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The design of the newly developed Toyota AZ series 4 cylinder engine has been optimized through both simulations and experiments to improve heat transfer, cooling water flow, vibration noise and other characteristics. The AZ engine was developed to achieve good power performance and significantly reduced vibration noise. The new engine meets the LEV regulations due to the improved combustion and optimized exhaust gas flow. A major reduction in friction has resulted in a significant improvement in fuel economy compared with conventional models. It also pioneered a newly developed resin gear drive balance shaft.

This paper describes a study of visual responses to center high mounted stop lamps (CHMSLs) using a newly developed sweeping neon lamp. This study compares sweeping neon, incandescent, and light-emitting diode (LED) technologies. The incandescent CHMSL was a conventional after-market CHMSL brake light. The sweeping neon CHMSL used a novel controller whereby the luminous signal started at the center of the neon tube and grew in a “sweeping” motion outward toward the ends of the tube at an adjustable rate. The sweeping LED CHMSL had a segmented display simulating the sweeping characteristics of the neon CHMSL. Both the neon and LED CHMSLs had faster onset times than the incandescent CHMSL. Experimental subjects performed a tracking task cognitively similar to driving, and released a flip switch upon detecting the onset of the CHMSLs, which were mounted so as to be seen peripherally.

This paper describes the cluster analysis technique and how it can be used to support menu interface design for in-vehicle multimedia applications. Cluster analysis and similar types of classifying techniques have proven effective for developing simple menu interfaces. This paper extends the use of the cluster analysis technique to a more complex system that consists of 201 generic functions. These functions are representative of those being incorporated into near-term multimedia products. Study results show promise for using cluster analysis as a tool for incorporating the user's organizational structure into the design of a complex menu architecture. Cluster analysis may also benefit the automotive menu designer by providing a means for partitioning menu tasks into chunkable units that can be easily accessed by the driver in single glances.

This paper will describe the BorgWarner Interactive Torque Management (ITM) system for FWD based AWD systems as well as the utilization of P/M technology for critical components within this system. The ITM is an electro-mechanical coupling device. The device consists of an electromagnet, ball ramp and wet clutch system. The system can be mounted anywhere in the drive line as well as integrated into components such as transfer cases and transaxles. The clutch actuation force is dependent on the current applied to the electromagnetic coil, providing a truly variable torque transfer device. The decision to make extensive use of P/M technology in the structural portion of this system was based on the net shape capability and weight reduction combined with the ability to chose from a wide range of engineered materials that resulted in the most economical total system package.

The confrontation between the lean, clean, fast and compact demands of an advanced manufacturing environment and the traditional parameters of impregnation are enormous. Impregnation is a sealing process, typically where hundreds of parts are manually packed into a process basket, and subsequently transferred between a series of large tanks, over a one-two hour cycle. Achieving the integration of impregnation into a lean manufacturing environment addresses: batch sizes, process times, equipment foot print, plant layout and mobility, environmental waste and automated component handling. Documented by case studies, a new generation of equipment and materials were developed. These advancements were the result of a systematic approach combining process, equipment and chemicals to enable a traditional batch process to be integrated onto the lean manufacturing shop floor.

Although computer models for vehicle and sub-system performance simulations have been developed and used extensively in the past several decades, there is currently a need to enhance the overall availability of these types of tools. Increasing demands on vehicle performance targets have intensified the need to obtain rapid feedback on the effects of vehicle modifications throughout the entire development cycle. At the same time, evolution of the PC and development of Web-based applications have contributed to the availability, accessibility, and user-friendliness of sophisticated computer analysis. Web engineering is an ideal approach in supporting globalization and is a cost-effective design-analysis integration business strategy. There is little doubt that this new approach will have positive impacts on product cost, quality, and development cycle time. This paper will show how Microsoft Excel and the Web can be powerful and effective tools in the development process.

This paper introduces the new 1.6L engine family, designed and developed by the Chrysler group of DaimlerChrysler Corporation in cooperation with BMW. An overview of the engine's design features is provided, with a detailed review of the performance development process with emphasis on airflow, combustion, thermal management and friction. This information is presented, to provide an understanding of how the engine simultaneously achieves outstanding levels of torque, power, fuel consumption, emissions and idle stability. The use of analytical tools such as Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) in the optimization of the engine is shown.

