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In electrified automobiles, wind noise significantly contributes to the overall noise inside the cabin. In particular, underbody airflow is a dominant noise source at low frequencies (less than 500 Hz). However, the wind noise transmission mechanism through a battery electric vehicle (BEV) underbody is complex because the BEV has a battery under the floor panel. Although various types of underbody structures exist for BEVs, in this study, the focus was on an underbody structure with two surfaces as inputs of wind noise sources: the outer surface exposed to the external underbody flow, such as undercover and suspension, and the floor panel, located above the undercover and battery. In this study, aero-vibro-acoustic simulations were performed to clarify the transmission mechanism of the BEV underbody wind noise. The external flow and acoustic fields were simulated using computational fluid dynamics.

The Test Device for Human Occupant Restraint (THOR) is an advanced crash test dummy designed for frontal impact. Originally released in a 50th percentile male version (THOR-50M), a female 5th version (THOR-05F) was prototyped in 2017 (Wang et al., 2017) and compared with biofidelity sub-system tests (Wang et al., 2018). The same year, Trosseille et al. (2018) published response corridors using nine 5th percentile female Post Mortem Human Subjects (PMHS) tested in three sled configurations, including both submarining and non-submarining cases. The goal of this paper is to provide an initial evaluation of the THOR-05F biofidelity in a full-scale sled test, by comparing its response with the PMHS corridors published by Trosseille et al. (2018). Significant similarities between PMHS and THOR-05F were observed: as in Trosseille et al. (2018), the THOR-05F did not submarine in configuration 1, and submarined in configurations 2 and 3.

This paper describes the equivalent temperature based on the mesh-free simulation proposed by the previous papers (Part1 and Part2) under the transient heating condition in a 3D-CAD vehicle cabin including the thermal manikin which takes into account the clothing shape. For this purpose, firstly, the experiments of vehicle cabin measuring for the thermal environment including the equivalent temperature are carried out under the transient heating condition. Then, the calculated results of the thermal environment in the vehicle cabin are compared with time series experimental data under the transient condition. They correspond to the experiments including transient changes well. The transient calculated equivalent temperature of thermal manikin is also compared with experiments. As a result, since it is difficult to control the thermal manikin ideally in the experiment, it is difficult to compare the transient behavior.

This paper describes a method for evaluating the equivalent temperature in vehicle cabins based on the new international standard ISO 14505-4, published in 2021. ISO 14505-4 defines two simulation methods to determine a thermal comfort index “equivalent temperature.” One method uses a numerical thermal manikin, and the other uses thermal factors to calculate. This study discusses the latter method to validate its accuracy, identify the key points to consider, and examine its advantages and disadvantages. First, the definition of equivalent temperature and the equation to calculate the equivalent temperature using thermal factors, such as air temperature, radiant temperature, solar radiation, and air velocity, are explained. In addition, the experiments and simulation methods are described.

It is well understood that using lower viscosity engine oils can greatly improve fuel economy [1, 2, 3, 4]. However, it has been impossible to evaluate ultra-low viscosity engine oils (SAE 0W-12 and below) utilizing existing fuel economy test methods. As such, there is no specification for ultra-low viscosity gasoline engine oils [5]. We therefore developed firing and motored fuel economy test methods for ultra-low viscosity oils using engines from Japanese automakers [6, 7, 8]. This was done under the auspices of the JASO Next Generation Engine Oil Task Force (“TF” below), which consists mainly of Japanese automakers and entities working in the petroleum industry. Moreover, the TF used these test methods to develop the JASO GLV-1 specification for next-generation ultra-low viscosity automotive gasoline engine oils such as SAE 0W-8 and 0W-12. In developing the JASO GLV-1 specification, Japanese fuel economy tests and the ILSAC engine tests for evaluating engine reliability were used.

Several studies, available in the literature, were conducted to establish the most relevant criterion for predicting the thoracic injury risk on the THOR dummy. The criteria, such as the maximum deflection or a combination of parameters including the difference between the chest right and left deflections, were all developed based on given samples of Post Mortem Human Subject (PMHS). However, they were not validated against independent data and they are not always consistent with the observations from field data analysis. For this reason, 8 additional PMHS and matching THOR tests were carried out to assess the ability of the criteria to predict risks. Accident investigations showed that a reduction of the belt loads reduces the risk of rib fractures. Two configurations with different levels of force limitation were therefore chosen. A configuration representing an average European vehicle was chosen as a reference.

