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Technical Paper

A Survey of Vehicle Dynamics Models for Autonomous Driving

2024-04-09
2024-01-2325
Autonomous driving technology is more and more important nowadays, it has been changing the living style of our society. As for autonomous driving planning and control, vehicle dynamics has strong nonlinearity and uncertainty, so vehicle dynamics and control is one of the most challenging parts. At present, many kinds of specific vehicle dynamics models have been proposed, this review attempts to give an overview of the state of the art of vehicle dynamics models for autonomous driving. Firstly, this review starts from the simple geometric model, vehicle kinematics model, dynamic bicycle model, double-track vehicle model and multi degree of freedom (DOF) dynamics model, and discusses the specific use of these classical models for autonomous driving state estimation, trajectory prediction, motion planning, motion control and so on.
Technical Paper

Identification of Low Vibration Damping Areas on Automotive Door Panel and Improvement Using Natural Fibers

2024-04-09
2024-01-2338
Vibrations constitute a pivotal factor affecting passenger comfort and overall vehicle performance in both Conventional Internal Combustion Engine (ICE) vehicles and Electric Vehicles (EVs). These vibrations emanate from various sources, including vehicle design and construction, road conditions, and driving patterns, thereby leading to passenger discomfort and fatigue. In the pursuit of mitigating these issues, natural fibers, known for their exceptional damping properties, have emerged as innovative materials for integration into the automotive industry. Notably, these natural fiber-based materials offer a cost-effective alternative to traditional materials for vibration reduction. This research focuses on evaluating natural fibers mainly hemp, jute and cotton fibers for their damping characteristics when applied to a steel plate commonly used in the automotive sector.
Technical Paper

Energy Dissipation Characteristics Analysis of Automotive Vibration PID Control Based on Adaptive Differential Evolution Algorithm

2024-04-09
2024-01-2287
To address the issue of PID control for automotive vibration, this paper supplements and develops the evaluation of automotive vibration characteristics, and proposes a vibration response quantity for evaluating the energy dissipation characteristics of automotive vibration. A two-degree-of-freedom single wheel model for automotive vibration control is established, and the conventional vibration response variables for ride comfort evaluation and the energy consumption vibration response variables for energy dissipation characteristics evaluation are determined. This paper uses the Adaptive Differential Evolution (ADE) algorithm to tune the PID control parameters and introduces an adaptive mutation factor to improve the algorithm's adaptability. Several commonly used adaptive mutation factors are summarized in this paper, and their effects on algorithm improvement are compared.
Technical Paper

Parameter Identification of Constitute Model of Glass Fiber Reinforced Polypropylene under Adiabatic Temperature Rise Loads

2024-04-09
2024-01-2355
To characterize the stress flow behavior of engineering plastic glass fiber reinforced polypropylene (PPGF) commonly used in automotive interior and exterior components, mechanical property is measured using a universal material testing machine and a servo-hydraulic tensile testing machine under quasi-static, high temperature, and high strain rate conditions. Stress versus strain curves of materials under different conditions are obtained. Based on the measured results, a new parameter identification method of the Johnson-Cook (J-C) constitutive model is proposed by considering the adiabatic temperature rise effect. Firstly, a material-level experiment method is carried out for glass fiber reinforced polypropylene (PPGF) materials, and the influence of wide strain rate range, and large temperature span on the material properties is studied from a macroscopic perspective.
Technical Paper

A Holistic Approach to Mitigating Warpage in Fiber-Reinforced Plastic Injection Molding for Automotive Applications

2024-04-09
2024-01-2358
Fiber-reinforced plastics (FRPs), produced through injection molding, are increasingly preferred over steel in automotive applications due to their lightweight, moldability, and excellent physical properties. However, the expanding use of FRPs presents a critical challenge: deformation stability. The occurrence of warping significantly compromises the initial product quality due to challenges in part mounting and interference with surrounding parts. Consequently, mitigating warpage in FRP-based injection parts is paramount for achieving high-quality parts. In this study, we present a holistic approach to address warpage in injection-molded parts using FRP. We employed a systematic Design of Experiments (DOE) methodology to optimize materials, processes, and equipment, with a focus on reducing warpage, particularly for the exterior part. First, we optimized material using a mixture design in DOE, emphasizing reinforcements favorable for warpage mitigation.
Technical Paper

