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The use of electric vehicles (EV) is becoming more widespread as a response to global warming. The major issues associated with EV are the annoyance represented by charging the vehicles and their limited cruising range. In an attempt to remove the restrictions on the cruising range of EV, the research discussed in this paper developed a dynamic charging EV and low-cost infrastructure that would make it possible for the vehicles to charge by receiving power directly from infrastructure while in motion. Based on considerations of the effect of electromagnetic waves, charging power, and the amount of power able to be supplied by the system, this development focused on a contact-type charging system. The use of a wireless charging system would produce concerns over danger due to the infiltration of foreign matter into the primary and secondary coils and the health effects of leakage flux.

We have developed a bench test method to assess driver distraction caused by the load of using infotainment systems. In a previous study, we found that this method can be used to assess the task loads of both visual-manual tasks and auditory-vocal tasks. The task loads are assessed using the performances of both pedal tracking task (PT) and detection response task (DRT) while performing secondary tasks. We can perform this method using simple equipment such as game pedals and a PC. The aim of this study is to verify the reproducibility of the PT-DRT. Experiments were conducted in three test environments in which test regions, experimenters and participants differed from each other in the US, and the test procedures were almost the same. We set two types of visual-manual tasks and two types of auditory-vocal tasks as secondary tasks and set two difficulties for each task type to vary the level of task load.

The goal of this research topic is to accurately and rapidly evaluate appearance marketability from the point of view of the customer. 3D data has been broadly used in automobile development in recent times, and utilizing digital models built by this data is effective for quickly and definitively evaluating marketability. Therefore, TOPS was developed, an optimal graphic tool for evaluating appearance marketability that anyone can easily use to portray graphics that are equivalent to the actual product. The development of TOPS increased the precision and efficiency of digital development in design.

Catalyst simulation, which can analyze the complicated reaction pathway of exhaust gas purifications and identify the rate-determining step, is an essential tool in the development of catalyst materials. This requires an elementary reaction model which describes the detailed processes, i.e. adsorption, decomposition, and others. In our previous work, the elementary reaction model on Pt/CeO2 catalyst was constructed. In this study, we focused on extending the Zeolite catalyst and including the gas diffusivity through the catalyst layer. The reaction rate of a Zeolite catalyst was expressed by an Arrhenius equation, and the elementary reaction model was composed of 17 reactions. Each Arrhenius parameter was optimized by the catalytic activity measurements. The constructed model was validated with NOx conversion in cyclic experiments which were repeated with Lean phase (NOx adsorption) and Rich phase (NOx reduction).

This paper describes the oil-film bearing analysis simulation was utilized for the optimization of pin boss form which reduces a piston-pin noise. It is clear from the mechanism analysis of the piston-pin noise which is the last research that an oil-film flow inside a pin boss is an important factor for pin noise reduction. So, in this research, the oil-film simulation of the piston-pin-boss bearing part was performed using oil-film bearing analysis tool. After setting up the simulation conditions of the oil-film bearing part so that actual pin behavior and high correlativity might be shown, a parameter, effective hydrodynamic angular velocity, and an oil flow rate of change suitable for evaluation of a pin noise were found out. The pin noise in semi floating piston was reduced to the same level as full floating type by applying pin boss form to which each evaluation parameter becomes the optimal to a piston.

A new piston secondary motion analysis has been developed that accurately predicts piston strength and the slap noise that occurs when the engine is running. For this secondary motion analysis, flexible bodies are used for the models of the piston, cylinder and cylinder head. This makes it possible to quantify the deformations and secondary motion occurring in each area of the engine. The method is a coupled analysis of the structure analysis and the multi body dynamics analysis. The accuracy of the results obtained in the new analysis method was verified by comparing them to measurement data of piston skirt stress and piston secondary motion taken during firing. To measure piston skirt stress, a newly developed battery-powered telemetric measurement system was used. The calculation results were close to the measurement results both for stress and for secondary motion from low to high engine speed.

The development of new design tools to predict the vibro-acoustic behavior within the vehicle development process is of essential importance to achieve better products in an ever shorter timeframe. In this paper, an energy flow post-processing tool for structural dynamic analysis is presented. The method is based on the conversion of conventional finite element (FE) results into energy quantities corresponding with each of the vehicle subcomponents. Based on the global dynamic system behavior and local subcomponent descriptions, one can efficiently evaluate the energy distribution and analyze the vibro-acoustic behavior in complex structures. By using energy as a response variable, instead of conventional design variables as pressure or velocity, one can obtain important information regarding the understanding of the vibro-acoustic behavior of the system.

