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This paper describes a novel approach for modeling an automotive HVAC unit. The model consists of black-box models trained with experimental data from a self-developed measurement setup. It is capable of predicting the temperature and mass flow of the air entering the vehicle cabin at the various air vents. A combination of temperature and velocity sensors is the basis of the measurement setup. A measurement fault analysis is conducted to validate the accuracy of the measurement system. As the data collection is done under fluctuating ambient conditions, a review of the impact of various ambient conditions on the HVAC unit is performed. Correction models that account for the different ambient conditions incorporate these results. Numerous types of black-box models are compared to identify the best-suited type for this approach. Moreover, the accuracy of the model is validated using test drive data.

The Hydrogen-Balance equation makes it possible to calculate the fuel economy or fuel consumption of hydrogen powered vehicles simply by analyzing exhaust emissions. While the benefits of such a method are apparent, it is important to discuss possible influencing factors that may decrease Hydrogen-Balance accuracy. Measuring vehicle exhaust emissions is done with a CVS (Constant Volume Sampling) system. While the CVS system has proven itself both robust and precise over the years, utilizing it for hydrogen applications requires extra caution to retain measurement accuracy. Consideration should be given to all testing equipment, as well as the vehicle being tested. Certain environmental factors may also play a role not just in Hydrogen-Balance accuracy, but as also in other low emission testing accuracy.

To meet LEV and EU Stage III emission requirements, it is necessary for new catalytic converters to be designed which exceed light-off temperature as quickly as possible. The technical solutions are secondary air injection, active heating systems such as the electrically heated catalytic converter, and the close coupled catalytic converter. Engine control functions are extensively used to heat the converter and will to play a significant role in the future. The concept of relocating the converter to a position close to the engine in an existing vehicle involves new conflicts. Examples include the space requirements, the thermal resistance of the catalytic coating and high temperature loads in the engine compartment.

In the present work we investigated experimentally and computationally the unsteady flow around a BMW car model including wheels*. This simulation yields mean flow and turbulence fields, enabling the study aerodynamic coefficients (drag and lift coefficients, three-dimensional/spatial wall-pressure distribution) as well as some unsteady flow phenomena in the car wake (analysis of the vortex shedding frequency). Comparisons with experimental findings are presented. The computational approach used is based on solving the complete transient Reynolds-Averaged Navier-Stokes (TRANS) equations. Special attention is devoted to turbulence modelling and the near-wall treatment of turbulence. The flow calculations were performed using a robust, eddy-viscosity-based ζ - ƒ turbulence model in the framework of the elliptic relaxation concept and in conjunction with the universal wall treatment, combining integration up to the wall and wall functions.

Although hydrogen ICE engines have existed in one sort or another for many years, the testing of fuel consumption by way of exhaust emissions is not yet a proven method. The current consumption method for gasoline- and diesel-fueled vehicles is called the Carbon-Balance method, and it works by testing the vehicle exhaust for all carbon-containing components. Through conservation of mass, the carbon that comes out as exhaust must have gone in as fuel. Just like the Carbon-Balance method for gas and diesel engines, the new Hydrogen-Balance equation works on the principle that what goes into the engine must come out as exhaust components. This allows for fuel consumption measurements without direct contact with the fuel. This means increased accuracy and simplicity. This new method requires some modifications to the testing procedures and CVS (Constant Volume Sampling) system.

A new simulation tool was established and approved by TRW as part of the continuous improvement of the development process. This tool allows the OEM and the system supplier to keep high quality even with further reduced development times. The introduction of the tool in a side air-bag development program makes it possible to ensure high development confidence with a reduced number of vehicle crash tests and late availability of interior component parts.

In automotive open-jet wind tunnels reference velocity is usually measured in terms of a static pressure difference between two different cross-sectional areas of the tunnel. Most commonly used are two sections within the nozzle (Method 1: ΔP-Nozzle). Sometimes, the reference velocity is deduced from the static pressure difference between settling chamber and plenum (Method 2: ΔP-Plenum). Investigations in three full-scale open-jet automotive wind tunnels have clearly shown that determination of reference dynamic pressure according to ΔP-Plenum is physically incorrect. Basically, all aerodynamic coefficients, including drag coefficient, obtained by this method are too low. For test objects like cars and vans it was found that the error ΔcD depends on the test object's drag blockage in an open-jet wind tunnel.

