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Recent field data have shown that the occupant protection in vehicle rear seats failed to keep pace with advances in the front seats likely due to the lack of advanced safety technologies. The objective of this study was to optimize advanced restraint systems for protecting rear seat occupants with a range of body sizes under different frontal crash pulses. Three series of sled tests (baseline tests, advanced restraint trial tests, and final tests), MADYMO model validations against a subset of the sled tests, and design optimizations using the validated models were conducted to investigate rear seat occupant protection with 4 Anthropomorphic Test Devices (ATDs) and 2 crash pulses.

In order to detect degradation of engine oil lubricant, bench testing along with a number of diesel-powered Ford trucks were instruments and tested. The purpose of the bench testing was primarily to determine performance aspects such as repeatability, hysteresis effects and so on. Vehicle testing was conducted by designing and installing a separate oil reservoir along with a circulation system which was mounted in the vicinity of the oil pan. An innovative oil sensor was directly installed on the reservoir which can measure five (5) independent oil parameters (viscosity, density, permittivity, conductance, temperature). In addition, the concept is capable of detecting the oil level continuously during normal engine operation. The sensing system consists of an ultrasonic transducer for the oil level detection as well as a Tuning Fork mechanical resonator for the oil condition measurement.

Hybrid drivetrain systems are becoming increasingly prevalent in Automotive and Commercial Vehicle applications and have also been introduced for the 2009 Formula1 motorsport season. The F1 development has the clear intent of directing technical development in motorsport to impact the key issue of fuel efficiency in mainstream vehicles. In order to promote all technical developments, the type of system (electrical, mechanical, hydraulic, etc) for the F1 application has not been specified. A significant outcome of this action is renewed interest and development of mechanical hybrid systems comprising a high speed composite flywheel and a full-toroidal traction drive Continuously Variable Transmission (CVT). A flywheel based mechanical hybrid has few system components, low system costs, low weight and dispenses with the energy state changes of electrical systems producing a highly efficient and power dense hybrid system.

Patents granted recently to Mr. Rode have changed the industry capability to adjust and verify wheel-end bearings on trucks. Until now it was believed1 that there was nothing available to confirm or verify the most desirable settings of preload on these bearings. The new, breakthrough invention is a tool and spindle-locking nut that permit quick and accurate wheel bearing adjustment by utilizing direct reading force measurement. Bearings can be set to either SAE recommended preloads or specific endplay settings. The author has been working on bearing adjustment methods for industrial applications for over forty years, and considers these inventions to be his most important breakthrough for solving this elusive bearing adjustment problem. Consistent wheel bearing preload adjustment was not possible before, even though it was widely known to achieve the best wheel performance as noted in SAE specification J2535 and re-affirmed in 2006 by the SAE Truck and Bus Wheel Subcommittee.

A heavy truck wind tunnel test program is currently underway at the Langley Full Scale Tunnel (LFST). Seven passive drag reducing device configurations have been evaluated on a heavy truck model with the objective of understanding the practical limits to drag reduction achievable on a modern tractor trailer through add-on devices. The configurations tested include side skirts of varying length, a full gap seal, and tapered rear panels. All configurations were evaluated over a nominal 15 degree yaw sweep to establish wind averaged drag coefficients over a broad speed range using SAE J1252. The tests were conducted by first quantifying the benefit of each individual treatment and finally looking at the combined benefit of an ideal fully treated vehicle. Results show a maximum achievable gain in wind averaged drag coefficient (65 mph) of about 31 percent for the modern conventional-cab tractor-trailer.

This paper presents a simulation of the cooling airflow and surface temperatures of a midsize truck. The simulation uses full detailed geometry of the truck. Performance of the under-hood cooling airflow is analyzed and potential design changes leading to better cooling airflow are highlighted. Surface temperature over certain under-hood part is studied. Possible optimizations using various material and configurations are proposed. It is shown that the presented simulation approach provides valuable information to evaluate cooling system and thermal protection performance. Fast design iterations can be achieved using this approach.

The timing and associated levels of braking between initial brake pedal application and actual maximum braking at the wheels for a tractor-semitrailer are important parameters in understanding vehicle performance and response. This paper presents detailed brake timing information obtained from full scale instrumented testing of a tractor-semitrailer under various conditions of load and speed. Brake timing at steer, drive and semitrailer brake positions is analyzed for each of the tested conditions. The study further seeks to compare the full scale test data to predicted response from detailed heavy truck computer vehicle dynamics simulation models available in commercial software packages in order to validate the model's brake timing parameters. The brake timing data was collected during several days of full scale instrumented testing of a tractor-semitrailer performed at the Transportation Research Center, in East Liberty, Ohio.