A new CAD-based model of the occupant/driver for interior and seat design has been developed. Unlike traditional automotive iterative design methods that begin with a 2D human manikin in an environment based on the location of H-point, the 3D ERL manikins determine the initial design positions of multiple occupants based on the simulated interactions of seat, driver package, skeletal linkage system and deflected human tissue. The 3D ERL human body representations come from measurements of posture-critical skeletal landmarks on 102 test subjects combined with measurements of “deflected human tissue” data from 60 test subjects. The result is a set of three dimensional, posture-biofidelic manikins that a computer algorithm optimizes the driver's workplace environment to fit the population range of sizes and postural preferences.

Comfort is more than ever one of the major factors of car performance. The seat, a central component of the vehicle interior, contributes heavily to this perception. The increasing partnership between car manufacturers and automotive system equipment manufacturers pushes Faurecia to propose not only standard components but also a complete seat, with its functional and safety criteria, as well as those including comfort. This last aspect is what we will treat here. We are going to show you how the Soft & Firm Seat, a technical innovation developed by Faurecia, improves seat tactile and contact comfort behavior perceived by customers. This innovation has been designed according to Faurecia comfort methodology, using subjective assessment, objective measurements and simulation. Its validation concerns tactile and contact comfort, interactions with other comfort aspects and consequently the improvement of overall comfort.

Industrial computed tomography has developed from a medical technology base. As such industrial systems reflect medical requirements which are not necessarily efficient for industrial applications. The Tangential CT scanner is truly a volume scanner system designed for industrial inspection. The part motions required for CT data collection are efficient and fit well with part handling motions normally used by industrial inspection equipment. The part enters the system, moves through the scanning station and exits with a single linear motion. The detectors are designed for industrial applications to maximize sensitivity while minimizing electronic and x-ray scatter noise. The system can be easily programed for different size parts with different resolution requirements. The result is a data set that is acquired efficiently and has the required volumetric data for Flaw detection, Metrology or Reverse Engineering.

Due to the wide and ever increasing application of thermoplastics for the transportation and automotive industries, the performance of the under-the-hood plastic parts depend upon optimized design and processing technology and properties of polymer based materials. Nylon (polyamide) based plastics are used widely for automotive cooling fans and various under-the-hood injection molded components. For injection molding of multi-blade cooling fans and various rotating plastic parts the complex of multiple gating injection molding tools were used. Both the design of the various rotating parts (including industrial and automotive cooling fan, and the molding tool design are very important to get optimum flow patterns and to predict the locations and interaction of stress-bearing areas and knit lines (planes or inter-phases)1. The mechanical performance of the injection-molded thermoplastic components depends on the peculiarity of the part and the molding tool design.

Engineering thermoplastics were successfully utilized in the design of injection molded rotating parts such as the impellers, wheels, and cooling fans of commercial air-cooled chillers, and gas and diesel engines. Complex aerodynamic and mechanical performance of impellers and cooling fans are very important for the efficiency of integrated air-movement, climate control and cooling systems of various types of engines of vehicles, cars, heavy-duty tractors and trucks. The transportation and automotive industries have developed a culture of reliability and cost effectiveness, in which high risks and adventures are not encouraged. Due to the wide and ever increasing application of thermoplastics for the transportation and automotive industries, the performance of the under-the-hood parts depend upon optimized design and processing technology and properties of polymer based materials.

A comparative study of the mechanical performance of welded polyamide joints is evaluated. Under optimized welding (linear and orbital vibration, hot plate, transmission laser) conditions, the tensile strength of welded polyamide/nylon (filled and fiber-reinforced) is close or slightly higher (up to 14%) than the tensile strength of the base polymer (non-filled polyamide). In this study, the influence of two important effects (local reinforcement and “memory”) on the mechanical performance of polyamide/nylon welds is analyzed and discussed. The results presented in this study will help plastic part designers, material developers and manufacturers, choose optimized welding conditions for polyamide/nylon parts in a wide range of industrial applications.

