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The analysis of airflow in an automotive HVAC cowl box is complicated by the cross sectional variations and abrupt changes in airflow direction. In this study, the complex three-dimensional turbulent flow found in a generic road vehicle cowl box is investigated experimentally and computationally. An optical anemometer is used to acquire the experimental data within a white metal sheet of a cowl box. The results are then used to validate and tune a Computational Fluid Dynamics (CFD) numerical cowl model.

An experimental field investigation is described that compares off-axis (peripheral) visual performance between high-intensity discharge (HID) forward lighting and halogen systems. The goal of the investigation is to determine if the higher off-axis intensity levels combined with the spectral properties of HID lamps provide any benefits to visual performance over conventional tungsten halogen lamps. In this study three current production European headlamp systems, one HID and two halogen, are compared. These systems are used to illuminate a fixed scene. Subjects perform a visual tracking task, cognitively similar to driving, while simultaneously small targets located at various angles in the periphery are activated. Subjects release a switch upon detection and reaction times and missed signals are measured.

The introduction of innovative new technologies is related to aspects of safety and to human factors as comfort level and visual appearance. The intelligent headlamp system that is currently being developed allows the combination of the different aspects of driving comfort and safety. The top performing headlamp generations of the future will be the successors of the today’s standard low beam. By using the sensor information available in the car, the light distribution will be adapted to different driving situations and generate an optimized light distribution. Relaxed and safe driving is the goal. Investigations concerning adaptive headlamps are presented. Highway, country road, curves and turning situations are examined by investigating detection distances of standard objects and by rating safety and comfort. Photometric measurements rating glare effects during curve road driving for different headlamp control algorithms are carried out.

The shape and configuration of the air ventilation system determines the ventilation performance while influencing the design and structure of a car. It is therefore necessary to decide the configuration of the air ventilation system in the early stages of design. We tried to analyze the pressure level of the ventilation ducts from the aerodynamics simulation results added to the cowl top which had the ventilation intake duct, and so on. Thus we succeeded in designing a new development process that can be used to predict the ventilation performance in a shorter time without the use of prototypes.

The Auto/Steel Partnership established the Light Truck Frame Project Group in 1996 with two objectives: (a) to develop materials, design and fabrication knowledge that would enable the frames on North American OEM (original equipment manufacturer) light trucks to be reduced in weight, and (b) to improve corrosion resistance of frames on these vehicles, thereby allowing a reduction in the thickness of the components and a reduction in frame weight. To address the issues relating to corrosion, a subgroup of the Light Truck Frame Project Group was formed. The group comprised representatives from the North American automotive companies, test laboratories, frame manufacturers, and steel producers. As part of a comprehensive test program, the Corrosion Subgroup has completed tests on frame coatings. Using coated panels of a low carbon hot rolled and pickled steel sheet and two types of accelerated cyclic corrosion tests, seven frame coatings were tested for corrosion performance.

Aqua-ammonia absorption refrigeration cycle and R-134a Vapor jet-ejector refrigeration cycle for automotive air-conditioning were studied and analyzed. Thermally activated refrigeration cycles would utilize combustion engine exhaust gas or engine coolant to supply heat to the generator. For the absorption system, the thermodynamic cycle was analyzed and pressures, temperatures, concentrations, enthalpies, and mass flow rates at every point were computed based on input parameters simulate practical operating conditions of vehicles. Then, heat addition to the generator, heat removal rates from absorber, condenser, and rectifying unit, and total rejection heat transfer area were all calculated. For the jet-ejector system, the optimum ejector vapor mass ratio based on similar input parameters was found by solving diffuser's conservation equations of continuity, momentum, energy, and flow through primary ejector nozzle simultaneously.

