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Lithium-ion battery systems are an energy source for a variety of electric-vehicle applications due to their high energy density and low discharge rates. Battery packs, whether made of prismatic, cylindrical or pouch cells, are cooled by common automotive thermal management systems. The rapid detection of battery pack coolant-system leaks during production operations is essential for meeting necessary safety and service-life requirements. Industry standards for measuring leak rates for both glycol-based and refrigerant-based cooling systems, however, currently do not exist. This presentation will discuss how leaks in water-glycol cooling circuits can be detected reliably and quantitatively through detection of escaping test gas as an indicator of ethylene glycol leaks and how the test gas leak rates correlate to the liquid leakage of the cooling liquid.

Baking ovens in the automotive paint shop are crucial to ensuring quality of paint curing and hence meet the corrosion protection targets in manufacturing process. Ovens are also among the most energy consuming processes in the entire paint shop. With the onset of Electric Vehicle revolution, original equipment manufacturers focus heavily on light weighting resulting in significant design changes to the body in white (BIW). This presents a challenge of achieving accurate curing in the existing ovens designed for the current and past generations of vehicles Using Computational fluid dynamics (CFD), this research intends to present a solution by minimizing the need for prototyping for design changes. Lattice Boltzmann Method (LBM) based thermal simulations are used to predict the curing behaviour on the BIW surface. The LBM based conjugated heat transfer simulations consider turbulence using a Large-Eddy Simulation (LES) approach and Boussinesq approximation.

Methanol is one of the most promising fuels for the decarbonization of the off-road and transportation sectors. Although methanol is typically seen as an alternative fuel for spark ignition engines, mixing-controlled compression ignition (MCCI) combustion is typically preferred in most off-road and medium-and heavy-duty applications due to its high reliability, durability and high-efficiency. In this paper, the potential of using ignition enhancers to enable methanol MCCI combustion was investigated. Methanol was blended with 2-ethylhexyl nitrate (EHN) and experiments were performed in a single-cylinder production-like diesel research engine, which has a displacement volume of 0.83 L and compression ratio of 16:1. The effect of EHN has been evaluated with three different levels (3%vol, 5%vol, and 7%vol) under low- and part-load conditions. The injection timing has been swept to find the stable injection window for each EHN level and load.

The automotive PowerNet is in the middle of a major transformation. The main drivers are steadily increasing power demand, availability requirements, and complexity and cost. These factors result in a wide variety of possible future PowerNet topologies. The increasing power demand is, among other factors, caused by the progressive electrification of formerly mechanical components and a constantly increasing number of comfort and safety loads. This leads to a steady increase in installed electrical power. X-by-wire systems1 and autonomous driving functions result in higher availability requirements. As a result, the power supply of all safety-critical loads must always be kept sufficiently stable. To reduce costs and increase reliability, the car manufacturers aim to reduce the complexity of the PowerNet system, including the wiring harness and the controller network. The wiring harness e.g., is currently one of the most expensive parts of modern cars.

Metal cutting/machining is a widely used manufacturing process for producing high-precision parts at a low cost and with high throughput. In the automotive industry, engine components such as cylinder heads or engine blocks are all manufactured using such processes. Despite its cost benefits, manufacturers often face the problem of machining chips and cutting oil residue remaining on the finished surface or falling into the internal cavities after machining operations, and these wastes can be very difficult to clean. While part cleaning/washing equipment suppliers often claim that their washers have superior performance, determining the washing efficiency is challenging without means to visualize the water flow. In this paper, a virtual engineering methodology using particle-based CFD is developed to address the issue of metal chip cleanliness resulting from engine component machining operations. This methodology comprises two simulation methods.

On the 25th December 2011 there was a hail storm in the state of Victoria, Australia, which caused approximately AU$712 million worth of damage. Some of this damage was caused to passenger vehicles. The authors conducted a number of inspections of hail-damaged vehicles as a result of insurance claims being disputed or rejected on the basis that some, or all, of the alleged hail damage was not created by hail but instead created intentionally by the vehicles' owners with the use of different tools and/or objects. As a result of the inspections and investigations of potentially fraudulent claims, the authors conducted a total of 119 tests designed to replicate damage caused to vehicle body panels by impacting hail and to recreate claimed hail damage by using tools and other objects. To do so, the authors created two sizes of hail: Ø20 mm and Ø40 mm hail. A total of 15 impact tests were conducted with Ø20 mm hail.

