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Simple component models are advantageous when simulating vehicle AC systems so that overall model complexity and computation time can be minimized. These models must be robust enough to avoid instability in the iteration method used for determining the AC system operating or “balance” point. Simplicity and stability are especially important when the AC system model is coupled with a vehicle interior model for studies of transient performance because these are more computationally intensive. This paper presents a semi-empirical modeling method for compressors based on dimensionless parameters. Application to some sample compressor data is illustrated. The model equations are simple to employ and will not introduce significant stability problems when used as part of a system simulation.

This paper presents the results of CFD study on sunroof buffeting suppression using a dividing bar. The role of a dividing bar in side window buffeting case was illustrated in a previous study [8]. For the baseline model of the selected vehicle in this study, a very high level of sunroof buffeting, 133dB, has been found. The CFD simulation shows that the buffeting noise can be significantly reduced if a dividing bar is installed at the sunroof. A further optimization study on the dividing bar demonstrates that the peak buffeting level can be reduced to 123dB for the selected vehicle if the dividing bar is installed at its optimal location, 65% of the total length from the front edge of the sunroof. The peak buffeting level can be further reduced to 100dB if the dividing bar takes its optimal width 80mm, 15% of the total length of the sunroof for this vehicle, while staying at its optimal location.

The National Renewable Energy Laboratory (NREL) collaborated with Millennium Cell and DaimlerChrysler to study heat and water management in a sodium borohydride (NaBH4) storage/processor used to supply hydrogen to a fuel cell in an automotive application. Knowledge of heat and water flows in this system is necessary to maximize the storage concentration of NaBH4, which increases vehicle range. This work helps evaluate the NaBH4 system's potential to meet the FreedomCAR program technical target of 6 wt% hydrogen for hydrogen storage technologies. This paper also illustrates the advantages of integrating the NaBH4 hydrogen processor with the fuel cell.

Researchers at the National Renewable Energy Laboratory conducted outdoor vehicle thermal soak tests in Golden, Colorado, in September 2002. The same environmental conditions and vehicle were then tested indoors in two DaimlerChrysler test cells, one with metal halide lamps and one with infrared lamps. Results show that the vehicle's shaded interior temperatures correlated well with the outdoor data, while temperatures in the direct sun did not. The large lamp array situated over the vehicle caused the roof to be significantly hotter indoors. Yet, inside the vehicle, the instrument panel was cooler due to the geometry of the lamp array and the spectral difference between the lamps and sun. Results indicate that solar lamps effectively heat the cabin interior in indoor vehicle soak tests for climate control evaluation and SCO3 emissions tests. However, such lamps do not effectively assess vehicle skin temperatures and glazing temperatures.

Today the worldwide convergence towards stricter fuel consumption and emission regulations is pushing carmakers and suppliers into new fields of innovation. Valeo Engine Cooling, VEC, is contributing towards these goals by applying its thermal management system expertise in order to reduce fuel consumption and emissions by using an advanced engine cooling system that incorporated variable speed PWM fans, an electric water pump and an electric water control valve. The paper discusses the benefits in terms of engine cooling, fuel economy and emissions over the FTP drive cycle. The paper gives some examples of advanced engine cooling strategies based on a virtual, predictive metal temperature sensor that is used to actuate the electrical water pump at the desired flow rate. The electrical balance between the 42V pump and fans has also been optimized to reduce the vehicle electrical power consumption and to keep the coolant temperature close to 110°C.

Airbag-related out-of-position (OOP) injuries in automotive crash accident have drawn great attention by public in recent years. In the interim-final rule of Federal Motor Vehicle Safety Standards that NHTSA issued in May 2000, OOP static test becomes a mandatory requirement of new regulation and will be phased in starting from year 2003. Due to the complexities and constraints of vehicle design, such as extreme vehicle styling and packaging as well as multiple safety requirements, it is a great challenge for both restraint safety suppliers and automobile manufacturers work together to come up with proper designs to meet requirements of new regulation and provide additional protection for both in-position and OOP occupants at various vehicle crash scenarios. In this paper, the technique of developing advanced restraint system and mitigating the OOP injuries is described.

