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This paper describes the design and implementation of the SEA, Ltd. Brake and Throttle Robot (BTR). Presented are the criteria used in the initial design and the development and testing of the BTR, as well as some test results achieved with the device. The BTR is designed for use in automobiles and light trucks. It is based on a servomotor driven ballscrew, which in turn operates either the brake or accelerator. It is easily portable from one vehicle to another and compact enough to fit even smaller vehicles. The BTR is light enough so as to have minimal effect on the measurement of vehicle parameters. The BTR is designed for use as a stand-alone unit or as part of a larger control system such as the Automated Test Driver (ATD) yet allows for the use of a test driver for safety, as well as test selection, initiation, and monitoring. Installation in a vehicle will be described, as well as electronic components that support the BTR.

The assessment of fuel economy of new vehicles is typically based on regulatory driving cycles, measured in an emissions lab. Although the regulations built around these standardized cycles have strongly contributed to improved fuel efficiency, they are unable to cover the envelope of operating and environmental conditions the vehicle will be subject to when driving in the “real-world”. This discrepancy becomes even more dramatic with the introduction of Connectivity and Automation, which allows for information on future route and traffic conditions to be available to the vehicle and powertrain control system. Furthermore, the huge variability of external conditions, such as vehicle load or driver behavior, can significantly affect the fuel economy on a given route. Such variability poses significant challenges when attempting to compare the performance and fuel economy of different powertrain technologies, vehicle dynamics and powertrain control methods.

A laboratory experiment is designed to examine the clunk phenomenon. A static torque is applied to a driveline system via the mass of an overhanging torsion bar and electromagnet. Then an applied load may be varied via attached mass and released to simulate the step down (tip-out) response of the system. Shaft torques and torsional and translational accelerations are recorded at pre-defined locations. The static torque closes up the driveline clearances in the pinion/ring (crown wheel) mesh. With release of the applied load the driveline undergoes transient vibration. Further, the ratio of preload to static load is adjusted to lead to either no-impact or impact events. Test A provides a ‘linear’ result where the contact stiffness does not pass into clearance. This test is used for confirming transient response and studying friction and damping. Test B is for mass release with sufficient applied torque to pass into clearance, allowing the study of the clunk.

Automating road vehicle control can increase the range and reliability of dynamic testing. Some tests, for instance, specify precise steering inputs which human test drivers are only able to approximate, adding uncertainty to the test results. An automated steering system has been developed which is capable of removing these limitations. This system enables any production car or light truck to follow a user-defined path, using global position feedback, or to perform specific steering sequences with excellent repeatability. The system adapts itself to a given vehicle s handling characteristics, and it can be installed and uninstalled quickly without damage or permanent modification to the vehicle.

As we continue to create ever-lighter road vehicles, the challenge of balancing weight reduction and structural performance also continues. One of the key parts this occurs on is the hood, where lighter materials (e.g. aluminum) have been used. However, the aerodynamic loads, such as hood lift, are essentially unchanged and are driven by the front fascia and front grille size and styling shape. This paper outlines a combination CFD/FEA prediction method for hood deflection performance at high speeds, by using the surface pressures as boundary conditions for a FEA linear static deflection analysis. Additionally, custom post-processing methods were developed to enhance flow analysis and understanding. This enabled the modification of existing test methods to further improve accuracy to real world conditions. The application of these analytical methods and their correlation with experimental results are discussed in this paper.

Modern passenger cars are being equipped with advanced driver assistance systems such as lane departure warning, collision avoidance systems, adaptive cruise control, etc. Testing for operation and effectiveness of these warning systems involves interaction between vehicles. While dealing with multiple moving vehicles, obtaining discriminatory results is difficult due to the difficulty in minimizing variations in vehicle separation and other parameters. This paper describes test strategies involving an automated test driver interacting with another moving vehicle. The autonomous vehicle controls its state (including position and speed) with respect to the target vehicle. Choreographed maneuvers such as chasing and overtaking can be performed with high accuracy and repeatability that even professional drivers have difficulty achieving. The system is also demonstrated to be usable in crash testing.

During a motor-vehicle collision, an occupant may interact with a variety of interior structures. The material properties and construction of these structures can directly affect the occupant's kinetic response. Simulation tools such as MADYMO (Mathematical Dynamical Models) can be used to estimate the forces imparted to an occupant for injury mechanism and causation evaluation relative to a particular event. Depending on the impact event and the specific injury mechanism being evaluated, the selection of proper material characteristics can be quite important. A comprehensive literature review of MADYMO studies illustrates the prevalent use of generic material characteristics and the need for improved property estimation and implementation methods.

