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ERRATUM: In the article Reference 24 should read as follows: 24. Han, T., Booth, A., Song, S., Styles, D., and Hoard, J., “Review and A Conceptual Model of Exhaust Gas Recirculation (EGR) Cooler Fouling Deposition and Removal Mechanism” Proceedings of the Int. Conf. on Heat Exchanger Fouling and Cleaning, 2015”

In an automotive cooling circuit, the wax melting process determines the net and time history of the energy transfer between the engine and its environment. A numerical process that gives insight into the mixing process outside the wax chamber, the wax melting process inside the wax chamber, and the effect on the poppet valve displacement will be advantageous to both the engine and automotive system design. A fully three dimensional, transient, system level simulation of an inlet controlled thermostat inside an automotive cooling circuit is undertaken in this paper. A proprietary CFD algorithm, Simerics-Sys®/PumpLinx®, is used to solve this complex problem. A two-phase model is developed in PumpLinx® to simulate the wax melting process. The hysteresis effect of the wax melting process is also considered in the simulation.

Control of vehicle powertrain thermal management systems is becoming more challenging as the number of components is growing, and as a result, advanced control methods are being investigated. Model predictive control (MPC) is particularly interesting in this application because it provides a suitable framework to manage actuator and temperature constraints, and can potentially leverage preview information if available in the future. In previous SAE publications (2015-01-0336 and 2016-01-0215), a robust MPC control formulation was proposed, and both simulation and powertrain thermal lab test results were provided. In this work, we discuss the controller deployment in a vehicle; where controller validation is done through road driving and on a wind tunnel chassis dynamometer. This paper discusses challenges of linear MPC implementation related to nonlinearities in this over-actuated thermal system.

Three computational gas and fluid dynamic methods, CV/UP (Control Volume/Uniform Pressure), CPM (Corpuscular Particle Method), and ALE (Arbitrary Lagrangian and Eulerian), were investigated in this research in an attempt to predict the responses of side crash pressure sensors. Acceleration-based crash sensors have been used extensively in the automotive industry to determine the restraint system firing time in the event of a vehicle crash. The prediction of acceleration-based crash pulses by using computer simulations has been very challenging due to the high frequency and noisy responses obtained from the sensors, especially those installed in crush zones. As a result, the sensor algorithm developments for acceleration-based sensors are largely based on prototype testing. With the latest advancement in the crash sensor technology, side crash pressure sensors have emerged recently and are gradually replacing acceleration-based sensor for side crash applications.

The airflow that enters the front grille of a ground vehicle for the purpose of component cooling has a significant effect on aerodynamic drag. This drag component is commonly referred to as cooling drag, which denotes the difference in drag measured between open grille and closed grille conditions. When the front grille is closed, the airflow that would have entered the front grille is redirected around the body. This airflow is commonly referred to as cooling interference airflow. Consequently, cooling interference airflow can lead to differences in vehicle component drag; this component of cooling drag is known as cooling interference drag. One mechanism that has been commonly utilized to directly influence the cooling drag, by reducing the engine airflow, is active grille shutters (AGS). For certain driving conditions, the AGS system can restrict airflow from passing through the heat exchangers, which significantly reduces cooling drag.

An eight-group taxonomy was created to classify real-world frontal crashes from the Crashworthiness Data System (CDS) component of the National Automotive Sampling System (NASS). Three steps were taken to develop the taxonomy: (1) frontal-impact towaway crashes were identified by examining 1985-2005 model year light passenger vehicles with Collision Deformation Classification (CDC) data from the 1995-2005 calendar years of NASS; (2) case reviews, engineering judgments, and categorization assessments were conducted on these data to produce the eight-group taxonomy; and (3) two subsets of the NASS dataset were analyzed to assess the consistency of the resulting taxonomic-group frequencies. “Full-engagement” and “Offset” crashes were the most frequent crash types, each contributing approximately 33% to the total. The group identified as “D, Y, Z No-Rail” was the most over-represented crash type for vehicles with at least one seriously-injured occupant.

