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Abstract The flow around and downstream of the front wheels of passenger cars is highly complex and characterized by flow structure interactions between the external flow, fluid exiting through the wheelhouse, flow from the engine bay and the underbody. In the present paper the near wall flow downstream of the front wheel house is analyzed, combining two traditional methods. A tuft visualization method is used to obtain the limiting streamline pattern and information about the near wall flow direction. Additionally, time resolved surface pressure measurements are used to study the pressure distribution and the standard deviation. The propagation of the occurring flow structures is investigated by cross correlations of the pressure signal and a spectral analysis provides the characteristic frequencies of the investigated flow.

Abstract Estimating the power demand of a steering system is one of the main tasks during steering system development in the concept phase of a vehicle development process. Most critical for typical axle kinematics are parking maneuvers with simultaneously high rack forces and velocities. Therefore, the focus of the article is a tire model for standstill, which can be parametrized without measurements, only having tire dimensions and conditions (inflation pressure and wheel load) as input. Combined with a double-track model, a vehicle model is developed, which is able to predict the rack force and is fully applicable during the concept phase. The article demonstrates quantitatively that the tie rod forces, and thereby especially the tire bore torque, cause the largest fraction of the power demand at the rack. For this reason, the prediction of the bore torque is investigated in detail, whereby basic approaches from the literature are analyzed and enhanced.

Abstract A new concept of instantaneous wheel turn center (IWTC) is proposed to evaluate and improve multi-axle vehicle steering coordination performance. The concept of IWTC and its calculation method are studied. The index named dispersion of IWTC is developed to evaluate the vehicle steering coordination performance quantitatively. The simulation tests based on a three-axle off-road vehicle model are conducted under different vehicle velocities and lateral accelerations. The simulation results show that the turn centers of different wheels are disperse, and the dispersion becomes larger with the increase of vehicle velocities and lateral acceleration. Since suspension has important influences on vehicle steering performance, the genetic algorithm is used to optimize the suspension hard points and bushing stiffness, aiming at minimizing the dispersion of wheel turn centers (DWTC) to improve the vehicle steering coordination performance.

Abstract The following article illustrates the detailed study of the development of a unique flywheel-based regenerative braking system (f-RBS) for achieving regenerative braking in a commercial electric bus. The f-RBS is designed for installation in the front wheels of the bus. The particular data values for modeling the bus are taken from multiple legitimate sources to illustrate the development strategy of the regenerative braking system. Mechanical components used in this system have either been carefully designed and analyzed for avoiding fatigue failure or their market selection strategies explained. The positioning of the entire system is decided using MSC Adams View®, hence determining a suitable component placement strategy such that the f-RBS components do not interfere with the bus components. The entire system is modeled on MATLAB Simulink® with sufficient accuracy to get various results that would infer the performance of the system as a whole.

Abstract Raceway Brinell damage is one major cause of wheel bearing (hub unit) noise during driving. Original Equipment Manufacturer (OEM) customers have asked continuously for its improvement to the wheel bearing supply base. Generally, raceway Brinelling in a wheel hub unit is a consequence of metallic yielding from high external loading in a severe environment usually involving a side impact to the wheel and tire. Thus, increasing the yielding strength of steel can lead to higher resistance to Brinell damage. Both the outer ring and hub based on Generation 3 (Gen. 3) wheel unit are typically manufactured using by AISI 1055 bearing quality steel (BQS); these components undergo controlled cooling to establish the core properties then case hardening via induction hardening (IH). This paper presents a modified grade of steel and its IH design that targets longer life and improves Brinell resistance developed by ILJIN AMRC (Advanced Materials Research Center).

Abstract The problem addressed in this work is how to formulate accurate targets for coil springs in passenger car suspensions to ensure that the required ride height and wheel rate are achieved. The issue arises because suspensions often tend to introduce significant spring deformations other than a purely axial compression. Although these effects are quite common, their influence on suspension performance is still not well understood. To this purpose, a new enhanced spring model is presented. The theory behind the model is explained and the relationship between spring and suspension performance discussed in detail. To validate formulations, a series of numerical simulations has been carried out demonstrating the model accuracy. Finally, a novel approach to spring target setting is proposed based on this advanced spring model.

Abstract To gain a better understanding of the characteristics of corrugation, including the development and propagation of corrugation, and impact of vehicle and track dynamics, a computational model was established, taking into account the nonlinearity of vehicle-track coupling. The model assumes a fixed train speed of 300 km/h and accounts for vertical interaction force components and rail wear effect. Site measurements were used to validate the numerical model. Computational results show that (1) Wheel polygonalisation corresponding to excitation frequency of 545-572 Hz was mainly attributed to track irregularity and uneven stiffness of under-rail supports, which in turn leads to vibration modes of the bogie and axle system in the frequency range of 500-600 Hz, aggregating wheel wear. (2) The peak response frequency of rail of the non-ballasted track coincides with the excitation frequency of wheel-rail coupling; the resonance results in larger wear amplitude of the rail.