Traditional methods used to produce a die set (from developing initial machining cutter paths through finalized die tryout to produce a part that meets design intent) begin with draw simulation and development. It is here, traditionally, that scientific evaluation of actual metal stretch and theoretical ideals end. In past programs, a designed part would be simulated for stretch and a development model created to include various die compensations (i.e. springback, overcrown, etc.) based on past experience for area and amount. At this point, the die is cut and undergoes a metamorphosis through die tryout to finally produce a quality part. This is currently an open loop system. This paper will focus on the differences in the predicted way the die should look and the actual outcome (after part buyoff).

Proper electric and thermal management of an HEV battery pack, consisting of many modules of cells, is imperative. During operation, voltage and temperature differences in the modules/cells can lead to electrical imbalances from module to module and decrease pack performance by as much as 25%. An active battery management system (BMS) is a must to monitor, control, and balance the pack. The University of Toledo, with funding from the U.S. Department of Energy and in collaboration with DaimlerChrysler and the National Renewable Energy Laboratory has developed a modular battery management system for HEVs. This modular unit is a 2nd generation system, as compared to a previous 1st generation centralized system. This 2nd generation prototype can balance a battery pack based on cell-to-cell measurements and active equalization. The system was designed to work with several battery types, including lithium ion, NiMH, or lead acid.

For the 2003 model year DaimlerChrysler Corporation will launch a totally new 5.7L V-8 engine for applications of the Dodge Ram pick-up truck. The new engine was created largely within a digital environment using the latest computer aided design (CAD) and computer aided engineering (CAE) techniques and tools. Utilizing a co-located team of design engineers, designers, and CAE engineers enabled the simulations to impact the design from program inception to the assembly line, saving program time and investment. This paper describes the successful merging of design and advanced analysis techniques by highlighting examples throughout the new HEMI® program. Case studies include issues in the areas of structural optimization, engine loading, lubrication circuit, cooling circuit, and manufacturing.

This paper presents an energy relationship between vehicle impact pulses and restraint systems and applies the relationship to formulations of response factors for linear and nonlinear restraints. It also applies the relationship to derive optimal impact pulses that minimize occupant response for linear and nonlinear restraints. The relationship offers a new viewpoint to impact pulse optimization and simplifies the process mathematically. In addition, the effects of different vehicle impact pulses on the occupant responses with nonlinear restraints are studied. Finally, concepts of equivalent pulses and equal intensity pulses are presented for nonlinear restraints.

The responses of the THOR and the Hybrid-III ATDs to head and neck loading due to a deploying air bag were investigated. Matched pair tests were conducted to compare the responses of the two ATDs under similar loading conditions. The two 50th percentile male ATDs, in the driver as well as the passenger positions, were placed close to the air bag systems, in order to enhance the interaction between the deploying air bag and the chin-neck-jaw regions of the ATDs. Although both ATDs nominally meet the same calibration corridors, they differ significantly in their kinematic and dynamic responses to interaction with a deploying air bag. The difference between the structural designs of the Hybrid-III's and the THOR's neck appears to result in significant differences in the manner in which the loads applied on the head are resisted.

This paper presents the results of optimization study for sunroof buffeting reduction using CFD technology. For an early prototype vehicle as a baseline model in this study a high level of sunroof buffeting 133dB has been found. The CFD simulation shows that the buffeting noise can be reduced by installing a wind deflector at its optimal angle 40 degrees from the upward vertical line. Further optimization study demonstrates that the buffeting peak SPL can be reduced to 97dB if the sunroof glass moves to its optimal position, 50% of the total length of the sunroof from the front edge. For any other vehicles, the optimization procedure is the same to get the optimal parameters. On the other hand, however, this optimization study is only based on fluid dynamics principle without considering manufacturability, styling, cost, etc. Further work is needed to utilize the results in the production design.

At one time it was considered imperative to collect high frequency accelerometer data for accurate analysis. As a result current FMVSS regulations and SAE J2570 require the use of accelerometers with damping ratio of 0.05 or less (designated as undamped). This prevents the use of damped accelerometers for regulated channels. Damped accelerometers can provide comparable data and in some cases better data than undamped accelerometers, as long as they meet specific minimum requirements. To collect the most useful data, damped accelerometers should be added to the tool box of transducers used by crash test facilities.

