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Journal Article

A Study on the Role of TRIZ in DFSS

2012-04-16
2012-01-0068
The Design For Six Sigma (DFSS) process consists of four phases, identification & definition of opportunity, concept development, design optimization, and design verification. In the phase of concept development, TRIZ (Russian acronym for Theory of Inventive Problem Solving) is useful for creating new ideas from the present ideas, which includes the trimming strategy, the antidote strategy, and the picket fence strategy. In this paper, systems of a vehicle such as Variable Compression Ratio (VCR) engine, windshield wiper blade, and Continuously Variable Valve Actuation (CVVA) of engine, are selected and new concepts for each system are created by applying the previously mentioned three strategies. FMEA (Failure Mode and Effects Analysis), the latter part in the phase of concept development in DFSS, is conducted for newly generated concepts of systems that are mentioned above. As a result of FMEA, it is found that the wind lift of the wiper blade can be a serious problem.
Technical Paper

High Strength Light-Weight Valve Spring for Automotive Engine to Enhance Fuel Efficiency

2012-04-16
2012-01-0528
High strength oil-tempered wire was developed to apply to light-weight valve spring for automotive engine. By adding Mo, V, B and Ni, tensile strength increased by 20% compared to the conventional oil-tempered wire. Higher tensile strength of wire enabled a constant of valve spring to lower by reducing the size of spring. As a result, reduction of spring constant lowers the load of spring, thereby enhancing fuel efficiency.
Technical Paper

The Procedure for Improving R&H Performance of the New 2010 Hyundai Sonata by Modal Parameter Modification of Its Body

2010-04-12
2010-01-1136
Various deformation shapes of the vehicle body were investigated for the purpose to establish vehicle body's performance criteria which correlates well to handling performance and ride comfort. Using CAE tool, the dynamic behavior of a structure by its modal parameter can be described instead of by its nodes and elements. Each modal characteristic in a dynamic system is reduced by its modal stiffness, its modal mass and its damping parameter in the model. This technology offers not only computational efficiency but also parametric model enabling easy what-if simulation. This reduced model can be obtained by modal test as well as simulation of full FE model. It was also investigated that which mode is sensitive to ride or handling performance using the parameterized model. The body stiffness of the brand new 2010 SONATA was improved on reference to the sensitivity analysis. The ride and handling performance of the 2010 SONATA were verified by computer simulation and vehicle field test
Technical Paper

A Study of LNT & Urea SCR on DPF System to Meet the Stringent Exhaust Emission Regulation

2014-10-13
2014-01-2810
In diesel engine development, the new technology is coming out to meet the stringent exhaust emission regulation. The regulation demands more eco-friendly vehicles. Euro6c demands to meet not only WLTP mode, but also RDE(Real Driving Emission). In order to satisfy RDE mode, the new technology to reduce emissions should cover all operating areas including High Load & High Speed. It is a big challenge to reduce NOx on the RDE mode and a lot of DeNOx technologies are being developed. So the new DeNOx technology is needed to cover widened operating area and strict acceleration / deacceleration. The existing LNT(Lean NOx Trap) and Urea SCR(Selective Catalytic Reduction) is necessary to meet the typical NEDC or WLTP, but the RDE mode demands the powerful DeNOx technology. Therefore, the LNT & Urea SCR on DPF was developed through this study.
Journal Article

FE Simulation of the Transmission Loss Performance of Vehicle Acoustic Components at Low and Medium Frequencies

2014-06-30
2014-01-2081
The assessment of the Transmission Loss (TL) of vehicle components at Low-Mid Frequencies generally raises difficulties associated to the physical mechanisms of the noise transmission through the automotive panel. As far as testing is concerned, it is common in the automotive industry to perform double room TL measurements of component baffled cut-outs, while numerical methods are rather applied when prototype or hardware variants are not available. Indeed, in the context of recent efforts for reduction of vehicle prototypes, the use of simulation is constantly challenged to deliver reliable means of decision during virtual design phase. While the Transfer matrix method is commonly and conveniently used at Mid-High frequencies for the calculation of a trimmed panel, the simulation of energy transfer at low frequencies must take into account modal interactions between the vehicle component and the acoustic environment.
Journal Article

Evaluation of Trim Absorption to Exterior Dynamic and Acoustic Excitations Using a Hybrid Physical-Modal Approach

2014-06-30
2014-01-2080
The NVH study of trimmed vehicle body is essential in improving the passenger comfort and optimizing the vehicle weight. Efficient modal finite-element approaches are widely used in the automotive industry for investigating the frequency response of large vibro-acoustic systems involving a body structure coupled to an acoustic cavity. In order to accurately account for the localized and frequency-dependant damping mechanism of the trim components, a direct physical approach is however preferred. Thus, a hybrid modal-physical approach combines both efficiency and accuracy for large trimmed body analysis. Dynamic loads and exterior acoustic loads can then be applied on the trimmed body model in order to evaluate the transfer functions between these loads and the acoustic response in the car compartment.
Technical Paper

