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The thermal operational safety (TOS) of a vehicle ensures that no component exceeds its critical temperature during vehicle operation. To enhance the current TOS validation process, a data-driven approach is proposed to predict maximum component temperatures of a new vehicle project by leveraging the historical thermal wind tunnel data from previous vehicle projects. The approach intends to support engineers with temperature predictions in the early phase and reduce the number of wind tunnel tests in the late phase of the TOS validation process. In the early phase, all measurements of the new vehicle project are predicted. In the late phase, a percentage of measurements with the test vehicle used for the model training and the remaining tests are predicted with the trained ML model. In a first step, data from all wind tunnel tests is extracted into a joint dataset together with metadata about the vehicle and the executed load case.

The NVH-development cycle of vehicle components often requires a source characterization separated from the vehicle itself, which leads to the implementation of test bench setups. In the context of frequency based substructuring and transfer path analysis, a component can be characterized using Blocked Forces. The following paper provides a comparison of methods between an acceleration-based in-situ and a new hybrid in-situ Blocked Force determination, using measurements of an artificially excited electric power steering (EPS). Under real-life conditions on a test rig, the acceleration-based in-situ approach often shows limitations in the lower frequency range, due to relatively bad signal-to-noise ratio at the indicator sensors, while delivering accurate results in the higher spectrum. Due to considerable loads on components in operation, the stiffness of the test-rig cannot be decreased arbitrarily.

Raising demands towards lightweight design paired with a loss of originally predominant engine noise pose significant challenges for NVH engineers in the automotive industry. From an aeroacoustic point of view, low frequency buffeting ranks among the most frequently encountered issues. The phenomenon typically arises due to structural transmission of aerodynamic wall pressure fluctuations and/or, as indicated in this work, through rear vent excitation. A possible workflow to simulate structure-excited buffeting contains a strongly coupled vibro-acoustic model for structure and interior cavity excited by a spatial pressure distribution obtained from a CFD simulation. In the case of rear vent buffeting no validated workflow has been published yet. While approaches have been made to simulate the problem for a real-car geometry such attempts suffer from tremendous computation costs, meshing effort and lack of flexibility.

Classical decentralized architectures based on large networks of microprocessor-based Electronic Control Units (ECU), namely those used in self-driving cars and other highly-automated applications used in the automotive industry, are becoming more and more complex. These new, high computational power demand applications are constrained by limits on energy consumption, weight, and size of the embedded components. The adoption of new embedded centralized electrical/electronic (E/E) architectures based on dynamically reconfigurable hardware represents a new possibility to tackle these challenges. However, they also raise concerns and questions about their safety. Hence, an appropriate evaluation must be performed to guarantee that safety requirements resulting from an Automotive Safety Integrity Level (ASIL) according to the standard ISO 26262 are met. In this paper, a methodology for the evaluation of dynamically reconfigurable systems based on centralized architectures is presented.

The Deep Orange program is a concept vehicle development program focused on providing hands-on experience in design, engineering, prototyping and production planning as part of students’ two-year MS graduate education. Throughout this project, the team was challenged to create innovative concepts during the ideation phase as part of building the running vehicle. This paper describes the usability studies performed on two of the vehicle concepts that require driver interaction. One concept is a human machine interface (HMI) that uses a holographic companion that can act as a concierge for all functions of the vehicle. After creating a prototype using existing technologies and developing a user interface controlled by hand gestures, a usability study was completed with older adults. The results suggest the input method was not intuitive. Participants demonstrated better performance with tasks using discrete hand motions in comparison to those that required continuous motions.

The analysis of the acoustic behavior of flow fields has gained importance in recent years, especially in the automotive industry. The comfort of the driver is heavily influenced by the noise levels and characteristics, especially during long distance drives. Simulation tools can help to analyze the acoustic properties of a car at an early stage of the development process. This work focuses on the low-frequency sound effects, which can be a significant noise component under certain operating conditions. As a first step in the fluid-structure interaction workflow, the flow around a series-production vehicle is simulated, including passenger cabin and underhood flow. The complexity of this model poses extensive demands on the simulation software, concerning meshing, turbulence modeling and level of parallelism. We conducted a transient simulation of the compressible fluid flow, using a hybrid RANS/LES approach.

Efforts in aerodynamic optimization of road vehicles have been steadily increasing in recent years, mainly focusing on the reduction of aerodynamic drag. Of a car's total drag, wheels and wheel houses account for approx. 25 percent. Consequently, the flow around automotive wheels has lately been investigated intensively. Previously, the authors studied a treaded, deformable, isolated full-scale tire rotating in contact with the ground in the wind tunnel and using the Lattice-Boltzmann solver Exa PowerFLOW. It was shown that applying a common numerical setup, with velocity boundary condition prescribed on the tread, significant errors were introduced in the simulation. The contact patch separation was exaggerated and the flow field from wind tunnel measurements could not be reproduced. This investigation carries on the work by examining sensitivities and new approaches in the setup.