A simulation framework for vehicle aerodynamics using up to 10 billion fully unstructured cells has been developed on a world-fastest class supercomputer, called the K computer, in Kobe, Japan. The simulation software FrontFlow/red-Aero was fully optimized on the K computer to utilize up to 10,000 processors with tens of thousands of cores. A hybrid parallelization method using MPI among processors and OpenMP among cores inside each processor was adopted. The code was specially tuned for unsteady aerodynamic simulation including large-eddy simulation, and low Mach number approximation was adopted to avoid excessive iterations usually required for the fully incompressible algorithm. The automated mesh refining system was developed to generate unstructured meshes of up to 10 billion cells. In the system, users only generate unstructured meshes in the order of tens of millions of cells directly using commercial preprocessing software.

There is insufficient time within a single technical elective to learn principles of internal combustion engine operation as well as specialized simulation tools such as GT Suite or Kiva. A number of authors have recognized this constraint, and they have structured their internal combustion engine text around use of programming languages such as FORTRAN, C++, and MATLAB®. This paper reports on how the capabilities of MATLAB® have been synergized with learning activities and homework assignments to set the stage for a successful final engine simulation project. The MATLAB® code involved in this effort can accept basic input parameters such as bore, stroke, compression ratio, spark advance, throttle position, RPM, air/fuel equivalence ratio, and volumetric efficiency. The code returns output power and torque using the Wiebe function and bulk temperature. The model uses a two-zone heat release model to predict power, torque, brake specific fuel consumption, and volumetric emissions.

This paper presents an analysis of the theory of the hydraulic dynamometer, the specific objective being to derive an expression for the capacity constant K in the well-known equation T = KN2D5 in terms of the relevant parameters. The major conclusion is that K is fundamentally a function of only five factors, all of which are discussed fully. The interrelation among the various factors is explained in detail. Based on certain simplifications, an experimental technique is suggested, from which a rational design of dynamometers becomes possible.

Analyses of some of available experimental results suggest that frontal and rear-end automobile collision processes may be simulated by a simple model with a mass, which represents the vehicle mass, and a spring, which represents the resisting force due to crushing of the vehicle structure. Indications are that in the case of barrier and head-on collisions, the spring is one-way linear, and the rate does not vary with colliding speeds provided that the type of vehicle and the mode of collisions remain the same. On the other hand, in the case of rear-end collisions, experiments indicate that the spring is almost rigid-plastic. The occupant's motion was also studied by a simulated model. A parametric study was made to obtain a design criterion for safety harnesses and vehicle interior geometry relative to occupants for injury reduction.

Battery electric transit buses sold in Canada generally include a fuel-fired diesel auxiliary heater for cabin heating in cold weather. This report details a test project, performed in collaboration with OC Transpo, to capture and quantify the emissions from such a fuel-fired heater (FFH) installed on a New Flyer XE40 battery electric transit bus from OC Transpo’s fleet in Ottawa, Canada. The FFH was tested while the bus was both stationary and being driven on-road in cold conditions. The results include the emissions rates of carbon dioxide, carbon monoxide, nitrogen oxides, hydrocarbons and methane, and soot. Additionally, total particulate matter results were obtained during stationary testing. The results of stationary testing were compared to the California Air Resources Board and European Union standards for FFH emissions, even though these standards do not apply directly to buses operated outside of these jurisdictions.

A new way of representing tyre data obtained from measurements in pure cornering and pure braking conditions has been developed in order to further improve the Dynamic Safety of vehicles. The method makes use of a formula with coefficients which describe some of the typifying quantities of a tyre, such as slip stiffnesses at zero slip and force and torque peak values. The formula is capable of describing the characteristics of side force, brake force and self aligning torque with great accuracy. This mathematical representation is limited to steady-state conditions during either pure cornering or pure braking and forms the basis for a model describing tyre behaviour during combined braking and cornering.

