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The electrical architecture design of a rear back glass defrost grid system encompasses many critical criteria that must be integrated into the design. For example, the defrost clip location and interface to the glass must meet all vehicle performance requirements. If the defrost clip to the glass interface is not resistant to vibration and relative movement, detachment and loss of function can occur. This paper describes a back glass defrost clip with a solder joint that is robust to manufacturing variations and customer usage conditions. A designed experiment using Design for Six Sigma methodologies was performed to understand the effects of the attachment interface to the electrical wiring pigtail, and parameters that affect performance. The working constraints, testing set up, validation, and root cause investigation of the clip detachment phenomenon is covered in this paper.

An actual trend in the automotive industry is to have global products in order to have economy of scale. This paper presents how a Belt Drive Rack EPS developed for the North American market had to be modified in order to be assembled in a Vehicle sold all around the world. Main technical challenges for achieving that goal were generated from different Architectures, whether electrical or mechanical, used in each vehicle, Packaging issues and Regional Requirements. Main features affected are Database Configuration, Electromagnetic Compatibility, Smooth Road Shake mitigation and Pull Compensation.

Electrification of the transportation industry is increasing rapidly with batteries currently the technology of choice. At the end of life, the battery chemistry used to electrify the vehicle may not be easily identifiable. A simple, common identifier is required to allow consumers, service and waste management personnel to direct unknown battery types to appropriate recyclers or secondary use markets. Recyclers also benefit from this identifier as it allows them to sort, screen for potential contamination to existing process streams, and identify the manufacturer so they may contact them to find detailed information about the battery to ensure proper and safe recycling. The SAE Battery Recycling Committee has recommended that batteries be identified by battery system, miscellaneous hazards and date of manufacture be identified as part of chemistry identification code. For the lithium-ion chemistry it is further recommended that cathode and anode be specified.

The comfort assessment of seats in the automotive industry has historically been accomplished by subjective ratings. This approach is expensive and time consuming since it involves multiple prototype seats and numerous people in supporting processes. In order to create a more efficient and robust method, objective metrics must be developed and utilized to establish measurable boundaries for seat performance. Objective measurements already widely accepted, such as IFD (Indentation Force Deflection) or CFD (Compression Force Deflection) [1], have significant shortcomings in defining seat comfort. The most obvious deficiency of these component level tests is that they only deal with a seats' foam rather than the system response. Consequently, these tests fail to take into account significant factors that affect seat comfort such as trim, suspension, attachments and other components.

Evaluating spot weld separation is one of the most challenging tasks in a quasi-static simulation. There are several factors that exist in modeling welds analytically that can influence correlation to physical test. This paper presents 4 specific factors: spot weld representation, weld thickness, weld strength, and metal forming effects around spot welds. There are many ways in which a spot weld can be modeled within an FEA model from mesh independent beams to mesh dependent hex clusters. While each modeling technique comes with its unique sets of advantages and disadvantages, a method is chosen to best balance correlation, model setup timing and computation time. Dependent on the way the thickness of the spot weld is represented, artificial moments can be induced which misrepresents structural behavior. The assigned yield strength of the spot weld influences the behavior of the joint.

Purpose - This research aimed to investigate the process of lean manufacturing implementation in automotive industry in China in order to identify the critical success factors. Design/methodology/approach - A review of relevant literature is used to identify potential critical success factors for lean manufacturing implementations. The research had targeted lean-manufacturing management, practitioners, process users, and consultants working in automotive industry in China. Data were collected with an electronic survey which included 20 close ended questions, each measured by using five-point scale, Out of total 200 questionnaire distributed, 80 useable responses were received resulting in 40 % response rate. A judgmental sampling technique had been selected. Both descriptive and inferential statistics had been used to analyze this data.

Increasing fuel injection pressure has enabled reduction of diesel emissions while retaining the advantage of the high thermal efficiency of diesel engines. With production diesel injectors operating in the range from 300 to 2400 bar, there is interest in injection pressures of 3000 bar and higher for further emissions reduction and fuel efficiency improvements. Fundamental understanding of diesel spray characteristics including very early injection and non-vaporizing spray penetration is essential to improve model development and facilitate the integration of advanced injection systems with elevated injection pressure into future diesel engines. Studies were conducted in an optically accessible constant volume combustion vessel under non-vaporizing conditions. Two advanced high pressure multi-hole injectors were used with different hole diameters, number of holes, and flow rates, with only one plume of each injector being imaged to enable high frame rate imaging.

