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California Ultra Low Emission Vehicle (ULEV) standards call for a significant reduction in the amount of harmful gases that enter the environment from vehicle exhaust. The Electrically Heated Catalyst (EHC) is a possible solution to reduce emissions. A competitive analysis benchmarking study was completed in order to find an optimum EHC design that will perform to ULEV standards. Four suppliers submitted samples and the EHC designs were rigorously tested for temperature, pressure drop, and emissions performance while being aged at different levels.

It has been reported that lower extremity injuries represent a measurable portion of all moderate-to-severe automobile crash- related injuries. Thus, a simple tool to assist with the design of leg and foot injury countermeasures is desirable. The objective of this study is to develop a mathematical model which can predict load propagation and kinematics of the foot and leg in frontal automotive impacts. A multi-body model developed at the University of Virginia and validated for blunt impact to the whole foot has been used as basis for the current work. This model includes representations of the tibia, fibula, talus, hindfoot, midfoot and forefoot bones. Additionally, the model provides a means for tensioning the Achilles tendon. In the current study, the simulations conducted correspond to tests performed by the Transport Research Laboratory and the University of Nottingham on knee-amputated cadaver specimens.

This paper presents a brake pressure estimation algorithm for Delphi Traction Control Systems (TCS). A control oriented lumped parameter model of a brake control system is developed using Matlab/Simulink. The model is derived based on a typical brake system and is generic to other types of brake control hardware systems. For application purposes, the model is simplified to capture the dominant dynamic brake pressure response. Vehicle experimental data collected under various scenarios are used to validate the algorithm. Simulation results show that the algorithm gives accurate pressure estimation. In addition, the calibration procedure is greatly simplified

It is well known that hydrocarbon reduction during a cold start is a major issue in achieving ultra low emissions standards. This paper describes one of the possible approaches for reducing the cold-start hydrocarbon emissions by using a fast “light-off” planar oxygen sensor. The goal of this study was to verify the operation characteristics of Delphi's fast “light-off” planar oxygen sensor's (INTELLEK OSP) operating characteristics and the closed-loop performance for achieving improved hydrocarbon control for stringent emission standards. Tests were conducted in open-loop and closed-loop mode under steady and transient conditions using a 1996 model year 2.4-liter DOHC in-line 4-cylinder engine with a close-coupled catalytic converter. Overall performance of the OSP showed relatively quick reaction time to reach the operating temperature.

Many companies around the world have adopted the lean thinking as their strategy to operate, in a global market where changes happen all the time. One foundation for the success of lean manufacturing appliance is the continuous improvement approach which has been considered even on company statements, or it can be also considered as part of the genetic code of any enterprise. However, if in one side the continuous improvement thinking, set people mind to look for opportunities of improvement all the time, on other hand these improvements are incremental and they do not have significant impact on company performance on both short-term and medium-term and sometimes, the activities performed by the employees are not sustainable due to the lack of structure to manage and follow up these activities.

Both evaporative emissions and tailpipe emissions have been reduced by more than 90% from uncontrolled levels in state-of-the-art. However, now that the objective is to reach near-zero emission levels, the need for aggressive purging of the canister and fuel tank and the need for extremely precise control of engine Air/Fuel ratio (A/F) come into conflict. On-board diagnostics and the wide variation in operating conditions and fuel properties in the “real world” add to the challenge of resolving these conflicting requirements. An advanced canister purge algorithm has been developed which substantially eliminates the effect of canister purge on A/F control by estimating and compensating for the fuel and air introduced by the purge system. This paper describes the objectives and function of this algorithm and the validation of its performance.

This paper first reports on the benchmarking of a gasoline- fueled vehicle currently for sale in California that is certified to ULEV standards. Emissions data from this vehicle indicate the improvements necessary over current technology to meet SULEV tailpipe standards. Tests with this vehicle also show emissions levels with current technology under off-cycle conditions representative of real-world use. We then present Delphi's strategy of on-board partial oxidation (POx) reforming with gasoline-fueled, spark-ignition engines. On-board reforming provides a source of hydrogen fuel. Tests were run with bottled gas simulating the output of a POx reformer. Results show that an advanced Engine Management System with a small on-board reformer can provide very low tailpipe emissions both under cold start and warmed-up conditions using relatively small amounts of POx gas. The data cover both normal US Federal Test Procedure (FTP) conditions as well as more extreme, off-cycle operation.

