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Fuel wall impingement commonly occurs in small-bore diesel engines. Particularly during engine starting, when wall temperatures are low, the evaporation rate of fuel film remaining from previous cycles plays a significant role in the autoignition process that is not fully understood. Pre-injection chemiluminescence (PIC), resulting from low-temperature oxidation of evaporating fuel film and residual gases, was measured over 3200 μsec intervals at the end of the compression strokes, but prior to fuel injection during a series of starting sequences in an optical diesel engine. These experiments were conducted to determine the effect of this parameter on combustion phasing and were conducted at initial engine temperatures of 30, 40, 50 and 60°C, at swirl ratios of 2.0 and 4.5 at 1000 RPM. PIC was determined to increase and be highly correlated with combustion phasing during initial cycles of the starting sequence.

Path planning and re-planning for serial 6 degree of freedom (DOF) robotic systems is challenging due to complex kinematic structure and application conditions which affects the robot's tool frame position, orientation and singularity avoidance. These three characteristics represent the key elements for production planning and layout design of the automated manufacturing systems. The robot trajectory represents series of connected points in 3D space. Each point is defined with its position and orientation related to the robot's base frames or predefined user frame. The robot will move from point to point using the desired motion type (linear, arc, or joint). The trajectory planning requires first to check if robot can reach the selected part(s). This can be simply done by placing the part(s) inside the robot's work envelope. The robot's work envelope represents a set of all robots' reachable points without considering their orientation.

This paper presents experimental investigations of determining and analyzing low-frequency, low-SNR (Signal to Noise Ratio) noise sources of an automobile by using a new technology known as Sound Viewer. Such a task is typically very difficult to do especially at low or even negative SNR. The underlying principles behind the Sound Viewer technology consists of a passive SODAR (Sonic Detection And Ranging) and HELS (Helmholtz Equation Least Squares) method. The former enables one to determine the precise locations of multiple sound sources in 3D space simultaneously over the entire frequency range consistent with a measurement microphone in non-ideal environment, where there are random background noise and unknown interfering signals. The latter enables one to reconstruct all acoustic quantities such as the acoustic pressure, acoustic intensity, time-averaged acoustic power, radiation patterns, etc.

This paper presents experimental investigations of diagnosing and analyzing the low-frequency, low- SNR (Signal to Noise Ratio) noise sources of three motorcycles using a hybrid technology that consists of a passive SODAR (Sonic Detection And Ranging) and modified HELS (Helmholtz Equation Least Squares) methods. The former enables one to determine the precise locations of multiple sound sources in 3D space simultaneously over the entire frequency range that is consistent with a measurement microphone in non-ideal environment, where there are random background noise and unknown interfering signals. The latter enables one to reconstruct all acoustic quantities such as the acoustic pressure, acoustic intensity, time-averaged acoustic power, radiation patterns, and sound transmission paths through arbitrarily shaped vibrating structures.

The ‘boundary of space’ model representing all possible positions which may be occupied by a mechanism during its normal range of motion (for all positions and orientations) is called the work envelope. In the robotic domain, it is also known as the robot operating envelope or workspace. Several researchers have investigated workspace boundaries for different degrees of freedom (DOF), joint types and kinematic structures utilizing many approaches. The work envelope provides essential boundary information, which is critical for safety and layout concerns, but the work envelope information does not by itself determine the reach feasibility of a desired configuration. The effect of orientation is not captured as well as the coupling related to operational parameters. Included in this are spatial occupancy concerns due to linking multiple kinematic chains, which is an issue with multi-tasking machine tools, and manufacturing cells.

Contemporary manufacturing systems are still evolving. The system elements, layouts, and integration methods are changing continuously, and ‘collaborative robots’ (CoBots) are now being considered as practical industrial solutions. CoBots, unlike traditional CoBots, are safe and flexible enough to work with humans. Although CoBots have the potential to become standard in production systems, there is no strong foundation for systems design and development. The focus of this research is to provide a foundation and four tier framework to facilitate the design, development and integration of CoBots. The framework consists of the system level, work-cell level, machine level, and worker level. Sixty-five percent of traditional robots are installed in the automobile industry and it takes 200 hours to program (and reprogram) them.

When performing trajectory planning for robotic applications, there are many aspects to consider, such as the reach conditions, joint and end-effector velocities, accelerations and jerk conditions, etc. The reach conditions are dependent on the end-effector orientations and the robot kinematic structure. The reach condition feasibility is the first consideration to be addressed prior to optimizing a solution. The ‘functional’ work space or work window represents a region of feasible reach conditions, and is a sub-set of the work envelope. It is not intuitive to define. Consequently, 2D solution approaches are proposed. The 3D travel paths are decomposed to a 2D representation via radial projections. Forward kinematic representations are employed to define a 2D boundary curve for each desired end effector orientation.