This paper reports on a field test with 23 Volvo D12C non-exhaust gas recirculation diesel engines using the Diesel Particulate Filter (DPF), Selective Catalytic Reduction (SCR), and urea system with Ultra-Low-Sulfur-Diesel (ULSD). This combination will be used to meet the on-highway emission standards for U.S. 2010, Japan 2010, and Europe 2013. Because of future widespread use of DPF-SCR, this study reports on our field experience with this system, and focuses on enhancing our understanding of the incombustible materials which are collected in the DPF with API CJ-4 and API CI-4 PLUS oils. The average weight of incombustibles was lower in the trucks using API CJ-4 oils at 1.0% sulfated ash, than in those using API CI-4 PLUS oils at 1.4% sulfated ash. The difference in weight between the two groups was highly significant. Further, the weight of the incombustibles per kilometer substantially decreased with each subsequent cleaning within a truck.

Compliance with tighter emission regulations has increased the proportion of parasitic weight in commercial vehicles. In turn, the amount of payload must be reduced to comply with transportation weight requirements. A re-design of commercial vehicle components is necessary to decrease the vehicle weight and improve payload capacity. Side rails have traditionally been manufactured from high strength steels, but significant weight reductions can be achieved by substituting steel side rails with 6013 high strength aluminum alloy side rails. Material and stress analyses are presented in this paper in order to understand the effect of manufacturing process on the material's mechanical behavior. Metallographic and tensile test experiments for the 6013-T4 alloy were performed in preparation for residual stress measurements of a punching operation. Punched holes are critical to the function of the side rail and can lead to high stress levels and cracking.

In 2006, there were approximately 23,500 rear-end crashes involving heavy trucks (i.e., gross vehicle weight greater than 4,536 kg). The Enhanced Rear Signaling (ERS) for Heavy Trucks project was developed by the Federal Motor Carrier Safety Administration (FMCSA) to investigate methods to reduce or mitigate those crashes where a heavy truck has been struck from behind by another vehicle. Visual warnings have been shown to be effective, assuming the following driver is looking directly at the warning display or has his/her eyes drawn to it. A visual warning can be placed where it is needed and it can be designed so that its meaning is nearly unambiguous. FMCSA contracted with the Virginia Tech Transportation Institute (VTTI) to investigate potential benefit of additional rear warning-light configurations as rear-end crash countermeasures for heavy trucks.

Diesel spray experimentation at controlled high-temperature and high-pressure conditions is intended to provide a more fundamental understanding of diesel combustion than can be achieved in engine experiments. This level of understanding is needed to develop the high-fidelity multi-scale CFD models that will be used to optimize future engine designs. Several spray chamber facilities capable of high-temperature, high-pressure conditions typical of engine combustion have been developed, but because of the uniqueness of each facility, there are uncertainties about their operation. For this paper, we describe results from comparative studies using constant-volume vessels at Sandia National Laboratories and IFP.

Prior technical work by various OEMs and lubricant formulators has identified lubricant-derived phosphorus as a key element capable of significantly reducing the efficiency of modern emissions control systems of gasoline-powered vehicles ( 1 , 2 , 3 , 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 ). However, measuring the exact magnitude of the detriment is not simple or straightforward exercise due to the many other sources of variation which occur as a vehicle is driven and the catalyst is aged ( 1 ). This paper, the second one in the series of publications, examines quantitative sets of results generated using various vehicle and exhaust catalyst testing methodologies designed to follow the path of lubricant-derived phosphorous transfer from oil sump to exhaust catalytic systems ( 1 ).

This study investigates the impact of mid-high biodiesel blends on the criteria and PAH emissions from a modern pick-up diesel vehicle. The vehicle was a Euro 4 (category N1, subclass III) compliant common-rail light-duty goods pick-up truck fitted with a diesel oxidation catalyst. Emission and fuel consumption measurements were performed on a chassis dynamometer equipped with CVS, following the European regulations. All measurements were conducted over the certification New European Driving Cycle (NEDC) and the real traffic-based Artemis driving cycles. Aiming to evaluate the fuel impact on emissions, a soy-based biodiesel, a palm-based biodiesel, and an oxidized biodiesel obtained from used frying oils were blended with a typical automotive ultra-low-sulfur diesel at proportions of 30, 50 and 80% by volume. The experimental results revealed that CO₂ emissions and fuel consumption exhibited an increase with biodiesel over all driving conditions.