Traditional warm forming of aluminum refers to sheet forming in the temperature range of 200°C to 350°C using heated, matched die sets similar to conventional stamping. While the benefits of this process can include design freedom, improved dimensional capability and potentially reduced cycle times, the process is complex and requires expensive, heated dies. The objective of this work was to develop a warm forming process that both retains the benefits of traditional warm forming while allowing for the use of lower-cost tooling. Enhanced formability characteristics of aluminum sheet have been observed when there is a prescribed temperature difference between the die and the sheet; often referred to as a non-isothermal condition. This work, which was supported by the USCAR-AMD initiative, demonstrated the benefits of the non-isothermal warm forming approach on a full-scale door inner panel. Finite element analysis was used to guide the design of the die face and blank shape.

In recent years, there has been a growing interest in driver visibility. This is, in part, due to increasing emphasis placed on design factors influencing visibility such as: aerodynamics, styling, structural stiffness and vehicle packaging. During the development process of a vehicle, it is important to be able to quantify all of these factors. Visibility, however, owing to its sensory nature, has been harder to quantify. As a result, General Motors (GM) has undertaken a study to gain deeper insight into customer perceptions surrounding visibility. Clinics were conducted to help determine the relative importance of different metrics. The paper also explores several new metrics that can help predict customer satisfaction based on vehicle configuration.

An extruded Mg-Al-Mn (AM30) magnesium alloy was subjected to uniaxial compression along the extrusion direction (ED) and the extrusion radial direction (RaD) at 450 °C and different strain rates. The microstructure and texture of the AM30 alloy under different deformation conditions were examined. Texture evolution was characterized by electron backscatter diffraction (EBSD). The activity of different deformation modes including twinning were simulated using the visco-plastic self-consistent (VPSC) and the simplistic Sachs polycrystal plasticity models. The results show that the microstructure and the mechanical property of the Mg alloy strongly depend on the strain rate, with twinning activated at strain rates >0.5 s−1. Dynamic recrystallization and twinning interacted with each other and affected the final microstructure and mechanical property of the magnesium alloy.

The U.S. Renewable Fuel Standard (RFS2) requires an increase in the use of advanced biofuels up to 36 billion gallons by 2022. Longer chain alcohols, in addition to cellulosic ethanol and synthetic biofuels, could be used to meet this demand while adhering to the RFS2 corn-based ethanol limitation. Higher carbon number alcohols can be utilized to improve the energy content, knock resistance, and/or petroleum displacement of gasoline-alcohol blends compared to traditional ethanol blends such as E10 while maintaining desired and regulated fuel properties. Part I of this paper focuses on the development of scenarios by which to compare higher alcohol fuel blends to traditional ethanol blends. It also details the implementation of fuel property prediction methods adapted from literature. Possible combinations of eight alcohols mixed with a gasoline blendstock were calculated and the properties of the theoretical fuel blends were predicted.

A new press/die system for restraining force control has been developed in order to facilitate an increased level of process control in sheet metal forming. The press features a built-in system for controlling drawbead penetration in real time. The die has local force transducers built into the draw radius of the lower tooling. These sensors are designed to give process information useful for the drawbead control. This paper focuses on developing models of the drawbead actuators and the die shoulder sensors. The actuator model is useful for developing optimal control methods. The sensor characterization is necessary in order to develop a relationship between the raw sensor outputs and a definitive process characteristic such as drawbead restraining force (DBRF). Closed loop control of local specific punch force is demonstrated using the die shoulder sensor and a PID controller developed off-line with the actuator model.

Inverse Numerical Acoustics (INA) is the process by which the measurements of the sound pressure near a vibrating object, such as an engine, can be used to reconstruct the surface velocities of the object. This is required when it is difficult to conduct measurement on the structure or when the full structural FE model is not available. In such scenarios, the INA technique allows to back calculate the operational vibrations based on operational near field pressure measurements. When the surface velocities of a vibrating object are known which are independent of the boundary conditions, then the object can be used as a source in any application to compute the sound pressure levels in the surrounding (far field). This paper describes an experimental procedure that relies on INA to characterize an engine noise source in this manner. To this end, a robotic manipulator first measured sound pressures at multiple points in the near acoustic field.