Compact heat exchangers are commonly used in diesel engines to reduce the temperature of recirculated exhaust gases, resulting in decreased NOx emissions. These exhaust gas recirculation (EGR) coolers experience fouling through deposition of particulate matter (PM) and hydrocarbons (HCs) that reduces the effectiveness of the cooler. Surrogate tubes have been used to investigate the impacts of gas flow rate and coolant temperature on the deposition of PM and HCs. The results indicate that mass deposition is lowest at high flow rates and high coolant temperatures. An oxidation catalyst was investigated and proved to effectively reduce deposition of HCs, but did not reduce overall mass deposition to near-zero levels. Speciation of the deposit HCs showed that a range of HCs from C15 - C25 were deposited and retained in the surrogate tubes.

This study demonstrates the use of pressure sensing technology to predict the crash severity of frontal impacts. It presents an investigation of the pressure change in the front structural elements (bumper, crush cans, rails) during crash events. A series of subsystem tests were conducted in the laboratory that represent a typical frontal crash development series and provided empirical data to support the analysis of the concept. The pressure signal energy at different sensor mounting locations was studied and design concepts were developed for amplifying the pressure signal. In addition, a pressure signal processing methodology was developed that relies on the analysis of the air flow behavior by normalizing and integrating the pressure changes. The processed signal from the pressure sensor is combined with the restraint control module (RCM) signals to define the crash severity, discriminate between the frontal crash modes and deploy the required restraint devices.

Described in this paper is a component test methodology to evaluate the door trim armrest performance in an Insurance Institute for Highway Safety (IIHS) side impact test and to predict the SID-IIs abdomen injury metrics (rib deflection, deflection rate and V*C). The test methodology consisted of a sub-assembly of two SID-IIs abdomen ribs with spine box, mounted on a linear bearing and allowed to translate in the direction of impact. The spine box with the assembly of two abdominal ribs was rigidly attached to the sliding test fixture, and is stationary at the start of the test. The door trim armrest was mounted on the impactor, which was prescribed the door velocity profile obtained from full-vehicle test. The location and orientation of the armrest relative to the dummy abdomen ribs was maintained the same as in the full-vehicle test.

This paper describes the development of a three-dimensional lumped-mass structure and dummy model to study barrier-to-car side impacts. The test procedures utilized to develop model input data are also described. The model results are compared to crash test results from a series of six barrier-to-car crash tests. Sensitivity analysis using the validated model show the necessity to account for dynamic structural rate effects when using quasi-statically measured vehicle crush data.

This study deals with passenger side restraint system design for frontal impact and four impact modes are considered in optimization. The objective is to minimize the Relative Risk Score (RRS), defined by the National Highway Traffic Safety Administration (NTHSA)'s New Car Assessment Program (NCAP). At the same time, the design should satisfy various injury criteria including HIC, chest deflection/acceleration, neck tension/compression, etc., which ensures the vehicle meeting or exceeding all Federal Motor Vehicle Safety Standard (FMVSS) No. 208 requirements. The design variables include airbag firing time, airbag vent size, inflator power level, retractor force level. Some of the restraint feature options (e.g., some specific features on/off) are also considered as discrete design variables. Considering the local variability of input variables such as manufacturing tolerances, the robustness and reliability of nominal designs were also taken into account in optimization process.

Optimization of heavy materials like steel, in order to create a lighter vehicle, it is a major goal among most automakers, since heavy vehicles simply cannot compete with a lightweight model's fuel economy. Thinking this way, this paper shows a case study where the Size Optimization technique is applied to a front floor reinforcement. The reinforcement is used by two different vehicles, a subcompact and a crossover Sport Utility Vehicle (SUV), increasing the problem complexity. The Size Optimization technique is supported by Finite Element Method (FEM) tools. FEM in Computer Aided Engineering (CAE) is a numerical method for solving engineering problems, and its use can help to optimize prototype utilization and physical testing.

The lack of electrical conductivity on materials, which are used in automotive fuel systems, can lead to electrostatic charges buildup in the components of such systems. This accumulation of energy can reach levels that exceed their capacity to withstand voltage surges, which considerably increases the risk of electrical discharges or sparks. Another important factor to consider is the conductivity of the commercially available fuels, such as biodiesel, which contributes to dissipate these charges to a proper grounding point in automobiles. From 2013, the diesel regulation in Brazil have changed and the levels of sulfur in the composition of diesel were reduced considerably, changing its natural characteristic of promoting electrostatic discharges, becoming more insulating.

