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In an effort to optmize the connecting rod of an internal combustion engine for both mass and reliability, an all-new forged steel design has been developed that is 37% lighter than the lightweight production design. The connecting rod has been optimized using 3D Modeling, FEA, advanced numerical simulation such as PIMO3D, and a variety of mechanical testing and lessons learned. The four critical areas of the connecting rod are defined and discussed in detail, and an optimization solution for each area is presented. Finally, the optimized connecting rod incorportating all of the knowledge and information from the previous sections is presented.

The arrival of new competitors and the continuous growth of the customer requirements, lead the OEM's to reduce the product development time; thus, the simulation tools available on the market became mandatory to the new products development in the automotive industry. However, to simulate a full connecting rod set is very time consuming. The goal of this work is to present the main simplifications that can be set on a connecting rod simulation using the Finite Elements Method (FEM) without jeopardizing the results accuracy. The main contribution of this study is to provide time optimization to the engineers and to avoid a wrong interpretation of the results according to the boundary conditions adopted on the simplified model.

Neck injury assessment reference values (IARVs) and tolerance values for children have been specified using animal data compared to the loading of anthropomorphic test devices (ATDs). However, there is a paucity of data regarding the neck loads generated during non-injurious situations for children. Six males and six females aged 8-11 years old were equipped with a validated head sensor package and upper neck loads and moments were calculated from measured head kinematics while performing a series of playground-type activities. The maximum forces were 686 N in compression, 177 N in tension, and 471 N in shear, the maximum moments were 18.2 N-m in flexion, 6.0 N-m in extension, 6.4 N-m in lateral bending, and 12.1 N-m in axial twist. Female subjects exhibited similar loads and moments to their male counterparts, but larger Nij values. The peak loads measured in this study are larger than or comparable to those undertaken with adult subjects participating in similar activities.

An Arbitrary Lagrangian Eulerian (ALE) approach was adopted in this study to predict the responses of side crash pressure sensors in an attempt to assist pressure sensor algorithm development by using computer simulations. Acceleration-based crash sensors have traditionally been used to deploy restraint devises (e.g., airbags, air curtains, and seat belts) in vehicle crashes. The crash pulses recorded by acceleration-based crash sensors usually exhibit high frequency and noisy responses depending on the vehicle's structural design. As a result, it is very challenging to predict the responses of acceleration-based crash sensors by using computer simulations, especially those installed in crush zones. Therefore, the sensor algorithm developments for acceleration-based sensors are mostly based on physical testing.

With the increasing need to have faster product development and yet achieve the optimum design, thrust on accurate FEA of components and system is felt. The connecting rod is an important component of the crank train and it has a significant mass contribution in multi-cylinder engine. Principal focus is directed to connecting rods having load ratio greater than or equal to 2. As the connecting rod operates in elastic range (i.e. high cycle fatigue life region) stress life approach is adopted for fatigue life evaluation. The three fold purpose of this paper is to establish an accurate FE modelling technique and analysis procedure that simulates the test conditions, aids in accurate fatigue life prediction and most importantly provides a simple procedure for virtual validation of connecting rod. To achieve this objective static strain measurement and fatigue test of connecting rod is carried out on a test bench.

While adult head injuries have been studied over the past six decades, few studies have investigated pediatric head injury mechanics. This paper presents non-injurious head accelerations during various activities in a pediatric population. Six males and six females aged 8–11 years old were equipped with a validated head sensor package and head kinematics were measured while performing a series of playground-type activities. Maximum resultant values across all participants and activities were 25.7 g (range 3.0 g to 25.7 g), 16.0 rad/s (range 10.4 rad/s to 16.0 rad/s), and 1705 rad/s2 (range 520 rad/s2 to 1705 rad/s2) for linear acceleration, angular velocity, and angular acceleration, respectively. Mean maximum resultant values across all participants and activities were 9.7 g (range 2.1 g to 9.7 g) and 734 rad/s2 (range 188 rad/s2 to 734 rad/s2) for linear and angular acceleration, respectively.

To meet stringent 2010 NOx emissions, many manufacturers are expected to deploy urea selective catalytic reduction systems. Indications from ARB are that a threshold monitor must be developed to monitor their performance. The most capable monitoring technology at this time relies on NOx sensors. This paper assesses the capability of the NOx sensor as an SCR monitoring device. To this end, the NOx sensor must be able to distinguish between a marginal and a threshold catalyst with enough separation to allow for variability. We present the noise factors associated with the NOx conversion of the SCR system, and analyze what NOx sensor accuracy we need to preserve separation in the face of those noise factors. It is shown that a 1.75 threshold monitor is not feasible with current NOx sensor technology. We analyze the benefit of a partial volume monitor, and show there is no advantage unless the slope error of the NOx sensor is drastically reduced from current levels.