Competitive pressures, globalization of markets, and integration of new materials and technologies into heavy vehicle suspension systems have increased demand for durability validation of new designs. Traditional Proving Ground and on-road testing for suspension development have the limitations of extremely long test times, poor repeatability and the corresponding difficultly in getting good engineering level data on failures. This test approach requires a complete vehicle driven continuously over severe Proving Ground events for extended periods. Such tests are not only time consuming but also costly in terms of equipment, maintenance, personnel, and fuel. Ideally multiple samples must be tested to accumulate equivalent millions of kilometers of operation in highly damaging environments.

The value of model-based design has been attempted to be communicated for more than a decade. As methods and tools have appeared and disappeared from a series of different vendors it has become apparent that no single vendor has a solution that meets all users’ needs. Recently standards (UML, MDA, MOF, EMF, etc.) have become a dominant force and an alternative to vendor-specific languages and processes. Where these standards have succeeded and vendors have failed is in the realization that they do not provide the answer, but instead provide the foundation to develop the answer. It is in the utilization of these standards and their capability to be customized that companies have achieved success. Customization has occurred to fit organizations, processes, and architectures that leverage the value of model-driven design.

As a virtual manufacturing press line, line die forming simulation provides a full range math-based engineering tool for stamping die developments of automotive structure and closure panels. Much beyond draw-die-only formability analysis that has been widely used in stamping simulation community during the last decade, the line die formability analysis allows incorporating more manufacturing requirements and resolving more potential failures before die construction and press tryout. Representing the most difficult level in formability analysis, conducting line die formability analysis of automotive body side outers exemplifies the greatest technological challenge to stamping CAE community. This paper discusses some critical issues in line die analysis of the body side outers, describes technical challenges in applications, and finally demonstrates the impact of line die forming simulation on the die development.

In GM R&D Powertrain/Engine Control Group, rapid prototyping controller (RPC) systems with Matlab/Simulink are used extensively to design, simulate and implement advanced engine control algorithms and models. However, those RPC systems use powerful microprocessors with large amounts of RAM contrary to engine control modules (ECM) in production vehicles. Therefore, a thorough analysis on the comparatively much more complicated algorithms and models cannot be performed during the research stage, since there are not enough tools to enable the smooth transition from Matlab/Simulink to the production type processor. The Real-Time Interface (RTI) Blockset for a production like microprocessor would close the transition gap between rapid prototyping controller systems and production type microprocessors by leveraging the power and popularity of Matlab/Simulink in control engineering world and automatic code generation tools.

This paper presents an empirical-based model which explains the force-deflection characteristics of disc stacks commonly used in automotive suspension dampers. The model provides tools for comparing different disc stacks to understand their effect on damper performance. Load-deflection data is presented on a variety of discs and combinations of discs. The data is analyzed to show how the diameter, thickness and relative position of discs in a stack can affect the stack stiffness throughout the range of disc deflections. A model is developed to show how changes in the disc stack will affect damper performance at different velocities. An example is provided that shows predicted changes in disc stack force-deflection characteristics and the resulting changes in a damper force-velocity curve. Ride results are also presented that confirm the validity of the model.

In recent years a predominant strategy for setting sound quality (SQ) requirements has been the sensory correlation approach (also called sensory evaluation or sensory science). Some users of this approach have reported their progress in numerous papers. Other SQ practitioners have made presentations on specific topics that show the linkage to music and musical notation. These specific links point to an alternative general strategy - “the Music Analogy for Sound Quality.” This paper begins by comparing the general methods of the music analogy and sensory correlation. Some major differences will be identified and implications discussed. Some existing specific tools for the music analogy will be identified as well as some gaps that need to be filled. Finally, reasons will be presented concerning why the music analogy should be considered when developing sound quality requirements.

