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Emissions of particulate matter, or PM, due to brake wear, are not well quantified in current air pollutant emission inventories. Current emission factor models need to be updated to reflect new technologies and materials and to incorporate the effects of changing driving habits and speeds. While emission regulations drive technical innovations that are significantly reducing PM emissions in vehicle exhaust, non-exhaust automotive emissions remain unregulated. Current emission factor models need to be updated to reflect the changes caused by new technologies, materials, and speed-dependent vehicle usage. Most research regarding brake emissions relies on a laboratory setting. Laboratory testing has allowed researchers, application engineers, data modeling engineers, and environmental agencies to generate large datasets for multiple vehicle configurations and friction couple designs.

There is a distinct difference between plug-in hybrid electric vehicles in the market today. One key distinction that can be made is to classify a plug-in hybrid electric vehicle (PHEV) according to its operational behavior in charge depleting (CD) mode. Some PHEVs are capable of using the electric-only propulsion system to achieve all-electric operation for all driving conditions in CD mode, including full power performance. In contrast, some PHEVs, henceforth termed “blended PHEVs”, cannot satisfy the power requirements of all driving conditions with the electric-only propulsion system and occasionally utilize blended CD operation whereby it is necessary to blend the use of the internal combustion (IC) engine with the use of the electric motor(s) to help power the vehicle.

Injury Risk Curves are developed from cadaver data for sternal deflections produced by anterior, distributed chest loads for a 25, 45, 55, 65 and 75 year-old Small Female, Mid-Size Male and Large Male based on the variations of bone strengths with age. These curves show that the risk of AIS ≥ 3 thoracic injury increases with the age of the person. This observation is consistent with NASS data of frontal accidents which shows that older unbelted drivers have a higher risk of AIS ≥ 3 chest injury than younger drivers.

Injury risk curves for SID-IIs thorax and abdomen rib deflections proposed for future NCAP side impact evaluations were developed from tests conducted with the SID-IIs FRG. Since the floating rib guide is known to reduce the magnitude of the peak rib deflections, injury risk curves developed from SID-IIs FRG data are not appropriate for use with SID-IIs build level D. PMHS injury data from three series of sled tests and one series of whole-body drop tests are paired with thoracic rib deflections from equivalent tests with SID-IIs build level D. Where possible, the rib deflections of SID-IIs build level D were scaled to adjust for differences in impact velocity between the PMHS and SID-IIs tests. Injury risk curves developed by the Mertz-Weber modified median rank method are presented and compared to risk curves developed by other parametric and non-parametric methods.

In 1983, General Motors Corporation (GM) petitioned the National Highway Traffic Safety Administration (NHTSA) to allow the use of the biofidelic Hybrid III midsize adult male dummy as an alternate test device for FMVSS 208 compliance testing of frontal impact, passive restraint systems. To support their petition, GM made public to the international automotive community the limit values that they imposed on the Hybrid III measurements, which were called Injury Assessment Reference Values (IARVs). During the past 20 years, these IARVs have been updated based on relevant biomechanical studies that have been published and scaled to provide IARVs for the Hybrid III and CRABI families of frontal impact dummies. Limit values have also been developed for the biofidelic side impact dummies, BioSID, ES-2 and SID-IIs.

Brake pad to rotor adhesion following exposure to corrosive environments, commonly referred to as “stiction”, continues to present braking engineers with challenges in predicting issues in early phases of development and in resolution once the condition has been identified. The goal of this study took on two parts - first to explore trends in field stiction data and how testing methods can be adapted to better replicate the vehicle issue at the component level, and second to explore the impacts of various brake pad physical properties variation on stiction propensity via a controlled design of experiments. Part one will involve comparison of various production hardware configurations on component level stiction tests with different levels of prior braking experience to evaluate conditioning effects on stiction breakaway force.

For higher mileage vehicles, noise from contaminant ingress is one of the largest durability issues for wheel bearings. The mileage that wheel bearing sealing issues increase can vary due to multiple factors, such as the level of corrosion for the vehicle and the mating components around the wheel bearing. In general, sealing issues increase after 20,000 to 30,000 km. Protecting the seals from splash is a key step in extending bearing life. Benchmarking has shown a variety of different brake corner designs to protect the bearing from splash. This report examines the effect of factors from different designs, such as the radial gap between constant velocity joint (CVJ) slinger and the knuckle, knuckle labyrinth height and varying slinger designs to minimize the amount of splash to the bearing inboard seal. This report reviews some of the bearing seal failure modes caused by splash.

