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This paper presents the work performed by the Wayne State University (WSU) EcoCAR 3 student design competition team in its preparation for the hybrid electric vehicle architecture selection process. This process is recognized as one of the most pivotal steps in the EcoCAR 3 competition. With a key lesson learned from participation in EcoCAR 2 on “truly learning how to learn,” the team held additional training sessions on architecture selection tools and exercises with the goal of improving both fundamental and procedural skills. The work conducted represents a combination of the architecture feasibility study and final selection process in terms of content and procedure, respectively. At the end of this study the team was able to identify four potentially viable hybrid powertrain architectures, and thoroughly analyze the performance and packaging feasibility of various component options.

A key aim of research into cell phone tasks is to obtain an unbiased estimate of their relative risk (RR) for crashes. This paper re-examines five RR estimates of cell phone conversation in automobiles. The Toronto and Australian studies estimated an RR near 4, but used subjective estimates of driving and crash times. The OnStar, 100-Car, and a recent naturalistic study used objective measures of driving and crash times and estimated an RR near 1, not 4 - a major discrepancy. Analysis of data from GPS trip studies shows that people were in the car only 20% of the time on any given prior day at the same clock time they were in the car on a later day. Hence, the Toronto estimate of driving time during control windows must be reduced from 10 to 2 min.

The present investigation details an experimental procedure for frontal impact responses of a generic steel front bumper crush can (FBCC) assembly subjected to a rigid full and 40% offset impact. There is a paucity of studies focusing on component level tests with FBCCs, and of those, speeds carried out are of slower velocities. Predominant studies in literature pertain to full vehicle testing. Component level studies have importance as vehicles aim to decrease weight. As materials, such as carbon fiber or aluminum, are applied to vehicle structures, computer aided models are required to evaluate performance. A novel component level test procedure is valuable to aid in CAE correlation. All the tests were conducted using a sled-on-sled testing method. Several high-speed cameras, an IR (Infrared) thermal camera, and a number of accelerometers were utilized to study impact performance of the FBCC samples.

Previously, a 10-year-old (YO) pediatric thorax finite element model (FEM) was developed and verified against child chest stiffness data measured from clinical cardiopulmonary resuscitation (CPR). However, the CPR experiments were performed at relatively low speeds, with a maximum loading rate of 250 mm/s. Studies showed that the biomechanical responses of human thorax exhibited rate sensitive characteristics. As such, the studies of dynamic responses of the pediatric thorax FEM are needed. Experimental pediatric cadaver data in frontal pendulum impacts and diagonal belt dynamic loading tests were used for dynamic validation. Thoracic force-deflection curves between test and simulation were compared. Strains predicted by the FEM and the injuries observed in the cadaver tests were also compared for injury assessment and analysis. This study helped to further improve the 10 YO pediatric thorax FEM.

Commotio Cordis (CC) is the second leading cause of mortality in youth sports. Impacts occurring directly over the left ventricle (LV) during a vulnerable period of the cardiac cycle can cause ventricular fibrillation (VF), which results in CC. In order to better understand the pathophysiology of CC, and develop a mechanical model for CC, appropriate injury criteria need to be developed. This effort consisted of impacts to seventeen juvenile porcine specimens (mass 21-45 kg). Impacts were delivered over the cardiac silhouette during the venerable period of the cardiac cycle. Four impact speeds were used: 13.4, 17.9, 22.4, and 26.8 m/s. The impactor was a lacrosse ball on an aluminum shaft instrumented with an accelerometer (mass 188 g - 215 g). The impacts were recorded using high-speed video. LV pressure was measured with a catheter. Univariate binary logistic regression analyses were performed to evaluate the predictive ability of ten injury criteria.

It is well known that sound radiation from a rectangular panel can be significantly affected by its boundary condition. However, most of the existing investigations are primarily focused on sound radiation from plates with simply supported boundary conditions. The objective of this paper is to study the effect on sound radiation of the boundary supporting conditions generally specified in the form of discrete and/or distributed restraining springs. This will have practical implications. For example, in automotive NVH design, it is of interest to understand how the sound radiation from a body panel can be affected by the number and distribution of spot-welds. It is demonstrated through numerical examples that the distribution of spot-welds can be tuned or optimized, like other conventional design parameters, to achieve maximum sound reduction.

