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Test Method for Seat Wrinkling and Bagginess

2012-05-22
This study evaluates utilizing an accelerated test method that correlates customer interaction with a vehicle seat where bagginess and wrinkling is produced. The evaluation includes correlation from warranty returns as well as test vehicle results for test verification. Consumer metrics will be discussed within this paper with respect to potential application of this test method, including but not limited to JD Power ratings. The intent of the test method is to aid in establishing appropriate design parameters of the seat trim covers and to incorporate appropriate design measures such as tie downs and lamination. This test procedure was utilized in a Design for Six Sigma (DFSS) project as an aid in optimizing seat parameters influencing trim cover performance using a Design of Experiment approach. Presenter Lisa Fallon, General Motors LLC
Technical Paper

N&V Component Structural Integration and Mounted Component Durability Implications

2020-04-14
2020-01-1396
Exterior component integration presents competing performance challenges for balanced exterior styling, safety, ‘structural feel’ [1] and durability. Industry standard practices utilize noise and vibration mode maps and source-path-receiver [2] considerations for component mode frequency placement. This modal frequency placement has an influence on ‘structural feel’ and durability performance. Challenges have increased with additional styling content, geometric overhang from attachment points, component size and mass, and sensor modules. Base excitation at component attachment interfaces are increase due to relative positioning of the suspension and propulsion vehicle source inputs. These components might include headlamps, side mirrors, end gates, bumpers and fascia assemblies. Here, we establish basic expectations for the behavior of these systems, and ultimately consolidate existing rationales that are applied to these systems.
Journal Article

Development of a Lightweight Third-Generation Advanced High-Strength Steel (3GAHSS) Vehicle Body Structure

2018-04-03
2018-01-1026
This article covers an application of third-generation advanced high-strength steel (3GAHSS) grades to vehicle lightweight body structure development. Design optimization of a vehicle body structure using a multi-scale material model is discussed. The steps in the design optimization and results are presented. Results show a 30% mass reduction potential over a baseline mid-size sedan body side structure with the use of 3GAHSS.
Technical Paper

Springback Prediction and Correlations for Third Generation High Strength Steel

2020-04-14
2020-01-0752
Third generation advanced high strength steels (3GAHSS) are increasingly used in automotive for light weighting and safety body structure components. However, high material strength usually introduces higher springback that affects the dimensional accuracy. The ability to accurately predict springback in simulations is very important to reduce time and cost in stamping tool and process design. In this work, tension and compression tests were performed and the results were implemented to generate Isotropic/Kinematic hardening (I/KH) material models on a 3GAHSS steel with 980 MPa minimum tensile strength. Systematic material model parametric studies and evaluations have been conducted. Case studies from full-scale industrial parts are provided and the predicted springback results are compared to the measured springback data. Key variables affecting the springback prediction accuracy are identified.
Technical Paper

Purge Pump Rotor Dynamics Subjected to Ball Bearing Inner and Outer Race Wear Defects

2020-04-14
2020-01-0403
The purge pump is used to pull evaporative gases from canister and send to engine for combustion in Turbocharged engines. The purge pump with impeller at one end and electric motor at the other end is supported by the ball bearing assembly. A bearing kinematic model to predict forcing function due to defect in ball bearing arrangement, coupled with bearing dynamic model of rotor because of rotating component, is proposed in this paper to get accumulated effect on transmitted force to the purge pump housing. Rotor dynamic of purge pump rotor components only produces certain order forcing responses which can be simulated into the multibody software environment, knowing the ball bearing geometry parameters hence providing stiffness parameter for rotor system.
Technical Paper

Investigation of Fracture Behavior of Deep Drawn Automotive Part affected by Thinning with Shell Finite Elements

2020-04-14
2020-01-0208
In the recent decades, tremendous effort has been made in automotive industry to reduce vehicle mass and development costs for the purpose of improving fuel economy and building safer vehicles that previous generations of vehicles cannot match. An accurate modeling approach of sheet metal fracture behavior under plastic deformation is one of the key parameters affecting optimal vehicle development process. FLD (Forming Limit Diagram) approach, which plays an important role in judging forming severity, has been widely used in forming industry, and localized necking is the dominant mechanism leading to fracture in sheet metal forming and crash events. FLD is limited only to deal with the onset of localized necking and could not predict shear fracture. Therefore, it is essential to develop accurate fracture criteria beyond FLD for vehicle development.
Journal Article

