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Technical Paper

The Advantages of Using Standard Vehicle Dynamics Procedures and Analysis Programs

1998-02-23
981077
Globalization in the automotive industry has resulted in a tremendous competitive advantage to those companies who can internally communicate ideas and information effectively and in a timely manner. This paper discusses one such effort related to objectively testing vehicles for steering and handling characteristics by implementing standard test procedures, data acquisition hardware and analysis methods. Ford Motor Company's Vehicle Dynamics Test Section has refined a number of test procedures to the point that, with proper training, all design and development engineers can quickly acquire, analyze and share test results. Four of these procedures and output are discussed in detail.
Technical Paper

Investigation of a Ford 2.0 L Duratec for Touring Car Racing

1998-11-16
983038
This paper summarizes an investigative study done to evaluate the feasibility of a Ford Duratec engine in 2.0 L Touring Car Racing. The investigative study began in early 1996 due to an interest by British Touring Car Championship and North American Touring Car Championship sanctioning bodies to modify rules & demand the engine be production based in the vehicle entered for competition. The current Ford Touring Car entry uses a Mazda based V-6. This Study was intended to determine initial feasibility of using a 2.0 L Duratec V-6 based on the production 2.5L Mondeo engine. Other benefits expected from this study included; learning more about the Duratec engine at high speeds, technology exchange between a production and racing application, and gaining high performance engineering experience for production engineering personnel. In order to begin the Duratec feasibility study, an initial analytical study was done using Ford CAE tools.
Technical Paper

Driver Understanding and Recognition of Automotive ISO Symbols

1988-02-01
880056
This study assesses the understanding and recognition, by U.S. drivers, of the 25 automotive ISO symbols specified in SAE Standard J1048. A two-part survey was administered to 505 volunteers at a Secretary of State's office located in a Detroit suburb. Percentage results for symbol understanding indicated low levels of understanding for many symbols; percentage results for symbol recognition were generally much higher for all symbols. The effects of gender, age, and education level on the percentage results are summarized.
Technical Paper

Pedestrian Head Impact Time Estimate based on Vehicle Geometric Parameters

2017-03-28
2017-01-1453
Pedestrian protection assessment methods require multiple head impact tests on a vehicle’s hood and other front end parts. Hood surfaces are often lifted up by using pyrotechnic devices to create more deformation space prior to pedestrian head impact. Assessment methods for vehicles equipped with pyrotechnic devices must also validate that the hood deployment occurs prior to head impact event. Estimation of pedestrian head impact time, thus, becomes a critical requirement for performance validation of deployable hood systems. In absence of standardized physical pedestrian models, Euro NCAP recommends a list of virtual pedestrian models that could be used by vehicle manufacturers, with vehicle FEA (Finite Element Analysis) models, to predict the potential head impact time along the vehicle front end profile. FEA simulated contact time is used as target for performance validation of sensor and pyrotechnic deployable systems.
Technical Paper

Folded Pelvis-Thorax Side Airbag Modeling with CFD Approach and Implementation in Full Vehicle Crash Analysis

2017-03-28
2017-01-1460
The Pelvis-Thorax Side Air Bag (PTSAB) is a typical restraint countermeasure offered for protection of occupants in the vehicle during side impact tests. Currently, the dynamic performance of PTSAB for occupant injury assessment in side impact is limited to full-vehicle evaluation and sled testing, with limited capability in computer aided engineering (CAE). The widely used CAE method for PTSAB is a flat bag with uniform pressure. The flat PTSAB model with uniform pressure has limitations because of its inability to capture airbag deployment during gap closure which results in reduced accuracy while predicting occupant responses. Hence there is a need to develop CAE capability to enhance the accuracy of prediction of occupant responses to meet performance targets in regulatory and public domain side impact tests. This paper describes a new CAE methodology for assessment of PTSAB in side impact.
Technical Paper

The Application of a One-Way Coupled Aerodynamic and Multi-Body Dynamics Simulation Process to Predict Vehicle Response during a Severe Crosswind Event

