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The performance enhancement of a vertical tail provided by aerodynamic flow control could allow for the size of the tail to be reduced while maintaining similar control authority. Decreasing tail size would create a reduction in weight, drag, and fuel costs of the airplane. The application of synthetic jet actuators on improving the performance of the vertical tail was investigated by conducting experiments on 1/9th and 1/19th scale wind tunnel models (relative to a Boeing 767 tail) at Reynolds numbers of 700,000 and 350,000, respectively. Finite-span synthetic jets were placed slightly upstream of the rudder hinge-line in an attempt to reduce or even eliminate the flow separation that commences over the rudder when it was deflected to high angles. Global force measurements on the 1/9th scale model showed that the flow control is capable of increasing side force by a maximum of 0.11 (19%). The momentum coefficient that created this change was relatively small (Cμ = 0.124%).

A field experiment was performed to measure the effects of oncoming illuminance profiles with different photometric and temporal characteristics on visual recovery and subjective discomfort. Target detection time was correlated with the dosage, and rated discomfort was correlated with the peak illuminance of each profile. Older subjects generally had longer recovery times, but there were no differences between the age groups in terms of rated discomfort. The results suggest that discomfort glare is not predictive of visual disability and that control of luminous intensity at isolated points within the distribution of headlamps alone is not sufficient to minimize glare recovery.

Modern roundabout facilities are increasing in number throughout North America and the world. Appropriate vehicle lighting, including the application of intelligent headlighting systems, might help support safe, efficient driving behavior while navigating through these new intersection types. We present the results of a field study conducted to compare different vehicle lighting systems in terms of drivers' ability to detect and identify pedestrian activity, under different amounts of illumination from fixed outdoor lighting systems. The results are compared to analytical predictions of visibility using a validated visual performance model.

Vehicle headlamps are essential for driver safety at night, and technological evolution of headlamps over several decades has brought substantial improvements to driver visibility and comfort. Nonetheless, glare remains an important concern among many in the driving public, perhaps even more so in North America, where requirements for headlamps differ from those in much of the rest of the world. In most of the world, headlamps producing higher luminous flux are required to have automatic leveling and cleaning systems, thought to help reduce glare. The arrival of headlamp systems in the worldwide marketplace with luminous flux values just below those triggering requirements for leveling and cleaning systems will bring new questions about the causes of and countermeasures for glare.

The present design standards for low beam headlamps offer significant flexibility regarding the distribution of light that they generate. Some headlamp systems produce significant amounts of foreground illumination, which increases the apparent brightness of the roadway surface close to the vehicle, and this increased brightness is seen as desirable by many individuals. Some individuals may prefer not only high but uniform foreground illumination. At almost any driving speed, however, any objects located in the visual foreground are too close to avoid with slowing or steering maneuvers. Further, published literature on the mechanisms for disability glare suggests that foreground illumination should have a negative impact in terms of the visibility of objects located well ahead in the visual field.

We summarize the development and initial deployment of a system that can be mounted along an intersection, curve, drive-in, or parking facility to efficiently gather relevant data about headlamp patterns that might relate to glare or visibility. The system can run autonomously to collect many vehicles per data collection period. The system includes a range finder to capture information when an approaching vehicle is at a specific location, a digital camera to store images of oncoming headlamp position (i.e., mounting height), two arrays of light sensors to measure the vertical headlamp illumination profile (e.g., angular position of headlamp beam cutoff or maximum luminous intensity), and a color-calibrated illuminance meter at the angular location of an oncoming driver's eyes. From the headlamp mounting height data and the vertical cutoff location data, an estimate of the headlamp aim distribution can be made.

In real world driving conditions, illumination from vehicle headlamps and, when present, from fixed roadway lighting combines to provide visibility for the driver. We present analyses of visibility along a representative roadway intersection scenario with median and market-weighted headlamp beam patterns including halogen and high intensity discharge headlamp beam patterns, and high beam headlamp beam patterns. Also investigated are interactions with the spatial extent of roadway lighting, either as part of a continuous lighting system or as a single roadway luminaire at the intersection junction, and the role of ambient illuminance from urban environments. The results of the analyses show the large influence of ambient illuminance from urban areas on the visibility of relevant targets, and show differential advantages of different headlamp beam patterns for different target locations where pedestrians might be encountered.

