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The optimum driving dynamics can be achieved only when the tire forces on all four wheels and in all three coordinate directions are monitored and controlled precisely. This advanced level of control is possible only when a vehicle is equipped with several active chassis control systems that are networked together in an integrated fashion. To investigate such capabilities, an electric vehicle model has been developed with four direct-drive in-wheel motors and an active steering system. Using this vehicle model, an advanced slip control system, an advanced torque vectoring controller, and a genetic fuzzy active steering controller have been developed previously. This paper investigates whether the integration of these stability control systems enhances the performance of the vehicle in terms of handling, stability, path-following, and longitudinal dynamics.

A two-passenger, all-wheel-drive urban electric vehicle (AUTO21EV) with four direct-drive in-wheel motors has been designed and developed at the University of Waterloo. An advanced genetic-fuzzy active steering controller is developed based on this vehicle platform. The rule base of the fuzzy controller is developed from expert knowledge, and a multi-criteria genetic algorithm is used to optimize the parameters of the fuzzy active steering controller. To evaluate the performance of this controller, a computational model of the AUTO21EV is driven through several standard test maneuvers using an advanced path-following driver model. As the final step in the evaluation process, the genetic-fuzzy active steering controller is implemented in a hardware- and operator-in-the-loop driving simulator to confirm its performance and effectiveness.

A two-passenger, all-wheel-drive urban electric vehicle (AUTO21EV) with four direct-drive in-wheel motors has been designed and developed at the University of Waterloo. A 14-degree-of-freedom model of this vehicle has been used to develop a genetic fuzzy yaw moment controller. The genetic fuzzy yaw moment controller determines the corrective yaw moment that is required to stabilize the vehicle, and applies a virtual yaw moment around the vertical axis of the vehicle. In this work, an advanced torque vectoring controller is developed, the objective of which is to generate the required corrective yaw moment through the torque intervention of the individual in-wheel motors, stabilizing the vehicle during both normal and emergency driving maneuvers. Novel algorithms are developed for the left-to-right torque vectoring control on each axle and for the front-to-rear torque vectoring distribution action.

Recent work at the University of Waterloo addressed the hot stamping of a lab-scale B-pillar using a heated and cooled die to produce a tailored part with a soft and hard region for which the microstructure was predominantly bainitic and martensitic, respectively. This paper addresses the tensile properties of the transition zone (hard to soft region) within this tailored hot stamping using experimental and numerical methods. Vickers hardness measurement showed that the fully softened and hardened material conditions were achieved across a 25 mm transition zone. Sub-size ASTM uniaxial tensile specimens were cut from the transition zone and pulled to failure. Due to the large variation in material properties within the gauge length of the specimens, apparent uniform elongations measured across the gauge length ranged from 0.02 to 0.04 engineering strain, while the calculated engineering ultimate tensile strength (UTS) varied from 798 to 913 MPa.

In this work, a new air hybrid engine configuration is introduced in which cam-based valvetrain along with three-way and unidirectional valves make the implementation of different air hybrid engine operational modes possible. This configuration simplifies the air hybrid engine valvetrain significantly and relaxes the necessity of using fully flexible valvetrain in air hybrid engines. Utilizing the proposed configuration allows compression braking (CB), air motor (AM), startup and conventional modes of operation to be realized. The proposed configuration is modeled in GT-Power and the deceleration of a typical vehicle, utilizing only regenerative braking system, is simulated. The efficiency of the system in storing the vehicle's kinetic energy is determined using second law definition for efficiency. The stored energy can be used to either start up the engine or run the off-engine accessories. These two modes are studied and compared.

Electric energy storage is among the most significant hurdles to deployment of electric vehicles (EVs). Present storage methods struggle to provide the capacity and the service life demanded by automotive use. Hybrid energy storage systems (HESS) use a combination of storage types, for example, different types of batteries and ultracapacitors, to tailor the characteristics of the storage system to each application. In addition to sizing the system for the intended application, a suitable strategy for the integration of the energy storage system must be adopted. In the present application, a HESS has been designed for the electrification of a 2004 Chrysler Pacifica, through consideration of a combination of high capacity batteries, high power batteries, and capacitors. Hybrid storage systems using batteries alone, batteries and capacitors, and dual batteries have been considered.