Development of a Dual Motor Beam eAxle for Medium Duty Commercial Vehicle Application

2024-04-09
2024-01-2162
Considering the current trend towards the electrification of commercial vehicles, the development of Beam eAxle solutions has become necessary. The utilization of an electric drive unit in heavy-duty solid axle-based commercial vehicles presents unique and demanding challenges. These include the necessity for elevated peak and continuous torque while meeting packaging constraints, structural integrity requirements, and extended service life. One such solution was developed by BorgWarner to address these challenges. This paper offers a comprehensive overview of the design and development process undertaken for this Dual Motor Beam eAxle system. This includes the initial comparison of various eAxle solutions, the specifications of components selected for this design, and the initial results from dyno and vehicle development.
Technical Paper

Enhancement of Physical and Mechanical Attributes of a Natural Fiber-Reinforced Composite for Engineering Applications

2024-04-09
2024-01-2237
A natural fiber based polymer composite has the advantage of being more environment-friendly from a life cycle standpoint when compared to composites reinforced with widely-used synthetic fibers. The former category of composites also poses reduced health risks during handling, formulation and usage. In the current study, jute polymer laminates are studied, with the polymeric resin being a general purpose polyester applied layer-by-layer on bi-directionally woven jute plies. Fabrication of flat laminates following the hand layup method combined with compression molding yields a jute polymer composite of higher initial stiffness and tensile strength, compared to commonly used plastics, coupled with consistency for engineering design applications. However, the weight-saving potential of a lightweight material such as the current jute-polyester composite can be further enhanced through improvement of its behavior under mechanical loading.
Technical Paper

Advanced Development of e-HMI Road Content Projection Headlamp

2024-04-09
2024-01-2232
Recently, with the advancement of autonomous driving technology, the function of external lamps has been changed. Previously, the focus was on the visibility of drivers, but with the advancement of autonomous driving technology, the concept of autonomous driving systems has been developed. Accordingly, the trend of automotive lamp lighting systems has been developed in terms of design, e-HMI (exterior-human machine interface), It is developing in accordance with three major fields such as sensor connection. Therefore, this paper will cover the prior development of road content projection headlamps that enable e-HMI implementation to reflect these new trends. Since the technology is mass-produced and sold by several manufacturers, our company also needs to quickly develop and apply the technology in advance. Only four types of symbols are allowed in European law.
Technical Paper

Bridging the Design Gap: Next-Level Automation in Automotive Design with the IncQuery AUTOSAR-UML Bridge

2024-04-09
2024-01-2050
The IncQuery AUTOSAR-UML Bridge is an innovative solution for Assisted Documentation Creation and Automated Handover, aiming at driving a paradigm shift in integrated digital engineering in the automotive domain. The AUTOSAR-UML Bridge is addressing a well-known gap in the engineering ecosystem of automotive design, where the co-design of AUTOSAR models and other model-based artifacts is often hampered by tedious workflows involving manual syncing of model contents between AUTOSAR and UML/SysML tools. The Bridge is aiming at streamlining the workflow by generating high-quality UML models from AUTOSAR projects, with built-in ISO26262 and ASPICE compliance. Automotive software architects and systems engineers spend a lot of time with creating ISO26262-compliant documentation, by creating UML models from AUTOSAR architecture designs, or establishing traceability between requirements captured in SysML and design artefacts that exist in both modeling languages.
Technical Paper

Art Meets Automotive: Design of a Curve-Adaptive Origami Gripper for Handling Textiles on Non-Planar Mold Surfaces

2024-04-09
2024-01-2575
The handling of flexible components creates a unique problem set for pick and place automation within automotive production processes. Fabrics and woven textiles are examples of flexible components used in car interiors, for air bags, as liners and in carbon-fiber layups. These textiles differ greatly in geometry, featuring complex shapes and internal slits with varying material properties such as drape characteristics, crimp resistance, friction, and fiber weave. Being inherently flexible and deformable makes these materials difficult to handle with traditional rigid grippers. Current solutions employ adhesive, needle-based, and suction strategies, yet these systems prove a higher risk of leaving residue on the material, damaging the weave, or requiring complex assemblies. Pincer-style grippers are suitable for rigid components and offer strong gripping forces, yet inadvertently may damage the fabric, and introduce wrinkles / folded-over edges during the release process.
Technical Paper