The Energy and Environment Test Centre (EVZ) is a complex comprising three large climatic wind tunnels, two smaller test chambers, nine soak rooms and support infrastructure. The capabilities of the wind tunnels and chambers are varied, and as a whole give BMW the ability to test at practically all conditions experienced by their vehicles, worldwide. The three wind tunnels have been designed for differing test capabilities, but share the same air circuit design, which has been optimized for energy consumption yet is compact for its large, 8.4 m₂, nozzle cross-section. The wind tunnel test section was designed to meet demanding aerodynamic specifications, including a limit on the axial static pressure gradient and low frequency static pressure fluctuations - design parameters previously reserved for larger aerodynamic or aero-acoustic wind tunnels. The aerodynamic design was achieved, in-part, by use of computational fluid dynamics and a purpose-built model wind tunnel.

Air charge calibration of turbocharged SI gasoline engines with both variable inlet valve lift and variable inlet and exhaust valve opening angle has to be very accurate and needs a high number of measurements. In particular, the modeling of the transition area from unthrottled, inlet valve controlled resp. throttled mode to turbocharged mode, suffers from small number of measurements (e.g. when applying Design of Experiments (DoE)). This is due to the strong impact of residual gas respectively scavenging dominating locally in this area. In this article, a virtual residual gas sensor in order to enable black-box-modeling of the air charge is presented. The sensor is a multilayer perceptron artificial neural network. Amongst others, the physically calculated air mass is used as training data for the artificial neural network.

Nowadays, a continually growing system complexity due to the development of an increasing number of vehicle concepts in a steadily decreasing development time forces the engineering departments in the automotive industry to a deepened system understanding. The virtual design and validation of individual components from subsystems up to full vehicles becomes an even more significant role. As an answer to the challenge of reducing complete hardware prototypes, the virtual competence in NVH, among other methods, has been improved significantly in the last years. At first, the virtual design and validation of objectified phenomena in analogy to hardware tests via standardized test rigs, e.g. four poster test rig, have been conceived and validated with the so called MBS (Multi Body Systems).

Air conditioning acoustics have become of paramount importance in electric vehicles, where noise from electromechanical components is no longer masked by the presence of the internal combustion engine. In a car HVAC systems, the coolant compressor is one of the most important sources in terms of vibration and noise generation. The paper, the generated structural noise is studied in detail on a prototype installation, and the noise transmission and propagation mechanisms are analyzed and discussed. Through ”in situ” measurements and virtual point transformation, the rotor unbalance forces and torque acting within the component are identified. The dynamic properties of the rubber mounts, installed between the compressor and its support, are identified thanks to matrix inversion methods. To assess the quality of the proposed procedure, the synthesized sound pressure level is compared with experimental SPL measurements in different operational conditions.

This paper provides a method that corrects errors induced by the empty-tunnel pressure distribution in the aerodynamic forces and moments measured on an automobile in a wind tunnel. The errors are a result of wake distortion caused by the gradient in pressure over the wake. The method is applicable to open-jet and closed-wall wind tunnels. However, the primary focus is on the open tunnel because its short test-section length commonly results in this wake interference. The work is a continuation of a previous paper [4] that treated drag only at zero yaw angle. The current paper extends the correction to the remaining forces, moments and model surface pressures at all yaw angles. It is shown that the use of a second measurement in the wind tunnel, made with a perturbed pressure distribution, provides sufficient information for an accurate correction. The perturbation in pressure distribution can be achieved by extending flaps into the collector flow.

Increasing demand for utilities like navigation systems or user-defined electronic phonebooks on one hand and sophisticated engine and gear controls on the other hand leads to growing bus load between distributed local control units. This paper shows the benefits and the characteristics of various state of the art data-compression algorithms and their impact on typical automotive multiplex dataclasses. The evaluation and optimization of promising algorithms can be done via a proposed “communications prototyping”-approach. The hardware/software components of such a rapid prototyping package are outlined. Finally, first performance results of suitable data-compression measures are presented.