This paper summarizes a systematic approach to control of nonlinear automotive systems exposed to fast transients. This approach is based on a combined application of hardware characterization, which inverts nonlinearities, and conventional Proportional-plus-Integral-plus-Derivative (PID) control. The approach renders the closed-loop system dynamics more transparent and simplifies the controller design and calibration for applications in automotive industry. The authors have found this approach effective in presenting and teaching PID controller design and calibration guidelines to automotive engineering audience, who at times may not have formal training in controls but need to understand the development and calibration process of simple controllers.

Hat sections made of steel are frequently encountered in automotive body structural components such as front rails. These components can absorb significant amount of impact energy during collisions thereby protecting occupants of vehicles from severe injury. In the initial phase of vehicle design, it will be prudent to incorporate the sectional details of such a component based on an engineering target such as peak load, mean load, energy absorption, or total crush, or a combination of these parameters. Such a goal can be accomplished if efficient and reliable data-based models are available for predicting the performance of a section of given geometry as alternatives to time-consuming and detailed engineering analysis typically based on the explicit finite element method.

The objective of this research is to investigate the effect of the blast load on the vehicle and occupant and identify the sensitivity of the vehicle parameters to the blast load, therefore figure out the design solution to protect the vehicle and occupant. CAE explicit commercial code, LSDYNA, is applied in this research with adopting CONWEP method for the blast load. The LSDYNA 95th percentile Hybrid III dummy model is used for occupant simulation. Seat, seat belt, and underbody and underbody armor are interested areas in the design to meet the survivability and weight target. The results show the protection can be effectively achieved through employing the new design method in three areas mentioned above.

Chapters written by professional and academic experts in the field cover: analytical modeling and analysis, CEA modeling and numerical methods, techniques for dynamometer and road test evaluation, critical parameters that contribute to brake squeal, robust design processes to reduce/prevent brake squeal via up-front design, and more.

Even under steady state operating conditions, the pressure variation in individual cylinders, and the corresponding gas-pressure torque are subjected to small random fluctuations from cycle to cycle. The gas-pressure torque of a cylinder may be expressed as a sum of harmonically variable components, each harmonic being affected by these fluctuations. A probabilistic model of the vector interpreting such a harmonic component is developed and used to determine the statistical parameters of the resultant random vector representing the corresponding harmonic order of the engine torque. At the low frequencies of the lowest harmonic orders of the engine torque the crankshaft behaves like a rigid body. This behavior permits to correlate the statistical parameters of the same harmonic components of the resultant torque and of the measured engine speed. This correlation is proved by experiments and used to identify faulty cylinders.

Analysis of flow field and charge distribution in a gasoline direct-injection (GDI) engine is performed by a modified version of the KIVA code. A particle-based spray model is proposed to simulate a swirl-type hollow-cone spray in a GDI engine. Spray droplets are assumed to be fully atomized and introduced at the sheet breakup locations as determined by experimental correlations and energy conservation. The effects of the fuel injection parameters such as spray cone angle and ambient pressure are examined for different injectors and injection conditions. Results show reasonable agreement with the measurements for penetration, dispersion, global shape, droplet velocity and size distribution by Phase Doppler Particle Anemometry(PDPA) in a constant-volume chamber. The test engine is a 4-stroke 4-valve optically accessible single-cylinder engine with a pent-roof head and tumble ports.

Rattling in the inevitable clearances between engaging teeth of mechanical power transmission components, such as gears, gear couplings and clutches, etc., is becoming a more and more important issue, especially for automotive applications. An extensive research effort in this area is mostly dedicated to modeling of complex nonlinear processes that develop after the tooth separation occurs, or to experimental studies of these processes. The available abatement techniques for the rattling noise are expensive while not providing desirable noise reduction results. The paper presents a criterial condition for opening of clearances derived for a simplified model and clearly showing importance of various design parameters on possibility of commencement of the rattling process. Also, a novel rattling noise abatement technique is described, based on incorporating simple means for prolongation of the impact interactions between the co-impacting engaging teeth.