Any equipment system or vehicle component like the Convenience Organizer storage system needs to be retained within the cargo compartment without intruding into the passenger compartment for occupant safety during a high speed impact. This paper outlines a test method to evaluate the retention of such a system in a rear impact environment. The method utilizes a low speed barrier to simulate a high speed RMB (Rear Moving Barrier) impact. The content of the low speed RMB impact test setup was developed utilizing DYNA3D analytical simulation results from a full vehicle model subjected to high-speed RMB impact. The retention of the equipment developed through this test method was confirmed on a full scale rear impact test.

The past 10 years have created such buzzwords as “model-based development” and “auto-code generation”. Conveniently absent from the tool literature on model-based development are the equally, or more important concepts of Software Architecture and Process. When developing product line software, the process and architecture form a critical foundation to base reusable products and components. The development process can no longer be viewed as “model-based”, but rather as “model-driven”, due to the reliance on the models as the source artifact as opposed to the creators of the source artifacts. A model-driven product line software development process allows capturing of behavior, for commonality across different products, and having a different implementation for a specific product release.

An onboard vehicle-to-vehicle multi-hop wireless networking system has been developed to test the real-world performance of telematics applications. The system targets emergency and safety messaging, traffic updates, audio/video streaming and commercial announcements. The test-bed includes a Differential GPS receiver, an IEEE 802.11a radio card modified to emulate the DSRC standard, a 1xRTT cellular-data connection, an onboard computer and audio-visual equipment. Vehicles exchange data directly or via intermediate vehicles using a multi-hop routing protocol. The focus of the test-bed is to (a) evaluate the feasibility of high-speed inter-vehicular networking, (b) characterize 5.8GHz signal propagation within a dynamic mobile ad hoc environment, and (c) develop routing protocols for highly mobile networks. The test-bed has been deployed across five vehicles and tested over 400 miles on the road.

This paper describes a vehicle-level simulation model for climate control and powertrain cooling developed and currently utilized at GM. The tool was developed in response to GM's need to speed vehicle development for HVAC and powertrain cooling to meet world-class program execution timing (18 to 24 month vehicle development cycles). At the same time the simulation tool had to complement GM's strategy to move additional engineering responsibility to its HVAC suppliers. This simulation tool called “e-Thermal” was quickly developed and currently is in widespread (global) use across GM. This paper describes GM's objectives and requirements for developing e-Thermal. The structure of the tool and the capabilities of the simulation tool modules (refrigeration, front end airflow, passenger compartment, engine, transmission, Interior air handling …) is introduced. Model data requirements and GM's strategy for acquiring component data are also described.

Hyundai Motor Company has combined physical and virtual testing tools to validate a full vehicle virtual prototype. Today a large number of physical tests are still required because the cycle of “design-build-test-change” relies on complex models of components and systems that typically are not easily validated. In order to shorten the development cycles, engineers perform multi-body simulations to dynamically excite components and systems and thereby estimate their durability under dynamic loads. The approach described herein demonstrates the feasibility of correlating the output from the corresponding physical and virtual prototype. Both synthetic and road load events are employed to excite physical and virtual vehicles, reveal difference in response, and ultimately improve the predictive capability of the model.

The automotive vehicle design process has relied for many years on both analytical studies and physical testing. Testing remains to be required due to the inherent complexities of structures and systems and the simplifications made in analytical studies. Simulation test methods, i.e. tests that load components with forces derived from actual operating conditions, have become the accepted standard. Advanced simulation tools like iterative deconvolution methods have been developed to address this need. Analytical techniques, such as multi body simulation have advanced to the degree that it is practical to investigate the dynamic behavior of components and even full vehicles under the influence of operational loads. However, the approach of testing and analysis are quite unique and no seamless bridge between the two exists. This paper demonstrates an integrated approach to combine testing and analysis together in the form of virtual testing.

This paper presents a case study on reducing road noise of a passenger vehicle. SEA, insertion loss and sound intensity measurements were the tools used in the study. A SEA model was constructed to predict the primary paths (panels or area) contributing to the overall interior sound field. Insertion loss measurements were used to verify the primary contributing paths identified using SEA. To provide further details of the primary paths, intensity maps of identified panels were measured allowing detailed reconstruction of the contributory panels. The SEA model, insertion loss, and intensity maps aided in providing possible design fixes that will effectively reduce road noise. Finally, comparisons of predicted results versus actual results at both a subsystem and a full vehicle level are included in this paper.