Anisotropic Material Behavior of 3D Printed Fiber Composites

2024-04-09
2024-01-2573
Literature has shown that 3D printed composites may have highly anisotropic mechanical properties due to variation in microstructure as a result of filament deposition process. Laminate composite theory, which is already used for composite products, has been proposed as an effective method for quantifying these mechanical characteristics. Continuous fiber composites traditionally have the best mechanical properties but can difficult or costly to manufacture, especially when attempting to use additive manufacturing methods. Traditionally, continuous fiber composites used specialized equipment such as vacuum enclaves or labor heavy hand layering techniques. An attractive alternative to these costly techniques is modifying discontinuous fiber additive manufacturing methods into utilizing continuous fibers. Currently there exist commercial systems that utilize finite-deposition (FD) techniques that insert a continuous fiber braid into certain layers of the composite product.
Technical Paper

FRAM Optimization: 3D Print Orientation and Concurrent Topology Optimization for Minimize Mass Problem Statements

2024-04-09
2024-01-2577
Fiber reinforced additive manufacturing (FRAM) is a fused deposition modelling (FDM) additive manufacturing (AM) process which produces composite print layers - polymer matrix and reinforcing fiber. This work proposes a novel method which utilizes FRAM design freedom and simultaneously optimizes 3D print orientation and component topology to improve the response of a mass minimization problem statement. The method is robust and is designed to solve industry-applicable problem statements (mass minimization) with complex geometry and loading. Design sensitivities of 3D print orientation design variables, (θ1, θ2, θ3), are calculated using finite differencing and gradient descent is used to converge to an optimized print orientation. Changing 3D print orientation alters anisotropic material properties to improve the structural response of the component in the prescribed load-cases.
Technical Paper

Quantifying uncertainty in bicycle-computer position measurements

2024-04-09
2024-01-2486
Bicycle computers record and store global position data that can be useful for forensic investigations. The goal of this study was to estimate the absolute error of the latitude and longitude positions recorded by a common bicycle computer over a wide range of riding conditions. We installed three Garmin Edge 530 computers on the handlebars of a bicycle and acquired 9 hours of static data and 96 hours (2214 km) of dynamic data using three different navigation modes (GPS, GPS+GLONASS, and GPS+Galileo satellite systems) and two geographic locations (Vancouver, BC, Canada and Orange County, CA, USA). We used the principle of error propagation to calculate the absolute error of this device from the relative errors between the three pairs of computers. During the static tests, we found 16 m to 108 m of drift during the first 4 min and 1.4 m to 5.0 m of drift during a subsequent 8 min period. During the dynamic tests, we found a 95th percentile absolute error for this device of ±8.04 m.
Technical Paper

A Novel Approach for Mechanical Characterization of Angle-Ply Composite Laminates

2024-04-09
2024-01-2435
​Composites made of continuous fibers generally have higher strength-to-weight ratios in fiber directions as compared to those made of discontinuous fibers. However, the latter tend to display quasi-isotropic properties which can be of advantage when directions of mechanical loading can vary. For many real-world applications such as robust design of vehicle body components for crashworthiness, impact loads are stochastic in nature both in terms of magnitude and direction. Hence, in order to realize the true potential of laminated composites with continuous fibers, instead of orthotropic laminates which are most common due to the ease of design and manufacturing, angle-ply laminates are necessary.
Technical Paper

A Holistic Approach to Next-Generation Polymer Composite Pickup Bed Development and Prototyping

2024-04-09
2024-01-2432
As we move toward electrification in future mobility, weight and cost reduction continue to be priorities in vehicle development. This has led to continued interest in advanced molding processes and holistic design to enable polymer materials for demanding structural applications such as pickup truck beds. In addition to performance, it is necessary to continue to improve styling, functionality, quality, and sustainability to exceed customer expectations in a competitive market. To support development of a lightweight truck bed design, a cross-functional team objectively explored the latest materials and manufacturing technologies relevant to this application. In Phase 1 of this work, the team considered a variety of alternatives for each functional area of the bed, including thermoplastic and thermoset materials with a range of processing technologies.
Technical Paper