When designing new rear lamps the hardest effort is to create something that satisfies the sake of novelty of the car maker. Main tasks of rear lamps are as follows: they must fulfil photometrical requirements, be as cheaper as possible, fit into the vehicle body and appear “interesting” under the stylistic point of view. This is the case of “second reflection rear lamps”: the light of the lamp is collected by a primary reflector that deviates it on a secondary segmented reflector, the conjunction of the first and second reflector gives the needed angular deviation. These devices offer the novelty of a hidden source and of an innovative outer aspect when compared to the “single reflection rear lamps” due to the fact that some sectors appear brilliant and some dark. In this paper different mathematical concepts of the double reflection reflectors for rear lighting are explained as well as the different approaches used to calculate them and the SW tools used.

HVE 1 and PC-Crash 2 have been the subject of numerous SAE papers. Both programs have been offered to reconstructionists for the purpose of analyzing vehicle accidents and presenting the resulting motions in 3D graphical form. This paper will give an overview of the theoretical basis for the two computerized accident reconstruction and simulation tools, the user interfaces, the way they present the results, and how they compare in the analysis of different types of accidents.

The piston ring design using low tangential force to reduce friction loss has become a general trend in engine development - especially in passenger car engine - in recent years. This trend emphasizes the importance of stable sealing function that does not require much tangential force. Thus, it is important to grasp the correct pressure distribution between the ring and the cylinder. Reliable and accurate calculation to understand the pressure distribution has been an issue for many years among the engineers. In this report, we propose a new calculation method based on the piston ring contour in a free condition. Generally, the piston ring contour is calculated to achieve its correspondence to a given pressure distribution. By analyzing inversely, the pressure distribution is calculated when a ring contour is given. But as is well known, the solution is often unstable in inverse analyses. We introduced the idea of the method of least squares to avoid this problem.

Beside the traditional prediction of stresses and verification by mechanical testing the optimization of cylinder liner bore distortion is one of today's most important topics in crankcase structure development. Low bore distortion opens up potentials for optimizing the piston group. As the piston rings achieve better sealing characteristics in a low deformation cylinder liner, oil consumption and blow-by are reduced. For unchanged oil consumption and blow-by demands, engine friction and subsequently, fuel consumption could be reduced by decreasing the pre-tension of the piston rings. From the acoustical point of view an optimization of piston-slap noise is often based on an optimized bore distortion behavior. Apart from basics to the behavior of liner bore distortion the paper presents advanced analytical and empirical methods for detailed prediction, verification and optimization of bore distortion taking into account the effective engine operation conditions.

Today, a number of simulation codes are available for pre-designing gas exchange systems of IC engines with good accuracy (e.g. PROMO, WAVE, GT-Power). However, optimizing such systems still requires numerous time consuming and inefficient trial and error runs. Also, accounting for constraints as size, volume, peak combustion pressure etc. multiplies the necessary efforts additionally. Hence there is a strong need for efficient procedures for finding optimum designs automatically and reliably. To automatically find the global optimum design parameters under a given set of real constraints of a practical case, a multi-membered evolution-strategy based optimization code was developed. The code which efficiently finds the true optimum dimensions of gas exchange systems (duct lengths, duct diameters, volumes) of an IC engine. The code can be readily generalized, and adapted to arbitrary optimization problems.

Coming along with the present movement towards the ultimately variable engine, the need for clear and simple models for complex engine systems is rapidly increasing. In this context Common-Rail-Systems cause a special kind of problem due to of the high amount of parameters which cannot be taken into consideration with simple map-based models. For this reason models with a higher amount of complexity are necessary to realize a representative behavior of the simulation. The high computational time of the simulation, which is caused by the increased complexity, makes it nearly impossible to implement this type of model in software in closed loop applications or simulations for control purposes. In this paper a method for decreasing the complexity and accelerating the computing time of automotive engine models is being evaluated which uses an optimized method for each stage of the diesel engine process.

An electromechanically driven valve train offers unprecedented flexibility to optimize engine operation for each speed load point individually. One of the main benefits is the increased fuel economy resulting from unthrottled operation. The absence of a restriction at the entrance of the intake manifold leads to wave propagation in the intake system and makes a direct measurement of air flow with a hot wire air meter unreliable. To deliver the right amount of fuel for a desired air-fuel ratio, we therefore need an open loop estimate of the air flow based on measureable or commanded signals or quantities. This paper investigates various expressions for air charge in camless engines based on quasi-static assumptions for heat transfer and pressure.