Search Results

A special spot weld element (SWE) is presented for simplified representation of spot joints in complex structures for structural durability evaluation using the mesh-insensitive structural stress method. The SWE is formulated using rigorous linear four-node Mindlin shell elements with consideration of weld region kinematic constraints and force/moments equilibrium conditions. The SWEs are capable of capturing all major deformation modes around weld region such that rather coarse finite element mesh can be used in durability modeling of complex vehicle structures without losing any accuracy. With the SWEs, all relevant traction structural stress components around a spot weld nugget can be fully captured in a mesh-insensitive manner for evaluation of multiaxial fatigue failure.

Carbon neutrality has become a significant target. One essential parameter regarding energy consumption and emissions is the mass of vehicles. Lightweight design improves the result of vehicle life cycle assessment (LCA), increases efficiency, and can be a step towards sustainability and CO2 neutrality. Weight reduction through structural optimization is a challenging task. Typical design development procedures have to be overcome. Instead of just a facelift or the creation of a derivative of the predecessor design, completely alternative design creation methods have to be applied. Automated structural optimization is one tool for exploring completely new design approaches. Different methods are available and weight reduction is the focus of topology optimization. This paper describes a fatigue life homogenization method that enables the weight reduction of vehicle parts. The applied CAE process combines fatigue life prediction and topology optimization.

The world is currently facing environmental issues such as global warming, air pollution, and high energy demand. To mitigate these challenges, the electrification of vehicles is essential as it is effective for efficient fuel utilization and promotion of alternative fuels. The optimal approach for electrification varies across different markets, depending on local energy conditions and current circumstances. Consequently, Toyota has taken the initiative to offer a comprehensive lineup of battery electric vehicles (BEV), hybrid electric vehicles (HEV), plug-in hybrid electric vehicles (PHEV), and fuel cell electric vehicles (FCEV), aiming to provide sustainable solutions tailored to the unique situations and needs of each region. As part of this effort, Toyota has developed the 5th generation of hybrid electric vehicles. This paper describes the electric motor used in the new Toyota Camry which achieves high torque, high power, low losses, and compact design.

The use of hydrogen produced from renewable energy sources is expected to be one of the most promising options for achieving carbon neutrality in automobiles, in addition to electrification and the use of biofuels and synthetic fuels. In recent years, along with fuel cell electric vehicles (FCEVs), there has been renewed interest in hydrogen engines that can utilize internal combustion engine technology. Although hydrogen has the property of a high laminar burning velocity and a wide flammable range compared to other fuels, the actual combustion phenomenon in a real engine is strongly influenced by the turbulence created by the in- cylinder flow and the distribution of fuel and air in the cylinder due to the formation of the mixture. Therefore, to fully utilize hydrogen as a fuel in actual engines and bring out its performance, it is important to understand the basic combustion characteristics of hydrogen in the cylinder and the effects of these factors on hydrogen combustion.

Finite element (FE) analyses of macroscopic stress-strain relations and failure modes for tensile tests of additively manufactured (AM) AlSi10Mg in different loading directions with respect to the building direction are conducted with consideration of melt pool (MP) microstructures and pores. The material constitutive relations in different orientations of AM AlSi10Mg are first obtained from fitting the experimental tensile engineering stress-strain curves by conducting axisymmetric FE analyses of round bar tensile specimens. Four representative volume elements (RVEs) with MP microstructures with and without pores are identified and selected based on the micrographs of the longitudinal cross-sections of the vertical and horizontal tensile specimens. Two-dimensional plane stress elastic-plastic FE analyses of the RVEs subjected to uniaxial tension are then conducted.

This paper describes a new control technology that coordinates the operation of multiple actuators in a new hybrid electric vehicle (HEV) system consisting of a turbocharged engine, front and rear electric motors, two clutches, and a 6-speed automatic transmission. The development concept for this control technology is to achieve the driver’s desired acceleration G with a natural feeling engine speed. First, to realize linear acceleration G even while the engine is starting from EV mode, clutch hydraulic pressure reduction control is implemented. Furthermore, the engine start timing is optimized to prevent delayed drive force response by predicting the required maximum power during cranking. Second, to realize linear acceleration, this control selects the proper gear position based on the available battery power, considering noise and vibration (NV) restrictions and turbocharging response delays.

The automotive industry widely accepted the launch of electric vehicles in the global market, resulting in the emergence of many new areas, including battery health, inverter design, and motor dynamics. Maintaining the desired thermal stress is required to achieve augmented performance along with the optimal design of these components. The HVAC system controls the coolant and refrigerant fluid pressures to maintain the temperatures of [Battery, Inverter, Motor] in a definite range. However, identifying the prominent factors affecting the thermal stress of electric vehicle components and their effect on temperature variation was not investigated in real-time. Therefore, this article defines the vector electric vehicle thermal operating point (EVTHOP) as the first step with three elements [instantaneous battery temperature, instantaneous inverter temperature, instantaneous stator temperature].