In this study, the occupant containment characteristics of automotive laminated safety glass in side window applications was evaluated through two full-scale, full-vehicle dolly rollover crash tests. The dolly rollover crash tests were performed on sport utility vehicles equipped with heat-strengthened laminated safety glass in the side windows in order to: (1) evaluate the capacity of laminated side window safety glass to contain unrestrained occupants during rollover, (2) analyze the kinematics associated with unrestrained occupants during glazing interaction and ejection, and (3) to identify laminated side window safety glass failure modes. Dolly rollovers were performed on a 1998 Ford Expedition and a 2004 Volvo XC90 at a nominal speed of 43 mph, with unbelted Hybrid II Anthropomorphic Test Devices (ATDs) positioned in the outboard seating positions.

A computational model of a mid-size sport utility vehicle was developed using MADYMO. The model includes a detailed description of the suspension system and tire characteristics that incorporated the Delft-Tyre magic formula description. The model was correlated by simulating a vehicle suspension kinematics and compliance test. The correlated model was then used to simulate a J-turn vehicle dynamics test maneuver, a roll and non-roll ditch test, corkscrew ramp and a lateral trip test, the results of which are presented in this paper. The results indicate that MADYMO is able to reasonably predict the vehicle and occupant responses in these types of applications and is potentially suited as a tool to help setup a suite of vehicle configurations and test conditions for rollover sensor testing. A suspension system sensitivity study is presented for the laterally tripped non-roll event.

An assessment tool was developed for rollover CAE signals evaluation to assess primarily the qualities of CAE generated sensor waveforms. This is a key tool to be used to assess CAE results as to whether they can be used for algorithm calibration and identify areas for further improvement of sensor. Currently, the method is developed using error estimates on mean, peak and standard deviation. More metrics, if necessary, can be added to the assessment tool in the future. This method has been applied to various simulated signals for laboratory-based rollover test modes with rigid-body-based MADYDO models.

Near Dry or Minimum Quantity Lubrication (MQL) Machining eliminates conventional flood coolant from the machining processes. In doing so, MQL reduces oil mist generation, biological contamination of coolant, waste water volume, costs for capital equipment and regulatory permitting. MQL also improves recycling and transport of coolant contaminated chips [1]. Although MQL machining technology has several advantages compared to wet machining, widespread implementation will require a paradigm shift among end-users, machine suppliers, and cutting tool suppliers. Successful implementation of MQL machining requires a high technical understanding and a solid infrastructure to support maintenance and on-going continuous improvement [2].

This study applies a detailed finite element model of the human body to simulate occupant knee impacts experienced in vehicular frontal crashes. The human body model includes detailed anatomical features of the head, neck, chest, thoracic and lumbar spine, abdomen, and lower and upper extremities. The material properties used in the model for each anatomic part of the human body were obtained from test data reported in the literature. The total human body model used in the current study has been previously validated in frontal and side impacts. Several cadaver knee impact tests representing occupants in a frontal impact condition were simulated using the previously validated human body model. Model impact responses in terms of force-time and acceleration-time histories were compared with test results. In addition, stress distributions of the patella, femur, and pelvis were reported for the simulated test conditions.

Assembly operators are rarely observed performing one-handed tasks where the unutilized hand is entirely inactive. Therefore, this study was designed to determine the forces applied to supporting hands, by automotive assembly operators, during common one-handed tasks such as hose installations or electrical connections. The data were computed as a percentage of body weight and a repeated measures analysis of variance (ANOVA) (p<0.05) was conducted. Supporting hand forces were observed to range from 5.5% to 12.1% of body mass across a variety of tasks. The results of this study can be used to account for these supporting hand forces when performing a biomechanical/ergonomic analysis.

Various frontal impact risk curves were assessed for the next-generation USA New Car Assessment Program (NCAP). Specifically, the “NCAP risk curves” — those chosen by the government for the 2011 model year NCAP — as well as other published risk curves were used to estimate theoretically the injury rates of belted drivers in real-world frontal crashes. Two perspectives were considered: (1) a “point” estimate of NCAP-type events from NCAP fleet tests, and (2) an “aggregate” estimate of 0 ≤ ΔV ≤ 56 km/h crashes from a modeled theoretical vehicle whose NCAP performance approximated the average of the studied fleet. Four body regions were considered: head, neck, chest, and knee-thigh-hip complex (KTH). The curve-based injury rates for each body region were compared with those of real-world frontal crashes involving properly-belted adult drivers in airbag-equipped light passenger vehicles. The assessment yielded mixed results.