2017-03-28
2017-01-1515
Industry trends towards lighter, more aerodynamically efficient road vehicles have the potential to degrade a vehicle’s response to crosswinds. In this paper, a methodology is outlined that indirectly couples a computational fluid dynamics (CFD) simulation of the vehicle’s aerodynamic characteristics with a multi-body dynamics simulation (MBD) to determine yaw, roll and pitch response characteristics during a severe crosswind event. This one-way coupling approach mimics physical test conditions outlined in open loop test procedure ISO 12021:2010 that forms part of the vehicle sign-off criterion at Ford Motor Company. The methodology uses an overset mesh CFD method to drive the vehicle through a prescribed crosswind event, providing unfiltered predictions of vehicle force and moment responses that are used as applied forces in the MBD model. The method does not account for changes in vehicle attitude due to applied aerodynamic forces and moments.
Technical Paper

Machine Health Prediction Enhancement Using Machine Learning

2017-03-28
2017-01-1625
Use of sensors to monitor dynamic performance of machine tools at Ford’s powertrain machining plants has proven to be effective. The traditional approach to convert sensor data to actionable intelligence consists of identifying single features from cycle based signatures and setting thresholds above acceptable performance limits based on trials. The thresholds are used to discriminate between acceptable and unacceptable performance during each cycle and raise alarms if necessary. This approach requires a significant amount of resource & time intensive set up work up-front and considerable trial and error adjustments. The current state does not leverage patterns that might be discernible using multiple features simultaneously. This paper describes enhanced methods for processing the data using supervised and unsupervised machine learning methods. The objective of using these methods is to improve the prediction accuracy and reduce up-front set up.
Technical Paper

Driver Identification Using Vehicle Telematics Data

2017-03-28
2017-01-1372
Increasing number of vehicles are equipped with telematics devices and are able to transmit vehicle CAN bus information remotely. This paper examines the possibility of identifying individual drivers from their driving signatures embedded in these telematics data. The vehicle telematics data used in this study were collected from a small fleet of 30 Ford Fiesta vehicles driven by 30 volunteer drivers over 15 days of real-world driving in London, UK. The collected CAN signals included vehicle speed, accelerator pedal position, brake pedal pressure, steering wheel angle, gear position, and engine RPM. These signals were collected at approximately 5Hz frequency and transmitted to the cloud for offline driver identification modeling. A list of driving metrics was developed to quantify driver behaviors, such as mean brake pedal pressure and longitudinal jerk. Random Forest (RF) was used to predict driver IDs based on the developed driving metrics.
Technical Paper

Fan Shroud Design for Low Speed Damageability

2017-03-28
2017-01-1300
An engine cooling system in an automotive vehicle comprises of heat exchangers such as a radiator, charge air cooler and oil coolers along with engine cooling fan. Typical automotive engine-cooling fan assembly includes an electric motor mounted on a shroud that encloses the radiator core. One of main drivers of fan shroud design is Noise, Vibration, and Harshness (NVH) requirements without compromising the main function of airflow for cooling requirements. In addition, there is also a minimum stiffness requirement of fan shroud which is often overlooked in arriving at optimal design of it. Low Speed Damageability (LSD) assessment of an automotive vehicle is about minimizing the cost of repair of vehicle damages in low speed crashes. In low speed accidents, these fan motors are subjected to sudden decelerations which cause fan motors to swing forward thereby damaging the radiator core. So designing fan shroud for low speed damageability is of importance today.
Technical Paper

Real-Time Implementation and Validation for Automated Path Following Lateral Control Using Hardware-in-the-Loop (HIL) Simulation

2017-03-28
2017-01-1683
Software for autonomous vehicles is highly complex and requires vast amount of vehicle testing to achieve a certain level of confidence in safety, quality and reliability. According to the RAND Corporation, a 100 vehicle fleet running 24 hours a day 365 days a year at a speed of 40 km/hr, would require 17 billion driven kilometers of testing and take 518 years to fully validate the software with 95% confidence such that its failure rate would be 20% better than the current human driver fatality rate [1]. In order to reduce cost and time to accelerate autonomous software development, Hardware-in-the-Loop (HIL) simulation is used to supplement vehicle testing. For autonomous vehicles, path following controls are an integral part for achieving lateral control. Combining the aforementioned concepts, this paper focuses on a real-time implementation of a path-following lateral controller, developed by Freund and Mayr [2].
Technical Paper