Usinor has developed organic and inorganic films, for many automotive applications. The surface post-treatments made by the coil-coater provide additional functions to the metallic coated steel, such as lubrication or corrosion protection, and offer an excellent compromise between car manufacturing, steel utilisation and costs saving. Even though the organic coating thickness can reach 8 μm, steel products can be welded and electro-painted, thanks to metallic pigments within the coating, which make the polymer conductive. In some particular cases, where high flexibility and formability are required, the best solution is organic non-pigmented systems with lower thickness from 1 to 2 μm. Other pre-painted steel systems with thicker organic coatings have the potential to replace ED-paint or to remove Primer-Surfacer on paint lines by the car manufacturer.

Fulfillment of SULEV standards without catalyst - this is a target engineers at IAV have been working on since the middle of the 1990s. The core of this development is an advanced steam engine with a high performance burner. This burner features extremely low raw pollutant emission. This paper describes new solutions that were found to solve the challenging tasks in the development of such an engine concept.

The future of automotive vehicle interiors is becoming more complex each year. Extensive consumer research demonstrates that consumers want new convenience features. However, increased electronics and communications content could potentially pose unwanted distractions to the driver. This study examined objective variations in driver performance while tasked with operating a variety of interior feature controls. Data from thirty-one test participants were used in the evaluation of three control interface alternatives. Objective driving simulator measurements included vehicle velocity, steering wheel angle, and vehicle position within the driving lane. Session video and subjective responses were also recorded. Examples of data analysis and interesting findings will be discussed.

This paper describes the cluster analysis technique and how it can be used to support menu interface design for in-vehicle multimedia applications. Cluster analysis and similar types of classifying techniques have proven effective for developing simple menu interfaces. This paper extends the use of the cluster analysis technique to a more complex system that consists of 201 generic functions. These functions are representative of those being incorporated into near-term multimedia products. Study results show promise for using cluster analysis as a tool for incorporating the user's organizational structure into the design of a complex menu architecture. Cluster analysis may also benefit the automotive menu designer by providing a means for partitioning menu tasks into chunkable units that can be easily accessed by the driver in single glances.

The desire to increase production and reduce cost while increasing environmental consciousness, is a constant challenge in the thermoplastic olefin (TPO) paint industry. Typically, TPO substrates are painted with an adhesion promoter for durability, and top coats for appearance. Although the adhesion promoter has an important function, the intrinsic value is not significant compared to top coats. A process and material was developed to eliminate conventional adhesion promoter spray application. By incorporating a novel adhesion promoter into the aqueous pretreatment system, many of the stresses of high production volumes, and operating costs were addressed while improving environmental awareness.

The transfer efficiency for painting processes utilizing water-borne materials is low, and the residual paint is disposed of as waste. In this study, we focused on a recycling system to collect and dissolve the paint over-spray in the booth water, and to concentrate and regenerate it by means of an ultra filter (UF). Paint adaptable to the recycling system has been developed by providing compatibility between the high hydrophilicity of liquid paint and the high hydrophobicity of the paint film, in order to ensure the recyclability and the high anti-corrosion performance required of paint on automobile underbody parts. This recycling technology is used in an actual propeller shaft painting process and provides large waste reduction and a decrease in painting cost.

An approach to a solution to conflicts of interest posed by new pedestrian safety requirements is presented here. The effects of various design parameters on pedestrian safety, and the resulting influence on other requirements are examined. Limitations and possible solution envelopes are determined with regard to styling, packaging and functionality. Material choice and the stiffness of the structure are used as variables to fine-tune the system. The paper explores the effects of using current front-end materials and new material options versus what can be achieved by modifying or developing designs and structures to fulfil the set of conflicting requirements. Computer Aided Engineering (CAE) techniques are used extensively for this work, in order to determine the sensitivity of the behaviour of front-end systems to design and material characteristics.

This study proposes an evaluation method for a verbal interface while driving. In this method, the reaction time is measured and the rate of the delayed reaction time trial is used as an index. We have designed a new reaction time test procedure that contains stimulus, perception, attention, choice and response. Based on results of an actual vehicle experiment, we indicate that our method has better examination capability than using the average reaction time as an index and that we can find the time that tends to delay the reaction during a verbal task by processing the delayed reaction time trial.

