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The advancements in automation, big data computing and high bandwidth networking has expedited the realization of Industrial Internet of Things (IIoT). IIoT has made inroads into many sectors including automotive, semiconductors, electronics, etc. Particularly, it has created numerous opportunities in the automotive manufacturing sector to realize the new aura of platform concepts such as smart material flow control. This paper provides a thought provoking application of IIoT in automotive composites body shop. By creating a digital twin for every physical part, we no longer need to adhere to the conventional manufacturing processes and layouts, thus opening up new opportunities in terms of equipment and space utilization. The century-old philosophy of the assembly line might not be the best layout for vehicle manufacturing, thus proposing a novel assembly grid layout inspired from a colony of ants working to accomplish a common goal.

In this paper, an analytical procedure for prediction of shell radiated noise of air induction systems (AIS) due to engine acoustic excitation, without a prototype and physical measurement, is presented. A set of modeling and simulation techniques are introduced to address the challenges to the analytical radiated noise prediction of AIS products. A filter seal model is developed to simulate the unique nonlinear stiffness and damping properties of air cleaner boxes. A finite element model (FEM) of the AIS assembly is established by incorporating the AIS structure, the proposed filter seal model and its acoustic cavity model. The coupled acoustic-structural FEM of the AIS assembly is then employed to compute the velocity frequency response of the AIS structure with respect to the air-borne acoustic excitations.

This paper describes a front road wheel steer-by-wire system with two actuator motors on the rack and pinion assembly to move the road wheels. Dual actuators are used to provide actuator redundancy and to enhance the fault tolerance capability. When one actuator faults or fails, the other actuator is designed to work independently and maintain full system performance. The paper emphasizes control method to implement the motion control for the front road wheel steer-by-wire system with two actuators on the common load. The proposed dual servo synchronization motion control implements the angle tracking for the road wheel reference input by controlling two actuators synchronously and cooperatively. It includes two servo feedback control loops to track the common reference input. The angular position error between two feedback loops is compensated using a synchronized compensator.

This paper proposes a conceptual design tool that could direct designers towards concepts that lead to reduced gaps on the exterior of an automobile. Apart from the manufacturing and assembly tolerance stack up, the design and integration method of the body panels in an automobile contribute to the gap. . A benchmark study suggested cursory concepts to avoid or minimize the gaps. The proposed design tool uses a modified morphological chart approach to populate a table with concepts obtained from the benchmark study and by other means. The design tool also incorporates decision alternatives and hence is different from a morphological chart. The design tool can be used to highlight the occurrence of a high level tolerance stack up chain on the structural/mounting members. Conceptual component architectures are arranged in such a fashion to facilitate combinations through visual means.

The objective of the present work was to improve the cold start NVH performance of an automotive power steering pump under low temperature conditions. This objective was accomplished through the use experimental study and measurement. The satisfactory operation of a fixed displacement vane pump in cold temperatures depends on a number of factors including; (1) filling characteristics, (2) the inlet conditions to the pump, (3) the fluid, and (4) the ability of the vanes to maintain contact with the cam surface. In this investigation, factor (4) was chosen for investigation. A unique outlet orifice was designed and tested at three different operating ambient temperatures, -19 °C, -29 °C, and -40 °C. Maximum “noise” duration was measured as the maximum duration of fluid borne pump outlet pressure oscillations greater the 345 kPa peak-to-peak. The results show that noise duration can reduced by as much as 50% at -40 °C.

The International Space Station (ISS) internal thermal control system (ITCS) has been developed jointly by the Boeing Corporation, Huntsville, Alabama, and Honeywell Engines & Systems, Torrance, California, to meet ISS internal thermal control needs. The ITCS provides heat removal for the critical life support systems and thermal conditioning for numerous experiment racks. The ITCS will be fitted on a number of modules on the ISS. The first module, the US Laboratory Module, was launched in February 2001 and is now operational on the ISS. The dual loop system is comprised of a low-temperature loop (LTL) and a moderate-temperature loop (MTL). Each loop has a pump package assembly (PPA), a system flow control assembly (SFCA), a three-way mixing valve (TWMV), several rack flow control assemblies (RFCA), cold plates, pressure sensors, temperature sensors, a pump bypass assembly (PBA), and a heat exchanger.

