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Flow bench and engine testing can be used to detect flow induced noise, but understanding the fundamental mechanisms of such noise generation is necessary for developing an effective design. This paper describes Computational Aero-Acoustic (CAA) analyses performed to obtain the broad-band and BPF noise sources A computational aero-acoustics simulation on the aerodynamic noise generation of an automotive radiator fan assembly is carried out. Three-dimensional Computational Fluid Dynamics (CFD) simulation of the unsteady flow field was performed including the entire impeller and shroud to obtain the source of an audible broad-band flow noise between 2 to 4 kHz. Static pressure probes placed around the outer-periphery and at the center of the impeller inlet side and, at the shroud cavities to capture the noise sources. The static pressure at all probe locations were FFT (Fast Fourier Transform) processed and sound pressure level (SPL) was calculated.

Environmental perception is a crucial subsystem in autonomous vehicles. In order to build safe and efficient traffic transportation, several researches have been proposed to build accurate, robust and real-time perception systems. Camera and LiDAR are widely equipped on autonomous self-driving cars and developed with many algorithms in recent years. The fusion system of camera and LiDAR provides state-of the-art methods for environmental perception due to the defects of single vehicular sensor. Extrinsic parameter calibration is able to align the coordinate systems of sensors and has been drawing enormous attention. However, differ from spatial alignment of two sensors’ data, joint calibration of multi-sensors (more than two sensors) should balance the degree of alignment between each two sensors.

Tracking vehicle trajectories is essential for autonomous vehicles and advanced driver-assistance systems to understand traffic environment and evaluate collision risk. In order to reduce the position deviation and fluctuation of tracking on-road vehicle by millimeter-wave radar (MMWR), an interactive multi-model Kalman filter (IMM-KF) tracking algorithm including data association and track management is proposed. In general, it is difficult to model the target vehicle accurately due to lack of vehicle kinematics parameters, like wheel base, uncertainty of driving behavior and limitation of sensor’s field of view. To handle the uncertainty problem, an interacting multiple model (IMM) approach using Kalman filters is employed to estimate multitarget’s states. Then the compensation of radar ego motion is achieved, since the original measurement is under the radar polar coordinate system.

Recently, electro-hydraulic brake systems (EHB) has been developed to take place of the vacuum booster, having the advantage of faster pressure build-up and continuous pressure regulation. In contrast to the vacuum booster, the pressure estimation for EHB is worth to be studied due to its abundant resource (i.e. electric motor) and cost-effective benefit. This work improves an interconnected pressure estimation algorithm (IPEA) based on actuator characteristics by introducing the vehicle dynamics and validates it via vehicle tests. Considering the previous IPEA as the prior pressure estimation, the wheel speed feedback is used for modification via a proportional-integral (PI) observer. Superior to the IPEA based on actuator characteristics, the proposed PEA improves the accuracy by more than 20% under the mismatch of pressure-position relation.

Blow moulding is one of the most important polymer processing methods for producing complex thermoplastic automotive parts. Contrary to injection molding, little attention has focused on process control and simulation of blow molding processes. Yet, there are still several problems that affect the overall success of forming these parts. Among them are thermally induced stresses, relevant shrinkage and part warpage deformations caused by inappropriate mold design and/or processing conditions. Tolerance issues are critical in automotive applications and therefore part deformation due to solidification needs to be controlled and optimized accordingly. The accurate prediction tool of part deformation due to solidification, under different cooling conditions in automotive formed parts, is important and highly suited for part designers to help achieve an efficient production.

The modeling of plastic fuel tank systems for crash safety applications has been very challenging. The major challenges include the prediction of fuel sloshing in high speed impact conditions, the modeling of multilayer thermoplastic fuel tanks with post-forming (non-uniform) material properties, and the modeling of tank straps with pre-tensions. Extensive studies can be found in the literature to improve the prediction of fuel sloshing. However, little research had been conducted to model the post-forming fuel tank and to address the tension between the fuel tank and the tank straps for crash safety simulations. Hoping to help improve the modeling of fuel systems, the authors made the first attempt to tackle these major challenges all at once in this study by dividing the modeling of the fuel tank into eight stages. An ALE (Arbitrary Lagrangian-Eulerian) method was adopted to simulate the interaction between the fuel and the tank.

Torque Vectoring Control for distributed drive electric vehicle is studied. A handling improvement algorithm for normal cornering maneuvers is proposed based on state variable feedback control: Yaw rate feedback together with steer angle feedforward is employed to improve transient response and steady gain of the yaw rate, respectively. According to the feedback coefficient's influence on the transient response, an optimization function is proposed to obtain optimum feedback coefficients under different speeds. After maximum feedforward coefficients under different speeds are obtained from the constraint of the motor exterior characteristic, final feedforward coefficients are calculated according to an optimal steering characteristic. A torque distribution algorithm is presented to help the driver to speed up during the direct yaw moment control.