Interest in magnesium, as the lightest engineering metal, has increased in the automotive industry as a result of requirements for lighter and cleaner vehicles. Resistance spot welding (RSW) is already the predominant mode of fabrication in this industry, and the fatigue of spot welded magnesium sheet must be studied. In this study, the tensile and fatigue strength of resistance spot welded AZ31 Mg alloy was studied. Three sets of tensile shear spot welded specimens were prepared with different welding parameters to achieve different nugget sizes. Metallographic examination revealed grain size changes from the base material (BM) to heat affected zone (HAZ) to the fusion zone (FZ). Monotonic tensile and fatigue tests were conducted and the effect of nugget size on tensile shear and fatigue strength was discussed.

Magnesium alloy extrusions offer potentially more mass saving compared to magnesium castings. One of the tasks in the United States Automotive Materials Partnership (USAMP) ?Magnesium Front End Research and Development? (MFERD) project is to evaluate magnesium extrusion alloys AM30, AZ31 and AZ61 for automotive body applications. Solid and hollow sections were made by lowcost direct extrusion process. Mechanical properties in tension and compression were tested in extrusion, transverse and 45 degree directions. The tensile properties of the extrusion alloys in the extrusion direction are generally higher than those of conventional die cast alloys. However, significant tension-compression asymmetry and plastic anisotropy need to be understood and captured in the component design.

Magnesium alloys are the lightest structural metal and recently attention has been focused on using them for structural automotive components. Fatigue and durability studies are essential in the design of these load-bearing components. In 2006, a large multinational research effort, Magnesium Front End Research & Development (MFERD), was launched involving researchers from Canada, China and the US. The MFERD project is intended to investigate the applicability of Mg alloys as lightweight materials for automotive body structures. The participating institutions in fatigue and durability studies were the University of Waterloo and Ryerson University from Canada, Institute of Metal Research (IMR) from China, and Mississippi State University, Westmorland, General Motors Corporation, Ford Motor Company and Chrysler Group LLC from the United States.

Fully Flexible Valve Actuation (FFVA) systems provide maximum flexibility to adjust lift profiles of engine intake and exhaust valves. A research grade electro-hydraulic servo valve based FFVA system was designed to be used with an engine in a test cell to precisely follow desired lift profiles. Repetitive control was chosen as the control strategy. Crank angle instead of time is used to trigger execution to ensure repeatability. A single control is used for different engine speeds even though the period for one revolution changes with engine speeds. The paper also discusses lift profile extension, instantaneous lift profile switching capability and built-in safety features.

Casting, machining and structural simulations were completed on a V8 engine block made in Compacted Graphite Iron (CGI) for use in a racing application. The casting and machining simulations generated maps of predicted tensile strength and residual stress in the block. These strength and stress maps were exported to a finite element structural model of the machined part. Assembly and operating loads were applied, and stresses due to these loads were determined. High cycle fatigue analysis was completed, and three sets of safety factors were calculated using the following conditions: uniform properties and no residual stress, predicted properties and no residual stress, and predicted properties plus residual stress.

Since 1997, General Motors Body Manufacturing Engineering - Die Engineering Services (BME-DES) has been working jointly with our software vendor to develop and implement a parallel version of stamping simulation software for mass production analysis applications. The evolution of this technology and the insight gained through the implementation of DMP/MPP technology as well as performance benchmarks are discussed in this publication.

Constrained Layer Damping (CLD) treatments have long provided a means to effectively impart damping to a structure [1, 2 and 3]. Traditionally, CLD treatments are constructed of a very thin polymer layer constrained by a thicker metal layer. Because the adhesion of a thin polymer layer is very sensitive to surface finish, surfaces that a CLD treatment can be effectively applied to have historically been limited to those that are very flat and smooth. New developments in material technology have provided thicker materials that are very effective and less expensive to apply when used as the damping layer in a CLD treatment. This paper documents the effectiveness of such a treatment on a cast aluminum front cover for a V6 engine. Physical construction of the treatment, material properties and design criteria will be discussed. Candidate applications, the assembly process, methods for secondary mechanical fastening will be presented.