Reducing powertrain losses is an important technical challenge to further improve the efficiency of electric vehicles as part of measures toward achieving carbon neutrality. One effective method of accomplishing this goal is to reduce the viscosity of transaxle lubricating oil. However, it is generally known that lowering viscosity can cause durability issues such as wear and seizure if the thickness of the lubricating oil film on metal sliding surfaces is insufficient. In gears and bearings, reducing the oil film thickness can increase direct contact with the base metal and may cause surface fatigue peeling. A new additive formulation for lubricating oil specifically for electrified vehicles has been designed in anticipation of the wider adoption of such vehicles in the future. The result has been a new transaxle fluid that ensures unit durability while reducing viscosity of 40°C to 12.2[mm2/sec].

To achieve carbon neutrality by reducing carbon dioxide (CO2) emissions, vehicles with an internal combustion engine have started to be replaced by electrification vehicles such as hybrid electric vehicles (HEVs), plug-in HEVs (PHEVs), and battery EVs (BEVs) worldwide, which have motors in their transaxles (T/As). Reducing transmission torque loss in the transaxles is effective to reduce CO2 emissions, and lowering the viscosity of lubrication fluids in T/As is a promising method for reducing churning and drag loss. However, lowering viscosity generally leads to thin oil films and makes the lubrication condition severe, resulting in worse anti-fatigue and anti-seizure performance. To deal with these issues, we made improvements on the additive formulation of fluid, such as the addition of an oil-film-forming polymer, chemical structure change of calcium detergents, and an increase of anti-wear additives including phosphorus and sulfur.

The new Toyota Mirai hydrogen fuel cell electric vehicle (FCEV) was launched in December 2020. Achieving a low-cost, high-performance FC stack is an important objective in FCEV development. At the same time, it is also necessary to ensure vehicle safety. This paper presents an overview of the safety requirements for onboard FC stacks. It also describes the simulation and evaluation methods for the following matters related to the FC stack. i) Impact force resistance: The FC stack was designed to prevent cell layer slippage due to impact. Constraint force between the cell layers is provided by the frictional force between the cells and an external constraint. A simulation of the behavior of the cell layers under impact force was developed. The impact force resistance was confirmed by an impact loading test. ii) Hydrogen safety: The FC stack was designed so that permeated hydrogen is ventilated and the hydrogen concentration is kept below the standard.

Since the regulations of CO2 emissions have been tightened in each country recently, each automotive manufacturer has responded by bringing competitive technologies that maximize efficiency while promoting vehicle electrification such as xEV. Not only the efficiency, we need to meet or exceed occupant performance and comfort expectations. The climate control system expends a large amount of energy to keep a comfortable environment, having a significant impact on fuel consumption and EV driving range. Therefore, many manufacturers try to save energy and improve occupant comfort quickly by using not only the conventional convective heating by HVAC but also the conductive heating to heat the human body directly such as seat and steering wheel heater. In this study, a radiative heater, which is more efficient than a convective heating to warm anterior thigh and shin where a conductive heating cannot warm, was applied to vehicle.

The reduction of CO2 emissions is one of the most important challenges for the automotive industry to contribute to address global warming. Reducing friction of internal combustion engines (ICEs) is one effective countermeasure to realize this objective. The improvement of engine oil can contribute to reduce fuel consumption by reducing friction between engine parts. Electrification of ICE powertrains increases the overall efficiency of powertrains and reduces the average engine oil temperature during vehicle operation, due to intermittent engine operation. An effective way of reducing engine friction is to lower the viscosity of the engine oil in the low to medium temperature range. This can be accomplished while maintaining viscosity at high temperatures by reducing the base oil viscosity and increasing the viscosity modifier (VM) content to raise the viscosity index (so-called “flat viscosity” concept).

In recent years, the realization of carbon neutrality has become an activity to be tackled worldwide, and automobile manufacturers are promoting electrification of power train by HEV, PHEV, BEV and FCEV. Although interest in BEV is currently growing, vehicles equipped with internal combustion engines (ICE) including HEV and PHEV will continue to be used in areas where conversion to BEV is not easy due to lack of sufficient infrastructures. For such vehicles, low-viscosity engine oil will be one of the most important means to contribute to further reduction of CO2 emissions. Since HEV requires less work from the engine, the engine oil temperature is lower than that of conventional engine vehicles. Therefore, the reduction of viscous resistance in the mid-to-low temperature range below 80°C is expected to contribute more to fuel economy. On the other hand, the viscosity must be kept above a certain level to ensure the performance of hydraulic devices in the high oil temperature range.