TPO is getting wider acceptance for automotive applications. An exterior application like a fascia is a very good example. Interiors are still a challenge due to many reasons including overall system cost. For interior applications, “all-olefin” means it mainly consists of three materials: TPO skin, cross-linked olefinic-based foam and PP substrate. The driving force for TPO in Europe is mainly recyclability while in the USA, it is long-term durability. This paper describes the key limitations of the current TPO systems which are: poor grain retention of TPO skin, shrinkage in-consistency of the skin, high cost of priming (or other treatments) and painting of the skin, lower process window of the semi-crystalline TPO material during thermoforming or In-mold lamination / Low pressure molding, high cost of the foam, low tear strength of the foam for deep draw ratio etc.

The industry strategy for automotive safety systems has been evolving over the last 20 years. Initially, individual passive devices and features such as seatbelts, airbags, knee bolsters, crush zones, etc. were developed for saving lives and minimizing injuries when an accident occurs. Later, preventive measures such as improving visibility, headlights, windshield wipers, tire traction, etc. were deployed to reduce the probability of getting into an accident. Now we are at the stage of actively avoiding accidents as well as providing maximum protection to the vehicle occupants and even pedestrians. Systems that are on the threshold of being deployed or under intense development include collision detection / warning / intervention systems, lane departure warning, drowsy driver detection, and advanced safety interiors.

In the catalytic converter, the thermal conductivity of the insulation material (intumescent mat) placed between the ceramic catalyst and the metal shell is strongly dependent on the temperature, resulting in the solving of non-linear heat conduction equations. In this paper, the analytic solution for the steady heat flow in a cylinder with temperature dependent conductivity is given. Using this analytic solution for the mat and including convection and radiation at the converter skin, an analytical expression for calculating converter skin temperature is obtained. This expression can be easily incorporated in a Fortran code to calculate the temperatures.

With new legislation and federal regulation for vehicle emission levels, automotive and truck manufacturers have been prompted to focus on emission control technologies that limit the level of exhaust pollutants. One of the primary pollutants, especially from diesel engines, is oxides of nitrogen (NOx). One possible solution to this pollution challenge is to design a more efficient internal combustion engine, which would require better engine operating parameter controls. However, there are limitations associated with such tight engine management. This need has led researchers and engineers to focus on the development of exhaust aftertreatment devices that will reduce NOx emissions with current diesel engines. An optimum aftertreatment device must be unaffected by exhaust-gas impurity poisoning such as sulfur products, and must have minimal impact on vehicle operations and fuel economy.

A Barometric Pressure Estimator (BPE) algorithm was implemented in a production speed-density Engine Management System (EMS). The BPE is a model-based, easily calibrated algorithm for estimating barometric pressure using a standard set of production sensors, thereby avoiding the need for a barometric pressure sensor. An accurate barometric pressure value is necessary for a variety of engine control functions. By starting with the physics describing the flow through the induction system, an algorithm was developed which is simple to understand and implement. When used in conjunction with the Pneumatic and Thermal State Estimator (PSE and TSE) algorithms [2], the BPE requires only a single additional calibration table, generated with an automated processing routine, directly from measured engine data collected at an arbitrary elevation, in-vehicle or on a dynamometer. The algorithm has been implemented on several different engines.

A high pressure outwardly opening fuel injector has been developed to produce sprays that meet the stringent requirements of gasoline direct injection (DI) combustion systems. Predictions of spray characteristics have been made using KIVA-3 in conjunction with Star-CD injector flow modeling. After some modeling iterations, the nozzle design has been optimized for the required flow, injector performance, and spray characteristics. The hardware test results of flow and spray have confirmed the numerical modeling accuracy and the spray quality. The spray's average Sauter mean diameter (SMD) is less than 15 microns at 30 mm distance from the nozzle. The DV90, defined as the drop diameter such that 90% of the total liquid volume is in drops of smaller diameter, is less than 40 microns. The maximum penetration is about 70 mm into air at atmospheric pressure. An initial spray slug is not created due to the absence of a sac volume.