Obtaining Diagnostic Coverage Metrics Using Rapid Prototyping of Multicore Systems

2011-04-12
2011-01-1007
With the introduction of the ISO26262 automotive safety standard there is a burden of proof to show that the processing elements in embedded microcontroller hardware are capable of supporting a certain diagnostic coverage level, depending on the required Automotive Safety Integrity Level (ASIL). The current mechanisms used to provide actual metrics of the Built-in Self Tests (BIST) and Lock Step comparators use Register Transfer Level (RTL) simulations of the internal processing elements which force faults into individual nodes of the design and collect diagnostic coverage results. Although this mechanism is robust, it can only be performed by semiconductor suppliers and is costly. This paper describes a new solution whereby the microcontroller is synthesized into a large Field Programmable Gate Array (FPGA) with a test controller on the outside.
Journal Article

Vehicle Integration Factors Affecting Brake Caliper Drag

2012-09-17
2012-01-1830
Disc brakes operate with very close proximity of the brake pads and the brake rotor, with as little as a tenth of a millimeter of movement of the pads required to bring them into full contact with the rotor to generate braking torque. It is usual for a disc brake to operate with some amount of residual drag in the fully released state, signifying constant contact between the pads and the rotor. With this contact, every miniscule movement of the rotor pushes against the brake pads and changes the forces between them. Sustained loads on the brake corner, and maneuvers such as cornering, can both produce rotor movement relative to the caliper, which can push it steadily against one or both of the brake pads. This can greatly increase the residual force in the caliper, and increase drag. This dependence of drag behavior on the movement of the brake rotor creates some vehicle-dependent behavior.
Technical Paper

Kriging-Assisted Structural Design for Crashworthiness Applications Using the Extended Hybrid Cellular Automaton (xHCA) Framework

2020-04-14
2020-01-0627
The Hybrid Cellular Automaton (HCA) algorithm is a generative design approach used to synthesize conceptual designs of crashworthy vehicle structures with a target mass. Given the target mass, the HCA algorithm generates a structure with a specific acceleration-displacement profile. The extended HCA (xHCA) algorithm is a generalization of the HCA algorithm that allows to tailor the crash response of the vehicle structure. Given a target mass, the xHCA algorithm has the ability to generate structures with different acceleration-displacement profiles and target a desired crash response. In order to accomplish this task, the xHCA algorithm includes two main components: a set of meta-parameters (in addition target mass) and surrogate model technique that finds the optimal meta-parameter values. This work demonstrates the capabilities of the xHCA algorithm tailoring acceleration and intrusion through the use of one meta-parameter (design time) and the use of Kriging-assisted optimization.
Journal Article

Cosmetic Corrosion Test for Aluminum Autobody Panels: Final Report

2010-04-12
2010-01-0726
Over the past several years a task group within the SAE Automotive Corrosion and Protection (ACAP) Committee has conducted extensive on-vehicle field testing and numerous accelerated lab tests with the goal of establishing a standard accelerated test method for cosmetic corrosion evaluations of finished aluminum auto body panels. This project has been a cooperative effort with OEM, supplier, and consultant participation and was also supported in part by DOE through USAMP (AMD 309). The focus of this project has been the identification of a standardized accelerated cosmetic corrosion test that exhibits the same appearance, severity, and type of corrosion products that are exhibited on identical painted aluminum panels exposed to service relevant environments. Multi-year service relevant exposures were conducted by mounting panels on-vehicles in multiple locations in the US and Canada.
Technical Paper

HEV Architectures - Power Electronics Optimization through Collaboration Sub-topic: Inverter Design and Collaboration