Speed and accuracy are the critical needs in software for the modeling and simulation of vehicle cooling systems. Currently, there are two approaches used in commercially available thermal analysis software packages: 1) detailed modeling using complex and sophisticated three-dimensional (3D) heat transfer and computational fluid dynamics, and 2) rough modeling using one-dimensional (1D) simplistic network solvers (flow and thermal) for quick prediction of flow and thermal fields. The first approach offers accuracy at the cost of speed, while the second approach provides the simulation speed, sacrificing accuracy and can possibly lead to oversimplification. Therefore, the analyst is often forced to make a choice between the two approaches, or find a way to link or couple the two methods. The linking between one-dimensional and three-dimensional models using separate software packages has been attempted and successfully accomplished for a number of years.

Up to now, there is no standard methodology that addresses how driver distraction is affected by perceptual demand and working memory demand - aside from visual allocation. In 2009, the Peripheral Detection Task (PDT) became a NHTSA recommended measure for driver distraction [1]. Then the PDT task was renamed as the Detection Response Task (DRT) because the International Standards Organization (ISO) has identified this task as a potential method for assessing selective attention in detection of visual, auditory, tactile and haptic events while driving. The DRT is also under consideration for adoption as an ISO standard surrogate test for driver performance for new telematics designs. The Wayne State University (WSU) driver imaging group [2, 3] improved the PDT and created the Enhanced Peripheral Detection Task I (EPDT-I) [4]. The EPDT-I is composed of a simple visual event detection task and a video of a real-world driving scene.

An iterative learning control (ILC) algorithm has been developed for a test cell electro-hydraulic, fully flexible valve actuation system to track valve lift profile under steady-state and transient operation. A dynamic model of the plant was obtained from experimental data to design and verify the ILC algorithm. The ILC is implemented in a prototype controller. The learned control input for two different lift profiles can be used for engine transient tests. Simulation and bench test are conducted to verify the effectiveness and robustness of this approach. The simple structure of the ILC in implementation and low cost in computation are other crucial factors to recommend the ILC. It does not totally depend on the system model during the design procedure. Therefore, it has relatively higher robustness to perturbation and modeling errors than other control methods for repetitive tasks.

Described in this paper is a component test methodology to evaluate the door trim armrest performance in an Insurance Institute for Highway Safety (IIHS) side impact test and to predict the SID-IIs abdomen injury metrics (rib deflection, deflection rate and V*C). The test methodology consisted of a sub-assembly of two SID-IIs abdomen ribs with spine box, mounted on a linear bearing and allowed to translate in the direction of impact. The spine box with the assembly of two abdominal ribs was rigidly attached to the sliding test fixture, and is stationary at the start of the test. The door trim armrest was mounted on the impactor, which was prescribed the door velocity profile obtained from full-vehicle test. The location and orientation of the armrest relative to the dummy abdomen ribs was maintained the same as in the full-vehicle test.

The effect of many operating parameters on the instantaneous frictional (IFT) torque was determined experimentally in a single cylinder diesel engine. The method used was the (P - ω)method developed earlier at Wayne State University. The operating parameters were load, lubricating oil grade, oil, temperature and engine speed. Also IFT was determined under simulated motoring conditions, commonly used in engine friction measurements. The results showed that the motoring frictional torque does not represent that under firing conditions even under no load. The error reached 31.4% at full load. The integrated frictional torque over the whole cycle and the average frictional torque were determined. A comparison of the average frictional torque under load was compared with the average motoring torque.

The piston secondary motion is an important phenomenon in internal combustion (IC) engine. It occurs due to the piston transverse and rotational motion during piston reciprocating motion. The piston secondary motion results in engine friction and engine noise. There has been lot of research activities going on in piston secondary motion using both analytical models and experimental studies. These studies are aimed at reducing the engine friction as well as the noise generated due to piston secondary motion. The aim of this paper is to compile the research actives carried out on the piston secondary motion and discuss the possible research opportunities for reducing the IC engine piston secondary motion.

In a frontal automotive crash, the driver's foot is usually stepping on the brake pedal as an instinctive response to avoid a collision. The tensile force generated in the Achilles tendon produces a compressive preload on the tibia. If there is intrusion of the toe board after the crash, an additional external force is applied to the driver's foot. A series of dynamic impact tests using human cadaveric specimens was conducted to investigate the combined effect of muscle preloading and external force. A constant tendon force was applied to the calcaneus while an external impact force was applied to the forefoot by a rigid pendulum. Preloading the tibia significantly increased the tibial axial force and the combination of these forces resulted in five tibial pylon fractures out of sixteen specimens.