Experimental and Numerical Momentum Flux Analysis of Jets from a Hydrogen Injector

2024-04-09
2024-01-2616
The use of hydrogen in internal combustion engines is an effective approach to significantly support the reduction of CO2 emissions from the transportation sector using technically affordable solutions. The use of direct injection is the most promising approach to fully exploit hydrogen potential as a clean fuel, while preserving targets in terms of power density and emissions. In this frame, the development of an effective combustion system largely relies on the hydrogen-air mixture formation process, so to adequately control the charge stratification to mitigate pre-ignitions and knock and to minimize NOx formation. Hence, improving capabilities of designing a correct gas jet-air interaction is of paramount importance. In this paper the analysis of the evolution of a high-pressure gas jet produced by a single-hole prototype injector operated with different pressure ratios is presented.
Technical Paper

Applying Concolic Testing to the Automotive Domain

2024-04-09
2024-01-2802
Symbolic code execution is a powerful cybersecurity testing approach that facilitates the systematic exploration of all paths within a program to uncover previously unknown cybersecurity vulnerabilities. This is achieved through a Satisfiability Modulo Theory (SMT) solver, which operates on symbolic values for program inputs instead of using their concrete counterparts. However, in complex code bases, this approach faces significant limitations, such as program path explosions or unavailable dependencies, which can result in conditions that the SMT solver cannot reason about. Consequently, SMT solvers are often considered as too costly to implement for automotive testing use cases and are rarely employed within this domain. In contrast, fuzz testing has recently gained traction in the automotive industry as an invaluable testing technique for identifying previously unknown vulnerabilities. Its initial setup is straightforward and typically yields useful findings.
Technical Paper

Wheel Drive Unit Lift Corrections in Automotive Wind Tunnels

2024-04-09
2024-01-2544
Correct simulations of rotating wheels are essential for accurate aerodynamic investigations of passenger vehicles. Therefore, modern automotive wind tunnels are equipped with five-belt moving ground systems with wheel drive units (WDUs) connected to the underfloor balance. The pressure distribution on the exposed areas of the WDU belts results in undesired lift forces being measured which must be considered to obtain accurate lift values for the vehicle. This work investigates the parasitic WDU lift for various configurations of a crossover SUV using numerical simulations that have been correlated to wind tunnel data. Several parameters were considered in the investigation, such as WDU size, WDU placement, tyre variants and vehicle configurations. The results show that the parasitic lift is more sensitive to the width than the length of the WDU. However, the belt length is also important to consider, especially if the wheel cannot be placed centred.
Technical Paper

Estimation of Poroelastic Material Properties of Noise Control Treatments Using Model Order Reduction

2024-04-09
2024-01-2336
Noise reduction is generally accomplished by applying appropriate noise control treatments at strategic locations. Noise control treatments consisting of poroelastic materials in layers are extensively used in noise control products. Sound propagation through poroelastic materials is governed by macroscopic material and geometric properties. Thus, a knowledge of material properties is important to improve the acoustical performance of the resulting noise control products. Since the direct measurement of these properties is cumbersome, these have been usually estimated indirectly from easily measurable acoustic performance metrics such as normal incidence sound transmission and/or absorption coefficient, measured using readily available impedance tube. The existing inverse characterization approaches fulfilled the estimation by curve fitting measured and predicted acoustic models.
Technical Paper

Vehicle Accelerations during Common Maneuvers: Speed Bumps, Dips, and Parking Blocks

2024-04-09
2024-01-2480
Typical everyday driving scenarios involve acceleration ranges which are relevant to accident reconstruction. Understanding the motions and accelerations endured in common driving maneuvers can help quantify the accelerations of vehicles and occupants when reconstructing a collision. This paper evaluates various everyday driving conditions, such as traversing speed bumps and dips, and impacting parking blocks. The purpose of this paper is to quantify the accelerations experienced during everyday driving scenarios to provide a reference for impact severity analysis in the field of accident reconstruction.
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