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Investigations of low drag shapes for passenger vehicles were conducted in the 1930s but production cars of today have yet to approach the potential drag coefficients shown by that early research. Furthermore, the adoption of low drag styles has been resisted because of a perception of compromise to the exterior style and so recent aerodynamic developments have concentrated on changes to non-styled surfaces. However, environmental and ecological pressures are placing increasing demands on manufacturers to produce energy efficient vehicles and the contribution of aerodynamics in that equation is increasing, particularly with the adoption of technologies such as regenerative braking and measurements being made using more real-world use driving cycles. Relying on non-styled surfaces alone for drag reduction is unlikely to be sufficient to deliver the improvements required.

With the ever increasing demand on automotive manufactures to reduce lead times, improve performance, add air conditioning, meet noise and pollution legislation the need to evaluate and improve cooling system performance at the design stage is becoming increasingly important. The cooling system is taken to encompass the full air path of grills, inlet plenum, cooling pack, under bonnet resistance and outlet to the free stream. This paper describes the main structure of a PC based computer program which is being developed to permit the cooling system performance to be optimized at the vehicle concept stage or prior to major updates to a model, which could be for example front end styling or a change of engine. Also discussed are details of how the air paths through the cooling pack, and the system resistances from the inlet grill to the engine compartment outlet are determined.

The topic of energy management in Hybrid Electric Vehicles (HEVs) has received a great deal of recent attention. Various methods have been proposed to develop algorithms which manage energy flows within HEVs so that to optimally exploit energy storage capability of the battery and reduce fuel consumption while maintaining battery State of Charge. In addition, to the rule-based approaches, systematic optimal control methods based on deterministic and stochastic dynamic programming have been explored for HEV energy management optimization. In this paper, another novel framework based on the application of game theory is proposed, in which the HEV operation is viewed as a non-cooperative game between the driver and the powertrain.

PICASSOS was a UK government funded programme to improve the ability of automotive supply chains to develop complex software-intensive systems with high safety assurance and at an acceptable cost. This was executed by a consortium of three universities and five companies including an automotive OEM and suppliers. Three major elements of the PICASSOS project were: use of automated model based verification technology utilising formal methods; application of this technology in the context of ISO 26262; and evaluation to measure the impact of this approach to inform key management decisions on the costs, benefits and risks of applying this technology on live projects. The project spanned system level design and software development. This was achieved by using a unified model based process incorporating SysML at the system level and using Simulink and Stateflow auto-coded into C at the software level.

Most ground vehicles related accidents occur when the friction demand to perform a maneuver with a certain vehicle and tires exceeds the coefficient of friction of the pavement surface. As generally known, the forces and moments acting on the vehicle body are mainly generated at the tire-road surface interface. The common characteristics of tire forces on any surface include a linear region where the forces vary linearly with respect to the relative slip values; and a nonlinear region where the forces saturate and may even start decreasing. The experience of most of the daily drivers on the roads is limited within this linear region where the dynamic behavior of the vehicle remains proportional to the driver’s inputs. Therefore, an unexpected change in tire or surface characteristics (due to a change in surface friction, large driver inputs, etc.) may easily cause the driver to panic and/or to lose his/her ability to maintain a stable vehicle.

In aftertreatment system design, flow uniformity is of paramount importance as it affects aftertreatment device conversion efficiency and durability. The major trend of downsizing engines using turbochargers means the effect of the turbine residual swirl on the flow needs to be considered. In this paper, this effect has been investigated experimentally and numerically. A swirling flow rig with a moving-block swirl generator was used to generate swirling flow in a sudden expansion diffuser with a wash-coated diesel oxidation catalyst (DOC) downstream. Hot-wire anemometry (HWA) was used to measure the axial and tangential velocities of the swirling flow upstream of the diffuser expansion and the axial velocity downstream the monolith. With no swirl, the flow in the catalyst monolith is highly non-uniform with maximum velocities near the diffuser axis. At high swirl levels, the flow is also highly nonuniform with the highest velocities near the diffuser wall.

As the need for automotive assurance continues to grow, it becomes necessary to develop approaches which can provide assurance cases in a systematic and efficient manner. In the case of cybersecurity, this problem is exacerbated by the increasing complexity of vehicular onboard systems, their inherent obscurity due to their heterogenous architecture, emergent behaviors, and the disparate motivations and resources of potential threat agents. Furthermore, the advancement of connected autonomous vehicles (CAV) may allow external attackers to leverage the naïve trust ECUs have for adjacent devices to compromise the safety and security of the vehicle. To that end, there is an increased interest in automatically producing threat models such as attack trees, which usually rely on intensive expert driven construction or rudimentary formally defined processes, to identify potential threats to a vehicle.