The requirement of the start of the internal combustion engine (ICE) not only at vehicle standstill is new for full hybrid electric vehicles in comparison to conventional vehicles. However, the customer will not accept any deterioration with respect to dynamics and comfort. ICE-starting-systems and -strategies have to be designed to meet those demands. Within this research, a method was developed which allows a reproducible maneuver-based analysis of ICE-starts. In the first step, a maneuver catalogue including a customer-oriented maneuver program with appropriate analysis criteria was defined. Afterwards, the maneuvers were implemented and verified in a special test bench environment. Based on the method, two sample hybrid vehicles were benchmarked according to the maneuver catalogue. The benchmarking results demonstrate important dependencies between the criteria-based assessment of ICE-starts and the embedded ICE-starting-system and -strategy.

At the rear of the vehicle an end acoustic silencer is attached to the exhaust system. This is primarily to reduce noise emissions for the benefit of passengers and bystanders. Due to the location of the end acoustic silencer conventional thermal protection methods (heat shields) through experimental means can not only be difficult to incorporate but also can be an inefficient and costly experience. Hence simulation methods may improve the development process by introducing methods of optimization in early phase vehicle design. A previous publication (Part 1) described a methodology of improving the surface temperatures prediction of general exhaust configurations. It was found in this initial study that simulation results for silencer configurations exhibited significant discrepancies in comparison to experimental data.

Over the past 30 years, the computer-aided engineering (CAE) tools have been applied extensively in the automotive industry. In order to accelerate time-to-market while coping with legal limits that have become increasingly restrictive over the last decades, CAE has become an indispensable tool covering all major fields in a modern automotive product design process. However, when tackling complex real-life engineering problems, the computational models might become rather involved and thus less efficient. Therefore, the overall trend in the automotive industry is currently heading towards combined approaches, which allow the best of the both worlds, namely the experimental measurement and numerical simulation, to be merged into one integrated scheme. In this paper, the so-called patch transfer function (PTF) approach is adopted to solve coupled vibro-acoustic problems. In the PTF scheme, the interfaces between fluid and structure are discretised in terms of patches.

Aerodynamic performance assessment of automotive shapes is typically performed in wind tunnels. However, with the rapid progress in computer hardware technology and the maturity and accuracy of Computational Fluid Dynamics (CFD) software packages, evaluation of the production-level automotive shapes using a digital process has become a reality. As the time to market shrinks, automakers are adopting a digital design process for vehicle development. This has elevated the accuracy requirements on the flow simulation software, so that it can be used effectively in the production environment. Evaluation of aerodynamic performance covers prediction of the aerodynamic coefficients such as drag, lift, side force and also lift balance between the front and rear axle. Drag prediction accuracy is important for meeting fuel efficiency targets, prediction of front and rear lifts as well as side force and yawing moment are crucial for high speed handling.

Plug-In Hybrid Electric Vehicles (PHEV) are becoming increasingly important as an intermediate step on the roadmap to Battery Electric Vehicles (BEV). Li-Ion is the most important battery technology for future hybrid and electrical vehicles. Cycle life of batteries for automotive applications is a major concern of design and development on vehicles with electrified powertrain. Cell manufacturers present various cell chemistries based on Li-Ion technology. For choosing cells with the best cycle life performance appropriate test methods and criteria must be obtained. Cells must be stressed with accelerated aging methods, which correlate with real life conditions. There is always a conflict between high accelerating factors for fast results on the one hand and best accordance with reality on the other hand. Investigations are done on three different Li-Ion cell types which are applicable in the use of PHEVs.

What are the requirements of customers in an urban environment? What will sustainable mobility look like in the future? This presentation gives an overview of the integrated approach used by BMW to develop the BMW i3 - a purpose-built battery electric vehicle. Very low driving resistances for such a vehicle concept enable the delivery of both impressive range and driving excitement. A small optional auxiliary power unit offers range security for unexpected situations and opens up BEVs to customers who are willing to buy a BEV but are still hesitant due to range anxiety. Additional electric vehicles sold to the formerly range anxious will create additional electric miles. Presenter Franz Storkenmaier, BMW Group

Unsteady aerodynamic flow phenomena are investigated in the wind tunnel by oscillating a realistic 50% scale model around its vertical axis. Thus the model is exposed to time-dependent flow conditions at realistic Reynolds and Strouhal numbers. Using this setup unsteady aerodynamic loads are observed to differ significantly from quasi-steady loads. In particular, the unsteady yaw moment exceeds the quasi-steady approximation by 80%. On the other hand, side force and roll moment are over predicted by quasi-steady approximation but exhibit a significant time delay. Using hotwire anemometry, a delayed reaction of the wake flow of Δt/T = 0.15 is observed, which is thought to be the principal cause for the differences between unsteady and quasi-steady aerodynamic loads. A schematic mechanism explaining these differences due to the delayed reaction of the wake flow is proposed.