2010-10-19
2010-01-2309
As the automotive industry quickly moves towards hybridized and electrified vehicles, the optimal integration of power electronics in these vehicles will have a significant impact not only on the cost, performance, reliability, and durability; but ultimately on customer acceptance and market success of these technologies. If properly executed with the right cost, performance, reliability and durability, then both the industry and the consumer will benefit. It is because of these interdependencies that the pace and scale of success, will hinge on effective collaboration. This collaboration will be built around the convergence of automotive and industrial technology. Where real time embedded controls mixes with high power and voltage levels. The industry has already seen several successful collaborations adapting power electronics to the automotive space in target vehicles.
Technical Paper

Power Semiconductors for Starter-Alternator Systems

2001-03-05
2001-01-0958
Modern semiconductor devices enable highly efficient conversion of electrical power. Together with the microcontroller, they are the key elements for generation of the alternating currents from the car's DC supply that are necessary to drive high-performance units such as starter-alternators. These allow the combustion engine to crank up in several 100 ms and deliver up to 15 kW of electrical power. Smart driver ICs such as the TLE6280 enable the fast development of the interface between the microcontroller and the power switches. Currents of some 100A can be handled with the new OptiMOS FETs. Their rugged and ultra-low ohmic technology and their innovative packaging concepts, such as Power Modules and Power-Bonded MOSFETs, allow the building of compact and efficient control units.
Technical Paper

Current Control Strategies for Quasi-Autonomous Gate Driver

2002-03-04
2002-01-0472
Infineon proposes a Quasi-Autonomous Gate Driver (QAGD) to manage an electrically actuated component, whether electromechanical, electromagnetic, or electrohydraulic. This paper examines some current control strategies that can be implemented within the QAGD, such as: Synchronous Sampling (SYSA), Hysteresis, Improved Synchronous Sampling-Hysteresis (ISSH), Suboscillation, Suboscillation with Back EMF Feedforward (SBEF) and Synchronous Control in Rotation Coordinates (SCRC). Analysis and simulation of these strategies indicate their advantages and disadvantages, which are then summarized in a comparison chart, from which the best solution for a given application can be determined. The QAGD IC proposed by Infineon adopts this solution by integrating the current controller and the driver unit for the MOSFETs in a single package. The inverter function can therefore be implemented using one QAGD and several MOSFETs, which greatly simplify the system and decrease the costs.
Technical Paper

Secure Boot Implementation for Hard Real-Time Powertrain System

2017-03-28
2017-01-1656
Vehicle Security means protecting potential threats, unintended malfunction and illegal tuning. In addition, it has become a more important issue on an automotive system as it is directly connected to the driver and pedestrian's life. Automotive industry significantly needs to enhance security policies to prevent attacks from hackers. Nevertheless, in some systems, performance still has to be considered at first when security functions are implemented. Especially, in case of Engine Management System (EMS), fast engine synchronization for starting should be considered as the first priority. This paper is intended to show an approach to design efficient secure boot implementation for EMS. At the beginning of this paper, the concept of secure boot is explained and several use cases are introduced according to execution modes, such as the foreground and background secure boot modes. As a next step, engine starting process by EMS is explained.
Technical Paper

Utilizing a Tracked 3-Dimensional Acoustic Probe in the Development of an Automotive Front-of-Dash

2017-06-05
2017-01-1869
During the development of an automotive acoustic package, valuable information can be gained by visualizing the acoustic energy flow through the Front-of-Dash (FOD) when a sound source is placed in the engine compartment. Two of the commonly used methods for generating the visual map of the acoustic field include Sound Intensity measurements and array technologies. An alternative method is to use a tracked 3-dimensional acoustic probe to scan and visualize the FOD in real-time when the sound source is injecting noise into the engine compartment. The scan is used to focus the development of the FOD acoustic package on the weakest areas by identifying acoustic leaks and locations with low Transmission Loss. This paper provides a brief discussion of the capabilities of the tracked 3-D acoustic probe, and presents examples of the implementation of the probe during the development of the FOD acoustic package for two mid-sized sedans.
Technical Paper

Defining In-Vehicle Location and Functional Attributes of a ‘Button-Style Electronic Automatic Transmission Shifter’ Using DFSS Methodology with Customer Clinic Approach