Nitro Fuel Funny cars have 7-8,000 hp and travel 330 mph in a quarter mile. These cars experience extreme forces in normal operation. One phenomenon familiar to drag racers is tire shake. Mild cases can cause loss of traction and vision. Extreme cases can cause injury or death. In March of 2007, a study and subsequent revision of the passenger compartment in a Fuel Funny car was performed after a fatal accident due to extreme tire shake. Tire shake on a drag race car normally occurs when the force on the rear tire causes the tire to roll over itself causing a loss of traction and side-to-side vibration. In other cases, if the tire fails at high speed, the tire may partially separate, causing an extreme vibration in the cockpit of the car. The vibration may set up a harmonic in the chassis, which is transferred to the driver since the rear end is bolted directly to the chassis with no suspension to absorb the energy.

A new inter-disciplinary degree program has been developed at Lawrence Technological University: the Master of Science in Mechatronic Systems Engineering Degree (MS/MSE). It is one of a few MS-programs in mechatronics in the U.S.A. today. This inter-disciplinary program reflects the main areas of ground vehicle mechatronic systems and robotics. This paper presents areas of scientific and technological principles which the Mechanical Engineering, Electrical and Computer Engineering, and Math and Computer Science Departments bring to Mechatronic Systems Engineering and the new degree program. New foundations that make the basis for the program are discussed. One of the biggest challenges was developing foundations for mechanical engineering in mechatronic systems design and teaching them to engineers who have different professional backgrounds. The authors first developed new approaches and principles to designing mechanical subsystems as components of mechatronic systems.

The direct injection spray-wall interactions were investigated experimentally using high-speed laser-sheet imaging, shadowgraphy, wetted footprints and phase Doppler interferometry techniques. A narrow-cone high-pressure swirl injector is used to inject iso-octane fuel onto a plate, at three different impact angles inside a pressurized chamber. Heated air and plate conditions were compared with unheated cases. Injection interval was also varied in the heated case to compare dry- and wet- wall impingement behaviors. High-speed macroscopic Mie-scattering images showed that presence of wall and air temperature has only minor effect on the bulk spray structure and penetration speed for the narrow-cone injector tested. The overall bulk motions of the spray plume and its spatial position at a given time are basically unaffected until a few millimeters before impacting the wall.

Simultaneous measurements of the radial and the tangential components of velocity are obtained in a high-speed, direct-injection diesel engine typical of automotive applications. Results are presented for engine operation with fuel injection, but without combustion, for three different swirl ratios and four injection pressures. With the mean and fluctuating velocities, the r-θ plane shear stress and the mean flow gradients are obtained. Longitudinal and transverse length scales are also estimated via Taylor's hypothesis. The flow is shown to be sufficiently homogeneous and stationary to obtain meaningful length scale estimates. Concurrently, the flow and injection processes are simulated with KIVA-3V employing a RNG k-ε turbulence model. The measured turbulent kinetic energy k, r-θ plane mean strain rates ( 〈Srθ〉, 〈Srr〉, and 〈Sθθ〉 ), deviatoric turbulent stresses , and the r-θ plane turbulence production terms are compared directly to the simulated results.

During the extensive testing under NATO and Commercial Standards, crack is observed in camshaft housing to initiate from the eccentric shaft bore and go toward the hold down bolt hole. Hence lab test proposal is originated to induce similar failure in a controlled method and then to compare new design alternatives. CAE analysis follows the same set up as the lab test to duplicate failure mode in stress analysis and fatigue analysis with duty cycle loads, and then figures out two strategies on how to improve the design, including geometry change and material change. In geometry wise, four new design iterations are evaluated for comparison. In material wise, one new material for camshaft housing and five manufacturing effect parameters for pin and rocker arm are compared, including ground, machined, machined and decarburization, casting, as well as casting and nitride. With those comparisons, all manufacturing parameters are compared based on effectiveness to affect the fatigue life.

Additive manufacturing (AM) of metals is finding numerous applications in automotive industry. In 21st century, aluminum is second to steel in automotive sector, because of its high strength to weight ratio. Hence developing AM for aluminum alloys become necessary to make sure industry gains maximum benefit from AM. This study specifically deals with the manufacturing of Al 7050 alloy, which is quite hardest alloy to manufacture using AM. The ultimate goal is to optimize the laser deposition parameters to deposit defect free Al 7050 alloy on rolled aluminum alloy substrate. Parameter optimization (laser power, powder flow rate, and scanning speed) gets difficult with the presence of various low melting and boiling point alloying elements such as Zn, Mg etc. Numerous other challenges faced while depositing Al 7050 alloy, are also briefly discussed in this article. Microstructural investigation using optical and scanning electron microscopy confirms greater than 99% component density.