Search Results

Automotive Rear Seats are designed as foldable seats to provide more luggage space to customers when the seat is unoccupied. Foldable seats are of two types, Free Standing Seats and High Latch Seats. Free standing seats are designed with recliner mechanism which allows the seat back to rotate and lock at any given position. High Latch Seats are designed with latches operated by CAMs & Springs which locks with striker wire mounted on the body or side pillars. Recliner Mechanism on free standing seat helps to rotate and lock the seat back at any position with ease. But high latch seats require higher efforts to push the seats towards the striker wire to lock. Efforts (Force in N) required to latch the seats with striker wire need to be in the operating range of customers to latch it easily. Hence latching effort calculations and study of design factors which influence the latching efforts get more importance to avoid any customer complaints at later stage.

Most of the applications of magnesium in lightweighting commercial cars and trucks are die castings rather than sheet metal, and automotive applications of magnesium sheet have typically been experimental or low-volume serial production. The overarching objective of this collaborative research project organized by the United States Automotive Materials Partnership (USAMP) was to develop new low-cost magnesium alloys, and demonstrate warm-stamping of magnesium sheet inner and outer door panels for a 2013 MY Ford Fusion at a fully accounted integrated component cost increase over conventional steel stamped components of no more than $2.50/lb. saved ($5.50/kg saved). The project demonstrated the computational design of new magnesium (Mg) alloys from atomistic levels, cast new experimental alloy ingots and explored thermomechanical rolling processes to produce thin Mg sheet of desired textures.

Prior to developing or modifying the protocol of a performance evaluation test, it is important to identify field relevant conditions. The objective of this study was to assess the distribution of selected crash variables from rear crash field collisions involving modern vehicles. The number of exposed and serious-to-fatally injured non-ejected occupants was determined in 2008+ model year (MY) vehicles using the NASS-CDS and CISS databases. Selected crash variables were assessed for rear crashes, including severity (delta V), impact location, struck vehicle type, and striking objects. In addition, 15 EDRs were collected from 2017 to 2019 CISS cases involving 2008+ MY light vehicles with a rear delta V ranging from 32 to 48 km/h. Ten rear crash tests were also investigated to identify pulse characteristics in rear crashes. The tests included five vehicle-to-vehicle crash tests and five FMVSS 301R barrier tests matching the struck vehicle.

Studies regarding the automotive communication networks has been a fast-growing subject of research through automotive companies. One of the main issues during a vehicle network prototype development is the necessity of a programmed hardware for gateway modules. The gateway developed by an automotive supplier, usually implemented at an Electronic Control Unit (ECU), is one of the last remaining modules to have a software available because it needs to wait the message list completion of all ECUs prior to set up its own message list and network interfaces. This paper proposes a method to design and test Controlled Area Network (CAN) gateways using Vector CANoe software by developing ways to facilitate a scalable code production in CAPL scripts. Use cases will use gatewayed signals virtually validated prior to software deployment, along with codes proposals and common cases examples.

The automotive industry is passing for a big transformation, due to technologies advance. The electrical technologies are also on a good rising curve, calling the attention of the Original Equipment Manufacturer (OEMs). This scenario generates the demand for a faster method to train their new hired engineers, when compared with usual on the job training. Model in the Loop (MiL) consists in one of the real-time embedded systems test phases, which is developed in a computational environment, performing a mathematical modeling of the system, presenting an interface that allows the visualization of its dynamics and the signals involved. Two powerful software in industry that apply MiL are the Matlab and Simulink. A project involving these applications was proposed for a team of new hired engineers, developing models of several vehicle Electronic Control Units (ECUs), with some scope reduction as an example the functional requirements reduction.

This article aims to analyze the potential economic effects for consumers with the implementation of the Vehicle-to-Grid (V2G) and the Vehicle-to-Home (V2H) networks in Brazil. Nowdays, the usage of both technologies in Brazil are at a regulatory vacuum for both Battery Electric Vehicles (BEVs), Plug-in Hybrid Electric Vehicles (PHEVs) and Hybrid Electric Vehicles (HEVs). Usually, when a legislation lack occurs, the local OEMs adopt IECs (International Electrotechnical Commissions) and/or SAEs (Society of Automotive Engineers) reference international standards, such as SAE J1634 for range test.