The paper reviews the role of drawbeads in sheet metal stamping. The design of drawbeads is discussed in depth, with treatment of different bead cross sections, bead end shapes, and bead materials. International standards and practices are included. This is followed by the historical development of the modeling of the drawbead restraining force, starting with basic equilibrium approaches, and leading to the use of the finite element method which permits the study of drawbead effects on sheet metal flow in three dimensions. Finally, the potential of active drawbeads is described based upon ongoing research which is directed toward closed-loop computer control of the stamping process through adjustment of the drawbead penetration.

Today many vehicles are being developed with advanced computing and sensing technologies. These new technologies have contributed in enhancing driving safety and convenience. As an example, the Adaptive Cruise Control (ACC) can automatically adjust the vehicle speed to driver's set speed and maintain the driver-requested headway distance to the lead vehicle. In this paper, we further consider the automatic control of speed according to the road attributes, e.g., the speed limit and curve of the road. Two new features, ‘speed limit follower’ and ‘curve speed control’ algorithms, are proposed in this paper. These new features communicate with the conventional ACC system and control the vehicle speed while traveling across different curved roads and speed limit zones. These new features were developed as an independent function, so they can be integrated with any other existing ACC systems.

Temperature effects on the deformation and fracture of a commercially produced transformation-induced plasticity (TRIP) steel subject to a two-step quenching and partitioning (Q&P) heat treatment are investigated. Strain field evolution at room temperature is quantified in this 980 MPa grade Q&P steel with a stereo digital image correlation (DIC) technique from quasi-static tensile tests of specimens with 0°, 45°, and 90° orientations. Baseline tensile properties along with the variation of the instantaneous hardening index with strain were computed. Variations of the bake-hardening index were explored under simulated paint bake conditions. Tensile properties were measured at selected temperatures between -100°C and 200°C and the TRIP effect was found to be temperature-dependent due to stress-induced martensitic transformation at lower temperatures versus strain-induced transformation at higher temperatures.

This paper proposes a model-based “Cascaded Dual Extended Kalman Filter” (CDEKF) for combined vehicle state estimation, namely, tire vertical forces and parameter identification. A sensitivity analysis is first carried out to recognize the vehicle inertial parameters that have significant effects on tire normal forces. Next, the combined estimation process is separated in two components. The first component is designed to identify the vehicle mass and estimate the longitudinal forces while the second component identifies the location of center of gravity and estimates the tire normal forces. A Dual extended Kalman filter is designed for each component for combined state estimation and parameter identification. Simulation results verify that the proposed method can precisely estimate the tire normal forces and accurately identify the inertial parameters.

Heavy-duty diesel engine particulate matter (PM) emissions must be reduced from 0.1 to 0.01 grams per brake horsepower-hour by 2007 due to EPA regulations [1]. A catalyzed particulate filter (CPF) is used to capture PM in the exhaust stream, but as PM accumulates in the CPF, exhaust flow is restricted resulting in reduced horsepower and increased fuel consumption. PM must therefore be burned off, referred to as CPF regeneration. Unfortunately, nominal exhaust temperatures are not always high enough to cause stable self-regeneration when needed. One promising method for active CPF regeneration is to inject fuel into the exhaust stream upstream of an oxidation catalytic converter (OCC). The chemical energy released during the oxidation of the fuel in the OCC raises the exhaust temperature and allows regeneration.

The SAE J2716 SENT (Single Edge Nibble Transmission) Protocol has entered production with a number of announced products. The SENT protocol is a point-to-point scheme for transmitting signal values from a sensor to a controller. It is intended to allow for high resolution data transmission with a lower system cost than available serial data solution. The SAE SENT Task Force has developed a number of enhancements and clarifications to the original specification which are summarized in this paper.

The drive of Design for the Environment is to reduce the environmental impact of both design and manufacturing processes. The most frequent method recommended is to substitute better materials and processes. However, there are processes that will continue to have undesirable environmental impacts due to the lack of knowledge of better methods. These processes are critical to manufacturing of products and can not be eliminated. All possible substitutions appear to have worse impacts. This paper explores modeling these processes and imposing a control method which permits an improvement of the environmental impact.