Search Results

Ride comfort is a critical factor to customer perception of vehicle quality as it is related to vehicle experience when driving. It adds value to the product and, consequently, to vehicle brand. It has become a demand not only for passenger unibody vehicles but also to larger segments including mid-size trucks. Ride quality is usually quantified as harshness which is a measure of how the vehicle transmits the road irregularities to the customer at the tactile points such as the steering wheel and seats. Improving harshness requires tuning of different parts including tires, chassis frame/subframe and suspension mounts and bushings. This paper describes the methodology to enhance the harshness performance for a mid-size truck using a full vehicle CAE model. The influence of stiffnesses of body mounts and control arms bushings to harshness response is investigated through sensitivity analysis and the optimal configuration is found.

In recent decades, significant technological advances have made cruise control systems safer, more automated, and available in more driving scenarios. However, comparatively little progress has been made in optimizing vehicle efficiency while in cruise control. In this paper, two distinct strategies are proposed to deliver efficiency benefits in cruise control by leveraging flexibility around the driver’s requested set speed, and road information that is available on-board in many new vehicles. In today’s cruise control systems, substantial energy is wasted by rigidly controlling to a single set speed regardless of the terrain or road conditions. Introducing even a small allowable “error band” around the set speed can allow the propulsion system to operate in a pseudo-steady state manner across most terrain. As long as the vehicle can remain in the allowed speed window, it can maintain a roughly constant load, traveling slower up hills and faster down hills.

Manual transmissions for passenger cars are facing pressures due to rapid growth of automatic transmissions, which already represents more than 60% of Brazil market, and from higher torque demand due to strict emission legislation, which turbo engines had presented great contribution to it. To solve this contradictory issue, gears with higher strength and lower cost have been studied to replacement Nickel by Niobium in the steels. Furthermore, this technology could be applied to solve the issues with electrified vehicle, where high torque, speed and lifetime are demanded pursued for gears. This study aimed to build prototypes and compare the S-N curves, fracture analysis, microstructure for three kinds of steels (QS4321 with Ni, QS1916 FG without Ni & with Nb and QS 1916 without Ni and Nb) in the condition carburized, hardened and tempered with and without shot peening.

As the automobile industry is moving towards Electrical vehicles, it becomes very important to have low cost and robust solution to seal all the internal Battery sub systems. It’s a known fact that various IC engine Vehicles are already using Room temperature vulcanized rubber (RTV) for many metal and composite sealing interfaces. Nevertheless, it always needs a good structural design to have good sealing performance. For designing a robust RTV joint for composite structures, it becomes important to have standard RTV chamfers. Sometimes even with these standards, it becomes very costly in having warranty issues when we have weak structure around RTV chamfers. Any joint structure involves multiple design parameters which might impact the sealing performance. Some of the joint structural parameters should be well designed at the early phase of product development cycle, which otherwise will later add lot of cost in modifying the product with its integrated components.

Any young person who has taken delight in playing with toy slot cars knows that the world of racing and the world of electric cars has been intertwined for a long time. And anyone who has driven a modern performance electric vehicle knows that the instant acceleration, exhilarating speeds, and joy of driving of slot cars is reflected in these full sized “toys”, with the many more practical benefits that come from being full-sized and steerable. There is strong foreshadowing of a vibrant future for performance cars in some of the EV’s on the market now and in the near future, some offering “ludicrous” acceleration, and others storied nameplates with performance to match. The ease at which powerful electric drives can capably hurtle a massive vehicle around the track at high speeds, combined with the potential for the same electric drives to exert powerful regenerative braking, creates a very interesting situation for brake engineers.

Over the last two decades, engine research has been mainly focused on reducing fuel consumption in view of compliance with stringent homologation targets and customer expectations. As it is well known, the objective of overall engine efficiency optimization can be achieved only through the improvement of each element of the efficiency chain, of which mechanical constitutes one of the two key pillars (together with thermodynamics). In this framework, the friction reduction for each mechanical subsystems has been one of the most important topics of modern Diesel engine development. In particular, the present paper analyzes the lubrication circuit potential as contributor to the mechanical efficiency improvement, by investigating the synergistic impact of oil circuit design, oil viscosity characteristics (including new ultra-low formulations) and thermal management. For this purpose, a combination of theoretical and experimental tools were used.

Historical metrics intended to drive the development of vehicle powertrains have focused on sounds that are characteristic of IC engines. The interior noise contribution of the propulsion system in electric vehicles has significantly more tonal noise (and much less impulsive and broadband noise) than their IC engine counterparts. This tonal noise is not adequately represented by current propulsion systems metrics. While metrics exist today that were developed to represent the presence of tones in sounds most have focused on the level aspect of the tones relative to the surrounding noise or masking level, some examples include tonality, tone-to-noise ratio, and prominence ratio. A secondary, but also important aspect of tones is the annoyance as a function of frequency. This paper will highlight the development of a tonal annoyance weighting curve that can be used to account for the frequency aspect of tonal annoyance relative to electric vehicles.