The emergence of additive manufacturing (AM) technology has enabled the internal cooling channel layout for high pressure aluminium die casting (HPADC) tools to be designed and modified without topological constraint. Optimisation studies of a full industrial HPADC mould for extending the tool service life has received limited attention due to the high geometrical complexity and the various physics with multi time- and length- scales in addition to the manufacturability limitations. In this work, a new computationally efficient algorithm that employs the adjoint optimisation method has been developed to optimise the coolant channels layout in a complete mould with various 3D printed inserts. The algorithms significantly reduced the computational time and resources by decoupling the fluid flow in the coolant channels from the tool and simulating them separately.

Remote Monitoring and Teleoperation (RMTO) of Autonomous Vehicles (AV) is advancing rapidly in the industry. Researchers and industrial partners explore the role RMTO plays in helping AV navigate complicated situations, among many others. At the heart of this lies the problem of potential pathways and attack vectors or threat surfaces by which a malicious attack can be carried out on an RMTO and an AV. The separation of cybersecurity considerations in RMTO is barely considered, as so far, most available research and activities are mainly focused on AV. The main focus of this paper is addressing RMTO cybersecurity utilising an adaptable security-by-design approach, although security-by-design is still in the infant state within automotive cybersecurity. An adaptable security-by-design approach for RMTO covers Security Engineering Life-cycle, Logical Security Layered Concept, and Security Architecture.

Automotive recycling within Europe increased with the analysis of the environmental focus of automotive products and their product system [1], which is reflected within Europe in new legislation governing the recyclability of vehicles. This paper presents a new tool for evaluating automotive recyclability in the design process, within a whole life cost methodology. The developed business model approach reviews automotive design practices and has adapted life cycle analysis techniques to give special consideration for recyclability and costing of alternative automotive design strategies. Engineering designers can utilise the business model approach to design and manufacture a more recyclable vehicle and incorporates the economic viability of the recycling process of a product or component at the design stage. This paper presents one example where the increasing complexity of product design can produce economic justifications for design for recycling.

The design of passive suspension systems is being improved since the early days of the automotive industry in order to obtain the best tradeoff between ride comfort and handling. In this context, passenger cars tend to prioritise ride comfort whilst racing cars tend to focus on handling. On the other hand, Formula SAE is a series of undergraduate competitions in which the students design, build and compete with small, formula-style, mono-seated vehicles. As part of the competition events, the vehicle experiences tight corners and short-length slaloms. The minimum turning diameter and the shortest length of slalom period conducted by Formula SAE prototypes are 9 m and 7.6 m, respectively. Therefore, high controllability of vehicle dynamic behaviour is required in order to enhance the cornering speed, this is achievable by working on the dampers to optimise the rates of load transfer in cornering.

The potential benefit for vehicles travelling in ‘platoon’ formations arises from a reduction in total aerodynamic drag which can result from the interaction of bluff bodies in close-proximity. During the 1980s this was considered as an opportunity to alleviate congestion and also for fuel-saving in response to the fuel crises of the 1970s. Early interest was limited partly due to the level of available control technology. But recent developments in vehicle-to-vehicle communication systems and autonomous driving technologies have provided the potential for platooning to be incorporated within future traffic management systems prompting renewed interest. For the investigation described in this paper, a new passenger car model was designed as the basis for determining the effectiveness of future low-drag styles in platoon formations. Small-scale models were tested in the Coventry University Wind Tunnel in platoons of up to 5 vehicles.

Additive manufacturing (AM) provides significant geometric design freedom for the cooling of high pressure die casting (HPDC) tools. Designing cooling channels that can achieve a uniform temperature throughout the tool-cast interface during the moulding process can limit part warping and sink marks, internal part stresses, and increase tool life. However, the design of the embedded cooling channels requires high computational resources to model the heat transfer process for the cast, mould, and coolant from the moment aluminium is injected into the cavity until the injection for the next cycle. To enable the examination of the effect of various parameters, a simplified 3-D CFD conjugate heat transfer model is introduced by considering the experimental observations. The model decouples the cast part from the mould.

