Search Results

With increasingly stringent emissions regulations and concurrent requirements for enhanced engine thermal efficiency, a comprehensive characterization of the automotive gasoline fuel spray has become essential. The acquisition of accurate and repeatable spray data is even more critical when a combustion strategy such as gasoline direct injection is to be utilized. Without industry-wide standardization of testing procedures, large variablilities have been experienced in attempts to verify the claimed spray performance values for the Sauter mean diameter, Dv90, tip penetration and cone angle of many types of fuel sprays. A new SAE Recommended Practice document, J2715, has been developed by the SAE Gasoline Fuel Injection Standards Committee (GFISC) and is now available for the measurement and characterization of the fuel sprays from both gasoline direct injection and port fuel injection injectors.

The primary function of an airbag control module is to detect crashes, discriminate and predict if a deployment is necessary, then deploy the restraint systems including airbags and where applicable, pretensioners. At General Motors (GM), the internal term for airbag control module is Sensing and Diagnostic Module (SDM). In the 1994 model year, GM introduced its SDM on some of its North American airbag-equipped vehicles. A secondary function of that SDM and all subsequent SDMs is to record crash related data. This data can include data regarding impact severity from internal accelerometers and pre-crash vehicle data from various chassis and powertrain modules. Previous researchers have addressed the accuracy of both the velocity change data, recorded by the SDM, and the pre-crash data, but the assessment of the timing of the pre-crash data has been limited to a single family of modules (Delphi SDM-G).

This work discusses the development of SAE procedure J2747, “Hydraulic Pump Airborne Noise Bench Test”. This is a test procedure describing a standard method for measuring radiated sound power levels from hydraulic pumps of the type typically used in automotive power steering systems, though it can be extended for use with other types of pumps. This standard was developed by a committee of industry representatives from OEM's, suppliers and NVH testing firms familiar with NVH measurement requirements for automotive hydraulic pumps. Details of the test standard are discussed. The hardware configuration of the test bench and the configuration of the test article are described. Test conditions, data acquisition and post-processing specifics are also included. Contextual information regarding the reasoning and priorities applied by the development committee is provided to further explain the strengths, limitations and intended usage of the test procedure.

Computer simulation was used as a complement to crash and injury field data analysis and physical sled and barrier tests to investigate and predict the spinal injuries of a rear impact in an IndyCar. The model was expected to relate the spinal loads to the observed injuries, thereby predicting the probability and location of spinal fractures. The final goal is to help reduce the fracture risk by optimizing the seat and restraint system design and the driver's position using computer modeling and sled testing. MADYMO Full FE Human Body Model (HBM) was selected for use because of its full spinal structural details and its compatibility with the vehicle and restraint system models. However, the IndyCar application imposed unique challenges to the HBM. First, the driver position in a race car is very different from that in a typical passenger car.

The need for improved emissions control in lean exhaust to meet tightening, world-wide NOx emissions standards has led to the development of selective catalytic reduction of NOx with ammonia as a major technology for emissions control. Current systems are being designed to use a solution of urea (32.5 wt %) dissolved in water or Diesel Exhaust Fluid (DEF) as the ammonia source. While DEF or AdBlue® is widely used as a source of ammonia, it has a number of issues at low temperatures, including freezing below −12 °C, solid deposit formation in the exhaust, and difficulties in dosing at exhaust temperatures below 200 °C. Additionally creating a uniform ammonia concentration can be problematic, complicating exhaust packaging and usually requiring a discrete mixer.

Both Crash-Avoidance and Pre-Crash active safety technologies are being developed to help reduce the number of crashes and minimize the severity of crashes. The root basis in the development of new and improved active safety technologies always begins with gaining further knowledge about crash kinds and causes. The dynamics of crashes are quite complex. The evolving precursor crash situation initiated in the Crash-Avoidance time-period will vary from the imminent crash situation in the Pre-Crash time-period. As such, in order to develop the appropriate requirements for both crash-avoidance and pre-crash technologies, they must be analyzed from their respective crash data. A data-driven methodology process has been developed which partitions the field data with a perspective to crash-avoidance and pre-crash.