The importance of bumper system lies not only in the styling and the protection of front end of vehicle from reasonable impact, but also in the protection of occupants - behavior of bumper-frame joint under low speed impact affects the must-fire/non-fire condition of airbag. Furthermore, new regulation, ‘Pedestrian protection’ which is anticipated to work in EC as well as the US and Japan, impose another heavy load on the role of bumper system. Under these requirements it's very hard to design an appropriate bumper system for all requirements since respective requirement is not necessarily compatible with each other. In this study, structural parameters of bumper system will be studied via analytical methods and through the comparison of parameters under two requirements, low speed impact performance and pedestrian protection, interdependency of parameters on a certain performance will be studied.

Traffic accidents in Japan claim some 10,000 precious lives every year, and there is seemingly no end to the problem. In an effort to overcome this situation, vehicle manufacturers have been pushing ahead with the development of a variety of advanced safety technologies. Joint public-private sector projects related to Intelligent Transport Systems (ITS) are also proceeding vigorously. Most accidents can be attributed to driver error in recognition, judgment or vehicle operation. This paper presents an analysis of driver behavior characteristics in emergency situations that lead to an accident, focusing in particular on operation of the brake pedal. Based on the insights gained so far, we have developed a Brake Assist System with a Preview Function (BAP) designed to prevent accidents by helping drivers with braking actions. Experimental results have confirmed that BAP is effective in reducing the impact speed and the frequency of accidents in emergency situations.

Metal Injection Molding (MIM) has become an established process over the past 20 years for producing small complex metal parts. A variety of industries have benefited from the capabilities of the MIM process. Some examples include orthodontic brackets, medical instruments, firearm components, lock mechanisms, and electronic data storage devices. More recently (over the past 5 years) the MIM process has found applications in the automotive industry in a variety of systems including steering columns, seat mechanisms, sunroof systems, ignition locks, airbags, and engines. This paper discusses some of the benefits that the MIM process has brought to these automotive applications.

This paper will describe the BorgWarner Interactive Torque Management (ITM) system for FWD based AWD systems as well as the utilization of P/M technology for critical components within this system. The ITM is an electro-mechanical coupling device. The device consists of an electromagnet, ball ramp and wet clutch system. The system can be mounted anywhere in the drive line as well as integrated into components such as transfer cases and transaxles. The clutch actuation force is dependent on the current applied to the electromagnetic coil, providing a truly variable torque transfer device. The decision to make extensive use of P/M technology in the structural portion of this system was based on the net shape capability and weight reduction combined with the ability to chose from a wide range of engineered materials that resulted in the most economical total system package.

Connecting rods manufactured by the Precision Powder Forged (P/F) process offer several distinct advantages over those produced by all other methods including the state-of-the-art forged steel process. Precision P/F connecting rods have mechanical properties equivalent to those made from forged steel, with the added benefits of greater design flexibility, superior dimensional and weight precision, simplified finish machining and assembly, better machinability, and increased consistency because of highly stable metallurgy and a robust and reliable manufacturing process. The inherent flexibility of the P/F process also facilitates tailoring materials to achieve the optimal balance of strength and machinability for a given application. In combination, these advantages result in a product that requires less capital investment for finish machining, is more environmentally conscious by generating substantially less waste, exhibits better total performance, and has lower total cost.

The paper describes a finite element procedure and material model that can be used to predict the post-impact geometry of a thermoplastic bumper energy absorber. The material used in the study is a thermoplastic PC/PBT blend. The methodology presented determines the final geometric shape based on a new finite element material model. The material model uses a secant return modulus that is a function of the plastic strain. The conversion of material data into a finite element material model, along with a finite element procedure for analyzing multiple impacts, is discussed. Comparisons of finite element predictions to test data are also presented.