Automotive occupant safety continues to evolve. At present this area has gathered a strong consumer interest which the vehicle manufacturers are tapping into with the introduction of many new safety technologies. Initially, individual passive devices and features such as seatbelts, knee- bolsters, structural crush zones, airbags etc., were developed for to help save lives and minimize injuries in accidents. Over the years, preventive measures such as improving visibility, headlights, windshield wipers, tire traction etc., were deployed to help reduce the probability of getting into an accident. With tremendous new research and improvements in electronics, we are at the stage of helping to actively avoid accidents in certain situations as well as providing increased protection to vehicle occupants and pedestrians.

Seat belts are the primary occupant-protection devices for vehicle crashes. Field statistics show that proper usage of seat belts substantially contributes to decreases in the fatality rate and injury level. To collect first-hand information regarding seat belt comfort and usability, a questionnaire survey was conducted. The most significant problems were found as belt trapping in the door, awkward negotiating with clothes, belt twisting, belt locking up, and difficulty to locate the buckle. The survey results indicated that drivers who are over 40 years old have more complaints than younger drivers. When the driver's age increases to 55 and above, belt pulling force and inappropriate and loose fitting of the belt on the body become major issues. Female drivers have more complaints than male drivers. Short statured drivers need both hands to pull and guide the retracting of the belt.

Hybrid electric vehicles have the potential to reduce air pollution and improve fuel economy without sacrificing the present conveniences of long range and available infrastructure that conventional vehicles offer. Hybrid vehicles are generally classified as series or parallel hybrids. A series hybrid vehicle is essentially an electric vehicle with an on-board source of power for charging the batteries. In a parallel hybrid vehicle, the engine and the electric motor can be used to drive the vehicle simultaneously. There are various possible configurations of parallel hybrid vehicles depending on the role of the electric motor/generator and the engine. In this paper, a comparative study of the drivetrains of five different hybrid vehicles is presented. The underlying design architectures are examined, with analysis as to the tradeoffs and advantages represented in these architectures.

The objective of this paper is to impart the challenges presented and the solutions derived to transform an artist's rendering into a production driver's door switch to be used in the interior of a high profile sports car. The challenges took many forms throughout the process, from data translation and packaging, to the final decorative issues. The results are a finished product providing a new approach to automotive interior switch design. It incorporates a low profile, continuous plane keypad with “soft touch” feel, tactile feedback, and integrated back lighting.

The interdependence of consumer features, new electronic and electrical architectures and hybrid propulsion systems are examined. There are two major forces driving future vehicle electronic and electrical systems, one is consumer demand for comfort and safety, and two is the demand for reduced fuel consumption and emissions. These forces are linked by the use of electronics to control vehicle energy generation and usage while providing managed solutions to these demands. Automobile consumer features are discussed and the case is made that these features will require more electric power to be installed on the vehicle. The presence of this increased electric power will then enable the hybrid vehicle functions that will benefit fuel economy and emissions performance.

Delphi has developed a second-generation Electronic Throttle Control system optimized for high volume applications. The Delphi system integrates several unique driver performance features, extensive security/diagnostics, and provides significant benefits for the vehicle manufacturer. For Model Year 2000, the Delphi ETC system has been successfully implemented on several popular SUVs and passenger cars built and sold around the world. The ETC driver features, security systems, and manufacturer benefits are presented as implemented on these Model Year 2000 applications.

Today, electrical/electronic systems like ABS/power brakes and electric power steering are all designed to enhance, not replace a mechanical function. If an electrical or electronic fault occurs, the function reverts to the base mechanical capability. Future E/E systems, such as steer-by-wire and brake-by- wire replace mechanical linkages with electrical or optical signals as in computer networks. While these systems offer many potential safety benefits, they will require different strategies for dependability, and as with any vehicle system, they will further require that dependability be an integral part of the overall E/E system design. This paper illustrates how by-wire systems drive different dependability requirements and discusses some key technologies that are emerging to meet these requirements.