In the previous paper (Part 1), measurements of equivalent temperature (teq) using a clothed thermal manikin and modeling of the clothed thermal manikin for teq simulation were discussed. In this paper (Part 2), the outline of the proposed mesh-free simulation method is described and comparisons between teq in the calculations and measurements under summer cooling with solar radiation and winter heating without solar radiation conditions in a vehicle cabin are discussed. The key factors for evaluating teq on each body segment of the clothed thermal manikin under cooling and heating conditions are also discussed. In the mesh-free simulation, even if there is a hole or an unnecessary shape on the CAD model, only a group of points whose density is controlled in the simulation area is generated without modifying the CAD model. Therefore, the fluid mesh required by conventional CFD code is not required, and the analysis load is significantly reduced.

The present paper is Part 1 of two consecutive studies. Part 1 describes three subjects: definition of the equivalent temperature (teq), measurements of teq using a clothed thermal manikin in a vehicle cabin, and modeling of the clothed thermal manikin for teq simulation. After defining teq, a method for measuring teq with a clothed thermal manikin was examined. Two techniques were proposed in this study: the definition of “the total heat transfer coefficient between the skin surface and the environment in a standard environment (hcal)” based on the thermal insulation of clothing (Icl), and a method of measuring Icl in consideration of the area factor (fcl), which indicates the ratio of the clothing surface to the manikin surface area. Then, teq was measured in an actual vehicle cabin by the proposed method under two conditions: a summer cooling condition with solar radiation and a winter heating condition without solar radiation.

In the last decade, extensive efforts have been made to understand the physics of submarining and its consequences in terms of abdominal injuries. For that purpose, 27 Post Mortem Human Subject (PMHS) tests were performed in well controlled conditions on a sled and response corridors were provided to assess the biofidelity of dummies or human body models. All these efforts were based on the 50th percentile male. In parallel, efforts were initiated to transfer the understanding of submarining and the prediction criteria to the THOR dummies. Both the biofidelity targets and the criteria were scaled down from the 50th percentile male to the 5th percentile THOR female. The objective of this project was to run a set of reference PMHS tests in order to check the biofidelity of the THOR F05 in terms of submarining. Three series of tests were performed on nine PMHS, the first one was designed to avoid submarining, the second and third ones were designed to result in submarining.

Petit et al. 2015 and Lebarbé et al. 2016 reported on two studies where the injury mechanism and threshold of the sacroiliac joint were investigated in two slightly oblique crash test conditions from 18 Post Mortem Human Subjects (PMHS) tests. They concluded that the sacroiliac joint fractures were associated with pubic rami fractures. These latter being reported to occur first in the time history. Therefore it was recommended not to define a criterion specific for the sacroiliac joint. In 2012, injury risk curves were published for the WorldSID dummy by Petitjean et al. For the pelvis, dummy and PMHS paired tests from six configurations were used (n = 55). All of these configurations were pure lateral impacts. In addition, the sacroiliac joint and femur neck loads were not recorded, and the dummy used was the first production version (WorldSID revision 1). Since that time, the WorldSID was updated several times, including changes in the pelvis area.

This study aims to provide a set of reference post-mortem human subject tests which can be used, with easily reproducible test conditions, for developing and/or validating pedestrian dummies and computational human body models against a road vehicle. An adjustable generic buck was first developed to represent vehicle front-ends. It was composed of four components: two steel cylindrical tubes screwed on rigid supports in V-form represent the bumper and spoiler respectively, a quarter of a steel cylindrical tube represents the bonnet leading edge, and a steel plate represents the bonnet. These components were positioned differently to represent three types of vehicle profile: a sedan, a SUV and a van. Eleven post-mortem human subjects were then impacted laterally in a mid-gait stance by the bucks at 40 km/h: three tests with the sedan, five with the SUV, and three with the van.