The strong focus on reducing brake drag, driven by a historic ramp-up in global fuel economy and carbon emissions standards, has led to renewed research on brake caliper drag behaviors and how to measure them. However, with the increased knowledge of the range of drag behaviors that a caliper can exhibit comes a particularly vexing problem - how should this complex range of behaviors be represented in the overall road load of the vehicle? What conditions are encountered during coastdown and fuel economy testing, and how should brake drag be measured and represented in these conditions? With the Environmental Protection Agency (amongst other regulating agencies around the world) conducting audit testing, and the requirement that published road load values be repeatable within a specified range during these audits, the importance of answering these questions accurately is elevated. This paper studies these questions, and even offers methodology for addressing them.

The measurement of SO2 levels in vehicle exhaust can provide important information in understanding the relative contribution of sulfur and sulfate from fuel vs. oil source to PM. For this study, a differential optical absorption spectrometer (DOAS) that can measure SO2 down to 20 ppbV in real-time was built and evaluated. The DOAS consisted of an extractive sampling train, a cylindrical sampling cell with a single-path design to minimize cell volume, a spectrometer, and a deuterium lamp light source with a UVC range of ∼200-230 nanometer (nm). Laboratory tests showed detection limits were approximately in the range of 12 to 15 ppbV and showed good linearity over SO2 concentration ranges of 20 to 953 ppbV. Interference tests showed some interference by NO and by NH3, at levels of 300 ppmV and 16.6 ppmV, respectively.

Present motor vehicle particulate matter (PM) emission measurement regulations (Code of Federal Regulations (CFR) 40 Part 1065, 1066) require gravimetric determination of PM mass collected onto filter media from dilute exhaust. To improve the current sampling and measurement procedures for TIER 3 PM emissions standard of 3 mg/mile, CFR part 1066 adopted five alternative PM sampling options. One option of great interest is sampling the entire test using a single flow-weighed filter rather than the conventional three-filter (one filter per test phase) approach. The single filter method could lessen the time needed for gravimetric determination by reducing the quantity of filters used for a test and possibly reduce the uncertainty in gravimetric measurements, particularly at sub 1 mg/mile PM levels. This study evaluates the single filter and, to a limited extent, the 2-filter alternatives adopted in 40 CFR Part 1066.

The human thermal comfort, which has been a subject of extensive research, is a principal objective of the automotive climate control system. Applying the results of research studies to the practical problems require quantitative information of the thermal environment in the passenger compartment of a vehicle. The exposure to solar radiation is known to alter the thermal environment in the passenger compartment. A photovoltaic-cell based sensor is commonly used in the automotive climate control system to measure the solar radiation exposure of the passenger compartment of a vehicle. The erroneous information from a sensor however can cause thermal discomfort to the occupants. The erroneous measurement can be due to physical or environmental parameters. Shading of a solar sensor due to the opaque vehicle body elements is one such environmental parameter that is known to give incorrect measurement.

The Chevrolet Volt is an electric vehicle with extended-range that is capable of operation on battery power alone, and on engine power after depletion of the battery charge. First generation Chevrolet Volts were driven over half a billion miles in North America from October 2013 through September 2014, 74% of which were all-electric [1, 12]. For 2016, GM has developed the second-generation of the Volt vehicle and “Voltec” propulsion system. By significantly re-engineering the traction power inverter module (TPIM) for the second-generation Chevrolet Volt extended-range electric vehicle (EREV), we were able to meet all performance targets while maintaining extremely high reliability and environmental robustness. The power switch was re-designed to achieve efficiency targets and meet thermal challenges. A novel cooling approach enables high power density while maintaining a very high overall conversion efficiency.

The vehicle air-conditioning system has significant impact on fuel economy and range of electric vehicles. Improving the fuel economy of vehicles therefore demand for energy efficient climate control systems. Also the emissions regulations motivate the reduced use of fuel for vehicle's cabin climate control. Solar heat gain of the passenger compartment by greenhouse effect is generally treated as the peak thermal load of the climate control system. Although the use of advanced glazing is considered first to reduce solar heat gain other means such as ventilation of parked car and recirculation of cabin air also have impetus for reducing the climate control loads.

In addition to the thermal comfort of the vehicle occupants, their safety by ensuring adequate visibility is an objective of the automotive climate control system. An integrated dew point and glass temperature sensor is widely used among several other technologies to detect risk of fog formation on the cabin side (or inner) surface of the windshield. The erroneous information from a sensor such as the measurement lag can cause imperfect visibility due to the delayed response of the climate control system. Also the high value, low cost vehicles may not have this sensor due to its high cost. A differential equation based model of the cabin air humidity is proposed to calculate in real-time specific humidity of the passenger compartment air. The specific humidity is used along with the windshield surface temperature to determine relative humidity of air and therefore, the risk of fog formation on the interior surface of a windshield.