This paper examines the consequences of fabrication effects on the performance of injection molded plastic light pipes for distributive automotive lighting. It discusses the magnitude of these effects on propagating and output light. Molding errors, such as sinks, voids, flow lines, knit lines, and warpage, will be examined through computer modeling and measurement of sample distributive lighting systems. Two example light pipe systems will be presented, an instrument cluster pointer system and a regional distributive interior lighting system. For the pointer system, computer modeling results, such as total light output and output exitance distributions will be presented. Modeling results will be presented for both an error free system and system that include the aforementioned molding errors. These results will be compared to determine the output light loss and redistribution.

Craters in galvannealed coatings on steel sheet are depressions caused by non-uniform diffusive growth. Correlations have been sought between “crater” densities in galvannealed sheet steel and friction, powdering, and paint adherence, as relevant to the appearance, corrosion resistance and processing of auto body panels. Crater densities were established on a series of samplings from major producers, and related to frictional measurements from a binder-radius simulator, powdering levels from bend testing, and paint adherence assessments from a stone-chipping test. Results suggest that increased crater density decreases powdering, but does not aid in lubrication. In fact, decreased powdering could be correlated with increased friction levels. A strong correlation was found between increased crater density and increased paint adherence.

Aggressive use of microscopy and profilometry can expedite trouble shooting of a wide variety of friction/lubrication/surface quality problems. Recent research at Rensselaer has focused on physical modelling of the sheet stamping operation, in particular the binder-radius and draw bead regions. Friction models are examined in conjunction with workpiece surface quality and binder-radius tooling topography. The friction coefficient remains stable throughout a wide variety of test conditions. Area-of-contact measurements confirm the model, although appreciable scatter is noted. Profilometry measurements, taken from a variety of tooling finishes, demonstrate that alternative indices may correlate with friction better than the traditionally quoted Ra.

Photometric performance specifications for vehicle headlamp specifications in North America are given in terms of luminous intensity values at various angular locations with the objective of providing sufficient illumination for forward visibility while controlling for glare toward oncoming and preceding vehicle drivers. Abundant evidence suggests that luminous intensity is an appropriate metric for characterizing the degree to which a headlamp can produce disability glare through veiling luminances under a wide range of viewing conditions. Notwithstanding that discomfort glare exhibits a differential spectral sensitivity from the photopic luminous efficiency function used to characterize light, luminous intensity does not always predict discomfort glare. For example, the luminance of the luminous element(s) can be more predictive of discomfort when headlamps are viewed from relative close distances.

Recent technological developments have begun to add a number of new configurations for vehicle forward lighting to the realm of possibility, including high-intensity discharge and light-emitting diode headlamps, and adaptive forward-lighting systems. These systems can offer substantial differences in performance and appearance from conventional filament-based headlamps that have been ubiquitous for many decades. These differences have not gone unnoticed by the U.S. driving public. A review of newspaper articles published during the past several years was conducted in order to assess public perceptions of vehicle headlamps in terms of their ability to support visibility and their impacts on headlamp glare.

Although adaptive driving beam headlight systems are not presently defined in North American headlighting standards, evidence for the potential safety benefits of these systems is increasing. Field measurements of the photometric performance of an adaptive driving bean system were made in response to simulated headlight and tail light conditions. Roadway geometries were varied and multiple measurements for many conditions were made to assess repeatability of measurements. The results of the testing are summarized in the context of validating the likely safety impacts of these systems and of providing recommendations for standardized measurement conditions to ensure reliability.