A novel surrogate model is presented, which predicts the engine-out Particle Number (PN) emissions of a light-duty, spray-guided, turbo-charged, GDI engine. The model is developed through extensive CFD analysis, carried out using the Siemens Simcenter STAR-CD, and considers a range of part-load operating conditions and single-variable sweeps where control parameters such as start of injection and injection pressure are varied in isolation. The work is attached to the Ford-led APC6 DYNAMO project, which aims to improve efficiency and reduce harmful emissions from the next generation of gasoline engines. The CFD work focused on the air exchange, fuel spray and mixture preparation stages of the engine cycle. A combined Rosin-Rammler and Reitz-Diwakar model, calibrated over a wide range of injection pressure, is used to model fuel atomization and secondary droplets break-up.

NVH problems are often the result of mechanisms that originate through complex interactions between different physical domains (flow, structural/mechanical, control logic, etc.). Parallel-shaft spur gears subject to light torque loading caused by the dynamic pressure fluctuation of the oil used in engine accessory or transmission pump drives are likely to exhibit unusual gear whine associated with higher order meshing harmonics, even when the tooth profile has a high-quality grade finishing. Therefore, accurate integrated models are becoming a requirement to solve modern NVH problems.

Noise and vibration evaluation of driveline clunk can be challenging as it is the result of driver input conditions and is transient in nature. As with many noise and vibration challenges, the use of computer-aided engineering (CAE) simulation is useful as it allows for detailed study of the phenomenon and prediction of potential improvements. A hybrid approach of physical test-based measurements and CAE analysis can be used to leverage the advantages of CAE in a comprehensive evaluation including the total vehicle noise, vibration, and harshness (NVH) performance. In this paper we present work performed to facilitate engineering evaluations of driveline clunk using both measured test and CAE simulation data. We explain how we used measured test data to inform the CAE analysis, how the simulation approached modelling of the transient clunk event, and how the measured data was used to provide contextual sound for realistic evaluation of the CAE output as heard by the passengers.

The ported shroud casing treatment for turbocharger compressors offers a wider operating flow range, elevated boost pressures at low compressor mass flow rates, and reduced broadband whoosh noise in spark-ignition internal combustion engine applications. However, the casing treatment elevates tonal noise at the blade-pass frequency (BPF). Typical rotational speeds of compressors employed in practice push BPF noise to high frequencies, which then promote multi-dimensional acoustic wave propagation within the compressor ducting. As a result, in-duct acoustic measurements become sensitive to the angular location of pressure transducers on the duct wall. The present work utilizes a steady-flow turbocharger gas stand featuring a unique rotating compressor inlet duct to quantify the variation of noise measured around the duct at different angular positions.

Capacity planning is one of the major factors in saving capital and avoiding unnecessary costs in any manufacturing system particularly large original equipment manufacturers (OEMs). However, many manufacturing systems still suffer from huge costs incurred due to a lack of applying a robust capacity planning optimization model. Most of the developed models in literature do not consider real-life situations in manufacturing systems and, hence, are not easy to implement. In this paper, a novel capacity planning optimization model considers various important features of a manufacturing system. The objective function of the model is to minimize the weighted sum of the total number of assets and changeovers. A unique feature of the developed model is the capability of providing the number of additional required assets of each type in case the existing assets are not capable of covering the entire demand.

As the automotive industry strives for an increased fuel economy, lightweighting is a key factor and can be realized through composite materials. Composites have better strength-to-weight ratio as compared to metals. In this paper, static and fatigue analysis is performed on an oil pan made of polyamide-6,6 and 50% glass fiber (PA66-GF50). PA66 has a glass transition temperature of 170°C; therefore, it is suitable for automotive applications where the operating range is −40°C to 150°C. Long glass fiber (LGF) composite has an aspect ratio of 30-50 in the oil pan. Fibers break in the molding process but are still considerably longer than with conventionally compounded short glass fiber (SGF) composite, where the aspect ratio of fiber is between 10 and 20. However, the computer-aided engineering (CAE) procedure for life prediction of short glass fiber-reinforced (SGFR) plastic versus LGF-reinforced plastic is the same.

In this paper, a novel methodology of nonlinear control is used, and a passivity-based control of contractive port-controlled Hamiltonian (PCH) systems is applied to a permanent magnet synchronous motor (PMSM). This methodology, also called “tIDA-PBC” (Trajectory Injection and Damping Assignment—Passivity-Based Control), uses passivity-based control of PCH systems “IDA-PBC” and exploits the properties of contractive Hamiltonian systems, resulting in a closed loop with its contractive system desired dynamics, thus obtaining an exponential trajectory tracking without relying on the error coordinates. In this system, a few steps are proposed in order to divide and modularize the methodology so it can be redesigned or reapplied in other systems by the reader. First, we define the model and set the way to solve the “matching equation.” Then the feasible and reference trajectories are obtained.