A finite element model of the Transport Research Laboratory (TRL) honeycomb barrier, which is being proposed for use in vehicle compatibility studies, has been developed for use in LSDYNA. The model employs penalty parameters to enforce continuity between adjacent finite elements of the honeycomb barrier. Results of impact tests with indentors of various shapes and sizes were used to verify the performance of the computational model. Numerical simulations show reasonably good agreement with the test results.

This paper presents a 2D model for frontal vehicle-to-vehicle crashes that can be used for fleet modeling. It presents the derivational details and a preliminary assessment of the model. The model is based on rigid-body collision principles, enhanced adequately to represent energy dissipation and lateral engagement that plays a significant role in oblique frontal vehicle-to-vehicle crashes. The model employs the restitution and the apparent friction in order to represent dissipation and engagement respectively. It employs the impulse ellipse to identify the physical character of the crash, based on the principal directions of impulse. The enhancement of the rigid body collision model with restitution and apparent friction is based on collision simulations that use very simple finite element vehicle representations. The dependence of the restitution and the apparent friction on the incidence angle, the frontal offset, and the mass ratio, as predicted by the 2D model, has been presented.

Advanced design of modern engine cooling and vehicle HVAC components involves sophisticated simulation. In particular, front end air flow models must be able to cover the complete range of conditions from idle to high road speeds involving multiple fans of varying types both powered and unpowered. This paper presents a model for electric radiator cooling fans which covers the complete range of powered and unpowered (freewheel) operation. The model applies equally well to mechanical drive fans.

The paper presents a comparison between the acceleration pulses of vehicle-to-vehicle crash tests with those of different single-vehicle crash tests. The severity of the full frontal rigid barrier test is compared with that of the vehicle- to-vehicle crash test based on average acceleration and time-to-zero-velocity. Based on this a 30mph full frontal rigid barrier test is found equivalent to a 41mph vehicle-to-vehicle crash. A reduced speed of 22mph for full frontal rigid barrier test is found to represent vehicle-to- vehicle crashes with 50%-100% overlap, with each vehicle travelling at 30mph. The paper also presents a comparison of the acceleration pulses from different crash tests based on the pulse shape and the pulse phase cross-correlation. None of the single-vehicle crash tests have been found to resemble vehicle-to-vehicle crashes in terms of the pulse shape and the pulse phase.

The relationship of the airbag fire-distribution as a function of impact velocity to the airbag fire-time is studied through the use of an optimization procedure. The study is conducted by abstracting the sensor algorithm and its associated constraints into a simple mathematical formulation. An airbag fire objective function is constructed that integrates the fire-rate and fire-time requirements. The function requires the input of a single acceleration time history; it produces an output depending on the airbag fire condition. Numerical search of the optimal fire threshold curve is achieved through parameterizing this curve and applying a modified simplex search optimization algorithm that determines the optimal threshold function parameters without computing the complete objective function in the parameter space. Numerical results are given to show the effectiveness and potential difficulties with the automatic search scheme.

The use of commercial finite element analysis (FEA) software to perform stamping feasibility studies of automotive components has grown extensively over the last decade. Although product and process engineers have now come to rely heavily on results from FEA simulation for manufacturability of components, the prediction of springback has still not been perfected. Springback prediction for simple geometries is found to be quite accurate while springback prediction in complex components fails to compare with experimental results. Since most forming simulation FEA software uses a dynamic explicit solution method, the choice of various input parameters greatly affects the prediction of post formed stresses in the final component. Accurate stress prediction is critical for determination of springback, therefore this study focuses on the effects of some of the simulation parameters such as, element size, tool/loading speed and loading profile.

This paper describes the approximation of the engine torque of an SI-engine using recurrent neural networks. As modern engine control units today are based on engine torque management, there is a need for an accurate determination of the produced engine torque. Since direct measurements of this value are not possible in series applications due to resulting high costs, a fast and accurate algorithm for the approximation of these values from other sensor signals has to be found. Dynamic neural networks are a promising method to fulfill these requirements.