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Low-pressure, Cooled Exhaust Gas Recirculation (LPC EGR) brings significant fuel economy, NOx reduction and knock suppression benefits to a modern, boosted, downsized Spark Ignition (SI) engine. As a prerequisite to design an engine control system for LPC EGR, this paper presents development of a set of estimation algorithms to accurately estimate the flow rate, pressure states and thermal states of the LPC EGR-related components.

Objective: A friction rollover test was conducted as part of a rollover sensing project. This study evaluates vehicle and occupant responses in the test. Methods: A flat dolly carried a Saab 9-3 sedan laterally, passenger-side leading to a release point at 42 km/h (26 mph) onto a high-friction surface. The vehicle was equipped with roll, pitch and yaw gyros near the center of gravity. Accelerometers were placed at the vehicle center tunnel, A-pillar near the roof, B-pillar near the sill, suspension sub-frame and wheels. Five off-board and two on-board cameras recorded kinematics. Hybrid III dummies were instrumented for head and chest acceleration and upper neck force and moment. Belt loads were measured. Results: The vehicle release caused the tires and then wheel rims to skid on the high-friction surface. The trip involved roll angular velocities >300 deg/s at 0.5 s and a far-side impact on the driver’s side roof at 0.94 s. The driver was inverted in the far-side, ground impact.

Purpose: This study investigates NASS-CDS data on basilar skull fractures by crash type and injury source for various crash scenarios to understand the injury risks, injury mechanisms and contact sources. Methods: 1993-2008 NASS-CDS data was used to study basilar skull fractures in adult front occupants by crash type and injury source. Injury risks were determined using weighted data for occupants with known injury status in 1994+ model year vehicles. In-depth analysis was made of far-side occupants in side impacts and rear crashes using the NASS electronic cases. Results: Basilar skull fractures occur in 0.507 ± 0.059% of rollovers and 0.255 ± 0.025% of side impacts. The lowest risk is in rear impacts at 0.015 ± 0.007%. The most common contact source is the roof, side rails and header (39.0%) in rollovers, the B-pillar (25.8%) in side impacts and head restraint (55.3%) in rear crashes.

A gasoline compression-ignition combustion system is being developed for full-time operation over the speed-load map. Low-temperature combustion was achieved using multiple late injection (MLI), intake boost, and moderate EGR for high efficiency, low NOx, and low particulate emissions. The relatively long ignition delay and high volatility of RON 91 pump gasoline combined with an advanced injection system and variable valve actuation provided controlled mixture stratification for low combustion noise. Tests were conducted on a single-cylinder research engine. Design of Experiments and response surface models were used to evaluate injection strategies, injector designs, and various valve lift profiles across the speed-load operating range. At light loads, an exhaust rebreathing strategy was used to promote autoignition and maintain exhaust temperatures. At medium loads, a triple injection strategy produced the best results with high thermal efficiency.

This paper presents production Engine Management System algorithms for Estimation and Control of Turbocharged engines with the following qualities; 1) Model based ensuring applicability at all ambient conditions, 2) Does not require Turbine data for calibration 3) Estimation logic form allows reuse for control applying predictive values for response and stability 4) Applies to all Waste-Gate types; passive and active, pneumatic and electrical, 5) Does not require Waste-Gate position measurement 5) Applies to engines with Variable Geometry Turbine.

Purpose: A better understanding of rear occupant fatality risks is needed to guide the development of safety improvements for 2nd and 3rd row occupants. This study investigates fatal accidents of 1st, 2nd and 3rd row occupants by principal direction of force (PDOF), irrespective of restraint use. It determined the number of fatalities, exposure and fatality risk. Methods: 1996-2005 FARS was analyzed for occupant fatalities by seating position (1st, 2nd and 3rd row) and principal direction of force (1-12 o'clock PDOF, rollover and other/unknown). Light vehicles were included with model year 1990+. 1996-2005 NASS-CDS was similarly analyzed for occupant exposure. Fatality risk was defined as the number of fatalities in FARS for a given category divided by the exposure from NASS-CDS. Results: Ten percent (9.6%) of fatalities were to 2nd row occupants in FARS. About 2,080 deaths occur to 2nd row occupants annually. 38.4% died in rollovers and 26.8% in frontal crashes.

Child safety is an important issue. The objective of this study was to analyze field accident data for 0-7 year old children in the 2nd row by vehicle and crash type, irrespective of restraint use. The data was obtained from NASS-CDS for calendar years 1991-2005. Accidents were selected based on 2nd row occupancy in towaway light vehicles with model year 1990 or newer. Side impacts caused 30.9% of serious-to-fatal injury (MAIS 3+F) to 2nd row children followed by frontal impacts (29.8%), rollovers (24.4%) and rear crashes (15.0%). The highest risk for MAIS 3+F was in rollovers (2.8 ± 0.7%) followed by rear (1.4 ± 0.4%), side (1.0 ± 0.2%) and frontal (0.46 ± 0.10%) crashes. The differences are statistically significant (p <0.01). Individual rear and frontal impact cases were also reviewed to better understand injury mechanisms of children in the 2nd row. The cases were obtained from the 1997-2005 NASS-CDS electronic database.

