that, in 2012 the IIHS began to evaluate the small overlap front crashworthiness in order to solve this problem.A set of small overlap tests were carried out at IDIADA’s (Institute of Applied Automotive Research ) passive safety laboratory and the importance of identifying the forces applied in each structural element involved in small overlap crash were determined. One of the most important structural elements in the small overlap test is the wheel. Its interaction in a small overlap crash can modify the vehicle interaction at the crash, which at the laboratory the interaction is with a barrier. That interaction has a big influence at the vehicle development and design strategy.

Nowadays vehicle quality is rated for noise and vibration and the interior sound levels have become a major target of automotive companies. Strides have been made in reducing power train, tire and external wind noise over the years. However, HVAC and blower fan flow-induced noise reaches the interior cabin without any sound isolation and can strongly impact customer comfort. In the early stage of vehicle design, it is experimentally difficult to get an estimate of the flow pattern and sound levels. The goal of this study is to develop and validate a numerical noise prediction tool for complete HVAC systems noise, defined as the arrangement of sub-systems such as air intake duct, thermal mixing unit, blower, ducts and outlet vents. This tool can then be used during the development of vehicles to evaluate and optimize the aeroacoustics performances of the system without additional or belated experiments.

Generally, an Urea-SCR system for diesel engines sets the NOx reduction efficiency to 80-90%. The SCR system is theoretically able to achieve the NOx reduction over 95%, but, due to the combination of design factors, the result is varying. The influence factors are the exhaust gas temperature, SCR control strategy, urea dosing parts, flow uniformity, etc. Some factors depend on the exhaust system package. Thus, a system engineer must consider the relation between variable requirements and variable design factors. The design targets for aftertreatment package in this work are following: Improvement of NOx reduction efficiency Improvement of noise reduction performance To meet Exhaust back-pressure requirement Minimization of package volume Minimization of urea-deposit The aftertreament strategy of the discussed subject are the SCR system for EURO V and the DPF+SCR system for Japan 2009, the developed vehicle are the heavy duty truck and the express bus.

A comprehensive investigation was carried out in order to develop the idle sound quality for diesel V6 engine when the engine development process is applied to power-train system, which included new 8-speed automatic transmission for breaking down the noise contribution between the mechanical excitation and the combustion excitation. First of all, the improvement of dynamic characteristic can be achieved during the early stages of the engine development process using experimental modal analysis (EMA) & the robust design of each engine functional system. In addition, the engine structural attenuation (SA) is enhanced such that the radiated combustion noise of the engine can be maintained at a target level even with an increased combustion excitation. It was found that the engine system has better parts and worse parts in frequency range throughout the SA analysis. It is important that weak points in the system should be optimized.

Press hardenable ultra high strength steel (UHSS) is commonly used for automotive components to meet crash requirements with minimal mass addition to the vehicle. Press hardenable steel (PHS) is capable of forming complex geometries with deep sections since the forming takes place at elevated temperatures up to 900 degrees Celsius (in the Austenitic phase). This forming process is known as hot-stamping. The most commonly used PHS grade is often referred to as PHS1500. After hot-stamping, it is typically required to have a yield strength greater than 950 MPa and a tensile strength greater than 1300 MPa. Most automotive design and material engineers are familiar with PHS, the hot-stamping process, and their capabilities. What is less known is the capability of 3rd Generation advanced high strength steels (AHSS) which are cold stamped, also capable of forming complex geometry, and are now in the process of, or have recently completed, qualification at most automotive manufacturers.

In an electric vehicle, a maximum cruising range is adversely affected by electric power consumption of auxiliary electric components for heating and cooling. Therefore, it is important for the air-conditioning to consume energy as efficiently as possible. This study describes how a proposed Occupied-Zone(OZ) HVAC system has attained a significant increase in the cruising range of an electric vehicle by air-conditioning occupied seats only. The idea of OZ HVAC is to confine air-conditioning to occupied-zones only. The OZ HVAC has an option of selectively air-conditioning three zones corresponding to driver, passenger and rear seating positions, while a conventional HVAC system air-conditions a whole cabin regardless of occupancy in each zone, which results in more power consumption compared to the proposed idea.

For passenger car diesel engines, higher air density or higher boost pressure is essential to enhance power density and meet stringent emission regulations. However, single variable geometry turbines (VGT) are limited to eliminate the inherent drawbacks of turbochargers; low-end torque and rated power are hard to reconcile. With a serial two-stage turbocharger, outstanding power density - rated power of 165kW and low-end torque of 350Nm - was obtained from Hyundai Motor's R2.2l engine. Also, it was possible to maintain the maximum torque of 500Nm evenly from 1250rpm up to 2250rpm. Compared to the current R2.2l engine with a single VGT turbocharger, more than 12% of power density increased. The fuel economy of the two-stage turbocharged engine was slightly better than the current R2.2l engine, which resulted in further reduction of fuel consumption compared to a 3.0l single VGT engine.

S.E.A.T (Seat Effective Amplitude Transmissibility) index is used to evaluate ride comfort under vehicle driving condition. The proposed objective evaluation methodology uses several accelerometers to derive an objective index which is more reasonable than subjective evaluation. Moreover, a CAE (Computer Aided Engineering) methodology is proposed to obtain simulation results using the measured acceleration data at seat mountings as input conditions to seat system assembly. Finally, several case studies are conducted for maximizing ride comfort using the CAE model.

Emission regulations and fuel economy regulations are becoming more severe simultaneously, and they give much issue for automotive diesel R&D society. Moreover, emission test cycles are getting more tough transient conditions, like as WLTP. To meet the emission regulations in this trend, in-cylinder combustion requires more precise control. Designing hardware robustly and improving controllable are possible solutions to accomplish the precise combustion control. On the other hand, combustion control based on in-cylinder pressure signal is helpful to control in-cylinder combustion directly. Combustion control using in-cylinder pressure signal is also known to be useful to reducing engine-by-engine exhaust emissions variation due to the manufacturing tolerance, variation of fuel specification and deterioration of engine component during the whole lifetime.

In this paper FR (Front Engine, Rear wheel Drive) based 4WD 5-link independent suspension systems are introduced which are developed for low friction road stability in the winter. The arrangement of the lower control arm of the newly developed suspensions has been changed in order to correspond to 4WD layout. And basic performance is satisfied due to the addition of the driveline. Also NVH (Noise, Vibration and Harshness) performance has improved, to enhance the comfort of the vehicle

To alleviate vibration of power-train system in hybrid electric vehicle (HEV) is one of the most difficult obstacles that most of engineers would face. The vibration of gear-shifting would be hider by precise synchronization of applied members in gear-shifting process; however, improvement of the vibration by calibrating conventional hydraulic control was limited. To transcend the limitation of hydraulic method, we developed a combined gear-shifting method assisted by motor speed feedback control to synchronize an input speed of transmission with a target input speed exactly. We divided a whole gear-shifting process into the following five phases to combined hydraulic control with motor speed control. In addition, to prevent the additional vibration, motor speed feedback control starts at the second phase and parameters of motor feedback control are categorized by each phases.