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A broad range of information is being delivered to and used within modern vehicles. Information-based applications are becoming more highly integrated into the automobile. Security services are necessary to provide appropriate protection for this information. Encryption, digital signature, and hash functionalities enable information security services such as confidentiality, authentication, integrity and non-repudiation. However, the consumer of in-vehicle information services will not accept security services that introduce any inconvenience to their activities. This paper will discuss various security service methods and security management systems and propose methods to integrate these services acceptably into vehicle-based applications.

Historically, the long development time required to produce a new automobile has meant that the electronics in that vehicle might lag the state-of-the-art by several years. For traditional vehicle electronics, this was certainly an appropriate delay, ensuring through extensive testing and qualification that the quality and reliability of the electronic systems met rigorous standards. However, with the growing consumer-oriented electronics content in today's vehicles, it is becoming more difficult for the automotive manufacturers to meet consumers' expectations with older technology. Couple this with the fast-paced consumer product cycle, typically nine to eighteen and the result is increasing pressure on the vehicle manufacturers from after-market electronics suppliers, who can update their product lines as fast as the component manufacturers can produce new models.

This paper discusses the feasibility and issues associated with integrating a consumer off-the shelf product into a vehicle. For this evaluation, we selected a handheld personal computer (HPC), cellular telephone and modem to integrate with the vehicle audio, climate and system controls. Connectivity between the HPC and the vehicle is established by the use of the standard infrared serial data link that comes with the HPC. Connectivity outside the vehicle uses a cellular telephone for voice and a cellular digital packet data (CDPD) modem for data. This system is built into the Dodge ESX-2 hybrid powered concept vehicle for demonstration.

The rapid growth of information technology has the potential to affect many of the reasons why people drive. The Internet is arguably the most significant recent milestone in the growth of information technology. This paper examines the ways Internet communication might affect the travel experience by a) eliminating traditional reasons for personal travel, b) providing new reasons, c) changing the balance between personal and freight travel, and d) changing trip length distribution. Changes of the types listed could affect the product demand "mix" for electric, hybrid-electric and fuel cell vehicles being developed.

As automotive electronic systems become more and more spread, the necessity for a complete portfolio of communication standards for automotive applications becomes obvious. In the low cost Class A Smart Sensor & Actuator arena Local Interconnect Network (LIN) is the top candidate to be used as a multiplex standard all over the world. The LIN concept includes not only the physical layer and the data link layer; it also defines the tool interfaces and network description to speed the development process for in vehicle networks. This article describes the development process for LIN applications and gives an example of a typical LIN application, explains the benefits of this solution from the major aspects, the usage of the different tool interfaces, and its representation on the data link layer and the physical layer.

This paper addresses feedforward tracking control for electronic throttles. A robust and accurate tracking control scheme based on the training of a Neural Network model and feedback term (PID) is developed. The Neural Network based term can be trained off-line. This feedfoward term serves as a mathematical model capable of describing Electronic Throttle dynamics over a wide range. We have shown that by adding the Neural Network based feedforward control to a common feedback control method, such as the gain-scheduled PID used in many ETC production controllers, that the tracking control performance criteria such as transient errors, steady state errors, response time and overshoot, are greatly improved. Experiments conducted on a production Electronic Throttle Body with a Motorola H-brigde driver IC have shown good results utilizing this approach.

The utilization of electro-mechanical relays in traditional automotive applications such as power door lock systems and vehicle lighting has been easily justified on the basis of performance, cost and reliability. However, with the advance of new vehicle systems, we find that new standards for the basic power switch must be established. When the control of anti-lock brake or suspension systems is to be considered, standards for performance and reliability must rise. This paper will examine a high current Solid State Relay (SSR) which has been developed for application within critical automotive systems. The design approach, technology utilized, and operating characteristics, as well as application justification will be discussed.

Higher horsepower per liter engines have put more demand on the crankshaft, often requiring the use of forged steel. This paper examines cost reduction opportunities to offset the penalties associated with forged steel, with raw material and machinability being the primary factors evaluated. A cost model for crankshaft processing is utilized in this paper as a design tool to select the lowest cost material grade. This model is supported by fatigue and machinability data for various steel grades. Materials considered are medium carbon, low alloy, and microalloy steels; the effects of sulfur as a machining enhancer is also studied.

A unique opportunity arose to make a direct comparison of aluminum, sheet molding compound (SMC) and steel using a common hood design. In considering all possible material combinations of inner and outer panels, it was discovered that some of the combinations were incompatible due to material properties. Only the compatible material combinations were considered. Three different joining techniques - welding, bonding and bonded hem flanging - were evaluated. The cost, weight and structural performance of the chosen hood material combinations were established. Areas of further development were identified, including design optimization for specific material combinations.

A computer-controlled body panel testing machine has been used to quantify stiffness and dent resistance of body panels at Chrysler. The influence of yield strength and local reinforcement on the mechanical behavior of automotive door panels has been investigated. Medium strength steels in the range of 210 -240 MPa yield strength have produced significant improvements in dent resistance over a 160 MPa yield strength steel. Considerable improvements in dent resistance can also be attributed to the use of local, adhesively attached, glass fiber reinforcement patches. The effects of boundary conditions and panel shape on stiffness and dent resistance are illustrated in this application.

An OEM Natural Gas Vehicle (NGV) has been developed to address recently enacted Clean-Fuel Vehicle legislation. The NGV incorporates advanced fuel storage and fuel metering technologies to produce very low emissions and to provide superior customer value compared to aftermarket conversion units.