A CVT variator chain system is superior in transmission efficiency to a belt system because of its lower internal friction. However, a chain produces more noise than a belt due to the long pitch length of contact between the pulleys and rocker pins. This study focuses on optimization of the pitch sequence for reducing chain noise. The previous pitch sequence was suitably combined of links of different lengths to improve noise dispersibility for reducing chain noise. First, the object function was defined as the reduction of the peak level of 1st-order chain noise combined with a well-balanced the levels on the low and high frequency sides. Interior background noise consisting of road noise and wind noise have the characteristic that they increase as the frequency decreases.

This paper presents the technologies incorporated in an electric vehicle (EV)/hybrid electric vehicle (HEV) inverter built with power semiconductors of silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFETs) instead of conventional silicon (Si) insulated gate bipolar transistors (IGBTs). A SiC inverter prototype of 2.9 L in size for driving an 80-kW motor was fabricated and evaluated on a motor test bench. The SiC inverter prototype attained average efficiency of 98.5% in the Worldwide harmonized Light-duty Test Cycle (WLTC) driving mode. The two main technologies achieved with this SiC inverter prototype are described. The first one is a new direct-cooled power module with a thick copper (Cu) heat spreader located under the semiconductors that improves thermal resistance by 34% compared with a conventional direct-cooled power module.

The aim of this study was to investigate the sacroiliac joint injury mechanism. Two test configurations were selected from full scale car crashes conducted with the WorldSID 50th dummy resulting in high sacroiliac joint loads and low pubic symphysis force, i.e. severe conditions for the sacroiliac joint. The two test conditions were reproduced in laboratory using a 150-155 kg guided probe propelled respectively at 8 m/s and 7.5 m/s and with different shapes and orientations for the plate impacting the pelvis. Nine Post Mortem Human Subject (PMHS) were tested in each of the two configurations (eighteen PMHS in total). In order to get information on the time of fracture, eleven strain gauges were glued on the pelvic bone of each PMHS. Results - In the first configuration, five PMHS out of nine sustained AIS2+ pelvic injuries. All five presented sacroiliac joint injuries associated with pubic area injuries.

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.

Interior noise caused by exterior air flow, or wind noise, is one of the noise-and-vibration phenomena for which a systematic simulation method has been desired for enabling their prediction. One of the main difficulties in simulating wind noise is that, unlike most other noises from the engine or road input, wind noise has not one but two different types of sources, namely, convective and acoustic ones. Therefore, in order to synthesize the interior sound pressure level (SPL), the body sensitivities (interior SPL/outer source level) for both types of sources have to be considered. In particular, sensitivity to the convective input has not been well understood, and hence it has not been determined. Moreover, the high-frequency nature of wind noise (e.g., the main energy range extends up to 4000 Hz) has limited the effective application of CAE for determining body sensitivities, for example, from the side window glass to the occupants’ ears.

Road Noise is generated by the change of random displacement input inside the tire contact patch. Since the existing 3 or 6 directional electromagnetic shakers have a flat surface at the tire contact patch, these shakers cannot excite the vehicle in a manner representative of actual on-road road noise input. Therefore, this paper proposes a new experimental method to measure the road noise vehicle transfer function. This method is based on the reciprocity between the tire contact patch and the driver's ear location. The reaction force sensor of the tire contact patch is newly developed for the reciprocal loud speaker excitation at the passenger ear location. In addition, with this equipment, it is possible to extract the dominant structural mode shapes creating high sound pressure in the automotive interior acoustic field. This method is referred to as experimental structure mode participation to the noise of the acoustic field in the vibro-acoustic coupling analysis.

In the ECE 127 Regulation on pedestrian leg protection, as well as in the Euro NCAP test protocol, a legform impactor hits the vehicle at the speed of 40 kph. In these tests, the knee is fully extended and the leg is not coupled to the upper body. However, the typical configuration of a pedestrian impact differs since the knee is flexed during most of the gait cycle and the hip joint applies an unknown force to the femur. This study aimed at investigating the influence of the inertia of the upper body (modelled using an upper body mass fixed at the proximal end of the femur) and the initial knee flexion angle on the lower limb injury outcome. In total, 18 tests were conducted on 18 legs from 9 Post Mortem Human Subjects (PMHS). The principle of these tests was to impact the leg at 40 kph using a sled equipped with 3 crushing steel tubes, the stiffness of which were representative of the front face of a European sedan (bonnet leading edge, bumper and spoiler).