The majority of all highway-type vehicle (cars, trucks, vans, buses, camping trailers, etc.) fire deaths result from fires caused by collisions or overturns. However, more than one third of these deaths resulted from fires that did not follow a collision or overturn. Compared to vehicle fire deaths from collisions or overturns, vehicle fire deaths resulting from non-collision, non-overturn fires are less likely to occur on highways or road properties, more likely to originate in the passenger area and more likely to have victims who are under 5 years of age or 65 or older.

In a controlled environment, bicycle crash tests were performed to analyze the dynamics of bicycle pitch-over, and the effect different test conditions would have on the motion of the bicyclist and the potential for serious head and neck injuries. The tests being evaluated within this paper will focus on a single size rider and bicycle with speed controlled between 19.3 and 22.5 kph (12.0 and 14.0 mph). The variables of the test conditions were the method of pitch-over initiation and configuration of the bicycle. Pitch-over was initiated by applying the front brake, impacting a rigid barrier, and inserting a dowel into the spokes of the front wheel. The bicycle configuration was varied by changing the frame, front fork, front wheel and stem. For all testing performed the event was captured on high speed video. As the testing progressed a force plate was added to measure the vertical loads and an impact plate was added to the barrier impacts to measure the horizontal impact loads.

The National Automotive Sampling System (NASS) Crashworthiness Data System (CDS) contains a wealth of field accident data. As the size of the database continues to grow, the statistical significance of the data increases and trends can be observed. Numerous papers contain analysis and graphs of particular aspects of the data, but they are usually included in a supporting role to the main topic of the paper, and are extremely difficult to locate in a focused document search. The purpose of this paper is to provide an updated, comprehensive resource to reference when looking for commonly sought-after accident statistics. Charts include accident distributions by Delta-V and impact direction with corresponding injury severity rates. Rollover data is also analyzed, as well as historical trends for injury severity, belt usage, and air bag availability.

Previous research has suggested that the pediatric ATD spine, developed from scaling the adult ATD spine, may not adequately represent a child's spine and thus may lead to important differences in the ATD head trajectory relative to a human. To gain further insight into this issue, the objectives of this study were, through non-injurious frontal sled tests on human volunteers, to 1) quantify the kinematic responses of the restrained child's head and spine and 2) compare pediatric kinematic responses to those of the adult. Low-speed frontal sled tests were conducted using male human volunteers (20 subjects: 6-14 years old, 10 subjects: 18-40 years old), in which the safety envelope was defined from an amusement park bumper-car impact.

Selective Catalytic Reduction (SCR) catalysts have been designed to reduce NOx with the assistance of an ammonia-based reductant. Diesel Particulate Filters (DPF) have been designed to trap and eventually oxidize particulate matter (PM). Combining the SCR function within the wall of a high porosity particulate filter substrate has the potential to reduce the overall complexity of the aftertreatment system while maintaining the required NOx and PM performance. The concept, termed Selective Catalytic Reduction Filter (SCRF) was studied using a synthetic gas bench to determine the NOx conversion robustness from soot, coke, and hydrocarbon deposition. Soot deposition, coke derived from propylene exposure, and coke derived from diesel fuel exposure negatively affected the NOx conversion. The type of soot and/or coke responsible for the inhibited NOx conversion did not contribute to the SCRF backpressure.

Automotive vehicle body electrophoretic (e-coat) and paint application has a high degree of complexity and expense in vehicle assembly. These steps involve coating and painting the vehicle body. Each step has multiple coatings and a curing process of the body in an oven. Two types of heating methods, radiation and convection, are used in the ovens to cure coatings and paints during the process. During heating stage in the oven, the vehicle body has large thermal stresses due to thermal expansion. These stresses may cause permanent deformation and weld/joint failure. Body panel deformation and joint failure can be predicted by using structural analysis with component surface temperature distribution. The prediction will avoid late and costly changes to the vehicle design. The temperature profiles on the vehicle components are the key boundary conditions used to perform structure analysis.

In an attempt to assist pressure sensor algorithm and calibration development using computer simulations, an Arbitrary Lagrangian Eulerian (ALE) approach was adopted in this study to predict the responses of side crash pressure sensors for body-on-frame vehicles. Acceleration based, also called G-based, crash sensors have been used extensively to deploy restraint devices, such as airbags, curtain airbags, seatbelt pre-tensioners, and inflatable seatbelts, in vehicle crashes. With advancements in crash sensor technologies, pressure sensors that measure pressure changes in vehicle side doors have been developed recently and their applications in vehicle crash safety are increasing. The pressure sensors are able to detect and record the dynamic pressure change when the volume of a vehicle door changes as a result of a crash.