Advanced High Strength Steels (AHSS) have been implemented in the automotive industry to balance the requirements for vehicle crash safety, emissions, and fuel economy. With lower ductility compared to conventional steels, the fracture behavior of AHSS components has to be considered in vehicle crash simulations to achieve a reliable crashworthiness prediction. Without considering the fracture behavior, component fracture cannot be predicted and subsequently the crash energy absorbed by the fractured component can be over-estimated. In full vehicle simulations, failure to predict component fracture sometimes leads to less predicted intrusion. In this paper, the feasibility of using computer simulations in predicting fracture during crash deformation is studied.

Intelligent tires are envisioned to be an important part of the future vehicle control systems and the three dimensional wireless MEMS accelerometers embedded inside the tire stand out as a promising candidate for the development of intelligent tires. The first part of the paper focuses on accelerometer based tire sensors for the estimation of slip angle and tire/road friction coefficient. We use a simple tire finite element model to generate lateral, tangential and radial tire accelerations for a fixed load and slip angle. The profiles are validated by using experimental data. The simulated acceleration profiles are used for the estimation of slip angle and tire/road friction coefficient. We present the estimation algorithms, promising simulative results and output sensitivities studies focused on the effects of changes in normal load, tire pressure and vehicle velocity.

Dimensional variation simulation is a computer aided engineering (CAE) method that analyzes the statistical efforts of the component variation to the quality of the final assembly. The traditional tolerance analysis method and commercial CAE software are often based on the assumptions of the rigid part assembly. However, the vehicle functional attributes, such as, ride and handling, NVH, durability and reliability, require understanding the assembly quality under various dynamic conditions while achieving vehicle dimensional clearance targets. This paper presents the methods in evaluating and analyzing the impacts of the assembly variations for the vehicle dynamic performance. Basic linear tolerance stack method and advanced study that applies various CAE tools for the virtual quality analysis in the product and process design will be discussed.

This paper describes a driving controller to improve vehicle lateral stability and maneuverability for a six wheel driving / six wheel steering (6WD/6WS) vehicle. The driving controller consists of upper and lower level controller. The upper level controller based on sliding control theory determines front, middle steering angle, additional net yaw moment and longitudinal net force according to reference velocity and steering of a manual driving, remote control and autonomous controller. The lower level controller takes desired longitudinal net force, yaw moment and tire force information as an input and determines additional front steering angle and distributed longitudinal tire force on each wheel. This controller is based on optimal distribution control and has considered the friction circle related to vertical tire force and friction coefficient acting on the road and tire.

This paper presents an integrated design method for active trailer steering (ATS) systems of articulated heavy vehicles (AHVs). Of all contradictory design goals of AHVs, two of them, i.e. path-following at low speeds and lateral stability at high speeds, may be the most fundamental and important, which have been bothering vehicle designers and researchers. To tackle this problem, a new design synthesis approach is proposed: with design optimization techniques, the active design variables of ATS systems and passive design variables of trailers can be optimized simultaneously; the ATS controller derived from this approach has two operational modes, one for improving lateral stability at high speeds and the other for enhancing path-following at low speeds. To demonstrate the effectiveness of the proposed approach, it is applied to the design of an ATS system for an AHV with a tractor and a full trailer.

Torsional stiffness properties were developed for both a 53-foot box trailer and a 28-foot flatbed control trailer based on experimental measurements. In order to study the effect of torsional stiffness on the dynamics of a heavy truck vehicle dynamics computer model, static maneuvers were conducted comparing different torsional stiffness values to the original rigid vehicle model. Stiffness properties were first developed for a truck tractor model. It was found that the incorporation of a torsional stiffness model had only a minor effect on the overall tractor response for steady-state maneuvers up to 0.4 g lateral acceleration. The effect of torsional stiffness was also studied for the trailer portion of the existing model.

In August 2005, National Highway Traffic Safety Administration (NHTSA) proposed to increase the roof strength requirement under Federal Motor Vehicle Safety Standard (FMVSS) 216 from 1.5 to 2.5 times unloaded vehicle weight (UVW). To meet the new requirement with a minimum impact on vehicle weight and cost, the automotive community is working actively to develop improved roof architectures using advanced high strength steels (AHSS) and other lightweight materials such as structural foam. The objective of this study is to develop an optimized steel-only solution with low material and part-manufacturing costs. Since the new regulation will present a particular challenge to the roof architectures of large vans, pickup trucks and SUVs due to their large mass and size, a validated roof crush model on a B-Pillar-less light truck is utilized in this study.