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This work discusses the development of SAE procedure J2747, “Hydraulic Pump Airborne Noise Bench Test”. This is a test procedure describing a standard method for measuring radiated sound power levels from hydraulic pumps of the type typically used in automotive power steering systems, though it can be extended for use with other types of pumps. This standard was developed by a committee of industry representatives from OEM's, suppliers and NVH testing firms familiar with NVH measurement requirements for automotive hydraulic pumps. Details of the test standard are discussed. The hardware configuration of the test bench and the configuration of the test article are described. Test conditions, data acquisition and post-processing specifics are also included. Contextual information regarding the reasoning and priorities applied by the development committee is provided to further explain the strengths, limitations and intended usage of the test procedure.

Computer simulation was used as a complement to crash and injury field data analysis and physical sled and barrier tests to investigate and predict the spinal injuries of a rear impact in an IndyCar. The model was expected to relate the spinal loads to the observed injuries, thereby predicting the probability and location of spinal fractures. The final goal is to help reduce the fracture risk by optimizing the seat and restraint system design and the driver's position using computer modeling and sled testing. MADYMO Full FE Human Body Model (HBM) was selected for use because of its full spinal structural details and its compatibility with the vehicle and restraint system models. However, the IndyCar application imposed unique challenges to the HBM. First, the driver position in a race car is very different from that in a typical passenger car.

This paper describes a new tool to capture cylinder pressure information, calculate combustion parameters, and implement control algorithms. There are numerous instrumentation and prototyping systems which can provide some or all of this capability. The Cylinder Pressure Development Controller (CPDC) is unique in that it uses advanced high volume automotive grade circuitry, packaging, and software methodologies. This approach provides insight regarding the implementation of cylinder pressure based controls in a production engine management system. A high performance data acquisition system is described along with a data reduction technique to minimize data processing requirements. The CPDC software architecture is discussed along with model-based algorithm development and autocoding. Finally, CPDC calculated combustion parameters are compared with those from a well established combustion analysis system and thermodynamic simulations.

In the field of vehicle diagnostics accurate instantaneous engine speed information enables the detection and diagnosis of many engine problems, even subtle ones. Currently, there is a limited choice in the ways of obtaining such information. For example, it is known that one can tap into the crank sensor wiring, or use a separate, intrusive method, such as mounting a sensor in the bell housing to sense the rotation of the ring gear. However, the shortcomings of these approaches are locating and gaining access to the crank sensor connector, the location of which varies from vehicle to vehicle. Thus, authors proposed a novel, robust and manufacturing friendly speed sensor. The concept is based on the Villari effect. The sensor, which is attached to the front end of the engine crankshaft, consists of a coil of magnetostrictive wire supplied with AC current. During engine rotation the magnetostrictive wire become stressed due to centrifugal force.

2-Step variable-valve lift and timing is a high-value technology for the further development of automotive internal combustion engines. 2-Step valve train systems provide improved engine efficiency, emissions, and performance using components that are relatively low-cost and compatible with new and existing cylinder heads. This paper describes the design and development of a 2-Step rocker arm using a combination of analytical tools and physical testing. Prototype hardware was built to confirm the design. Performance and durability test results are presented.

Some Electronic Throttle Control (ETC) Air Control Valves (ACV) on automotive internal combustion engines are susceptible to icing of the throttle valve. Ice formation can result in an increase in torque required to open or close the valve. Laboratory studies were conducted to improve the understanding of throttle valve icing on electronic throttle control valves with both aluminum and composite (plastic) bodies over various bore sizes (4 cylinder to 8 cylinder engines). Study results indicated that ice compression at the bore and valve gap, not ice adhesion, is the major contributor to the ETC-ACV icing phenomenon. In addition, testing of parts with various bore sizes, orientations and surface cleanliness resulted in further understanding of the icing issue.

Worldwide regulatory demands to reduce emissions of greenhouse gases and other airborne pollutants are leading to significant changes in internal combustion engines. Many engine subsystems such as fuel injection, valvetrain, turbochargers and EGR, are being changed to address these demands. Additionally, advanced combustion modes such as HCCI are being pursued to address the key shortcomings of today's gasoline and diesel engines. Cylinder pressure based control is an enabling technology to the development and application of advanced engine subsystems and a key control element for advanced combustion modes. This paper describes a tool for rapid development of closed-loop cylinder pressure based algorithms. The Cylinder Pressure Development Controller (CPDC) is an affordable, automotive grade package containing a unique architecture enabling real-time, next engine cycle combustion feedback control.