A novel ambient dilution tunnel has been designed, tested and employed to measure the emissions from active parked regenerations of Diesel Particulate Filters (DPFs) for 2007 and 2010 certified heavy duty diesel trucks (HDDTs). The 2007 certified engine had greater regulated emissions than the 2010 certified engine. For a fully loaded 2007 DPF there was an initial period of very large mass emissions, which was then followed by very large number of small particle emissions. The Particle Size Distribution, PSD, was distributed over a large range from 10 nm to 10 μm. The parked regenerations of the 2010 DPF had a much lower initial emission pattern, but the second phase of large numbers of small particles was very similar to the 2007 DPF. The emission results during regeneration have been compared to total emissions from recent engine dynamometer testing of 2007 and 2010 DPFs, and they are much larger.

The California Air Resources Board (CARB) adopted the Low Emission Vehicle (LEV) III regulations in January 2012, which lowered the particulate matter (PM) emissions standards for light-duty vehicles (LDVs) from 10 milligrams per mile (10 mg/mile) to 3 mg/mile beginning with model year (MY) 2017 and 1 mg/mile beginning with MY 2025. To confirm the ability to measure PM emissions below 1 mg/mile, a total of 23 LDVs (MY pre-2004 to 2009) were tested at CARB's Haagen-Smit Laboratory (HSL) (10 LDVs) and the United States Environmental Protection Agency's (US EPA) National Vehicle and Fuel Emissions Laboratory (NVEFL) (13 LDVs) using the federal test procedure (FTP) drive schedule. One LDV with PM emissions ranging from 0.6 - 0.8 mg/mile was tested at three CARB HSL test cells to investigate intra-lab and inter-lab variability. Reference, trip, and tunnel filter blanks were collected as part of routine quality control (QC) procedures.

This study provides one of the first evaluations of the integrated particle size distribution (IPSD) method in comparison with the current gravimetric method for measuring particulate matter (PM) emissions from light-duty vehicles. The IPSD method combines particle size distributions with size dependent particle effective density to determine mass concentrations of suspended particles. The method allows for simultaneous determination of particle mass, particle surface area, and particle number concentrations. It will provide a greater understanding of PM mass emissions at low levels, and therefore has the potential to complement the current gravimetric method at low PM emission levels. Six vehicles, including three gasoline direct injected (GDI) vehicles, two port fuel injected (PFI) vehicles, and one diesel vehicle, were tested over the Federal Test Procedure (FTP) driving cycle on a light-duty chassis dynamometer.

This paper covers work performed for the California Air Resources Board and US Environmental Protection Agency by Southwest Research Institute. Emission measurements were made on four in-use off-road two-stroke motorcycles and all-terrain vehicles utilizing oxygenated and non-oxygenated fuels. Emission data was produced to augment ARB and EPA's off-road emission inventory. It was intended that this program provide ARB and EPA with emission test results they require for atmospheric modeling. The paper describes the equipment and engines tested, test procedures, emissions sampling methodologies, and emissions analytical techniques. Fuels used in the study are described, along with the emissions characterization results. The fuel effects on exhaust emissions and operation due to ethanol content and fuel components is compared.

This paper covers work performed for the California Air Resources Board and the United States Environmental Protection Agency by Southwest Research Institute. Emission measurements were made on nine types of off-road equipment with small (<19kW) spark-ignited engines including handheld and non-handheld equipment utilizing oxygenated and non-oxygenated fuels. Emission data was produced to augment ARB and EPA's off-road emission inventory. It was intended that this program provide ARB and EPA with emission test results they require for atmospheric modeling. The paper describes the equipment and engines tested, test procedures, emissions sampling methodologies, and emissions analytical techniques. Fuels used in the study are described, along with the emissions characterization results. The fuel effects on exhaust emissions and operation due to ethanol content and fuel components is compared.

The study was aimed at assessing in-use emissions of a USEPA 2010 emissions-compliant heavy-duty diesel vehicle powered by a model year (MY) 2011 engine using West Virginia University's Transportable Emissions Measurement System (TEMS). The TEMS houses full-scale CVS dilution tunnel and laboratory-grade emissions measurement systems, which are compliant with the Code of Federal Regulation (CFR), Title 40, Part 1065 [1] emissions measurement specifications. One of the specific objectives of the study, and the key topic of this paper, is the quantification of greenhouse gas (GHG) emissions (CO2, N2O and CH4) along with ammonia (NH3) and regulated emissions during real-world operation of a long-haul heavy-duty vehicle, equipped with a diesel particulate filter (DPF) and urea based selective catalytic reduction (SCR) aftertreatment system for PM and NOx reduction, respectively.