For an electric vehicle driven by four in-wheel motors, the torque of each wheel can be controlled precisely and independently. A closed-loop control method of differential drive assisted steering (DDAS) has been proposed to improve vehicle steering properties based on those advantages. With consideration of acceleration requirement, a three dimensional characteristic curve that indicates the relation between torque and angle of the steering wheel at different vehicle speeds was designed as a basis of the control system. In order to deal with the saturation of motor's output torque under certain conditions, an anti-windup PI control algorithm was designed. Simulations and vehicle tests, including pivot steering test, lemniscate test and central steering test were carried out to verify the performance of the DDAS in steering portability and road feeling.

To analyze the K&C (kinematics and compliance), handling and stability performance of the vehicle chassis, some simulations are usually performed using a multi-body dynamics software named ADAMS. This software introduces assumptions that simplify the components of the suspension as rigid bodies. However, these assumptions weaken the accuracy of the simulation of ADAMS. Therefore the use of flexible bodies in K&C and handling and stability simulation in ADAMS is needed to conduct more precise suspension system designs. This paper mainly analyses the influences of the subframe flexibility on handling and stability simulation in ADAMS/Car. Two complete vehicle models are built using ADAMS/Car and Hypermesh. The only difference between the two models is the subframe of the front McPherson suspension. One of the subframes is simplified as a rigid body. The other one is a flexible body built using the MNF file from Hypermesh.

Two control strategies, safety preferred control and master cylinder oscillation control, were designed for anti-lock braking on a novel integrated-electro-hydraulic braking system (I-EHB) which has only four solenoid valves in its innovative hydraulic control unit (HCU) instead of eight in a traditional one. The main idea of safety preferred control is to reduce the hydraulic pressure provided by the motor in the master cylinder whenever a wheel tends to be locking even if some of the other wheels may need more braking torque. In contrast, regarding master cylinder oscillation control, a sinusoidal signal is given to the motor making the hydraulic pressure in the master cylinder oscillate in certain frequency and amplitude. Hardware-in-the-loop simulations were conducted to verify the effectiveness of the two control strategies mentioned above and to evaluate them.

Hood opening/closing is a necessary function in a vehicle, but the closing often results in an impact known as hood slam. The damage to the components of the FEM (Front End Module), induced by the hood slam, accumulates over the vehicle lifetime and may lead to failure. In a traditional design process, an impact test is conducted on prototype FEM to evaluate its integrity. It is, however, very costly and time-consuming to achieve a statistical based confidence. Presented in this paper is a methodology of CAE hood-slam simulation that intends to replace the test and drive FEM design. This CAE method includes two aspects: impact simulation and fatigue life evaluation. An impact loading is applied by converting potential energy to kinetic energy, mimicking the hood dropping from a specified height on the hood latch. The impact loading causes the local deformation and stress concentration, which may become potential failure spots.

With development of vehicle advanced driver assistant system and intelligent techniques, safer and more intelligent Integrated-Electro-Hydraulic Braking System is required to realize brake-by-wire. Thus, more and more companies and universities developed Integrated-Electro-Hydraulic Braking System to fulfill these requirements. In this paper, an Integrated-Electro-Hydraulic Braking System is introduced, which consists of active source power, pedal feel emulator and electro control unit. As a composite system of mechanic, electron and hydraulic pressure, the Integrated-Electro-Hydraulic Braking System has complex system characteristics. Integrated-Electro-Hydraulic Braking System and active power source have very different dynamic characteristics. So algorithms of hydraulic pressure control and motor control should be apart, but algorithm of them should be united in hardware to meet integration demand.

An integrated-electro-hydraulic brake system (I-EHB) is presented to fulfill the requirements of active safety. Because I-EHB can control the brake pressure accurately and fast. Furthermore I-EHB is a decoupled system, so it could make the maximum regenerative braking while offers the same brake pedal feeling and also good for ADAS and unmanned driving application. Based on the analysis of current electrohydraulic brake systems, regulation requirements and the requirements for brake system, the operating mode requirements of I-EHB are formed. Furthermore, system topological structure and a conceptual design are proposed. After the selection of key components, the parameter design is accomplished by modeling the system. According to the above-mentioned design method, an I-EHB prototype and test rig is made. Through the test rig, characteristics of the system are tested. Results show that this I-EHB system responded rapidly.