Study on Sound Insulation Performance of Vehicle Dash Reinforcements

2014-06-30
2014-01-2085
Dash panel is the most important path of structure-borne and air-borne interior noise for engine-driven vehicles. Reinforcements, which are added to dash panel, are mainly designed in order to suppress the structure-borne noise contribution from the dash panel. However, the effects of dash reinforcements do not seem clear in the viewpoint of air-borne noise. In this paper, the insulation performance of a dash structure with spot-welded reinforcements is studied through several STL (Sound Transmission Loss) tests and STL simulations. The results of this study could be utilized for increasing the sound insulation performance of vehicle body structure.
Journal Article

Direct Sound Radiation Testing on a Mounted Car Engine

2014-06-30
2014-01-2088
For (benchmark) tests it is not only useful to study the acoustic performance of the whole vehicle, but also to assess separate components such as the engine. Reflections inside the engine bay bias the acoustic radiation estimated with sound pressure based solutions. Consequently, most current methods require dismounting the engine from the car and installing it in an anechoic room to measure the sound emitted. However, this process is laborious and hard to perform. In this paper, two particle velocity based methods are proposed to characterize the sound radiated from an engine while it is still installed in the car. Particle velocity sensors are much less affected by reflections than sound pressure microphones when the measurements are performed near a radiating surface due to the particle velocity's vector nature, intrinsic dependency upon surface displacement and directivity of the sensor. Therefore, the engine does not have to be disassembled, which saves time and money.
Technical Paper

A Development of Smart Ventilation System

2015-03-10
2015-01-0018
There are some problems “windows fog up a lot” for ventilation system. We have Test Development Procedure to prevent the fog problems. But, Many fog problems occurred in the cars that we made. So in this paper, new ventilation system is needed and developed. The Smart Ventilation System automatically controls indoor air quality even though the blower motor is off. There are two sensors that is used for AutoDefogSensor system and CO2 CONTROL system.. The sensor is on when blower motor and heater control is off. We use these signals and make new ventilation logics. We evaluate this system in chamber & '13 winter test in USA.
Technical Paper

A Study on Prediction of Door Deformation in High Speed Passenger Vehicle at Cross Wind

2015-03-10
2015-01-0010
In this study, several design factors are considered to predict door deformation. Door deformation is mainly influenced by air flow around A-pillar and door static stiffness. Therefore design factors can be divided into two categories. First, design elements determined by the appearance of a car affect to the air flow around A-pillar. Second, door static stiffness is determined by engineering design parameters. Kriging method is used to predict door deformation by means of the design factors. Door deformation can be successfully predicted with this method.
Technical Paper

Analysis of Sensitivity and Optimization for Chassis Design Parameters on the X-Wind Stability

2015-03-10
2015-01-0025
In the view point of driving safety, the crosswind sensitivity of a vehicle becomes more important, as the driving speed in highway gets higher in these days. The sensitivity of a vehicle to crosswind depends on many factors, including the design of the suspension and aerodynamics of the body, etc. However, the knowledge about this phenomenon has still to be improved, in order to develop vehicle with optimum characteristics for crosswind stability. In this research, the physics behind the sensitivity of a vehicle is discussed in detail through various kinds of virtual test using computer aided engineering (CAE) simulation scheme. In the first, a reliable simulation model for vehicle, driver, wind generator and interactions among them is built. This simulation model is verified by comparison with test results of real vehicle. Then, the sensitivity analysis is carried out to find out the most influential design parameters.
Technical Paper

Energy Management Strategy of Hybrid Electric Vehicle using Stochastic Dynamic Programming

2015-03-10
2015-01-0019
This paper is concerned with the energy management strategy of hybrid electric vehicle using stochastic dynamic programming. The aim is the control strategy of the power distribution for hybrid electric vehicle powertrains to minimize fuel consumption while maintaining drivability. The fuel economy of hybrid electric vehicle is strongly influenced by power management control strategy. Rule-based control strategy is popular strategy thanks to its effectiveness in real-time implementation, but rule should be designed and efficiency of entire drive trains is not optimized. Dynamic programming, one of optimization-based control strategy presents outstanding performance, but cannot be used as real-time control strategy directly, since its non-causal property and drawback that global optimal solution can only be obtained for specific driving cycle. In this paper, stochastic dynamic programming is applied to parallel hybrid electric vehicle to optimize vehicle performance in average sense.
Technical Paper

A Development of Active Vent Airbag for the Passenger New NCAP

2015-03-10
2015-01-0024
For the robust passenger NCAP(New Car Assessment Program) 5star and the stable neck injury performance, a new concept of passenger airbag has been required. Especially, the deployment stability and the vent hole control technology of the passenger airbag can be improved. According to these requirements, the deployment stability technique has been studied and the ‘Active Vent’ technology has been developed. As a result, these technologies have led to achieve the robust NCAP rating and are applied to the production vehicles.
Technical Paper