Abstract In this article, a new road load simulation technology is presented for commercial vehicle driveline. In order to assess the performance of vehicle driveline, the chassis dynamometer system is introduced on the basis of the traditional vehicle driveline test bench, which improves the accuracy of the simulation system without the need of complex modeling of commercial vehicle tire dynamics. The vertical load of the vehicle is emulated by the hydraulic loading mechanism, and the influence of the vertical load on commercial vehicle driveline is emulated when the vehicle passes the bumpy road. The evaluate control method of commercial vehicle acceleration inertia based on wheel rotational speed and vehicle dynamics model is designed.

Abstract A classical antiskid brake system (ABS) is typically used to control the brake fluid pressure by creating repeated cycles of decreasing and increasing brake force to avoid wheel locking, causing the fluctuation of the brake hydraulic pressure and resulting in vibration during wheel rotation. This article proposes a new approach of skid control for ABS by controlling the disk pad position. This new approach involves using a modest control method to determine the optimal skid that allows the wheel to exert maximum friction force for decelerating the vehicle by shifting the brake pad position instead of modulating the brake fluid pressure. This pad position control (PPC) method works in a continuous manner. Therefore, no rapid changes are required in the brake pressure and wheel rotation speed. To identify the PPC braking performance, braking test simulations and experiments have been carried out.

Abstract Wheel alignment audit systems are used in vehicle service environments to identify vehicles which may benefit from a comprehensive evaluation on a precision static alignment measurement system. Non-contact dynamic wheel alignment audit systems acquire measurement data from vehicles in motion passing between sensors in an inspection lane. The dynamic nature of the moving vehicles introduces variables which are not present when auditing wheel alignment on a static vehicle. Measurement results are affected by changes in vehicle velocity, steering movement, suspension movement, floor surface conditions, tire sidewall profiles, and driver presence, as well as other variables.

Abstract The steering centers of four wheels for passenger car do not coincide, which may result in tire wear and the unharmoniously movement of the vehicle. In this article, an optimization control method for Four Wheel Independent Steering (4WIS) electric vehicle based on the coincidence degree of steering centers is proposed, to improve the driving performance. The nonlinear vehicle model of the four-wheel independent steering vehicle is established, and the formula of the wheel steering center is derived. The coincidence degree of wheel steering centers is defined as the evaluation index, to describe and evaluate the performance of the coordination for wheels’ movement. Meanwhile, the structure design of 4WIS system and the establishment of Direct-Current (DC) steering motor model are carried out, and the Model Predictive Control (MPC) controller for steering actuator is designed.

Abstract To track desired slip ratios and desired longitudinal speeds at the centers of driving wheels in the curve, this article proposes a hierarchical structured electronic differential control (EDC) of rear-wheel independent-drive electric vehicle (EV). In the high-level control, a fuzzy algorithm-based coefficient is computed according to the driver’s emotional intention of acceleration. The fuzzy algorithm-based coefficient is used to correct the desired driving torque of vehicle transmitting to the medium-level control. In the medium-level control, an optimization algorithm is developed to allocate the desired torques with requirement of as much accurate yaw moment as possible by the desired driving torque of the vehicle and yaw moment. And the desired longitudinal speeds at the centers of the rear left and right wheels are corrected twice, respectively, by Ackermann steering principle, considering the slip angle of the wheel and yaw moment.

Abstract Articulated vehicles contribute to the major portions of cargo transport through roads. Fifth wheel (FW) is an important component in these vehicles, which acts as the bridge between tractor and trailer and is often used as a parameter to adjust the axle loads. Ride and comfort studies linked to FW position exist. However, its influence on durability is often not considered seriously. In this article, three different FW positions placed at 200 mm, 400 mm, and 600 mm in front of the rear axle are studied virtually on a 4×2 tractor with three-axle semitrailer combination. To assess the risk associated with FW movement, acceleration-based pseudo-relative damage, power spectral density (PSD), and level crossing plots are analyzed for each FW position. Further, fatigue analysis is done on the cab structural components to understand the durability. Outcome shows that the FW position has an influence in determining the cab dynamics and durability of the components to a great extent.