This paper presents the development of a transmission closed loop pressure control system. The objective of this system is to improve transmission pressure control accuracy by employing closed-loop technology. The control system design includes both feed forward and feedback control. The feed forward control algorithm continuously learns solenoid P-I characteristics. The closed loop feedback control has a conventional PID control with multi-level gain selections for each control channel, as well as different operating points. To further improve the system performance, Robust Optimization is carried out to determine the optimal set of control parameters and controller hardware design factors. The optimized design is verified via an L18 experiment on spin dynamometer. The design is also tested on vehicle.

This paper provides an overview of rollover crash safety, including field crash statistics, pre- and rollover dynamics, test procedures and dummy responses as well as a bibliography of pertinent literature. Based on the 2001 Traffic Safety Facts published by NHTSA, rollovers account for 10.5% of the first harmful events in fatal crashes; but, 19.5% of vehicles in fatal crashes had a rollover in the impact sequence. Based on an analysis of the 1993-2001 NASS for non-ejected occupants, 10.5% of occupants are exposed to rollovers, but these occupants experience a high proportion of AIS 3-6 injury (16.1% for belted and 23.9% for unbelted occupants). The head and thorax are the most seriously injured body regions in rollovers. This paper also describes a research program aimed at defining rollover sensing requirements to activate belt pretensioners, roof-rail airbags and convertible pop-up rollbars.

Adaptive Cruise Control (ACC) technology is presently emerging in the automotive market as a convenience function intended to reduce driver workload. It allows the host vehicle to maintain a set speed and distance from preceding vehicles by a forward object detection sensor. The forward object detection sensor is the focal point of the ACC control system, which determines and regulates vehicle acceleration and deceleration through a powertrain torque control system and an automatic brake control system. This paper presents a design of an automatic braking system that utilizes a microprocessor-controlled brake hydraulic modulator. The alternatively qualified automatic braking means is reviewed first. The product level requirements of the performance, robustness, and durability for an automatic brake system are addressed. A brief overview of the presented system architecture is described.

Implementation of engine turnoff at idle is desirable to gain improvements in vehicle fuel economy. There are a number of alternatives for implementation of the restarting function, including the existing cranking motor, a 12V or 36V belt-starter, a crankshaft integrated-starter-generator (ISG), and other, more complex hybrid powertrain architectures. Of these options, the 12V belt-alternator-starter (BAS) offers strong potential for fast, quiet starting at a lower system cost and complexity than higher-power 36V alternatives. Two challenges are 1) the need to accelerate a large engine to idle speed quickly, and 2) dynamic torque control during the start for smoothness. In the absence of a higher power electrical machine to accomplish these tasks, combustion-assisted starting has been studied as a potential method of aiding a 12V accessory drive belt-alternator-starter in the starting process on larger engines.

Among the performance concerns in brake design, drag and fluid displacement are getting more attention in the requirement definition. High drag not only affects fuel efficiency and lining life, it is also a contributing factor to rotor thickness variation and brake pulsation. In this paper, a system approach to drag performance of a disc brake caliper is presented. A one-dimensional simulation model, which considers all the significant factors, including lining stiffness and hysteresis, housing stiffness, seal/groove characteristic, and stick-slide behavior between the seal and piston, is developed to capture the interactive impact of each parameter to caliper drag performance. The system model is validated with experimental measurements for caliper fluid displacement and piston retraction. A parameter study is then conducted to investigate the component interactive impact to the drag performance.

In 2002, NHTSA statistics indicate air bag deployments saved an estimated 1,500 lives; however, reports of occupants having serious or fatal injuries during air bag deployment appear low relative to the number of accidents with air bag deployments. To avoid air bag induced injuries, a variety of occupant sensing technologies are being developed. One of the critical logic deployment challenges faced by these technologies is whether the system can accurately determine if the occupant is in a posture or a position such that air bag deployment may result in an injury. To improve accuracy, it is necessary to understand what postures the occupants are likely to assume during a ride and how often. For this purpose, Delphi Corporation has conducted a survey to solicit opinions on the posture usage rate. With 560 responses, the frequencies for 29 sitting postures for adult passengers and 13 child postures or positions were estimated.

