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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.

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.

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 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.

A method of developing more representative test factors and respective minimum cycles is proposed in practices such as J328 and J2530. The method includes recent 6061-T6 material fatigue characterization from specimens originating in wheels. The characterization uses a fully reversed (R=−1) loading method and the specimen is in un-notched condition. Results of finite element analyses of different wheel designs are observed to verify the proposition of usage of R= −1 as appropriate for such material characterization. The results of recent fatigue response of 6061-T6 indicate that the accelerated test load factors found in SAE J328 and SAE J2530 can be reduced by 10%, while rendering at least the same structural margin as that of other ferrous and nonferrous materials. SAE J2562 illustrates a methodology for testing the structural adequacy of a wheel design using loads and cycles that more closely replicate on-vehicle service than those of J328 and J2530.

The development of the WorldSID 50th percentile male dummy was initiated in 1997 by the International Organization for Standardization (ISO/SC12/TC22/WG5) with the objective of developing a more biofidelic side impact dummy and supporting the adoption of a harmonized dummy into regulations. More than 45 organizations from all around the world have contributed to this effort including governmental agencies, research institutes, car manufacturers and dummy manufacturers. The first production version of the WorldSID 50th male dummy was released in March 2004 and demonstrated an improved biofidelity over existing side impact dummies. Full-scale vehicle tests covering a wide range of side impact test procedures were performed worldwide with the WorldSID dummy. However, the vehicle safety performance could not be assessed due to lack of injury risk curves for this dummy. The development of these curves was initiated in 2004 within the framework of ISO/SC12/TC22/WG6 (Injury criteria).

Automotive engines are regularly utilized in the material handling market where LPG is often the primary fuel used. When compared to gasoline, the use of gaseous fuels (LPG and CNG) as well as alcohol based fuels, often result in significant increases in valve seat insert (VSI) and valve face wear. This phenomenon is widely recognized and the engine manufacturer is tasked to identify and incorporate appropriate valvetrain material and design features that can meet the ever increasing life expectations of the end-user. Alternate materials are often developed based on laboratory testing – testing that may not represent real world usage. The ultimate goal of the product engineer is to utilize accelerated lab test procedures that can be correlated to field life and field failure mechanisms, and then select appropriate materials/design features that meet the targeted life requirements.

The auto industry has had decades of experience with designing safe vehicles. The introduction of highly integrated features brings new challenges that require innovative adaptations of existing safety methodologies and perhaps even some completely new concepts. In this paper, we describe some of the new challenges that will be faced by all OEMs and suppliers. We also describe a set of generic top-level potential hazards that can be used as a starting point for the Preliminary Hazard Analysis (PHA) of a vehicle software-intensive motion control system. Based on our experience with the safety analysis of a system of this kind, we describe some general categories of hazard causes that are considered for software-intensive systems and can be used systematically in developing the PHA.

The purpose of this paper is to present the results of hot surface ignition (HSI) testing and American Society for Testing and Materials (ASTM) auto-ignition testing (AIT) performed on gasoline fuel mixtures containing varying levels of ethanol. With the increased consumer interest in ethanol-based fuels as a measure of reducing the United States dependence on foreign oil, the use of E85 and other ethanol/petroleum fuel blends is on the increase. While some autoignition data for summer and winter blends of gasoline on hot surfaces exist beyond the standard ASTM E659-78 test procedure [1], there is little data on ethanol-based fuels and their HSI characteristics.

By adapting vehicle control systems to the skill level of the driver, the overall vehicle active safety provided to the driver can be further enhanced for the existing active vehicle controls, such as ABS, Traction Control, Vehicle Stability Enhancement Systems. As a follow-up to the feasibility study in [1], this paper provides some recent results on data-driven driving skill characterization. In particular, the paper presents an enhancement of discriminant features, the comparison of three different learning algorithms for recognizer design, and the performance enhancement with decision fusion. The paper concludes with the discussions of the experimental results and some of the future work.

Model-based design is a collection of practices in which a system model is at the center of the development process, from requirements definition and system design to implementation and testing. This approach provides a number of benefits such as reducing development time and cost, improving product quality, and generating a more reliable final product through the use of computer models for system verification and testing. Model-based design is particularly useful in automotive control applications where ease of calibration and reliability are critical parameters. A novel application of the model-based design approach is demonstrated by The Ohio State University (OSU) student team as part of the Challenge X advanced vehicle development competition. In 2008, the team participated in the final year of the competition with a highly refined hybrid-electric vehicle (HEV) that uses a through-the-road parallel architecture.

We start our study with a survey of existing variable valve actuation (VVA) devices. We then describe our work, taken place over a time period from 2001 to 2007, on several VVA concepts. All of our projects described include pre-design modeling and simulation. Also, for each one of the proposed designs, a bench-top motorized test fixture was built and ran for proof of concept. Our projects represent a mixture of exploratory research and production-related development work. They can be classified in four broad categories: discrete-step systems; mechanical continuously-variable systems; active stationary-hydraulic lash adjusters; cam-driven hydraulic-lost-motion mechanism. These devices differ in their complexity and versatility but offer a spectrum of design solutions applicable to a range of products. Specific attributes of these different approaches are analyzed and discussed, and some test results are presented.