This paper presents the details of the model for the physical steering system used on the National Advanced Driving Simulator. The system is basically a hardware-in-the-loop (steering feedback motor and controls) steering system coupled with the core vehicle dynamics of the simulator. The system's torque control uses cascaded position and velocity feedback and is controlled to provide steering feedback with variable stiffness and dynamic properties. The reference model, which calculates the desired value of the torque, is made of power steering torque, damping function torque, torque from tires, locking limit torque, and driver input torque. The model also provides a unique steering dead-band function that is important for on-center feel. A Simulink model of the hardware/software is presented and analysis of the simulator steering system is provided.

The knowledge of frequency-dependent dynamic stiffnesses of mounts, in axial and flexural motions, is needed to determine the behavior of many automotive sub-systems. Consequently, characterization and modeling of vibration isolators is increasingly becoming more important in mid and high frequency regimes where very few methods are known to exist. This paper critically examines some of the approximate identification methods that have been proposed in the literature. Then we present a new experimental identification method that yields frequency-dependent multi-dimensional dynamic stiffnesses of an isolator. The scope is however limited to a linear time-invariant system and our analysis is restricted to the frequency domain. The new characterization method uses two inertial elements at both ends of an isolator and free boundary conditions are maintained during testing.

Aircraft incidents and accidents in icing are often the result of degradation in performance and control. However, current ice sensors measure the amount of ice and not the effect on performance and control. No processed aircraft performance degradation information is available to the pilot. In this paper research is reported on a system to estimate aircraft performance and control changes due to ice, then use this information to automatically operate ice protection systems, provide aircraft envelope protection and, if icing is severe, adapt the flight controls. Key to such a safety system would be he proper communication to, and coordination with, the flight crew. This paper reviews the basic system concept, as well as the research conducted in three critical areas; aerodynamics and flight mechanics, aircraft control and identification, and human factors.

It is commonly recommended to use infant/child restraints in the rear seat, and that until an infant reaches certain age, weight and height criteria, the infant restraint should be placed rear facing. This paper will describe the injuries suffered by an infant that was restrained in a forward-facing child seat placed in the front passenger seating position during a real world collision. Based on this collision, a full-scale vehicle to barrier impact test was performed. For this test, two 6-month-old CRABI dummies were used in identical child restraints. One of the restraints was placed in the front passenger seat in a forward facing configuration, and the other was placed in the right rear seating position in a rear-facing configuration. This paper provides a detailed discussion of the results of this test, including comparisons of the specific kinematics for both the restraint/child dummy configurations.

This year, in the third year of FutureTruck competition, the Ohio State University team has taken the challenge to convert a 2002 Ford Explorer into a more fuel efficient and environmentally friendly SUV. This goal was achieved by use of a post-transmission, charge sustaining, parallel hybrid diesel-electric drivetrain. The main power source is a 2.5-liter, 103 kW advanced CIDI engine manufactured by VM Motori. A 55 kW Ecostar AC induction electric motor provides the supplemental power. The powertrain is managed by a state of the art supervisory control system which optimizes powertrain characteristics using advanced energy management and emission control algorithms. A unique driver interface implementing advanced telematics, and an interior designed specifically to reduce weight and be more environmentally friendly add to the utility of the vehicle as well as the consumer appeal.

Modal sound radiation of a brake rotor is expressed in terms of analytical solutions of a generic thick annular disk having similar geometric dimensions. Finite element method is used to determine structural modes and response. Vibro-acoustic responses such as surface velocities and radiated sound pressures due to a multi-modal excitation are calculated from synthesized structural modes and modal acoustic radiation of the rotor using the modal expansion technique. In addition, acoustic power and radiation efficiency spectra corresponding to a specific force excitation are obtained from the sound pressure data. Accuracy of the new semi-analytical method has been confirmed by purely numerical analyses based on finite element and boundary element models. Our method should lead to an improved understanding of the sound radiation from a brake rotor and strategies to minimize squeal noise radiation could be formulated.