With the requirements for reducing the emissions and improving the fuel economy, the automotive companies are developing hybrid, 42 V and fuel cell vehicles. Power electronics is an enabling technology for the development of environmental friendly vehicles, and to implement the various vehicle electrical architectures to obtain the best performance. In this paper, the requirements of the power semiconductor devices and the criteria for selecting the power devices for various types of low emission vehicles are presented. A comparative study of the most commonly used power devices is presented. A brief review of the future power devices that would enhance the performance of the automotive power conversion systems is also presented.

Regulatory and market pressures continue to challenge the automotive industry to develop technologies focused on reducing exhaust emissions and improving fuel economy. This paper introduces a practical model, which evaluates the economic value of various technologies based on their ability to reduce fuel consumption, improve emissions or provide consumer benefits such as improved performance. By evaluating the individual elements of economic value as viewed by the OEM manufacturer, while keeping the end consumer in mind, technology selection decisions can be made. These elements include annual fuel usage, vehicle performance, mass reduction and emissions, among others. The following technologies are discussed and evaluated: gasoline direct injection, variable valvetrain technologies, common-rail diesel and hybrid vehicles.

The industry strategy for automotive safety systems has been evolving over the last 20 years. Systems, such as frontal and side airbags, are available today on the worldwide market that provide proven safety benefits. Interest in advanced safety systems for occupant protection and accident avoidance, is focused on making further reductions in road fatalities and injuries. Interior occupant sensing systems for advanced restraint systems, trapped occupant sensing, and driver monitoring are today under intense development as part of the industry's safety vision. In this paper, we will discuss the need for and requirements of interior occupant sensing systems, as well as applicable technologies

This paper presents a methodology to predict component and system reliability and durability. The methodology is illustrated with an electronic diesel fuel injector case study that integrates customer usage data, component failure distribution, system failure criteria, manufacturing variation, and variation in customer severity. Extension to the vehicle system level enables correlation between component and system requirements. Further, this analysis provides the basis to establish a knowledge-based test option for a success test validation program to demonstrate reliability.

Electro-hydraulic actuation has been used widely in automatic transmission designs. With greater demand for premium shift quality of automatic transmissions, higher pressure control accuracy of the transmission electro-hydraulic control system has become one of the main factors for meeting this growing demand. This demand has been the driving force for the development of closed loop pressure controls technology. This paper presents the further research done based upon a previously developed closed loop system. The focus for this research is on the system requirements, such as solenoid driver selection and system latency handling. Both spin-stand and test vehicle setups are discussed in detail. Test results for various configurations are given.

The information provided by the in-cylinder pressure signal is of great importance for modern engine management systems. The obtained information is implemented to improve the control and diagnostics of the combustion process in order to meet the stringent emission regulations and to improve vehicle reliability and drivability. The work presented in this paper covers the experimental study and proposes a comprehensive and practical solution for the estimation of the in-cylinder pressure from the crankshaft speed fluctuation. Also, the paper emphasizes the feasibility and practicality aspects of the estimation techniques, for the real-time online application. In this study an engine dynamics model based estimation method is proposed. A discrete-time transformed form of a rigid-body crankshaft dynamics model is constructed based on the kinetic energy theorem, as the basis expression for total torque estimation.

The intensity of a combustion flame ionization current signal (ionsense) can be used to monitor and control combustion in individual cylinders during a cold engine start. The rapid detection of poor or absence of combustion can be used to determine fuel delivery corrections that may prevent engine stalls. With the ionsense cold start control active, no start failures were recorded even when the initially (prior to ionsense correction) commanded fueling had failed to produce a combustible mixture. This new dimension in fuel control allows for leaner cold start calibrations that would still be robust against the possible use of low volatility gasoline. Consequently, when California Phase 2 fuel is used, cold start hydrocarbon emissions could be lowered without the risk of an engine stall if the appropriate fuel is replaced with a less volatile one.