The perceived interior noise has been one of the major driving factors in the design of automotive interior assemblies. Buzz, Squeak and Rattle (BSR) issues are one of the major contributors toward the perceived quality in a vehicle. Traditionally BSR issues have been identified and rectified through extensive hardware testing. In order to reduce the product development cycle and minimize the number of costly hardware builds, however, one must rely on engineering analysis and simulation upfront in the design cycle. In this paper, an analytical and experimental study to identify potential BSR locations in a cockpit assembly is presented. The analytical investigation utilizes a novel and practical methodology, implemented in the software tool Nhance.BSR, for identification and ranking of potential BSR issues. The emphasis here is to evaluate the software for the BSR predictions and the identification of modeling issues, rather than to evaluate the cockpit design itself for BSR issues.

Data suggest that in response to substantial educational efforts, more children are being placed in the rear seats of vehicles. As this transition occurs, it is important to make efforts to optimize the performance of rear seat restraints for children. Prior to developing new restraints for children for the rear seat, a better understanding of child responses in various crash scenarios is needed. The objective of this study was to evaluate the performance of various restraint systems and countermeasures for child occupants in different crash scenarios. Sled tests were carried out with a Hybrid III 6 year old anthropomorphic test device (ATD) in frontal, oblique and side impact configurations. The performance of a highback and a backless booster seat was assessed. The results were compared with two standard 3 point belt restraint systems: 1. a package shelf mounted belt, and 2. a C-pillar mounted belt.

This paper provides an overview of rollover crash safety, including field crash statistics, pre- and rollover dynamics, test procedures and dummy responses as well as a bibliography of pertinent literature. Based on the 2001 Traffic Safety Facts published by NHTSA, rollovers account for 10.5% of the first harmful events in fatal crashes; but, 19.5% of vehicles in fatal crashes had a rollover in the impact sequence. Based on an analysis of the 1993-2001 NASS for non-ejected occupants, 10.5% of occupants are exposed to rollovers, but these occupants experience a high proportion of AIS 3-6 injury (16.1% for belted and 23.9% for unbelted occupants). The head and thorax are the most seriously injured body regions in rollovers. This paper also describes a research program aimed at defining rollover sensing requirements to activate belt pretensioners, roof-rail airbags and convertible pop-up rollbars.

Automotive rollover is a complex mechanical phenomenon. In order to understand the mechanism of rollover and develop any potential countermeasures for occupant protection, efficient and repeatable laboratory tests are necessary. However, these tests are not well understood and are still an active area of research interest. It is not always easy or intuitive to estimate the necessary initial and boundary conditions for such tests to assure repeatability. This task can be even more challenging when rollover is a second or third event (e.g. frontal impact followed by a rollover). In addition, often vehicle and occupant kinematics need to be estimated a-priori, first for the safe operation of the crew and equipment safety, and second for capturing and recording the event. It is important to achieve the required vehicle kinematics in an efficient manner and thus reduce repetitive tests. Mathematical modeling of the phenomenon can greatly assist in understanding such kinematics.

Since its invention in early 1990s, the side curtain airbag has become an important part of the occupant restraint system for side impact and rollover protection. Computer Aided Engineering (CAE) is often used to help side curtain airbag design. Because of the unique characteristics of side curtain airbag systems, the simulation of side curtain airbag systems faces different challenges in comparison to the simulation of driver and passenger airbag systems. The typical side curtain airbag CAE analysis includes, but is not limited to, cushion volume evaluation, cushion coverage review, cushion shrinkage and tension force review, deployment timing review and seam shape and location review. The commonly used uniform pressure airbag models serve the purpose in most cases.

In 2002, NHTSA statistics indicate air bag deployments saved an estimated 1,500 lives; however, reports of occupants having serious or fatal injuries during air bag deployment appear low relative to the number of accidents with air bag deployments. To avoid air bag induced injuries, a variety of occupant sensing technologies are being developed. One of the critical logic deployment challenges faced by these technologies is whether the system can accurately determine if the occupant is in a posture or a position such that air bag deployment may result in an injury. To improve accuracy, it is necessary to understand what postures the occupants are likely to assume during a ride and how often. For this purpose, Delphi Corporation has conducted a survey to solicit opinions on the posture usage rate. With 560 responses, the frequencies for 29 sitting postures for adult passengers and 13 child postures or positions were estimated.

