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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.

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.

The Buckeye Bullet set domestic as well as international speed records for electric vehicles in 2004. The next generation of land speed vehicle from Ohio State called the Buckeye Bullet 2 (henceforth the BB2) will again challenge and hopefully achieve several new speed records. The Buckeye Bullet suspension worked relatively well but was found to not be quite optimal for the vehicle. The purpose of the work outlined here was to develop a new front and rear suspension for the BB2 that would be an improvement over the suspension of the original Bullet. Previous to the start of this work part of the suspension had already been designed in the form of an upright/control arm setup. This paper works on taking the suspension to completion from this point of design. Work done includes developing the final design, determining suspension parameters, building an ADAMS model, and testing the ADAMS model.

The paper presents the development of a methodology for the evaluation of the Wide-Open-Throttle (WOT) torque production when the engine is running free. Under such conditions the engine speed shows a sudden increase due to the high engine torque production associated with the WOT conditions, and to the absence of a load connected to the engine. The acoustic emission of the engine contains information related to this speed increase and thus to the engine torque production. The methodology unveils the information contained in the engine acoustic emission to estimate the torque produced under WOT operating conditions. This estimation can be performed without the need of coupling the engine to a brake, and does not require installing any additional sensor. For this reason the approach here presented could be very useful for engine testing at the end of the assembly line.

The EcoCAR 2: Plugging into the Future team at the Ohio State University is designing a Parallel-Series Plug-in Hybrid Electric Vehicle capable of 50 miles of all-electric range. The vehicle features a 18.9-kWh lithium-ion battery pack with range extending operation in both series and parallel modes. This is made possible by a 1.8-L ethanol (E85) engine and 6-speed automated manual transmission. This vehicle is designed to drastically reduce fuel consumption, with a utility factor weighted fuel economy of 51 miles per gallon gasoline equivalent (mpgge), while meeting Tier II Bin 5 emissions standards. This report details the fabrication and control implementation process followed by the Ohio State team during Year 2 of the competition. The fabrication process includes finalizing designs based on identified requirements, building and assembling components, and performing extensive validation testing on the mechanical, electrical and control systems.

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.

Adequacy of resistance spot welds in low carbon steels in relation to structural integrity can become an issue in the reconstruction of automotive accidents. Because formation of a plug (or button or slug) in a peel test is used as a quality control criterion for welds, it is sometimes assumed conversely that a weld which failed is defective if no plug is present. Spot welds do not necessarily form a plug when fractured. Fracture behavior of spot welds both by overload and fatigue is reviewed. Then techniques for examination of field failures are discussed. Finally two case histories are discussed.

In this paper, we propose an IC engine fuel system diagnostic algorithm based on a discrete-event nonlinear observer using the production oxygen sensor. A mean value engine model is used to describe the engine dynamics. A procedure for designing the discrete event based observer is presented and applied to estimate important engine variables using the measured binary oxygen sensor output. The estimated variables are then used to perform diagnostics of the fuel system of the IC engine. Experimental results on a multi-cylinder production engine are presented to demonstrate the effectiveness of the proposed method.

This paper presents the application of detection filters to the diagnosis of sensor and actuator failures in automotive control systems. The detection filter is the embodiment of a model-based failure detection and isolation (FDI) methodology, which utilizes analytical redundancy within a dynamical system (e.g., engine/controller) to isolate the cause and location of abnormal behavior (i.e., failures). The FDI methodology has been used, among other applications, in the aerospace industry for fault diagnosis of inertial navigation systems and flight controllers. This paper presents the philosophy and essential features of FDI theory, and describes the practical application of the method to the diagnosis of faults in the throttle position sensor in an electronically controlled IC engine. The paper also discusses the incorporation of FDI systems in the design process of a control strategy, with the aim of increasing reliability by embedding diagnostic features within the control strategy.

Composite material roof structures for multipurpose vehicles are comprised of a composite shell molded without metal frames as in most automobile rooftops. This paper experimentally analyzes the roof structure performance for a static uniformly distributed load over the roof surface and examines the tensile properties, effects of high temperatures and sound absorption characteristics of the random, chopped glass fiber reinforced epoxy resin material. The roof performance includes the load-strain history and the load-deflection behavior of the structure.

The objective of this paper is to develop a self-tuning optimal control of an active suspension. An active suspension composed of an identifier and a controller is proposed in this paper. Although control strategies on active (or semi-active) suspensions have been investigated during the past few decades, some problems are not well understood yet. One of them arising from the ride control of an active suspension is that when the weight and the moments of inertia of the sprung mass are varied, the feedback gains of the controller should vary with the variation of parameters accordingly. Therefore, the identifier is proposed before the controller is designed. In the real situations, the parameter variation may occur when loadings on vehicles vary - either from passengers or payloads, especially, in the case of loading on a truck. An identification structure using parallel model reference adaptive system (MRAS) is proposed to identify the true parameters.

This paper presents the real time implementation of detection filters for the diagnosis of incipient failures in electronically controlled internal combustion (IC) engines. The detection filters are implemented in a production vehicle. Recent results [1] have demonstrated the feasibility of a model-based failure detection and isolation (FDI) methodology for detecting partially failed components in electronically controlled vehicle subsystems. The present paper describes the real time application of the FDI concept to the detection of faults in sensors associated with the engine/controller In a detection filter, the performance of the engine/controller system is continuously compared to a prediction based on sensor measurements and an analytical model (typically a control model) of the system. Any discrepancy between actual and predicted performance is analyzed to identify the unique failure signatures related to specific system components.

This paper introduces a high accuracy method of measuring crankshaft angular position of an I-C engine. The method uses a sensor which couples magnetically to the starter ring gear. There are many automotive applications of this measurement of crankshaft angular position including ignition timing reference, engine performance measurement and certain diagnostic functions. The present paper disusses only the ignition timing application. Engine performance measurements are reported in refs. (1,2,3). The diagnostic application is discussed in refs. (4-5). The passage of a starter ring gear tooth past the sensor axis causes a pulse to be generated in the sensor output. The waveform of this sensor voltage is independent of engine angular speed (including zero speed). However, this waveform is a function of gear tooth profile and is consequently influenced by gear wear. The present method uses a finite state machine to process the sensor output signal.