The first MIRAI was launched in 2014 as the world’s first commercial fuel cell vehicle (FCV) [1]. Compared to the FC stack used in the first MIRAI, the FC stack in the new MIRAI achieved one of the highest volumetric power densities in the world (5.4 kW/L, excluding end plates, 1.5 times higher than the FC stack in the first MIRAI) by adopting a new flow channel for the bipolar plate and an improved electrode [2]. Enhancing the current density is an important means of increasing power performance and reducing size. The bipolar plate functions to distribute gas and drain water inside the cells to stabilize current generation. However, a conventional straight flow channel tends to cause flooding, which makes it difficult to maintain stable current generation. A partially narrow flow channel was developed to enhance oxygen diffusion without the 3D fine-mesh flow field that was adopted in the previous FC stack.

Strain-rate sensitivity has been neglected in the simulation of the traditional stamping process because the strain rate typically does not significantly impact the forming behavior of sheet metals in such a quasi-static process, and traditional crank or link mechanical presses lack the flexibility of slide motion. However, the recent application of servo drive presses in stamping manifests improvement in formability and reduction of springback, besides increased productivity and energy savings. An accurate simulation of servo stamping entails constitutive models with strain-rate sensitivity. This study evaluated a few strain rate-sensitive models including the power-law model, the linear power-law model, the Johnson-Cook model, and the Cowper-Symonds model through the exercise of fitting these models to the experimental data of a deep draw quality (DDQ) steel.

An experimental investigation of non-intrusive combustion sensing was performed using a tri-axial accelerometer mounted to the engine block of a small-bore high-speed 4-cylinder compression-ignition direct-injection (CIDI) engine. This study investigates potential techniques to extract combustion features from accelerometer signals to be used for cycle-to-cycle engine control. Selection of accelerometer location and vibration axis were performed by analyzing vibration signals for three different locations along the block for all three of the accelerometer axes. A magnitude squared coherence (MSC) statistical analysis was used to select the best location and axis. Based on previous work from the literature, the vibration signal filtering was optimized, and the filtered vibration signals were analyzed. It was found that the vibration signals correlate well with the second derivative of pressure during the initial stages of combustion.

Further fuel economy improvement of the internal combustion engine is indispensable for CO2 reduction in order to cope with serious global environmental problems. Although lowering the viscosity of engine oil is an effective way to improve fuel economy, it may reduce the wear resistance. Therefore, it is important to achieve both improved fuel economy and reliability. We have developed new 0W- 8 engine oil of ultra-low viscosity and achieved an improvement in fuel economy by 0.8% compared to the commercial 0W-16 engine oil. For this new oil, we reduced the friction coefficient under boundary lubrication regime by applying an oil film former and calcium borate detergent. The film former increased the oil film thickness without increasing the oil viscosity. The calcium borate detergent enhanced the friction reduction effect of molybdenum dithiocarbamate (MoDTC).

The article solves the problem of reducing electric power losses of the traction induction machine rotor to prevent its overheating in nominal and high-load modes. Electric losses of the rotor power are optimized by the stabilization of the main magnetic flow of the electric machine at a nominal level with the amplitude-frequency control in a wide range of speeds and increased loads. The quasi-independent excitation of the induction machine allows us to increase the rigidity of mechanical characteristics, decrease the rotor slip at nominal loads and overloads and significantly decrease electrical losses in the rotor as compared to other control methods. The article considers the technology of converting the power of individual phases into a single energy flow using a three-phase electric machine equivalent circuit and obtaining an energy model in the form of equations of instantaneous active and reactive power balance.

This paper describes the development of a simplified fracture finite element (FE) model for resistance spot welds (RSW) of ultra-high-strength steel (UHSS) that can be incorporated into large-scale vehicle FE model. It is known that the RSW of UHSS generates two types of fracture modes: heat-affected zone (HAZ) and nugget zone fractures. Lap shear and peeling coupon tests using UHSS sheets found that the different RSW fracture modes occurred at different nugget diameters. To analyze this phenomenon, detailed simulated coupon tests were carried out using solid hexahedral elements. The analytical results revealed that RSW fractures are defined by both the application of plastic strain on the elements and the stress triaxiality state of the elements. A detailed model incorporating a new fracture criteria model recreated the different UHSS RSW fracture modes and achieved a close correlation with the coupon test results.

Aircraft components are commonly produced with 7000 series aluminum alloys (AA) due to its weight, strength, and fatigue properties. Auto Industry is also choosing more and more aluminum component for weight reduction. Current additive manufacturing (AM) methods fall short of successfully producing 7000 series AA due to the reflective nature of the material along with elements with low vaporization temperature. Moreover, lacking in ideal thermal control, print inherently defective products with such issues as poor surface finish alloying element loss and porosity. All these defects contribute to reduction of mechanical strength. By monitoring plasma with spectroscopic sensors, multiple information such as line intensity, standard deviation, plasma temperature or electron density, and by using different signal processing algorithm, AM defects have been detected and classified.