The rapid development of driver assistance systems, such as lane-departure warning (LDW) and lane-keeping support (LKS), along with widely publicized reports of automated vehicle testing, have created the expectation for an increasing amount of vehicle automation in the near future. As these systems are being phased in, the coexistence of automated vehicles and human-driven vehicles on roadways will be inevitable and necessary. In order to develop automated vehicles that integrate well with those that are operated in traditional ways, an appropriate understanding of human driver behavior in normal traffic situations would be beneficial. Unlike many research studies that have focused on collision-avoidance maneuvering, this paper analyzes the behavior of human drivers in response to cut-in vehicles moving at similar speeds. Both automated and human-driven vehicles are likely to encounter this scenario in daily highway driving.

In this research, cervical muscle behavior in rear impact accidents was investigated. Specifically, cervical muscle forces and muscle lengthening velocities were investigated with respect to cervical injuries. Variation of the onset time for muscle activation, variation of muscle activation level and variation of rear impact pulses were considered. The human body simulation computer program, MADYMO and anthropometric numerical human model were used to evaluate the neck. The factors mentioned above were examined with specific data being obtained from several different literature sources. Cervical muscles were separated into three groups, the sternocleidomastoideus, the flexor muscle group and the extensor muscle group. Longuscolli and spleniuscapitis were selected to represent the flexor muscle and extensor muscle groups respectively. The values and trends of the muscle forces and lengthening velocities are investigated in each muscle group.

Fault diagnosis for automotive systems is driven by government regulations, vehicle repairability, and customer satisfaction. Several methods have been developed to detect and isolate faults in automotive systems, subsystems and components with special emphasis on those faults that affect the exhaust gas emission levels. Limit checks, model-based, and knowledge-based methods are applied for diagnosing malfunctions in emission control systems. Incipient and partial faults may be hard to detect when using a detection scheme that implements any of the previously mentioned methods individually; the integration of model-based and knowledge-based diagnostic methods may provide a more robust approach. In the present paper, use is made of fuzzy residual evaluation and of a fuzzy expert system to improve the performance of a fault detection method based on a mathematical model of the engine.

During high-speed rear impacts with delta-V > 25 km/h, the front seats may rotate rearward due to occupant and seat momentum change leading to possibly large seat deflection. One possible way of limiting this may be by introducing a structure that would restrict large rotations or deformations, however, such a structure would change the front seat occupant kinematics and kinetics. The goal of this study was to understand the influence of seat back restriction on head, neck and torso responses of front seat occupants when subjected to a moderate speed rear-impact. This was done by simulating a rear impact scenario with a delta-V of 37.4 km/h using LS-Dyna, with the GHBMC M50 occupant model and a manufacturer provided seat model. The study included two parts, the first part was to identify worst case scenarios using the simplified GHBMC M50-OS, and the second part was to further investigate the identified scenarios using the detailed GHBMC M50-O.

The prospect of a vehicle occupant sustaining injury in a crash is dependant on many factors, including deceleration, restraint availability, restraint usage, vehicle interior geometry, and seating configuration. The relationship between these factors and injury potential has been determined by testing post-mortem human subjects and anthropomorphic test devices to evaluate occupant response to impact. Such testing by the host of researchers studying occupant injury has generated information on occupant response to impact covering a wide range of factors influencing injury outcome. There has been little testing performed with the seatback reclined from the normal position. As a result, little is known of the response of a vehicle occupant in this configuration beyond the obvious potential of the pelvis to submarine under the lap belt. There exists a need to study occupant response with a reclined seatback when submarining is not present.

Springback affects the dimensional accuracy and final shape of stamped parts. Accurate prediction of springback is necessary to design dies that produce the desired part geometry and tolerances. Springback occurs after stamping and ejection of the part because the state of the stresses and strains in the deformed material has changed. To accurately predict springback through finite element analysis, the material model should be well defined for accurate simulation and prediction of stresses and strains after unloading. Despite the development of several advanced material models that comprehensively describe the Bauschinger effect, transient behavior, permanent softening of the blank material, and unloading elastic modulus degradation, the prediction of springback is still not satisfactory for production parts. Dies are often recut several times, after the first tryouts, to compensate for springback and achieve the required part geometry.

The influence of die corner geometry on the attainable draw depth of rectangular parts was investigated using 3-D FEM and optimum rectangular blanks. Axisymmetric cup analysis was not adequate because a corner assist effect promotes corner draw. Guidelines for selecting corner radius were developed and the sensitivities of the maximum part depth to other process variables, such as drawbead restraint force; die clearance gap; friction coefficient; strain rate sensitivity; material anisotropy; and strain hardening exponent, were simulated. The results are much more conservative than handbook rules, which to not to take into account the details of blank size, drawbead restraint, die geometry, material properties, and friction.