As automakers continue to develop new lightweight vehicles, the application of multi-material parts, assemblies and systems is needed to enhance overall performance and safety of new and emerging architectures. To achieve these goals conventional material selection and design strategies may be employed, such as standard material performance indices or full-combinatorial substitution studies. While these detailed processes exist, they often succeed at only suggesting one material per component, and cannot consider a clean-slate design; here, multi-material topology optimization (MMTO) is suggested as an effective computational tool for performing large-scale combined multi-material selection and design. Unlike previous manual methods, MMTO provides an efficient method for simultaneously determining material existence and distribution within a predefined design domain from a library of material options.

Many countries including India have aggressively aimed to implement electric vehicles (EVs) usage from 2030 onwards. Companies such as General Motors, Uber, Waymo and Nissan etc. are exploring the realm of autonomous vehicles (AV) for use as taxis as early as 2019. Above facts logically arrive at the solution of Autonomous EVs as taxis. With the commitment towards enabling an all-electric future, there exists a need to provide suitable infrastructure for recharging. Major urban cities located by the shoreline such as New York, Hong Kong, Mumbai, Los Angeles etc. have been facing the space crunch, with real estate prices sky-rocketing exponentially. With this premise, the operating company would need a large amount of space to store their EVs for charging which attributes to a longer downtime. This brings a need for an economical charging location that has a reduced usage of urban infrastructure and energy consumption.

With rapid increase of vehicles on the road, safety concerns have become increasingly prominent. Since the leading cause of many traffic accidents is known to be by human drivers, developing autonomous vehicles is considered to be an effective approach to solve the problems above. Although trajectory tracking plays one of the most important roles on autonomous driving, handling the coupling between trajectory-tracking control and ESP under certain driving scenarios remains to be challenging. This paper focuses on trajectory-tracking control considering the role of ESP. A vehicle model is developed with two degrees of freedom, including vehicle lateral, and yaw motions. Based on the proposed model, the vehicle trajectory is separated into both longitudinal and lateral motion. The coupling effect of the vehicle and ESP is analyzed in the paper. The lateral trajectory-tracking algorithm is developed based on the preview follower theory.

This paper describes recently developed test methods and instrumentation to address the specific noise and vibration measurement challenges posed by large-diameter single-piece tubular aluminum propeller (prop) shafts with high modal density. The prop shaft application described in this paper is a light duty truck, although the methods described are applicable to any rotating shaft with similar dynamic properties. To provide a practical example of the newly developed methods and instrumentation, impact FRF data were acquired in-situ for two typical prop shafts of significantly different diameter, in both rotating and stationary conditions. The example data exhibit features that are uniquely characteristic of large diameter single-piece tubular shafts with high modal density, including the particular effect of shaft rotation on the measurements.

Interior permanent magnet machines are being widely used in hybrid vehicles owing to their compact size and high power density. Vehicle level application requires the motor to operate at high speed beyond the base speed of the motor. This is accomplished through flux weakening control. Nonfunctioning of inverter switches and/or gate driver circuit during flux weakening could give rise to a potential fault scenario called Un-Controlled Generation (UCG). This paper gives a detailed background of UCG and its impact on the high voltage and propulsion systems. In further sections the details related to modelling and analysis of UCG will be discussed. Finally, the paper will conclude with simulation results and comparison of the results with motor dynamometer test data.

In practice, the piston wrist pin is either fixed to the connecting rod or floats between the connecting rod and the piston. The tribological behavior of fixed wrist pins have been studied by several researchers, however there have been few studies done on the floating wrist pin. A new bench rig has been designed and constructed to investigate the tribological behavior between floating pins and pin bore bearings. The experiments were run using both fixed pins and floating pins under the same working conditions. It was found that for fixed pins there was severe damage on the pin bore in a very short time (5 minutes) and material transfer occurs between the wrist pin and pin bore; however, for the floating pin, even after a long testing time (60 minutes) there was minimal surface damage on either the pin bore or wrist pin.

The Chevrolet Volt is an electric vehicle (EV) with extended-range (ER) that is capable of operation on battery power alone, and on power generated by an on-board gasoline engine after depletion of the battery charge. For 2016, GM has developed the next generation of the Volt vehicle and “Voltec” propulsion system. Building on the experience of the first generation Volt, the second generation targeted improved all-electric range, improved charge sustaining fuel economy, and improved performance. All of this was to be accomplished while maintaining the EV character of the first generation Volt which customers clearly valued. This paper describes the next generation “Voltec” system and the realized improvements in efficiency and performance. The features of the propulsion system components, including energy storage, transaxle, electric motors and power electronics, on-board charging, and engine are described and compared with the previous generation.