Volunteer subject studies in low-speed rear impacts have shown that significant lumbar spine injuries are unlikely in such collisions. Anthropomorphic test devices (ATD) used in low to medium speed rear impact simulations have similarly revealed an unlikely mechanism to cause lumbar spine injuries. However, low back complaints after rear impacts are common in clinical practice. We attempt here to determine the incidence of lumbar spine injuries from actual field data which may provide an insight into the apparent paradox between experimental data and clinical practice. We examined the incidence of all spine injuries in the NASSCDS (National Automotive Sampling System - Crashworthiness Data System) database from 1993 to 2009. We limited the data to only look at rear-end crashes involving two vehicles.

Previous studies have shown that occupant kinematics in lateral impacts are different for near- and far-side occupants. Additionally, injuries to far-side occupants in high-speed lateral impacts have been better documented in the scientific literature; few studies have looked at low-speed far-side occupants. The purpose of this study was to determine the risk of lumbar spine injury for restrained and unrestrained far-side occupants in low- to moderate- speed lateral impacts. The NASS/CDS database was queried for far-side occupants in lateral impacts for different levels of impact severity (categorized by Delta-V): 0 to 8 km/h, 8 to 16 km/h, 16 to 24 km/h and 24 to 32 km/h. To further understand the lumbar spine injuries sustained by occupants in real-world impacts, far-side lateral impact tests with ATDs from the NHTSA Biomechanics Test Database were used to estimate lumbar loads in generic far-side sled tests.

Diesel exhaust fluid, DEF, (32.5 wt.% urea aqueous solution) is widely used as the NH3 source for selective catalytic reduction (SCR) of NOx in diesel aftertreatment systems. The transformation of sprayed liquid phase DEF droplets to gas phase NH3 is a complex physical and chemical process. Briefly, it experiences water vaporization, urea thermolysis/decomposition and hydrolysis. Depending on the DEF doser, decomposition reaction tube (DRT) design and operating conditions, incomplete decomposition of injected urea could lead to solid urea deposit formation in the diesel aftertreatment system. The formed deposits could lead to engine back pressure increase and DeNOx performance deterioration etc. The formed urea deposits could be further transformed to chemically more stable substances upon exposure to hot exhaust gas, therefore it is critical to understand this transformation process.

In aftertreatment system design, flow uniformity is of paramount importance as it affects aftertreatment device conversion efficiency and durability. The major trend of downsizing engines using turbochargers means the effect of the turbine residual swirl on the flow needs to be considered. In this paper, this effect has been investigated experimentally and numerically. A swirling flow rig with a moving-block swirl generator was used to generate swirling flow in a sudden expansion diffuser with a wash-coated diesel oxidation catalyst (DOC) downstream. Hot-wire anemometry (HWA) was used to measure the axial and tangential velocities of the swirling flow upstream of the diffuser expansion and the axial velocity downstream the monolith. With no swirl, the flow in the catalyst monolith is highly non-uniform with maximum velocities near the diffuser axis. At high swirl levels, the flow is also highly nonuniform with the highest velocities near the diffuser wall.

The acquisition of more authentic cylinder pressure data is the basis of engine combustion analysis. Due to the multiple advantages, quartz piezoelectric pressure transducers are generally applied to the measurement of the cylinder pressure. However, these transducers can only produce dynamic cylinder pressure data which may be significantly different from the actual values. Thus, the cylinder pressure data need to be corrected through a certain method, while different cylinder pressure correction methods will cause result divergences of the combustion analysis. This paper aims to acquire a proper cylinder pressure correction method by carrying out theoretical analysis based on the polytropic process in the compression stroke as well as the experimental research of the cylinder pressure of a turbocharged eight-cylinder diesel engine.

It is extremely important to accurately depict photographs or video taken of a scene at night, when attempting to show how the subject scene appeared. It is widely understood that digital image sensors cannot capture the large dynamic range that can be seen by the human eye. Furthermore, todays commercially available printers, computer monitors, TV’s or other displays cannot reproduce the dynamic range that is captured by the digital cameras. Therefore, care must be taken when presenting a photograph or video while attempting to accurately depict a subject scene. However, there are many parameters that can be altered, while taking a photograph or video, to make a subject scene either too bright or too dark. Similarly, adjustments can be made to a printer or display to make the image appear either too bright or too dark. There have been several published papers and studies dealing with how to properly capture and calibrate photographs and video of a subject scene at night.