Unsteady aerodynamic flow phenomena are investigated in a wind tunnel by oscillating a realistic 50% scale model around the vertical axis. Thus the model is exposed to time-dependent flow conditions at realistic Reynolds and Strouhal numbers. Using this setup unsteady aerodynamic loads are observed to differ significantly from quasi steady loads. In particular, the unsteady yaw moment exceeds the quasi steady approximation significantly. On the other hand, side force and roll moment are over predicted by quasi steady approximation but exhibit a significant time delay. Part 2 of this study proves that a delayed and enhanced response of the surface pressures at the rear side of the vehicle is responsible for the differences between unsteady and quasi steady loads. The pressure changes at the vehicle front, however, are shown to have similar amplitudes and almost no phase shift compared to quasi steady flow conditions.

This paper presents a new approach to analyzing and developing low-drag cooling systems. A relation is derived which describes cooling drag by a number of contributions. Interference drag clearly can be identified as one of them. Cooling system parameters can be assigned to different terms of the relation, so that differences due to parameter variations of the individual drag contributions can be estimated. In order to predict the interference-drag dependency on the outlet location and the local outlet mass flow, an extensive study on a standard BMW sedan has been carried out, both experimentally and by CFD. The results show the importance of providing consistent outflow conditions which take into account the outlet location and flow direction, in order to minimize cooling drag.

For most car manufacturers, aerodynamic noise is becoming the dominant high frequency noise source (> 500 Hz) at highway speeds. Design optimization and early detection of issues related to aeroacoustics remain mainly an experimental art implying high cost prototypes, expensive wind tunnel sessions, and potentially late design changes. To reduce the associated costs as well as development times, there is strong motivation for the development of a reliable numerical prediction capability. The goal of this paper is to present a computational approach developed to predict the greenhouse windnoise contribution to the interior noise heard by the vehicle passengers. This method is based on coupling an unsteady Computational Fluid Dynamics (CFD) solver for the windnoise excitation to a Statistical Energy Analysis (SEA) solver for the structural acoustic behavior.

The G-equation model was implemented in the commercial code ANSYS CFX and validated against experimental data in order to successfully simulate turbulent premixed combustion in internal combustion engines. The model is based on the level-set approach. Two transport equations are solved respectively for the G-scalar mean value, representing the local distance function from the time-averaged mean flame front, and its variance, correlated to the turbulent flame brush thickness. The model closure for tracking the flame front is based on an algebraic expression for the turbulent burning velocity. The composition of the reacted mixture is evaluated by coupling the code with flamelet libraries generated with the ANSYS CFX-RIF package by means of a reaction progress variable computed as a function of the G-related quantities.

While hybrid-electric powertrain features such as regenerative braking and electric driving can improve the fuel economy of a vehicle significantly, these features may also have a considerable impact on driving dynamics. That is why extra effort is necessary to ensure safety and comfort that customers usually expect from a conventional vehicle. The purpose of this paper is to initiate a discussion regarding different drivetrain concepts, necessary changes in chassis systems, and the impact on vehicle dynamics. To provide input to this essential discussion, braking and steering systems, as well as suspension design, are analyzed regarding their fit with hybrid systems. It is shown how an integration of hybrid technology and chassis systems benefits vehicle dynamics and why “by-wire” technology is a key enabler for safe and comfortable hybrid-electric vehicles.

As the popularity of vehicle navigation systems rises, incorporating Real Time Traffic Information (RTTI) has been shown to enhance the systems' value by helping drivers avoid traffic delays. As an innovative premium automaker, BMW has developed a testing process to acquire and analyze RTTI data in order to ensure delivery of a high quality service and to enhance the customer experience compared to audible broadcast services. With a methodology to obtain valid and repeatable RTTI data quality measurements, BMW and its service partner, Clear Channel's Total Traffic Network (TTN), can improve its offered service over time, implement corrective measures when appropriate, and confidently ensure the service meets its premium objectives. BMW has partnered with TTN and SoftSolutions GmbH to implement a traffic data quality process and software tools.