In racetrack conditions, brake systems are subjected to extreme energy loads and energy load distributions. This can lead to very high friction surface temperatures, especially on the brake corner that operates, for a given track, with the most available traction and the highest energy loading. Individual brake corners can be stressed to the point of extreme fade and lining wear, and the resultant degradation in brake corner performance can affect the performance of the entire brake system, causing significant changes in pedal feel, brake balance, and brake lining life. It is therefore important in high performance brake system design to ensure favorable operating conditions for the selected brake corner components under the full range of conditions that the intended vehicle application will place them under. To address this task in an early design stage, it is helpful to use brake system modeling tools to analyze system performance.

A task group within the SAE Automotive Corrosion and Protection (ACAP) Committee continues to pursue the goal of establishing a standard test method for in-laboratory cosmetic corrosion evaluations of finished aluminum auto body panels. The program is a cooperative effort with OEM, supplier, and consultant participation and is supported in part by USAMP (AMD 309) and the U.S. Department of Energy. Numerous laboratory corrosion test environments have been used to evaluate the performance of painted aluminum closure panels, but correlations between laboratory test results and in-service performance have not been established. The primary objective of this project is to identify an accelerated laboratory test method that correlates with in-service performance. In this paper the type, extent, and chemical nature of cosmetic corrosion observed in the on-vehicle exposures are compared with those from some of the commonly used laboratory tests

Over the past decade, the automotive industry has seen a rapid decrease in product development cycle time and an ever increasing need by original equipment manufacturers and their suppliers to differentiate themselves in the marketplace. This differentiation is increasingly accomplished by introducing new technology while continually improving the performance of existing automotive systems. In the area of automotive brake system design, and, in particular, the brake apply subsystem, an increased focus has been placed on the development of electrohydraulic apply systems and brake-by-wire systems to replace traditional pneumatic and hydraulic systems. Nevertheless, the traditional brake apply systems, especially vacuum-based or pneumatic systems, will continue to represent the majority of brake apply system production volume into the foreseeable future, which underscores the need to improve the performance and application of these traditional systems in passenger cars and light-trucks.

With increasingly stringent emissions regulations and concurrent requirements for enhanced engine thermal efficiency, a comprehensive characterization of the automotive gasoline fuel spray has become essential. The acquisition of accurate and repeatable spray data is even more critical when a combustion strategy such as gasoline direct injection is to be utilized. Without industry-wide standardization of testing procedures, large variablilities have been experienced in attempts to verify the claimed spray performance values for the Sauter mean diameter, Dv90, tip penetration and cone angle of many types of fuel sprays. A new SAE Recommended Practice document, J2715, has been developed by the SAE Gasoline Fuel Injection Standards Committee (GFISC) and is now available for the measurement and characterization of the fuel sprays from both gasoline direct injection and port fuel injection injectors.

A key element of General Motors' Advanced Propulsion Technology Strategy is the electrification of the automobile. The objectives of this strategy are reduced fuel consumption, reduced emissions and increased energy security/diversification. The introduction of hybrid vehicles was one of the first steps as a result of this strategy. To determine future opportunities and direction, an extensive study was completed to better understand the ability of Plug-in Hybrid Electric Vehicles (PHEV) and Extended-Range Electric Vehicles (E-REV) to address societal challenges. The study evaluated real world representative driving datasets to understand actual vehicle usage. Vehicle simulations were conducted to evaluate the merits of PHEV and E-REV configurations. As derivatives of conventional full hybrids, PHEVs have the potential to deliver a significant reduction in petroleum usage.

Robust assessment using standardized signal-to-noise (SS/N) is a Design For Six Sigma (DFSS) methodology used to assess the mating quality of USCAR electrical connectors. When the insertion force vs. distance relationship is compared to a standard under varying environmental and system-related noise conditions, the ideal function is transformed into a linear relationship between actual and ideal force at the sample points acquired during the mating displacement. Since the ideal function used in the robust assessment of competing designs has a linear slope of 1 through the origin, the SS/N function used is of the form 10 log (1/σ2), also known as nominal-the-best type 2. Using this assessment methodology, designs are compared, with a higher SS/N indicating lower variation from the standard.

The drum brake pulsation is an issue that may cause a major customer complaint. One of the root causes of the drum pulsation is the deformation of the drum to an out of roundness (OOR) shape during the wheel-drum-axle assembly process under the presence of the uneven wheel flatness. This paper summarizes the newly developed OOR simulation method using ABAQUS and the counter-measures to reduce the OOR, and subsequently pulsation, by identifying the drum design parameter effects on OOR.

It is well known that lining reduction through wear affects contact pressure profile and noise generation. Due to high complexity in brake noise analysis, many factors were not included in previous analyses. In this paper, a new analysis process is performed by running brake “burnishing” cycles first, followed by noise analysis. In the paper, brake lining reduction due to wear is assumed to be proportional to the applied brake pressure with ABAQUS analysis. Brake pads go through four brake application-releasing cycles until the linings settle to a more stable pressure distribution. The resulting pressure profiles show lining cupping and high pressure spots shifting. The pressure distributions are compared to TekScan measurements. Brake noise analysis is then conducted with complex eigenvalue analysis steps; the resulting stability chart is better correlated to testing when the wear is comprehended.