This study analyzes the vibration characteristics of the valve train of a 2.0L SOHC Chrysler Corp. Neon engine over a range of operating speeds to investigate and demonstrate the advantages and limitations of various dynamic measurements such as displacement, velocity, and acceleration in this application. The valve train was tested in a motoring fixture at speeds of 500 to 3500 camshaft rpm. The advantages of analyzing both time and frequency domain measurements are described. Both frequency and order analysis were done on the data. The theoretical order spectra of cam displacement and acceleration were computed and compared to the experimental data. Deconvolution was used to uncover characteristic frequencies of vibration in the system. The theoretical cam acceleration spectrum was deconvolved from measured acceleration spectra to reveal the frequency response function of the follower system.

A selection of commercially available chromium and chromium-free post phosphate rinses along with a deionized water rinse were evaluated over several zinc and zinc-alloy coated sheet steels. The test specimens were pretreated and electrocoated on-line in an automotive assembly plant. The effect of the rinse treatments on the cosmetic corrosion performance of the substrates, after 5 years of exposure in an outdoor scab corrosion test was determined. After this exposure none of the rinse treatments had performed better than deionized water rinse on zinc and zinc-iron coated sheet. The zinc-nickel coating showed improved scribe creepage when treated with the Cr+6/Cr+3 rinse. Data is provided comparing the concentration of the treatments used vs scribe creepage and chipping corrosion paint loss.

A comprehensive selection of automotive sheet steels were exposed in an outdoor scab corrosion test to provide a base-line of cosmetic corrosion performance. Eighteen different coated sheet steels along with CRS as a control were processed using two commercially available zinc phosphate chemistries. The phosphating was done using both immersion and spray phosphate processes in a laboratory and an automotive assembly plant. Scribe creepage results are reported for 5 years outdoor scab exposure. Comparisons of the scribe creepage behavior of CRS, zinc, and zinc alloy coatings and the effect of the phosphate treatment are provided. An estimate of 10 years field performance is made.

A Methanol Concentration Smart Sensor has been developed to support the demand for alternately fueled vehicles operating on blends of methanol and gasoline in any mixture up to 85% methanol. The sensor measures concentration by exploiting the difference in dielectric properties between methanol and gasoline. The measurement is made based on the distributed capacitance of a coil of wire, contained in a reservoir through which the fuel passes. This signal, along with temperature compensation inputs, is then fed to an integral microprocessor, which provides a voltage output proportional to the methanol concentration of the fuel. The Powertrain Controller uses this information to modify injector pulse width and provide proper spark advance. This paper will explain the sensor's development methodology and function.

Typical sand-casting techniques have been shown to be inappropriate in pouring particulate reinforced aluminum metal matrix composite (Al-MMC) castings. New gating/risering configurations were necessary to produce castings of acceptable soundness. Several automotive components, including brake rotors, cylinder liners and camshaft thrust plates, were prepared using special techniques. Initial durability test results of several Al-MMC prototype components are presented.

Chrysler Corporation has developed an 8.0-liter engine for light truck applications. Numerous features combine to produce the highest power and torque ratings of any gasoline-fueled light truck engine currently available while also providing commensurate durability. These features include: a deep-skirt ten-cylinder 90° “V” block, a Helmholtz resonator intake manifold that enhances both low and mid-range torque, light die cast all-aluminum pistons for low vibration, a unique firing order for smooth operation, a “Y” block configuration for strength and durability, a heavy duty truck-type thermostat to control warm up, and a direct ignition system.

A new 3.5 liter, 60 degrees V6 engine has been designed specifically for Chrysler's 1993 MY line of mid-size sedans - Dodge Intrepid, Eagle Vision, Chrysler Concorde and New Yorker. This new engine features many new components for enchanced performance. The cylinder head has a single overhead cam, four valve-per - cylinder design. The intake system is a cross-flow design equipped with dual throttle bodies, and the manifold also incorporates a vacuum operated tuning valve that increases the mid-range torque of the engine. A windage tray is used on every engine to reduce drag on the rotating components within the crankcase. Dual knock sensors (one per cylinder bank) are used to take advantage of the aggressive spark advance and high compression ratio. The engine also utilizes a plastic, helical, water pump impeller that contributes to low parasitic power losses. The engine incorporates many components and features to ensure durability.

Five heats of vanadium-microalloyed steel with carbon contents from 0.29% to 0.40% and sulfur contents from 0.031% to 0.110% were forged into automotive spindles and air cooled. Three of the steels were continuously cast whereas the other two were ingot cast. The forged spindles were subjected to microstructural analysis, mechanical property testing, full component testing and machinability testing. The microstructures of the five steels consisted of pearlite and ferrite which nucleated on prior austenite grain boundaries and predominantly on intragranularly dispersed sulfide inclusions of the resulfurized grades. Ultimate tensile strengths and room temperature Charpy V-notch impact toughness values were relatively insensitive to processing and compositional variations. The room temperature tensile and room-temperature impact properties ranged from 820 MPa to 1000 MPa (120 to 145 ksi) and from 13 Joules to 19 Joules (10 to 14 ft-lbs), respectively, for the various steels.

Most United States vehicle assembly plants produce significantly more automatic transmission equipped vehicles than manual transmission vehicles. Assembling these two vehicles on a common production line can create complexity problems. This paper describes the design and development of a pre-assembled manual transmission clutch and flywheel modular assembly which reduces most of these problems. This assembly is used on the 1993 model year mini-van with a 2.5L four cylinder engine. This modular clutch system utilizes the same starter ring gear carrier (driveplate) used on automatic transmission equipped vehicles. It pilots into the crankshaft similar to the automatic transmission torque converter. It is balanced as an assembly which results in a lower system imbalance. A significant system piece cost saving, in comparison with today's competitive market, was achieved.