This paper addresses the longstanding problems of residual gas measurement during engine dynamometer testing, and of real-time residual modeling for engine control applications. A new method is described which is simple to apply, requiring only currently standard calibration test cell instrumentation. Experimental validation against measurements using direct in-cylinder CO2 sampling is presented, and a comprehensive error sensitivity analysis is included. A real-time capable, controls-oriented model is also described. Its accuracy is assessed by comparison to engine-simulation-generated residual values after using these values to determine the model parameters.

Objective: This study analyzes rear sled tests with a 95th% male and 5th% female Hybrid III dummy in various seating positions on ABTS (All Belt to Seat) seats in severe rear impact tests. Dummy interactions with the deforming seatback and upper body extension around the seat frame are considered. Methods: The 1st series involved an open sled fixture with a Sebring ABTS seat at 30 mph rear delta V. A 95th% Hybrid III dummy was placed in four different seating positions: 1) normal, 2) leaning inboard, 3) leaning forward and inboard, and 4) leaning forward and outboard. The 2nd series used a 5th% female Hybrid III dummy in a Grand Voyager body buck at 25 mph rear delta V. The dummy was leaned forward and inboard on a LeSabre ABTS or Voyager seat. The 3rd series used a 5th% female Hybrid III dummy in an Explorer body buck at 26 mph rear delta V. The dummy was leaned forward and inboard on a Sebring ABTS or Explorer seat.

This paper is an overview of the current state (calendar year 2010) of in-vehicle multiplexing and what pertinent technologies are emerging. Usage and trends of in-vehicle networking protocols will be presented and categorized. The past few years have seen a large growth in the number and type of communication buses used in automobiles, trucks, construction equipment, and military, among others. Development continues even into boating and recreation vehicles. Areas for discussion will include SAE Class A, B, C, Diagnostics, SafetyBus, Mobile Media, Wireless, and X-by-Wire. All existing mainstream vehicular multiplex protocols (approximately 40) are categorized using the SAE convention as well as categories previously proposed by this author. Top contenders will be pointed out along with a discussion of the protocol in the best position to become the industry standard in each category.

The current study focused on the effects B20 fuel (20% soybean-based biodiesel) and SCR entrance shapes on a light-duty, high-speed, 2.8L common-rail 4-cylinder diesel engine, at different exhaust temperatures. The results indicate that B20 has less deNOX efficiency at low temperature than ULSD, and that N₂O emission need to be characterized as well as NH₃ slip. If a mixer and enough mixing length are used, longer divergence section does not improve the deNOX efficiency significantly under the speed ranges tested.

Estimation of vehicle roll angle, lateral velocity and side slip angle for the purpose of crash sensing is considered. Only roll rate sensor and the sensors readily available in vehicles equipped with ESC (Electronic Stability Control) systems are used in the estimation process. The algorithms are based on kinematic relationships, thus avoiding dependence on vehicle and tire models, which minimizes tuning efforts and sensitivity to parameter variations. The estimate of roll angle is obtained by blending two preliminary estimates, each valid in different conditions, in such a manner that the final estimate continuously favors the more accurate one. The roll angle estimate is used to compensate the gravity component in measured lateral acceleration due to vehicle roll or road bank angle. This facilitates estimation of lateral velocity and side slip angle from fundamental kinematic relationships involving the gravity-compensated lateral acceleration, yaw rate and longitudinal velocity.

Gasoline Direct Injection (GDi) system is a relatively new technology. In early implementations, its major components, i.e. high pressure fuel pump, injectors, and fuel rails, emit objectionable acoustic noise during normal operation. This paper will focus on making an objective comparison (assessment) of acoustic noise emitted by several cam-driven high pressure fuel pumps during their normal operation, especially at engine idle. Taguchi robust engineering methods will be used to conduct the robust assessment study of six GDi high-pressure pumps. A-weighted total sound pressure level (SPL), processed from two free-field microphones around each pump, will be used as the main function in the Taguchi design of experiments (DOE).

It is rare for a single technology to have the power to dramatically influence almost every major industry in the world. Nanotechnology falls into this category and offers fundamentally new capabilities to architect a broad array of novel materials, composites and structures on a molecular scale. This technology has the potential to drastically re-define the methods used for developing lighter, stronger, and high-performance structures and processes with unique and non-traditional properties. This paper focuses on some of the automotive applications for nanotechnology and showcases a few of them that are believed to have the highest probability of success in this highly competitive industry. No discussion of nanotechnology is complete without touching upon its health and environmental implications.