This paper introduces the Driver Stability System (DSS) at Visteon. DSS is a new active comfort / safety system for automobiles which controls the seat bolsters independently in real time to enhance the lateral support of the occupants. Under turning maneuvers, DSS reacts to the vehicle dynamics to provide an increased contact area between the occupants and their seats, allowing optimal occupant location with respect to such variables as steering wheel angle, lateral acceleration, yaw rate, and vehicle velocity. The lateral force compensation is directly coupled to the dynamic movement of vehicle chassis and the change of road profile. The system consists of the seat bolster assembly including DC motors, wheel speed sensors, steering wheel sensor, lateral accelerometer, yaw rate sensor, and electronic control unit (ECU). This paper also discusses the control concept of DSS and its realistic controller structure.

Visteon has developed a CAE procedure to qualify plastic door trim assemblies under the vehicle door slam Key Life Test (KLT) environments. The CAE Virtual Door Slam Test (VDST) procedure simulates the environment of a whole door structural assembly, as a hinged in-vehicle door slam configuration. It predicts the durability life of a plastic door trim sub-assembly, in terms of the number of slam cycles, based on the simulated stresses and plastic material fatigue damage model, at each critical location. The basic theory, FEA methods and techniques employed by the VDST procedure are briefly described in this paper. Door trim project examples are presented to illustrate the practical applications and their results, as well as the correlation with the physical door slam KLTs.

The quietness of the interior of automobiles is perceived by consumers as a measure of quality and luxury. Great strides have been achieved in isolating interiors from noise sources. As noise is reduced, in particular wind and power train noise, other noise sources become evident. Noise reduction efforts are now focused on components like power steering pumps. To understand the contribution of power steering pumps a world-class noise and vibration test stand was developed. This paper describes the development of the test stand as well as it's objective to understand and improve the sound quality of power steering pumps.

Analytical methods are used extensively in the automotive industry to validate the feasibility of component and assembly designs and their dynamic behavior. Correlation of analytical models with test data is an important step in this process. This paper discusses the Finite Element model of an innovative Slip-in-Tube Propshaft design. The Slip-in-Tube joint (slip joint) poses challenges for its dynamic simulation. This paper discusses the methods of simulating the joint and correlating it to experimental results. Also, the Noise and Vibration (NVH) characteristics of the Slip-in-Tube Propshaft design. In this paper, a Finite Element model of the proposed propshaft is developed using shell and beam element formulations. Each model is verified to optimize the feasibility of using accurate and computationally efficient elements for the dynamic analysis.

Emerging autonomous driving technologies, with emergency navigating capabilities, necessitates innovative vehicle steering methods for operators during unanticipated scenarios. A reconfigurable “plug and play” steering system paradigm enables lateral control from any seating position in the vehicle’s interior. When required, drivers may access a stowed steering input device, establish communications with the vehicle steering subsystem, and provide direct wheel commands. Accordingly, the provision of haptic steering cues and lane keeping assistance to navigate roadways will be helpful. In this study, various steering devices have been investigated which offer reconfigurability and haptic feedback to create a flexible driving environment. A joystick and a robotic arm that offer multiple degrees of freedom were compared to a conventional steering wheel.

In an effort to understand steering systems performance and properties at the microscopic level, we developed Multibody simulations that include multiple three-dimensional gear surfaces that are in a dynamic state of contact and separation. These validated simulations capture the dynamics of high-speed impact of gears traveling small distances of 50 microns in less than 10 milliseconds. We exploited newly developed analytic, numeric, and computer tools to gain insight into steering gear forces, specifically, the mechanism behind the inception of mechanical knock in steering gear. The results provided a three dimensional geometric view of the sequence of events, in terms of gear surfaces in motion, their sudden contact, and subsequent force generation that lead to steering gear mechanical knock. First we briefly present results that show the sequence of events that lead to knock.

Steer-by-wire systems (SBW) offer the potential to enhance steering functionality by enabling features such as automatic lane keeping, park assist, variable steer ratio, and advanced vehicle dynamics control. The lack of a steering intermediate shaft significantly enhances vehicle architectural flexibility. These potential benefits led GM to include steer-by-wire technology in its next generation fuel cell demonstration vehicle, called “Sequel.” The Sequel's steer-by-wire system consists of front and rear electromechanical actuators, a torque feedback emulator for the steering wheel, and a distributed electronic control system. Redundancy of sensors, actuators, controllers, and power allows the system to be fault-tolerant. Control is provided by multiple ECU's that are linked by a fault-tolerant communication system called FlexRay. In this paper, we describe the objectives for fault tolerance and performance that were established for the Sequel.