With the development of vehicle electrification, electronic hydraulic brake system is gradually applied. Many companies have introduced products related to integrated electronic hydraulic brake system (I-EHB). In this paper, an I-EHB system is introduced, which uses the motor to drive the reduction mechanism as a power source for braking. The reduction mechanism is composed of a turbine, a worm, a gear and a rack. A control method based on command feed-forward is proposed to improve the hydraulic pressure control of I-EHB. Based on previous research, we simplify the system to first order system, and the theoretical design of the command feed-forward compensator is carried out. The feed-forward controller is applied, including the velocity feed-forward and the acceleration feed-forward, to improve the response speed and tracking effect of the system.

In this paper, a novel method is proposed to establish the vehicle yaw stability criterion based on the sideslip angle-yaw rate (β-r) phase plane method. First, nonlinear two degrees of freedom vehicle analysis model is established by adopting the Magic Formula of nonlinear tire model. Then, according to the model in the Matlab/Simulink environment, the β-r phase plane is gained. Emphatically, the effects of different driving conditions (front wheels steering angle, road adhesion coefficient and speed) on the stability boundaries of the phase plane are analyzed. Through a large number of simulation analysis, results show that there are two types of phase plane: curve stability region and diamond stability region, and the judgment method of the vehicle stability domain type under different driving conditions is solved.

In this paper, a speed tracking controller is designed for the All-terrain vehicles. The method of feedforward with state variable feedback based on conditional integrators is adopted by the proposed control algorithm. The feedforward is designed considering the influence of the road slope on the longitudinal dynamics, which makes the All-terrain vehicles satisfy the acceleration demand of the upper controller when it tracks the desired speed on the road with slope varying greatly. The road slope is estimated based on a combined kinematic and dynamic model. This method solves the problem that road slope estimation requires an accurate vehicle dynamic model and are susceptible to acceleration sensor bias. Based on the vehicle dynamic model and the nonlinear tire model, the method of conditional integration is used in the state variable feedback, which considers the saturation constraint of the actuator with the intention of preventing the divergent integral operation.

BBW (Brake-by-wire) can increase the electric and hybrid vehicles performance and safety. This paper proposes a novel mechatronic booster system, which includes APS (active power source), PFE (pedal feel emulator), ECU (electronic control unit). The system is easily disturbed when the system parameters and the outside conditions change. The system performance is weakened. The cascade control technique can be used to solve the problem. This paper develops an adaptive cascade optimum control (ACOC) algorithm based on the novel mechatronic booster system. The system is divided into main loop and servo loop, both of them are closed-loop system. The servo-loop system can eliminate the disturbance which exists in the servo loop. So the robustness of the cascade control system is improved than which of the general closed-loop control system. Different control object is respectively chosen. The control-oriented mathematical model is designed.

In this paper, an integrated electronic hydraulic brake(I-EHB) system is introduced, which is mainly composed of a motor, a worm gear, a worm, a gear, a rack etc. The friction leads the system to the creeping phenomenon and the dead zone. These phenomenon seriously affect the response speed and the hydraulic pressure control .In order to realize the accurate hydraulic pressure control of I-EHB system, a new friction compensation control method is proposed based on LuGre dynamic friction model. And the theoretical design of adaptive control method is designed based on the feedback of the master cylinder pressure and the operating state of the system. Then the stability of the control method is proved by Lyapunov theorem. A co-simulation model is built with Matlab/Simulink and AMESim, so as to prove the validity of the control method.

Degas bottles have been extensively used in vehicles in order to act as an air pillow on top of the cooling loop and provide space for expansion. One of the important characteristics of the bottle which defines if it will work in a certain loop is the so called “capacity” of the bottle which defines the flowrate that degas bottle would be able to pass through without any foaming. Considering the complex geometry of degas bottle and the foaming phenomena, predicting the behavior of coolant in the bottle passages is challenging which requires costly tests. Computational Fluid Dynamics (CFD) has been extensively used in simulating multi-phase flows in automotive components. In the current project, CFD has been used to simulate the behavior of flow in bottle chambers and to provide guidelines for the design team in order to increase the bottle performance/capacity. The CFD guidelines were in agreement with test results and lead to improving the degas bottle capacity.

A dynamic controller is designed for unmanned skid-steering vehicle. The vehicle speed is controlled through driving torque of engine to achieve the desired vehicle speed and the steering is controlled through hydraulic braking on each side of the vehicle to achieve the desired yaw rate. Contrary to the common approaches by considering non-holonomic constraints, tire slip and saturation of actuators torque influencing the driving and braking are considered, based on the analysis of vehicle dynamic model and nonlinear tire model. Hence, with conditional integrators, the dynamic controller overcoming integral saturation is designed to ensure the accurate tracking for desired signals under influence of tire forces and constraint of actuators. In addition, the exponential kind filter is utilized to enhance the ability of smoothing noise of wheel speed. To perform small radius cornering maneuvers, a dynamic control strategy for steering when vehicle speed is zero is also designed.