Electromagnetic compatibility (EMC) is becoming more important in power converters and motor drives as seen in hybrid electric vehicles (HEV) to achieve higher reliability of the vehicle and its components. Electromagnetic interference (EMI) of the electronic components for a vehicle are evaluated and validated at a component-level test bench; however, it is sometimes observed that the EMI level of the components can be changed in a vehicle-level test due to differences in the vehicle's configuration (cable routing, connecting location etc.). In this presentation, a vehicle-level EMC simulation methodology is introduced to estimate radiated emissions from a vehicle. The comparison between the simulation and measurement results is also presented and discussed.

The paper examines how the issue of lengthy development times can be mitigated by adopting a multivariable physics based control method for the development and deployment of complex engine control algorithms required for modern diesel engines equipped with Lean NOx Trap aftertreatment technology. The proposed approach facilitates manufacturers to consider lower cost powertrain configurations for selected markets while maintaining higher performance configurations for other markets. The contribution includes on-engine results from joint work between General Motors and Honeywell. The Honeywell OnRAMP Design Suite which applies model predictive control techniques was used for model identification, control design (using model predictive control) and its calibration. With no prior work on the engine this process of calibrating an engine model and achieving transient drive cycle control on the engine required ten days in the test cell and five days of offline work using the OnRAMP software.

To cope with the increasing number of advanced features (e.g., smart-phone integration and side-blind zone alert.) being deployed in vehicles, automotive manufacturers are designing flexible hardware architectures which can accommodate increasing feature content with as fewer as possible hardware changes so as to keep future costs down. In this paper, we propose a formal and quantitative definition of flexibility, a related methodology and a tool flow aimed at maximizing the flexibility of an automotive hardware architecture with respect to the features that are of greater importance to the designer. We define flexibility as the ability of an architecture to accommodate future changes in features with no changes in hardware (no addition/replacement of processors, buses, or memories). We utilize an optimization framework based on mixed integer linear programming (MILP) which computes the flexibility of the architecture while guaranteeing performance and safety requirements.

Vehicle dynamics simulation with Hardware In the Loop (HIL) has been demonstrated to reduce development and validation time for dynamic control systems. For dynamic control systems such as Anti-lock Braking System (ABS) and Electronic Stability Control (ESC), an accurate vehicle dynamics performance simulation system requires the Electronic Brake Control Module (EBCM) coupled with the vehicles brake system hardware. This kind of HIL simulation-specific software tool can further increase efficiency by means of automation and optimization of the development and validation process. This paper presents a method for HIL vehicle dynamics simulator optimization through Brake Response Time (BRT) correlation. The paper discusses the differences between the physical vehicle and the HIL vehicle dynamics simulator. The differences between the physical and virtual systems are used as factors in the development of a Design Of Experiment (DOE) quantifying HIL simulator performance.

The SAE Fuel Cell Vehicle (FCV) Safety Working Group has been addressing FCV safety for over 9 years. The initial document, SAE J2578, was published in 2002. SAE J2578 has been valuable as a Recommended Practice for FCV development with regard to the identification of hazards and the definition of countermeasures to mitigate these hazards such that FCVs can be operated in the same manner as conventional gasoline internal combustion engine (ICE)-powered vehicles. SAE J2578 is currently being revised so that it will continue to be relevant as FCV development moves forward. For example, test methods were refined to verify the acceptability of hydrogen discharges when parking in residential garages and commercial structures and after crash tests prescribed by government regulation, and electrical requirements were updated to reflect the complexities of modern electrical circuits which interconnect both AC and DC circuits to improve efficiency and reduce cost.

The SAE FCV Safety Working Group has been addressing fuel cell vehicle (FCV) safety for over 8 years. The initial document, SAE J2578, was published in 2002. SAE J2578 has been valuable to FCV development with regard to the identification of hazards and the definition of countermeasures to mitigate these hazards such that FCVs can be operated in the same manner as conventional gasoline internal combustion engine (ICE)-powered vehicles. J2578 is currently being updated to clarify and update requirements so that it will continue to be relevant and useful in the future. An update to SAE J1766 for post-crash electrical safety was also published to reflect unique aspects of FCVs and to harmonize electrical requirements with international standards. In addition to revising SAE J2578 and J1766, the Working Group is also developing a new Technical Information Report (TIR) for vehicular hydrogen systems (SAE J2579).