Virtual design validation of an air induction system (AIS) requires a proper finite element (FE) assembly model for various simulation based design tasks. The effect of the urethane air filter seal within an AIS assembly, however, still poses a technical challenge to the modeling of structural dynamic behaviors of the AIS product. In this paper, a filter seal model and its modeling approach for AIS assemblies are introduced, by utilizing the feature finite elements and empiric test data. A bushing element is used to model the unique nonlinear stiffness and damping properties of the urethane seal, as a function of seal orientation, preloading, temperature and excitation frequency, which are quantified based on the test data and empiric formula. Point mobility is used to character dynamic behaviors of an AIS structure under given loadings, as a transfer function in frequency domain.

The Internal Thermal Control System (ITCS) has been developed jointly by Boeing Corporation, Huntsville, Alabama and Honeywell Engines & Systems, Torrance, California to meet the internal thermal control needs for the International Space Station (ISS). The ITCS provides heat removal for the critical life support systems and thermal conditioning for numerous experiment racks. The ITCS will be fitted on a number of modules on the ISS. The first US Element containing the ITCS, Node 1, was launched in December 1998. Since Node 1 does not contain a pump to circulate the fluid it was not filled with ITCS fluid until after the US Laboratory Module was installed. The second US Element module, US Laboratory Module, which contains the pumps and all the major ITCS control hardware, was launched in February 2001. The third US Element containing the ITCS, the US Airlock, was launched in July 2001.

An important aspect of air revitalization for life support in spacecraft is the removal of carbon dioxide from cabin air. Several types of carbon dioxide removal systems are in use in spacecraft life support. These systems rely on various removal techniques that employ different architectures and media for scrubbing CO2, such as permeable membranes, liquid amine, adsorbents, and absorbents. Sorbent systems have been used since the first manned missions. The current state of key technology is the existing International Space Station (ISS) Carbon Dioxide Removal Assembly (CDRA), a system that selectively removes carbon dioxide from the cabin atmosphere. The CDRA system was launched aboard UF-2 in February 2001 and resides in the U.S. Destiny Laboratory module. During the past three years, the CDRA system has operated with varying degrees of success.

This work demonstrates a practical method for predicting vehicle-level automotive steering system NVH performance from component-level NVH measurements of hydraulic steering pumps. For this method, in-vehicle measurements were completed to quantify vehicle noise path characteristics, including steering system structure borne, fluid borne and airborne paths. At the component level, measurements of steering pump reaction forces, sound power and dynamic hydraulic pressure were also completed. The vehicle-level measurement data was used to construct NVH transfer functions for the vehicle. These transfer functions were in turn combined with the pump component data measured on a test stand to create a prediction for steering pump order vehicle interior noise. The accuracy of these predicted values was assessed through comparison with actual vehicle interior noise measurements.

A hydraulic steering pump system will be considered in this report. The objective is to improve the design of a specific power steering pump using computational fluid dynamics (CFD) tools. The first part of this report deals with a pump oil seal leak. The thermal and fluid environments have been simulated. A variable fluid viscosity is used, showing a 15-20% increase in peak temperature. Potential improvements in product design have been suggested. The second part deals with using computer tools to reduce redundant testing. This includes use of parametric approach towards optimization. A rotating grid approach (basic moving mesh technique) is used.

Plastic air induction system (AIS) has been widely used in vehicle powertrain applications for reduced weight, cost, and improved engine performance. Physical design validation (DV) tests of an AIS, as to meet durability and reliability requirements, are usually conducted by employing the frequency domain vibration tests, either sine sweep or random vibration excitations, with a temperature cycling range typically from -40°C to 120°C. It is well known that under high vibration loading and large temperature range, the plastic components of the AIS demonstrate much higher nonlinear response behaviors as compared with metal products. In order to implement a virtual test for plastic AIS products, a practical procedure to model a nonlinear system and to simulate the frequency response of the system, is crucial. The challenge is to model the plastic AIS assembly as a function of loads and temperatures, and to evaluate the dynamic response and fatigue life in frequency domain as well.

Nowadays, ever market vehicle change affects body, suspension & steering gear systems. The purpose of this report is to quantify the methodology for evaluating and improving rattle mechanical noises in power rack & pinion steering systems. It is very important the correct process be used to adjust and approve the power steering gears in order to prevent the knock noise issue on services (warranty). This report describes how Visteon's Engineering makes efforts to achieve a reduction in warranty issues due to mechanical noise in the power steering gear, which affects its performance. We refer to this mechanical noise as “Knocking Noise” which derives from the gearing (meshing) adjustment loss. This experiment, supported by the Six Sigma methodology, led to new knowledge on how to improve the method of meshing adjust and test approval in process through of Design of Experiments (DOE).