Acquisition of Transient Tire Force and Moment Data for Dynamic Vehicle Handling Simulations

1983-11-07
831790
This paper describes the issues encountered in using conventionally acquired tire test data for dynamic total vehicle handling simulations and the need for improved methodology. It describes the new test procedure that was used to acquire all three forces and three moments in a transient mode for a matrix of loads, slip and camber angles. A study of the test data supports the premises that the overturning moment, Mx, should not be neglected in dynamic simulations, and that the effects of camber should not be treated as only an independent, linearly additive, camber thrust. Instead of the conventional application of a bi-cubic regression fit to a six region data division, a new algorithm is applied. The data is divided differently into five regions in the α - Fz plane, and a variable format regression equation is applied as appropriate. The resulting regression coefficients matrix is readily usable in dynamic simulations, and is shown to have a superior curve fit to the test data.
Technical Paper

Driver Workload Effects of Cell Phone, Music Player, and Text Messaging Tasks with the Ford SYNC Voice Interface versus Handheld Visual-Manual Interfaces

2009-04-20
2009-01-0786
A fixed-base driving simulator study was conducted to compare driver performance and eye glance behavior effects of tasks performed using the voice interface in Ford Motor Company’s SYNC® system versus handheld operation of portable music players and cellular phones. Data were analyzed from a sample of 25 test participants. All test participants were regular SYNC users (but not SYNC developers), though they varied in their familiarity with SYNC functions. During a car-following scenario at highway speeds on the simulator, the participants performed 7 tasks using SYNC’s voice interface and those same 7 tasks with their own handheld music player and cellular phone. The seven tasks under test were: dial a 10-digit number; call a specific person from a phonebook; receive a call while driving; play a specific song; play songs from a specific artist; review (listen to or read) a text message; and select a reply from a list or type a reply to a text message.
Technical Paper

A Practical Approach to Consider Forming Effects for Full Vehicle Crash Application

2009-04-20
2009-01-0471
The forming effects along with strain rate, actual material properties and weld effects have been found to be very critical for accurate prediction of crash responses especially the prediction of local deformation. As a result, crash safety engineers started to consider these factors in crash models to improve the accuracy of CAE prediction and reduce prototype testing. The techniques needed to incorporate forming simulation results, including thickness change, residual stresses and strains, in crash models have been studied extensively and are well known in automotive CAE community. However, a challenge constantly faced by crash safety engineers is the availability of forming simulation results, which are usually supplied by groups conducting forming simulations. The forming simulation results can be obtained by either using incremental codes with actual stamping processes or one-step codes with final product information as a simplified approach.
Technical Paper

Vehicle System Controls for a Series Hybrid Powertrain

2011-04-12
2011-01-0860
Ford Motor Company has investigated a series hybrid electric vehicle (SHEV) configuration to move further toward powertrain electrification. This paper first provides a brief overview of the Vehicle System Controls (VSC) architecture and its development process. The paper then presents the energy management strategies that select operating modes and desired powertrain operating points to improve fuel efficiency. The focus will be on the controls design and optimization in a Model-in-the-Loop environment and in the vehicle. Various methods to improve powertrain operation efficiency will also be presented, followed by simulation results and vehicle test data. Finally, opportunities for further improvements are summarized.
Technical Paper

Optimizing R&H and NVH Performances Early in the Design Process via Multi Body Simulation

2009-05-19
2009-01-2087
This paper presents a CAE based approach to accurately simulate and optimize Ride and Handling metrics. Because of the wide range of vehicle phenomena involved, across the variety of frequency ranges, it is essential that the vehicle model includes proper representation of the dynamic properties of the various subsystems (e.g. tires, steering, PT, etc.) Precise correlation between test and simulation for standalone vehicle components and systems is achieved by replicating in the MBS (Multi-body Simulation) the same tests and boundary conditions. This allows the analyst to correctly define those crucial elements and parameters which have the greatest effect on the R&H attribute to be investigated. Setting up the simulation to correctly represent only one single maneuver simulation at a time would not allow the analyst to consider how the dynamic properties of the chassis design variables should be tuned to achieve to best balance and trade-offs.
Technical Paper