The average body weight of the US population has increased over time. This study investigates the effect of increasing weight on seat and occupant responses in 15-18 km/h and 42 km/h rear sled tests. The effect of initial occupant posture is also discussed. Seven tests were conducted with lap-shoulder belted ATDs (anthropometric test device) placed on older and modern driver seats. Four tests were conducted with a 50th percentile male Hybrid III, two with 95th percentile male Hybrid III and one with a BioRID. The ATDs were ballasted to represent a Class I or II obese occupant in three tests. The tests were matched by seat model and sled velocity. The effect of occupant weight was assessed in three matches. The results indicated an increase in seatback deflection with increasing occupant weight.

Researchers and engineers are utilizing big data analytics to draw further insights into transportation systems. Large amounts of data at the individual vehicle trip level are being collected and stored. The true potential of such data is still to be determined. In this paper, we are presenting a data-driven, novel, and intuitive approach to model driver behaviors using microscopic traffic simulation. Our approach utilizes metaheuristic methods to create an analytical tool to assess vehicle performance. Secondly, we show how microscopic simulation run outputs can be post-processed to obtain vehicle and trip level performance metrics. The methodology will form the basis for a data-driven approach to unearthing trip experiences as realized by drivers in the real world. The methodology will contribute to, A.) Using vehicle trajectory traces to identify underlying vehicle maneuver distributions as obtained from real-world driver data, B.)

Exhaust sensors and actuators used in automotive applications are subjected to wide variety of operating ambient conditions , the performance of these actuators is challenging especially at cold ambient operating conditions, active exhaust tuning valves with position sensors are used to adjust the sound levels, or noise, vibration and harshness (NVH) from a control unit within the vehicle that leads to an improved driving experience wherein the driver selects their preferred sound levels. However, the operating behavior is crucially influenced by the characteristics of the drive cycle and ambient temperature. The study in this paper is intended to evaluate the icing formation at the start of drive cycle and at different ambient temperature conditions. The test data were obtained through real road and chassis dyno testing at different ambient conditions.

Occupant protection in rear crashes is complex. While seatbelts and head restraints are effective in rear impacts, seatbacks offer the primary restraint component to front-seat occupants in rear impacts. Seatback deflection due to occupant loading can occur in a previous rear crash and/or in multiple-rear event crashes. Seatback deflection will in-turn affect the plastic seatback deformation and energy absorption capabilities of the seat. This study was conducted to provide information on seatback deflection and seat energy consumption in low and high-speed rear impacts. The results can be used to examine seatback deflection and energy consumed in a previous rear impact, or in collisions with multiple rear impacts. Prior seatback deflection and energy absorption can affect the total remaining energy absorption and seat performance for a subsequent rear impact.

A cast magnesium AE44 subframe was designed and manufactured for a C Class sedan to reduce weight and improve vehicle fuel economy. Corrosion mitigation strategies were developed to reduce the likelihood of galvanic corrosion. Both a proving ground vehicle corrosion test and a laboratory component corrosion test were conducted. The vehicle test result demonstrated that the corrosion mitigation strategies were effective. They also provided lessons learned on clearance between magnesium and steel components and options to improve the subframe’s corrosion resistance. The magnesium subframe achieved 5 kg (32%) weight reduction from the equivalent steel subframe and met all the required structural performance targets.

A cast magnesium subframe was designed and manufactured for a C Class sedan to reduce weight and improve vehicle fuel economy. The magnesium subframe achieved 5 kg (32%) weight reduction from the equivalent steel subframe and met all the required structural performance targets. All the joints of the magnesium subframe were tested for bolt load retention. The tests were conducted with a temperature profile of 100°C to -30°C designed to investigate the creep behavior of the selected magnesium alloy AE44 under high stress.

As the world searches for ways to reduce humanity’s impact on the environment, the automotive industry looks to extend the viable use of the gasoline engine by improving efficiency. One way to improve engine efficiency is through more effective control. Torque-based control is critical in modern cars and trucks for traction control, stability control, advanced driver assistance systems, and autonomous vehicle systems. Closed loop torque-based engine control systems require feedback signal(s); indicated mean effective pressure (IMEP) is a useful signal but is costly to measure directly with in-cylinder pressure sensors. Previous work has been done in torque and IMEP estimation using crankshaft acceleration and ion sensors, but these systems lack accuracy in some operating ranges and the ability to estimate cycle-cycle variation.