This paper identifies a select method for performing cylinder imbalance measurement, correction and diagnosis. The impetus is to address new U.S. Federal regulations that require the detection of excessive cylinder air-fuel ratio (AFR) imbalance, and doing so requires the foundational ability to measure and preferably remove cylinder imbalance via active closed-loop control. This function is called Individual Cylinder Fuel Control (ICFC). ICFC starts by extracting cylinder-imbalance information from the front oxygen sensor, and that information comes in the form a of continuous data stream. That stream is then parsed to create virtual sensors- one for each cylinder. Each virtual sensor acts as an imbalance or error signal which ICFC uses to correct and learn via feedback and feed-forward control for each cylinder. The cylinder imbalance diagnostic is enabled by the presence of ICFC.

Modern automatic transmissions use various methods to estimate fluid line pressures in order to improve shift quality and reduce energy losses. These estimations lead to improvements in fuel economy, customer satisfaction and reduced exhaust emissions. The further addition of pressure feedback switches improves operational knowledge by verifying when clutches have received their commanded pressures. Product reliability above the industry standard for transmission pressure switches was developed through the use of multiple FEA platforms combined with advanced design optimization software, robust optimization and Shainin® tools. In this optimized design, ferromagnetic non-contact pressure switches operate by translating fluid pressure into piston motion, isolated by a sealed proprietary diaphragm.

This paper provides an overview of rollover crash safety, including field crash statistics, pre- and rollover dynamics, test procedures and dummy responses as well as a bibliography of pertinent literature. Based on the 2001 Traffic Safety Facts published by NHTSA, rollovers account for 10.5% of the first harmful events in fatal crashes; but, 19.5% of vehicles in fatal crashes had a rollover in the impact sequence. Based on an analysis of the 1993-2001 NASS for non-ejected occupants, 10.5% of occupants are exposed to rollovers, but these occupants experience a high proportion of AIS 3-6 injury (16.1% for belted and 23.9% for unbelted occupants). The head and thorax are the most seriously injured body regions in rollovers. This paper also describes a research program aimed at defining rollover sensing requirements to activate belt pretensioners, roof-rail airbags and convertible pop-up rollbars.

Unburned hydrocarbon (UBHC) emissions from gasoline engines remain a primary engineering research and development concern due to stricter emission regulations. Gasoline engines produce more UBHC emissions during cold start and warm-up than during any other stage of operation, because of insufficient fuel-air mixing, particularly in view of the additional fuel enrichment used for early starting. Impingement of fuel droplets on the cylinder wall is a major source of UBHC and a concern for oil dilution. This paper describes an experimental study that was carried out to investigate the distribution and “footprint” of fuel droplets impinging on the cylinder wall during the intake stroke under engine starting conditions. Injectors having different targeting and atomization characteristics were used in a 4-Valve engine with optical access to the intake port and combustion chamber.

Objective: This study analyzed available rear impact sled tests with Starcraft-type seats that use a diagonal belt behind the seatback. The study focused on neck responses for out-of-position (OOP) and in-position seated dummies. Methods: Thirteen rear sled tests were identified with out-of-position and in-position 5 th , 50 th and 95 th Hybrid III dummies in up to 47.6 mph rear delta Vs involving Starcraft-type seats. The tests were conducted at Ford, Exponent and CSE. Seven KARCO rear sled tests were found with in-position 5 th and 50 th Hybrid III dummies in 21.1-29.5 mph rear delta Vs involving Starcraft-type seats. In all of the in-position and one of the out-of-position series, comparable tests were run with production seats. Biomechanical responses of the dummies and test videos were analyzed.

Purpose: This study presents cases of fracture-dislocation of the thoracic spine in extension during severe rear impacts. The mechanism of injury was investigated. Methods: Four crashes were investigated where a lap-shoulder-belted, front-seat occupant experienced fracture-dislocation of the thoracic spine and paraplegia in a severe rear impact. Police, investigator and medical records were reviewed, the vehicle was inspected and the seat detrimmed. Vehicle dynamics, occupant kinematics and injury mechanisms were determined in this case study. Results: Each case involved a lap-shoulder-belted occupant in a high retention seat with ≻1,700 Nm moment or ≻5.5 kN strength for rearward loading. The crashes were offset rear impacts with 40-56 km/h delta V involving under-ride or override by the impacting vehicle and yaw of the struck vehicle. In each case, the occupant's pelvis was restrained on the seat by the open perimeter frame of the seatback and lap belt.