The porous medium approach is widely used to represent high-resistance devices, such as catalysts, filters or heat exchangers. Because of its computational efficiency, it is invaluable when flow losses need to be predicted on a system level. One drawback of using the porous medium approach is the loss of detailed information downstream of the device. Correct evaluation of the turbulence downstream affects the calculation of the related properties, e.g. heat and mass transfer. The novel approach proposed in the current study is based on a modified distribution of the resistance across the porous medium, which allows to account for the single jets developing in the small channels, showing an improved prediction of the turbulence at the exit of the device, while keeping the low computational demand of the porous medium approach. The benefits and limitations of the current approach are discussed and presented by comparing the results with different numerical approaches and experiments.

This study presents a one-dimensional model for the prediction of the pressure loss across a wall-flow gasoline particulate filter (GPF). The model is an extension of the earlier models of Bissett [1] and Konstandopoulos and Johnson [2] to the turbulent flow regime, which may occur at high flow rates and temperatures characteristic of gasoline engine exhaust. A strength of the proposed model is that only one parameter (wall permeability) needs to be calibrated. An experimental study of flow losses for cold and hot flow is presented, and a good agreement is demonstrated. Unlike zero-dimensional models, this model provides information about the flow along the channels and thus can be extended for studies of soot and ash accumulation, heat transfer and reaction kinetics.

The potential benefit for passenger cars when travelling in a ‘platoon’ formation results from the total aerodynamic drag reduction which may result from the interaction of bluff bodies in close-proximity. In the 1980s this was considered as an opportunity to alleviate congestion and also for fuel-saving in response to the oil crises of the 1970s. Early interest was limited by the availability of suitable systems to control vehicle spacing. However, recent developments in communication and control technologies intended for connected and autonomous driving applications has provided the potential for ‘platooning’ to be incorporated within future traffic management systems. The study described in this paper uses a systematic approach to changes in vehicle shape in order to identify the sensitivity of the benefits of platooning to vehicle style.

Lithium-ion batteries (LiBs) have been widely used in electrified vehicles, and the battery thermal management (BTM) system is needed to maintain the temperature that is critical to battery performance, safety, and health. Conventionally, three-dimensional battery thermal models are developed at the early stage to guide the design of the BTM system, in which battery thermophysical parameters (radial thermal conductivity, axial thermal conductivity, and specific heat capacity) are required. However, in most literature, those parameters were estimated with greatly different values (up to one order of magnitude). In this paper, an investigation is carried out to evaluate the magnitude of the influence of those parameters on the battery simulation results. The study will determine if accurate measurements of battery thermophysical parameters are necessary.

The work described in this paper is a continuation of an investigation into the effects of systematic changes in upper-body geometry on the aerodynamic drag of passenger-car-like bluff-body models in close longitudinal proximity and operating in platoon formations. The original work, presented in SAE paper 2019-01-0659, showed measurements of the aerodynamic drag of individual models within three-model platoons and for which each model was tested in three different upper-body configurations This provided a data-set of 27 platoon configurations to compare with the three baseline conditions of the isolated models. The work contrasted with other published platooning research in which the spacing, between homogeneous models in the platoons, was the only variable to be considered. In this publication the results of further wind tunnel tests, using the same models as before but in two-model platoons, providing a further 9 test configurations are compared with the original data.

Porous wall permeability is one of the most critical factors for the estimation of backpressure, a key performance indicator in automotive particulate filters. Current experimental and analytical filter models could be calibrated to predict the permeability of a specific filter. However, they fail to provide a reliable estimation for the dependence of the permeability on key parameters such as wall porosity and pore size. This study presents a novel methodology for experimentally determining the permeability of filter walls. The results from four substrates with different porosities and pore sizes are compared with several popular permeability estimation methods (experimental and analytical), and their validity for this application is assessed. It is shown that none of the assessed methods predict all permeability trends for all substrates, for cold or hot flow, indicating that other wall properties besides porosity and pore size are important.

Micro-mobility vehicles such as electric scooters and bikes are increasingly used for urban transportation; their designs usually trade off performance and range. Addressing thermal and cooling issues in such vehicles could enhance performance, reliability, life, and range. Limited packaging space within the wheels precludes the use of complex cooling systems that would also increase the cost and complexity of these mass-produced wheel motors. The present study begins by evaluating the external aerodynamics of the scooter to characterise the airflow conditions near the rotating wheel; then, a steady-state conjugate heat transfer model of a commercially available wheel hub motor (500W) is created using commercial computational fluid dynamics (CFD) software, StarCCM+. The CAD model of the motor used for this analysis has an external rotor permanent magnet (PM) brushless DC topology.