Present standards for vehicle forward lighting specify two headlamp beam patterns: a low beam when driving in the presence of other nearby vehicles, and a high beam when there is not a concern for producing glare to other drivers. Adaptive lighting technologies such as curve lighting systems with steerable headlamps may be related to increments in safety according to the Insurance Institute for Highway Safety, but isolating the effects of lighting is difficult. Recent analyses suggest that visibility improvements from adaptive curve lighting systems might reduce nighttime crashes along curves by 2%-3%. More advanced systems such as adaptive high-beam systems that reduce high-beam headlamp intensity toward oncoming drivers are not presently allowed in the U.S. The purpose of the present study is to analyze visual performance benefits and quantify potential safety benefits from adaptive high-beam headlamp systems.

Approximately twenty-five percent of automotive shredder residue (ASR) consists of the many different types of plastics typically utilized in a vehicle. In order to recover and re-use this material from the ASR, certain separation techniques for each polymer are needed. This paper will discuss the feasibility of applying the selective dissolution method to the recycling of commingled automotive plastics. In the first stage, an instrument panel consisting of more than twelve different polymers from Toyota Motor Manufacturing U.S.A., Inc. (TMM) in Kentucky, was selected to study. These polymers are typical of materials used in automotive applications and represent the variety of polymers used widely in other automotive parts. Next, it was necessary to fully understand each virgin polymer's material composition and properties, so that precise analytical data and physical properties of the recovered polymers could be compared and discussed.

A bending and springback analysis method for 2D-draw bending parts has been developed based on a new mathematical model. The main feature of the new model is described and the analysis results obtained from this model are compared with those from other methods. These results show consistent springback behavior for the selected cases. Roles of blankholder force and friction are investigated using the new method, as well as the effect of material properties on springback behavior, e.g., strain hardening index, Young's modulus, plastic anisotropy, etc. The trends are illustrated graphically and some conclusions are drawn based on the analysis.

A methodology is presented for springback analysis and control in forming two-step rail-shaped sheet metal parts. A computer system for bending and springback analysis of two-step rails is developed and described. Effects of tool corner radii, material properties and process variables on the springback behavior of two-step rails is investigated using the analysis system, and conclusions are drawn based on the sensitivity analysis result. An example of springback control is provided in obtaining an accurate shape of a given part in the design stage by changing some of the variables.

Taking advantage of growing consumer interest in light emitting diode (LED) headlights, an increasing number of after-market LED replacement bulbs is available on the market. They are designed to have similar socket shapes and sizes as halogen bulbs, in order to fit into existing headlight housings. Although none of these LED replacement bulbs conform to present federal headlighting regulations, and some are labeled for "off road use" only, others claim to meet current regulations. Regardless, many different LED bulbs can be easily purchased and installed by vehicle owners, who may or may not be aware of their regulatory status. Several different LED replacement bulb kits, each designed to replace a conventional 55-W H11 halogen bulb, were purchased and tested in three different low-beam headlight units.

Headlight glare is a major concern of the driving public. In the past couple of years there have been concerns expressed about the use of light emitting diode (LED) lighting technologies and possible impacts LEDs may have on people, including circadian disruption, retinal hazards, and glare. Under typical use cases, vehicle headlight exposures are insufficient to cause circadian disruption or retinal damage, but can result in disability and discomfort glare, as well as glare recovery. In general, white LEDs used for illumination have greater short-wavelength content than halogen lamps used in many headlights, and short wavelengths have been implicated in visual discomfort from bright lights at night. Previous literature is inconsistent regarding whether the spectral (color) content of a glare source affects the amount of recovery time needed to see objects, following exposure to a bright light such as a vehicle headlight.

The advent of light-emitting diode (LED) technology for automotive lighting allows flexibility of the spectral distribution of forward headlighting systems, while meeting current requirements for “white” illumination. As vehicle headlights have become whiter (with more short-wavelength light output) over the past several decades, their potential impacts on visual discomfort for oncoming and preceding drivers have been hotly debated. It is known that a greater proportion of short-wavelength energy increases discomfort glare, and that increasing the background light level (e.g., through roadway lighting) will decrease perceptions of discomfort. More recently it has been demonstrated that the visual system exhibits enhanced short-wavelength sensitivity for perceptions of scene brightness.