The ozone forming potential (OFP) and specific reactivity (SR) of tailpipe exhaust are among the factors that determine the environmental impact of a motor vehicle. OFP and SR measurements require a lengthy determination of about 190 non-methane hydrocarbon species. A rapid gas chromatography (GC) instrument has been constructed to separate both the light (C2 - C4) and the midrange (C5 - C12) hydrocarbons in less than 10 minutes. The limit of detection is about 0.002 parts per million carbon (ppmC). Thirty exhaust samples from natural gas vehicles (NGV's) were analyzed to compare the rapid GC method with the standard GC method, which required 40-minute analyses on two different instruments. In general, evaluation of the commercial prototype from Separation Systems, Inc., indicates that a high speed, high resolution gas chromatograph can meet the need for fast, efficient exhaust hydrocarbon speciation.

In a complex system, large numbers of design variables and responses are involved in performance analysis. Relationships between design variables and individual responses can be complex, and the outcomes are often competing. In addition, noise from manufacturing processes, environment, and customer misusage causes variation in performance. The proposed method utilizes the two-step optimization process from robust design and performs the optimization on multiple responses using Hotelling's T2 statistic. The application of the T2-statistic allows the use of univariate tools in multiple objective problems. Furthermore, the decomposition of T20 into a location component, T2M and a dispersion component, T2D substitutes a complex multivariate optimization process with the simpler two-step procedure. Finally, using information from the experiment, a multivariate process capability estimates for the design can be made prior to hardware fabrication.

The goal of this study is to assess the total Life Cycle Global Warming Impact of the current HFC-134a (R134a) refrigeration system and compare it with the effect of proposed alternatives, HFC-134a Enhanced, HFC-152 (R152a), R744, R744 Enhanced and R290, based on life cycle analysis (LCA). The enhanced systems include control strategies to elevate the compressor suction pressure as the evaporator load is reduced. The hydrofluorocarbons HFC-134a and HFC-152a are greenhouse gases (GHGs) and are subject to the Kyoto Protocol timetables, which when the treaty takes effect will require participating developed countries to reduce their overall CO2 equivalent emissions of six GHGs by at least 5% by 2012 from 1990 levels.

This report summarizes the methodology used in automotive industry for virtual evaluation of vehicle structural integrity under abusive load cases. In particular, the development of a nonlinear finite element (FE) centric approach is covered that is based on the functions implemented in ABAQUS (by ABAQUS Inc.). An overview is also given for comparative study of the ABAQUS capability with the existing ADAMS (MSC Software) based methods.

Auto components with large manufacturing variation may cause vehicle quality problems after they are assembled. The impact of this variation depends on the assembly process used. If the assembly process is sensitive to the component variation, the impact may be more significant. In this case, an assembly process with lower sensitivity to component variation will solve the problem. This paper presents an example where the component variation largely impacted the quality of the car, and a more robust assembly process solved the problem.

The development and application of a traction control Kodiak and GMC TopKick are explained. Most traction systems use engine management to enable traction control, while the adaptive braking system can provide traction assist for either gas or Diesel powered vehicles from 14,000 lbs. to 33,000 lbs. GVW. The performance driven criteria that established the design requirements and the development of a new product to meet these objectives are discussed. Both the vehicle manufacturer and the traction controller supplier provided these criteria. The basic ABS and traction control hydraulic schematics will be described as they apply to the vehicles. The results of the development program will be compared to the criteria used to establish the goals, and the benefits of the traction control system will be discussed.

This study examined whether the effect of subsidiary tasks on driving performance can be predicted from stationary (static) testing. Alternative methods for assessing the performance of drivers during their use of in-vehicle information systems were examined. These methods included static testing in stationary vehicles, as well as dynamic, on-road testing. The measures that were obtained from static tests were evaluated in terms of how well they could predict measures obtained from driving performance during on-road testing (which included concurrent use of secondary information systems). The results indicated that measures obtained in static test settings were highly correlated with corresponding measures obtained from on-road performance testing.