Abstract Road test is hitherto the most common approach to assess vehicle durability and structural performance. Moreover, the measurements serve as the final validation of the road load simulation, which is currently widely used in vehicle development cycles. The virtual simulation requires digitized road surfaces, a suitable tire model, and suspension model. The whole procedure is time consuming for outdoor measurements and costly to automotive OEMs for road modeling, tire model parametrization, and the like. However, the respective error from each subsystem model keep uncertain during the whole vehicle simulation. Meanwhile, quantitative evaluation of the simulation quality is always tough to conduct due to variability of measurements and limited test configurations. To overcome such challenges, a new approach with higher operational feasibility for the acquisition of durability loads at wheel rim was proposed.

Abstract In India, vehicle population increases every day along with road accidents by 2.5% every year. About 7.7% of accidents are caused by wheel separation, 60% of which are due to nut-related problems. Wheel separations in vehicles occur due to fastener issues and fatigue failures in bolts. A study of the reasons for and mechanisms of nut loosening showed that left-hand side wheels detached and fracture failure occurred in right-hand side studs. Fatigue life of wheels with Nord-Lock washer and without washer is determined by using numerical analysis as per the IS 9438 cornering fatigue test. These numerical results are compared with experimental results.

Abstract With the increase of electric vehicles on the roads, there is also an increase with vehicles that use regenerative braking (RB). This novel braking method differs from traditional service braking (SB) because RB decelerates the moment the driver releases the accelerator pedal and continues to actively brake if neither pedal is depressed. Since the vehicle actively decelerates when neither pedal is depressed in a vehicle with RB, we hypothesized that this would result in a difference in driver foot behavior. There were two pieces to explore this potential difference. The first piece was to explore time-based measures. The first measure was the time period from when the lead vehicle brake lights illuminate, to when the driver releases the accelerator pedal. The second measure was the time period from when the driver releases the accelerator pedal, to when the driver presses the brake pedal.

Abstract Wheel chocks are rather simple compliant mechanisms for stabilizing vehicles at rest. However, chocks must be carefully designed given the complex interaction between the chock and the tire/suspension system. Despite their importance for safety, literature is surprisingly limited in terms of what makes a wheel chock efficient. Using simple but reliable quasi-static mechanical models, this study identifies mechanical requirements that help to avoid a number of failure modes associated with many existing wheel chocks. Given that chock grounding is not always possible, a chock’s maximum restraining capacity is only obtained when the wheel is completely supported by the chock. A generic chock profile is proposed to achieve this objective while mitigating undesirable failure modes. The profile is based on fundamental mechanical principles and no assumption is made on the load interaction between the chock and the wheel.

Abstract As the basic function of the active safety configuration of a vehicle, the anti-lock braking system will compromise the driving safety if it fails. Based on the self-designed electro-hydraulic braking system, this article proposes an anti-lock brake redundant control architecture. The electro-hydraulic braking system is mainly composed of four parts: a brake pedal unit, a hydraulic drive unit, a brake execution unit, and a control unit. The mechanical structure is compact and exquisite, and the system has the function of precise and adjustable hydraulic pressure. The control architecture adopts a hierarchical control design, which is mainly composed of an upper wheel slip rate controller and a lower hydraulic pressure controller. Both the upper and lower controllers use a sliding mode variable structure control to improve the robustness and accuracy of the control.

Abstract Brake-by-wire (BbW) systems are one key technology in modern vehicles. Due to their great potential in the areas of energy efficiency and automated driving, they receive more and more attention nowadays. However, increased complexity and reliance on electric and electrical components in BbW systems bring about new challenges. This applies in particular to the fault tolerance of the brake system. Since drivers cannot form a fallback layer of braking functions due to the mechanical decoupling of the brake pedal, known BbW concepts provide a redundant system layer. However, driving is significantly limited in the event of a failure in the BbW system and is only possible under certain restrictions. The reason for that is a further possible failure (double point of failure scenario), which can result in a significant loss of braking performance.

Abstract The tailpipe zero-emission legislation has pushed the automotive industry toward more electrification. Regenerative braking is the capability of electric machines to provide brake torque. So far, the regenerative braking feature is primarily considered due to its effect on energy efficiency. However, using individual e-machines for each wheel makes it possible to apply the antilock braking function due to the fast torque-tracking characteristics of permanent magnet synchronous motors (PMSM). Due to its considerable cost reduction, in this article, a feasibility study is carried out to investigate if the ABS function can be done purely through regenerative braking using a mid-fidelity model-based approach. An uni-tire model of the vehicle with a surface-mount PMSM (SPMSM) model is used to verify the idea. The proposed ABS control system has a hierarchical structure containing a high-level longitudinal slip controller and a low-level SPMSM torque controller.