A RTD (resistive temperature device) high temperature sensor was developed for exhaust gas temperature measurement. Extensive modeling and optimization was used to supplement testing in development. The sensor was developed to be capable of withstanding harsh environments (-40° to 1000°C), typical of engine applications, including poisons, while maintaining high accuracy (< 0.5% drift after 500 hrs of aging at 950°C). The following sensor characteristics are presented: resistance-temperature curve, accuracy, response time, and long-term durability. In addition, a system error analysis program was developed with representative results.

With the requirements for reducing the emissions and improving the fuel economy, the automotive companies are developing hybrid, 42 V and fuel cell vehicles. Power electronics is an enabling technology for the development of environmental friendly vehicles, and to implement the various vehicle electrical architectures to obtain the best performance. In this paper, the requirements of the power semiconductor devices and the criteria for selecting the power devices for various types of low emission vehicles are presented. A comparative study of the most commonly used power devices is presented. A brief review of the future power devices that would enhance the performance of the automotive power conversion systems is also presented.

In this paper, we review existing software safety standards, guidelines, and other software safety documents. Common software safety elements from these documents are identified. We then describe an adaptable software safety process for automotive safety-critical systems based on these common elements. The process specifies high-level requirements and recommended methods for satisfying the requirements. In addition, we describe how the proposed process may be integrated into a proposed system safety process, and how it may be integrated with an existing software development process.

Computer modeling and simulation have become one of the primary methods for development and design of automobile occupant protection systems (OPS). To ensure the accuracy and reliability of a math-based OPS design, the correlation quality assessment of mathematical models is essential for program success. In a typical industrial approach, correlation quality is assessed by comparing chart characteristics and scored based on an engineer's modeling experience and judgment. However, due to the complexity of the OPS models and their responses, a systematic approach is needed for accuracy and consistency. In this paper, a correlation grading methodology for the OPS models is presented. The grading system evaluates a wide spectrum of a computer model's performances, including kinematics, dynamic responses, and dummy injury measurements. Statistical analysis is utilized to compare the time histories of the tested and simulated dynamic responses.

The interaction between the deploying airbag and the Out-Of-Position (OOP) occupants remains a challenge in occupant protection system simulations. The integration of Computational Fluid Dynamics (CFD) analysis into Finite Element (FE) airbag model is a helpful and important tool to address this challenge. Three major commercial crash simulation software packages widely used in the automotive safety industry, LS-DYNA, MADYMO and PAM-CRASH are in the process of implementing different approaches for airbag CFD simulation. In this study, an attempt was made to evaluate and compare the CFD integrated airbag models in these software packages. Specially designed tests were conducted to study and capture the pressure distribution inside a flat airbag and the test results were used for the evaluation. Strengths and limitations of each software package are discussed in this paper.

Regulatory and market pressures continue to challenge the automotive industry to develop technologies focused on reducing exhaust emissions and improving fuel economy. This paper introduces a practical model, which evaluates the economic value of various technologies based on their ability to reduce fuel consumption, improve emissions or provide consumer benefits such as improved performance. By evaluating the individual elements of economic value as viewed by the OEM manufacturer, while keeping the end consumer in mind, technology selection decisions can be made. These elements include annual fuel usage, vehicle performance, mass reduction and emissions, among others. The following technologies are discussed and evaluated: gasoline direct injection, variable valvetrain technologies, common-rail diesel and hybrid vehicles.

The industry strategy for automotive safety systems has been evolving over the last 20 years. Systems, such as frontal and side airbags, are available today on the worldwide market that provide proven safety benefits. Interest in advanced safety systems for occupant protection and accident avoidance, is focused on making further reductions in road fatalities and injuries. Interior occupant sensing systems for advanced restraint systems, trapped occupant sensing, and driver monitoring are today under intense development as part of the industry's safety vision. In this paper, we will discuss the need for and requirements of interior occupant sensing systems, as well as applicable technologies

This paper presents a methodology to predict component and system reliability and durability. The methodology is illustrated with an electronic diesel fuel injector case study that integrates customer usage data, component failure distribution, system failure criteria, manufacturing variation, and variation in customer severity. Extension to the vehicle system level enables correlation between component and system requirements. Further, this analysis provides the basis to establish a knowledge-based test option for a success test validation program to demonstrate reliability.