A Research of Interior Layout Considering the Voice Recognition Usability

2015-03-10
2015-01-0034
The need for a voice recognition system in the automotive industry is growing day by day. In our current voice recognition system, Hyundai's ‘Blue-Link’ and KIA's ‘UVO’ are developed with Microsoft which is a global software company. The system launched domestic market recently. Since usage of voice recognition system are increasing, research and development of Voice Recognition system also increase very fast. Research is mostly focus on increase recognition rate of speech. However there is no research of interior layout considering voice recognition usability. So in this research, we discover interior design factors for maximizing voice recognition usability.
Technical Paper

The Optimization of Vehicle Performances Using Dynamic Models with Two Steps

2015-03-10
2015-01-0028
This paper presents an industrial application of the Analytical Target Cascading (ATC) methodology to the optimal design of commercial vehicle steering and suspension system. This is a pilot study about the suspension and steering design of a semi medium bus, whose objective is to develop and introduce an ATC methodology to an automobile development process. In the conventional process, it is difficult not only to find design variables which meet the target of Ride and Handling (R&H) performance using a detailed full car model, but also to figure out the interrelation between the vehicle and its subsystems. In this study, ATC methodology is used in order to obtain the optimal values such as geometric characteristics satisfying both the vehicle's R&H target and the subsystem (suspension and steering system) 's target.
Technical Paper

Optimization of WRC Race Car Body and Rollcage Structure

2015-03-10
2015-01-0064
The rollcage for WRC race body/rollcage has been developed and optimized by DFSS methodology. It is designed on the principle of reducing it to a Min. of weight compared to the other OEM and the initial set-up model with the torsional stiffness and strength increased. As a result, 12% increased torsional stiffness, maximized strength and 3.7% weight reduction could be achieved. In terms of economics, it is feasible to have a production cost savings of about 11% per car and the effect is further, considering the development period is substantially decreased, 5 to 2 months. Also, in the process of optimizing rollcage structure, applicable items to monocoque body are suggested by investigating the parts and structures that highly affect the body performance.
Technical Paper

A BIW Structure Research of Light Weight Vehicle with High Stiffness by Steel

2015-03-10
2015-01-0061
The focus of this paper is to develop an innovative vehicle layout and optimize vehicle body structure with the latest lightweight steel technologies, such as hydro-forming and hot stamping. Our BIW structure achieved a mass savings of 28 kg (−10%) compared to the mass of baseline BIW structure. (Base BIW : MD_Elantra)
Technical Paper

Development of Two-Shot Injection-Compression Soft Instrument Panel

2015-03-10
2015-01-0065
In order to reduce the cost and weight of the soft-foamed instrument-panel (IP), we developed the new IP which is made by the 2 kinds of injection methods. One is the compression-injection with back-foamed foil inserted, and the other is two-shot injection with the passenger-side airbag (PAB) door. We named it ‘IMX-IP’ which means that all components (‘X’) of the IP with different resins are made In a Mold. The development procedure of this technology was introduced (1) Design of the new injection mold through TRIZ application, (2) Optimization of the injection conditions and back foamed-foil for minimizing the foam loss and thickness deviation, (3) Development of CAE method for two-shot injection compression, (4) Reliability performance test and application to the mass production. The reduction of the processes through the two-shot molding with back foamed-foil inserted made it possible to enhance soft feeling on IP and reduce the cost and weight simultaneously.
Technical Paper

Analysis of Microorganism Causing Odor in an Air-Conditioning System

2015-04-14
2015-01-0354
This study has been conducted to analyze microbial diversity and its community by using a method of NGS(Next generation sequencing) technique that is not rely on cultivation for microbial community in an core evaporator causing odor of car air conditioner. The NGS without any cultivation method of cultivation, has been developed recently and widely. This method is able to research a microorganism that has not been cultivated. Differently with others, it can get a result that is closer to fact, also can acquire more base sequence with larger volume in relatively shorter time. According to bacteria population analysis of 23 samples, It can be known limited number of bacteria can inhabit in Evaporator core, due to small exposure between bacteria and evaporate, as well as its environmental characteristics. With the population analysis, only certain group of it is forming biofilm in proportion.
Technical Paper

Development of Mild Hybrid City Bus with a Single Voltage Source of 28 V

2008-04-14
2008-01-0086
The most popular issues nowadays in the automotive industry include reduction of environmental impacts by emission materials from automobiles as well as improvement of fuel economy. This paper deals with development of a ¡mild-hybrid¡ system for a city bus as an effort to increase fuel economy in a relatively reasonable expense. Three different technical tactics are employed; an engine is shut down at an engine idle state, a vehicle kinetic energy when the bus is decelerated is re-saved to a battery in the form of electricity, and finally the radiator cooling fan is operated by an electric motor using the saved electric energy with an optimal speed control. It has been demonstrated through the driving tests in a specific city mode, ¡Suwon city mode¡, that an average fuel economy is improved more than 12%, and the system can be a feasible choice in a city bus running in a city mode experiencing many stop and go¡s.
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