In this paper, the effects of tire cornering stiffness on vehicle frequency responses have been investigated. The high speed force and moment test data of four different groups of tires were collected. These tires had different constructions and wide ranges of cornering stiffness. The tire nonlinear lateral force and aligning moment were modeled using the Pacejka Magic Formula tire model. Based on a full nonlinear vehicle model, vehicle linear handling performance was simulated with the above tires during pulse steer and step steer maneuvers. To evaluate the vehicle linear handling performance, the following vehicle dynamic parameters were selected: sideslip angle, yaw rate peak time, phase lags of yaw rate and lateral acceleration, yaw rate gain, yaw damping ratio and natural frequency. The sideslip angle and yaw rate peak time were obtained from the vehicle responses to a step steer input.

Frontal crashes and near-side crashes were compared and found to be significantly different events. In a frontal crash, the energy to be dissipated from the occupant is constant for a given speed. In a side crash, the energy transferred to a struck-side occupant depends highly on his interaction with the door. That difference has important implications on the choice of countermeasures, injury criteria, and subsystem tests. In a frontal crash, chest and abdominal injuries occur in the “second” impact when the occupant, acting like a free-flight mass, strikes the interior. Padding can absorb some of the free-flight energy, reduce the impact force, and provide earlier and longer contact of the occupant with the interior. The earlier contact decreases the differential velocity of the occupant to the interior, and the longer contact allows more time and greater distance to dissipate the kinetic energy.

This paper presents a practical analytical approach for evaluating sideswipe collision severity from residual vehicular deformation. A simplified mathematical procedure was developed to evaluate vehicular speed changes, effective average vehicular acceleration rates and the collision duration from measurements of vehicular damage. Several series of sideswipe collisions were staged to acquire empirical sliding contact data. The results of this testing were employed to provide a preliminary validation of the proposed analysis model. The limited validation supported the use of the proposed analysis technique to assess a vehicle's speed change resulting from a sideswipe collision.

Performing a reconstruction of sideswipe interactions is difficult due to the lack of permanent crush sustained by the vehicles involved. Previous studies have provided insight into the forces involved in creating various types of damage for vehicle-to-vehicle interactions during a sideswipe interaction. However, these data may not be applicable to the interaction that occurs when a tractor-trailer steer tire is involved. As demonstrated in previous studies, steer tire interaction produces a unique pattern of markings on the struck vehicle by the protruding lugs (wheel stud) of the steer tire. These studies have demonstrated that the pattern of cycloidal marks created by the wheel lugs can be used to calculate the relative speeds of the vehicles. While this is helpful in understanding the relative motion of the vehicles, it does not provide information regarding the forces applied at the point of contact.

Vehicle to vehicle sideswipe collisions may involve contact between a vehicle body and a contacting vehicle's rotating wheels, tires and lug nuts. During a sideswipe collision between a truck and an automobile it is not uncommon to see lug marks in the shape of consecutive damage loops or strikes on the side of the impacted vehicle. The damage loops or strikes are generated by the protruding lug nuts of the truck wheel as it passes by the impacted vehicle at a shallow angle. Additionally, rubber transfers due to contact with the tire sidewall and metal scraping from the wheel rim also leave distinctive shapes on the sides of the contacted vehicle body. The tire, rim, lug nut markings and associated damage manifest themselves as a special case of the epitrochoid and can be geometrically and mathematically described. Presented is a derivation of the equations that govern the lug, rim and tire positions and relative motions.

There have been a number of papers written about the dynamic effects of low speed front to rear impacts between motor vehicles during the last several years. This has been an important issue in the field of accident analysis and reconstruction because of the frequency with which the accidents occur and the costs of injuries allegedly associated with them. Sideswipe impacts are another, often minor, type of motor vehicle impact that generate a significant number of injury claims. These impacts are difficult to analyze for a number of reasons. First, there have been very few studies in the literature describing the specific dynamic effects of minor sideswipe impacts on the struck vehicles and their occupants. Those that have been performed have focused on the impact of two passenger cars.

Due to the compact structure of the Bacha Racing vehicle, the continuously variable transmission (CVT) serves as a crucial transmission component. It is essential to tune and verify its performance to ensure the power matching and transmission efficiency of the entire vehicle. This paper conducts a kinematic analysis of CVT based on transmission theory, designs real vehicle traction experiments, and CVT bench tests. Additionally, it proposes a method to utilize Hall sensors for real-time monitoring of CVT motion to assist in its tuning. The results demonstrate that the optimal performance tuning of the CVT for the Bacha Racing vehicle has been achieved through various experiments.