The use of micro controllers in automotive systems renders the coordination of about 150 actors (70 electric motors, 15 magnetic valves and 50 relays). The resulting complexity of those systems as well as the requested zero defects demands time consuming testing. This work describes a method of performing test-scenarios, starting from a zero defect running specification, modeled by finite state machines. The test-scenarios are intended to determine whether a given system meets all specification requirements. First, a kind of structured modelling reactive automotive systems is deduced. Next, some important test selection methods, developed for the case the specification is given in the form of a finite state machine, are considered. Finally, a procedure and method for performing minimized complete test-scenarios for automotive systems are presented.

The size of the room surrounding the wind tunnel test section, the so called wind tunnel plenum, is always seen as an important parameter of the wind tunnel building, but has rarely been the subject of systematic investigation regarding minimal requirements to meet quality objectives for aerodynamic testing. Experimental investigations of this object were made in a quarter-scale wind tunnel (nozzle area 1.4m2). The plenum dimensions were changeable by combinations of different side wall and ceiling positions. The results have shown, that the plenum can have a significant effect on the flow around the vehicle and therefore on the measured forces. Drag coefficient is under prediced if the wind tunnel plenum is too small. Recommendations are provided for the geometric dimensions of a wind tunnel plenum. The data obtained are a valuable tool for the layout of wind tunnel design concepts and for the evaluation of interference free wind tunnel simulation.

The increasing complexity of communication protocols for asynchronous multiplex systems requires the use of simulation during the optimisation of these protocols or the integration of other control units. Consideration of realistic communication behaviour of the connected control units is essential for performance analysis of multiplex systems. For a first pass, the use of simple statistical distributions (e.g. Poisson distribution) is suitable to get some simulation results. A better way to get realistic results is the approximation of empirical communication data through the use of more complex statistical distribution (e.g. mixed Erlang distributions). In this paper several approaches for the approximation of empirical data are presented. Beside simple statistical distributions (with one parameter), the use of more complex statistical distributions is discussed and methods for the identification of their parameters are presented.

A lot of very valuable information has already been gained in the process of dismantling, assorting and reconditioning plastic parts on old cars, in reconditioning defective plastic parts from workshops, and in the use of reject parts from production. This know-how is now applied primarily to increase the use of recycled plastics and to optimise the composition and design of future plastic components in the interest of recycling, since further development in these areas is essential in order to establish economically stable material cycles functioning properly in the long term. The present paper describes the most important criteria through which the materials and designs chosen affect the processes and principles of recycling in the case of plastic parts and components.

BMW has introduced new test stands for noise measurements on passenger cars and motorcycles. Information is given on room conditions, machinery equipment, sound levels, frequency ranges and types of measurement. The semi-anechoic room is designed for measuring the sound distribution emitted by a single vehicle. Road influence is simulated by a reflecting floor and a roller-dynamometer. The free field sound distribution in terms of distance and direction is measured in the anechoic room. This room has high-precision installations for sound source identification and noise mapping. The reverberation room serves to measure sound power emitted by the test object. Its second purpose is to subject the bodywork to a high-power external sound source and to measure the sound-deadening effect of the passenger compartment. In conclusion, the presentation provides reports on the initial experience with these test facilities.

How can car manufacturers, which are primary mechanical engineers, become software specialists? This is a question of prime importance for car electronics in the future. Modern vehicles offer a large number of electronic and software based functions to achieve a high level of safety, fuel economy, comfort, entertainment and security which are developed under pressure of regulations, of consumers needs and of competitive time to market aspects. This contribution draws a picture, what could be important in future for in car communication and information system in terms of development process, HW & SW architectures, partnerships in automotive industry and security of industrial properties. For this purpose the automotive development is reviewed and actual examples of system designs are given.

In order to optimise the vibro-acoustic behaviour of panel-like structures in a more systematic way, accurate structural models are needed. However, at the frequencies of relevance to the vibro-acoustic problem, the mode shapes are very complex, requiring a high spatial resolution in the measurement procedure. The large number of required transducers and their mass loading effects limit the applicability of accelerometer testing. In recent years, optical measuring methods have been proposed. Direct electronic (ESPI) imaging, using strobed continuous laser illumination, or more recently, pulsed laser illumination, have lately created the possibility to bring the holographic testing approach to the level of industrial applicability for modal analysis procedures. The present paper discusses the various critical elements of a holographic ESPI modal testing system.