Numerical analyses of head and neck response during side impact are presented in this paper. A mathematical human model for side impact simulation was developed based on previous studies of other researchers. The effects of muscular activities during severe side impact were analyzed with the use of this model. This study shows that the effect of muscular activities is significant especially if the occupant is prepared to resist the impact. This result suggests that the modeling of muscles is important for the simulation of real accident situation.

A humerus provisional reference value (PRV) based on human surrogate data was developed to help evaluate upper arm injury potential. The proposed PRV is based on humerus bone bending moments generated by testing pairs of cadaver arms to fracture in three-point bending on an Instron testing machine in either lateral-medial (L-M) or anterior-posterior (A-P) loading, at 218 mm/s and 0.635 mm/s loading rates. The results were then normalized and scaled to 50th and 5th percentile sized occupants. The normalized average L-M bending moment at failure test result was 6 percent more than the normalized average A-P bending moment. The normalized average L-M shear force at failure was 23 percent higher than the normalized average A-P shear force. The faster rate of loading resulted in a higher average bending moment overall - 8 percent in the L-M and 14 percent in the A-P loading directions.

More stringent regulations have been enforced over the past few years on diesel exhaust emissions. White smoke emission, a characteristic of diesel engines during cold starting, needs to be controlled in order to meet these regulations. This study investigates the sources and constituents of white smoke. The effects of fuel properties, design and operating parameters on the formation and emissions of white smoke are discussed. A new technique is developed to measure the real time gaseous hydrocarbons (HC) as well as the solid and liquid particulates. Experiments were conducted on a single cylinder direct injection diesel engine in a cold room. The gaseous HC emissions are measured using a high frequency response flame ionization detector. The liquid and solid particulates are collected on a paper filter placed upstream of the sampling line of the FID and their masses are determined.

An experimental study was carried out to characterize the spray atomization process of automotive port fuel injectors retrofitted to a novel pressure modulation piezoelectric driver, which generates a pressure perturbation inside the fuel line. Unlike many other piezoelectric atomizers, this unit does not drive the nozzle directly. It has a small size and can be installed easily between regular port injector and fuel lines. There is no extra control difficulty with this system since the fuel injection rate and injection timing are controlled by the original fuel-metering valve. The global spray structures were characterized using the planar laser Mie scattering (PLMS) technique and the spray atomization processes were quantified using phase Doppler anemometry (PDA) technique.

Dynamic data, forces, moments and displacements are widely used parameters in a simulation environment for design and testing. These results may be obtained from field tests, laboratory measurements, and numerical simulations. The correctness of the simulation results depends strongly on the models and numerical solution techniques. This paper presents a preliminary examination of the differences between results obtained from the computer code DADS (Dynamic Analysis and Design System) [1] and the field data for the response of a military tank. The differences are analyzed by standard statistical methods in the frequency domain. The statistical tests show that DADS results differ from the measured field data and that the errors are not white noise. Moreover, the principal frequencies of the differences are identified.

A global characterization of the spray distribution of various current and development types of automotive fuel injectors was obtained. Axial and radial measurement of droplet sizes, velocities and volume fluxes were made with a phase Doppler particle analyzer (PDPA) for a transient port injector spray in quiescent atmospheric conditions. Time-resolved measurements involving the time-of-arrival of each droplet associated with its size and velocity components were also acquired. Additionally, the liquid sprays emanating from various types of port fuel injectors were visualized, through planar laser induced fluorescence (PLIF) technique, at different time instants. Such detailed study provides an improved understanding of the temporal or unsteady behavior of port injector spray.

The flow structure inside the catalytic converter of gasoline engines is very important for consideration of the catalyst light-off condition, converter durability and conversion efficiency. However, the available experimental data under actual engine exhaust conditions are quite limited due to its complicated configuration, critical operating conditions and difficult optical access. Therefore, an experimental study was performed, using laser Doppler velocimetry technique, to measure the velocity distributions inside two production dual-monolith catalytic converters fitted on a firing gasoline engine over several engine operating conditions. This paper reports the normal velocity characteristics measured in a plane 1 mm away from the front surface of first monolith. A small fraction of titanium (IV) isopropoxide was dissolved in gasoline for generating titanium dioxide seeding particles during the engine combustion.