2017-03-28
2017-01-1131
The implementation of electronic shifters (e-shifter) for automatic transmissions in vehicles has created many new opportunities for the customer facing transmission interface and in-vehicle packaging. E-shifters have become popular in recent years as their smaller physical size leads to packaging advantages, they reduce the mass of the automatic transmission shift system, they are easier to install during vehicle assembly, and act as an enabler for autonomous driving. A button-style e-shifter has the ability to create a unique customer interface to the automatic transmission, as it is very different from the conventional column lever or linear console shifter. In addition to this, a button-style e-shifter can free the center console of valuable package space for other customer-facing functions, such as storage bins and Human-Machine Interface controllers.
Technical Paper

Self-Certification Requirements for Adaptive Driving Beam Headlamps

2017-03-28
2017-01-1365
Vehicle certification requirements generally fall into 2 categories: self-certification and various forms of type approval. Self-certification requirements used in the United States under Federal Motor Vehicle Safety Standards (FMVSS) regulations must be objective and measurable with clear pass / fail criteria. On the other hand, Type Approval requirements used in Europe under United Nations Economic Commission for Europe (UNECE) regulations can be more open ended, relying on the mandated 3rd party certification agency to appropriately interpret and apply the requirements based on the design and configuration of a vehicle. The use of 3rd party certification is especially helpful when applying regulatory requirements for complex vehicle systems that operate dynamically, changing based on inputs from the surrounding environment. One such system is Adaptive Driving Beam (ADB).
Technical Paper

High Power Cell for Mild and Strong Hybrid Applications Including Chevrolet Malibu

2017-03-28
2017-01-1200
Electric vehicles have a strong potential to reduce a continued dependence on fossil fuels and help the environment by reducing pollution. Despite the desirable advantage, the introduction of electrified vehicles into the market place continues to be a challenge due to cost, safety, and life of the batteries. General Motors continues to bring vehicles to market with varying level of hybrid functionality. Since the introduction of Li-ion batteries by Sony Corporation in 1991 for the consumer market, significant progress has been made over the past 25 years. Due to market pull for consumer electronic products, power and energy densities have significantly increased, while costs have dropped. As a result, Li-ion batteries have become the technology of choice for automotive applications considering space and mass is very critical for the vehicles.
Technical Paper

NVH Development of EU5 2.0L and 2.2L Diesel Engine

2011-04-12
2011-01-0932
There is higher and higher demand by customers for vehicles with the maximum level of comfort, this aspect being a target to be achieved together with the general trend to increase performance and also with the necessity to reduce engine out emissions to satisfy the new environmental regulations. GMDAT has recently developed new EU5 2.0 and 2.2 liter L4-cylinder turbocharged Diesel engines that, to address customer demands, have improved power, lower exhaust gas emissions and NVH performance aligned to best in class in its segment. With the final aim of making this engine best in class from an NVH perspective, the NVH development has been executed in a very structured way, going through target setting and deployment, concept and design, combustion and mechanical development through computational analysis first and subsequently experimental tests.
Technical Paper

Particulate Characteristics for Varying Engine Operation in a Gasoline Spark Ignited, Direct Injection Engine

2011-04-12
2011-01-1220
The objective of this research is a detailed investigation of particulate sizing and number count from a spark-ignited, direct-injection (SIDI) engine at different operating conditions. The engine is a 549 [cc] single-cylinder, four-valve engine with a flat-top piston, fueled by Tier II EEE. A baseline engine operating condition, with a low number of particulates, was established and repeatability at this condition was ascertained. This baseline condition is specified as 2000 rpm, 320 kPa IMEP, 280 [°bTDC] end of injection (EOI), and 25 [°bTDC] ignition timing. The particle size distributions were recorded for particle sizes between 7 and 289 [nm]. The baseline particle size distribution was relatively flat, around 1E6 [dN/dlogDp], for particle diameters between 7 and 100 [nm], before dropping off to decreasing numbers at larger diameters. Distributions resulting from a matrix of different engine conditions were recorded.
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