Sound Simulation and NVH Tuning of a Multi-Mode Engine

2009-05-19
2009-01-2191
This paper describes the use of an interactive NVH simulator in simulating and designing the sound character of a vehicle with a multi-mode engine and active exhaust valve. When designing a vehicle for sound quality, it is not sufficient to merely record some discreet operating conditions and modify these in a traditional sound quality program. The ability to simulate the sound quality of the vehicle over the full operating envelope is a necessity. Additionally, the ability to break down the sound contributions from intake, exhaust and other key contributors to the driver's ear, and manipulate these independently is also essential. In the case described here, an additional factor makes it mandatory that an accurate vehicle sound simulation is performed. The state of the engine and exhaust contribution, and thus the sound of the vehicle, change based on several parameters - vehicle speed, load demand and gear.
Technical Paper

A semi-analytical approach for vehicle ride simulation

2008-10-07
2008-36-0048
Vehicle dynamics CAE capabilities has increased in the past few years, specially, for handling and steering attributes. However, secondary ride simulations are still highly depended on the tire model. Such tire model must be capable to simulate high order phenomenon such as impact and harshness transmissibility in three directions. In order to gather tire information sufficient to cope with these phenomena, one needs to perform a series of specific tests, and so be able to build the intended tire model. Still, there could be correlation issues. This whole process takes a lot of time and resources. This article presents a semi-analytical approach, using data gathered via wheel force transducers (WFTs) that are typically used for load cascading and durability purposes. The method main advantage is that since it relies on measured data at the wheel center, it is independent of a tire model, and, as such, it demands less time and resources.
Technical Paper

Automotive Manufacturing Task Analysis: An Integrated Approach

2008-06-17
2008-01-1897
Automotive manufacturing presents unique challenges for ergonomic analysis. The variety of tasks and frequencies are typically not seen in other industries. Moving these challenges into the realm of digital human modeling poses new challenges and offers the opportunity to create and enhance tools brought over from the traditional reactive approach. Chiang et al. (2006) documented an enhancement to the Siemen's Jack Static Strength Prediction tool. This paper will document further enhancements to the ErgoSolver (formerly known as the Ford Static Strength Prediction Solver).
Technical Paper

EPAS System Tests Using Rack Force Models

2016-04-05
2016-01-1544
Evaluation of electric steering (EPAS) system performance using vehicle specific load conditions is important for steering system design validation and vehicle steering performance tuning. Using real-time vehicle dynamics mathematical models is one approach for generating steering loads in steering hardware-in-the-loop (HIL) testing. However achieving a good correlation of simplified mathematical models with real vehicle dynamics is a challenge. Using rack force models from measured steering tie rod forces or from simulations using a high-fidelity vehicle dynamics model is an effective data-driven modelling method for testing EPAS systems under vehicle specific load conditions. Rack force models are identified from physical measurements or validated vehicle simulations of selected steering test maneuvers. The rack force models have been applied in steering system performance evaluation, benchmarking, and steering model validation.
Technical Paper

Exploring Transitional Automation with New and Old Drivers

2016-04-05
2016-01-1442
Age and experience influence driver ability to cope with transitions between automated and manual driving, especially when drivers are engaged in media use. This study evaluated three age cohorts (young/new drivers, adults, and seniors) on their performance in transitions from automated driving to manual vehicle control in a laboratory driving simulator. Drivers were given three tasks to perform during the automated driving segments: to watch a movie on a tablet, to read a story on a tablet, or to supervise the car's driving. We did not find significant differences in people's driving performance following the different tasks. We also did not find significant differences in driving performance between the people in each age group who successfully completed the study; however, the rejection rate of the senior age group was over 30% because many of the people in this age group had difficulty hearing instructions, understanding tasks, or remembering what to do.
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