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This paper presents the “Virtual Failure Mode and Effects Analysis (vFMEA)” system, which is a high-fidelity electrical-failure-simulation platform, and applies it to the software verification of an electric power steering (EPS) system. The vFMEA system enables engineers to dynamically inject a drift fault into a circuit model of the electronic control unit (ECU) of an EPS system, to analyze system-level failure effects, and to verify software-implemented safety mechanisms, which consequently reduces both cost and time of development. The vFMEA system can verify test cases that cannot be verified using an actual ECU and can improve test coverage as well. It consists of a cycle-accurate microcontroller model with mass-production software implemented in binary format, analog and digital circuit models, mechanical models, and a state-triggered fault-injection mechanism.

“Virtual Failure Mode and Effects Analysis” (vFMEA), a novel safety-verification method of control software for automotive electronic systems, was proposed to save prototyping cost at verification stage. The proposed vFMEA is system-level FMEA method, which uses virtualized electronic control units (ECUs) consisting of microcontroller models on a microcontroller simulator and a transistor-level circuit models on a circuit simulator. By using the structure, the control software in binary code formats can be verified when a circuit-level fault occurs in the ECU hardware. As an illustrative example, vFMEA was applied to an engine ECU. As a result of short-circuit fault into a driver IC, engine revolution and engine speed decreased. However, the engine continued to operate normally when an open-circuit fault occurred in a capacitor connected in parallel. Effects of the hardware faults in ECU on a vehicle are demonstrated; thereby software verification can be performed using vFMEA system.

The intention of this paper is to discuss the importance of analysis of some electrical parameters in order to design analog circuits in electronic modules, including automotive ones. Today, the challenge is to have devices which consume less power, high performance and higher integration density, so that it explains why such analysis is crucial to achieve better performances and meet the desired results.

Sintered parts mechanical properties are very sensitive to final density, which inevitable cause an enormous density gradient in the green part coming from the compaction process strategy. The current experimental method to assess green density occurs mainly in set up by cutting the green parts in pieces and measuring its average density in a balance using Archimedes principle. Simulation is the more accurate method to verify gradient density and the main benefit would be the correlation with the critical region in terms of stresses obtained by FEA and try to pursue the optimization process. This paper shows a case study of a part that had your fatigue limit improved 1000% using compaction process simulation for better optimization.

This paper presents a simplified approach for formability simulation of automotive body structural sections in the early design stage of vehicle development process. Plane strain approach is investigated for its applicability and accuracy by comparing the analytical results with the measured results of automotive body side panel. The plane strain approach was tried based on the fact that for a certain section location of a stamped panel, the minor strains are relatively small and negligible compared to the major strains. The state of plane strain can be induced mainly through symmetry and applied boundary conditions. This approach is both cost effective and time saving for analyzing sheet metal formability in early vehicle development stage, since only few sections of the entire panel need be analyzed.

Suspension is an important chassis part which is vital to ride comfort [1]. However, it is difficult to achieve our targeted comfortability level in a short time. Therefore, improving efficiency of damper development is our primary challenge. We have launched a project which aims to reduce the workload on developing dampers by introducing analytical approaches to the improvement of ride comfort. To be more specific, we have been putting effort into developing the damping force prediction, the vehicle dynamics prediction and subjective rating prediction. This paper describes subjective rating prediction method which output a subjective rating corresponding to the physical value of the vehicle dynamics with deep learning. As a result of verification using objective data which was not used for learning process, DNN (Deep Neural Network) prediction method could fairly precisely predict subjective rating of the expert driver.

The flight area of drones and other unmanned aerial vehicles (UAVs) had been highly restricted but has been relaxing, including flights beyond the scope of sight. Deregulation without aircraft-reliability improvement increases the risk of accidents. However, demanding high reliability for all aircraft leads to an increase in the price of the aircraft. Therefore, if airspace restrictions are relaxed for more reliable aircraft, the cost of higher reliability and its benefits can be balanced. This will improve efficiency and optimize cost-effectiveness. The purpose of this proposal is to balance the cost of aircraft-reliability improvement (which allows flight to continue in the event of a failure) and its advantages. Specifically, the author proposes rules that apply more relaxed airspace restrictions to UAVs with higher FCLs (Flight Continuity Possibility Levels) and stricter airspace restrictions to those with lower FCLs.

Planetary gear set is one of the most commonly used gear systems in automotive industry as they cater to high power density requirements. A simple planetary gear set consists of a sun gear, ring gear, planets and carrier which houses planet gears. Efficiency of a transmission is dependent upon performance of gear sets involved in power transfer to a great extent. Structural rigidity of a planetary carrier is critical in a planetary gear set as its deflection may alter the load distribution of gears in mesh causing durability and noise issues. Limited studies exist based on geometrical parameters of a carrier which would help a designer in selecting the dimensions at an early stage. In this study, an end to end automated FEA process based on DOE and optimization in Isight is developed. The method incorporates a workflow allowing for an update of carrier geometry, FE model setup, analysis job submission and post-processing of results.

Structures with multiple materials have now become one of the perceived necessities for automotive industry to address vehicle design requirements such as light-weight, safety, and cost. The objective of this study is to develop a design methodology for multi-material structures accountable for vehicle crash durability. The heuristic topology synthesis approach of Hybrid Cellular Automaton (HCA) framework is implemented to generate multi-material structures with the constraint on the volume fraction of the final design. The HCA framework is integrated with ordered-SIMP (solid isotropic material with penalization) interpolation, artificial material library, as well as statistical analysis of material distribution data to ensure a smooth transition between multiple practical materials during the topology synthesis.

We developed a thermal calculation 1D simulator for an electric valve timing control system (VTC). A VTC can optimize the open and close timing of the intake and exhaust valves depending on the driving situation. Since a conventional VTC is driven hydraulically, the challenges are response speed and operation limit at low temperature. Our company has been developing an electric VTC for quick response and expansion of operating conditions. Currently, it is necessary to optimize the motor and reduction gear design to balance quicker response with downsizing. Therefore, a coupled simulator that can calculate electricity, mechanics, control, and thermo characteristics is required. In 1D simulation, a thermal network method is commonly used for thermal calculation. However, an electric VTC is attached to the end of a camshaft; therefore, determining thermal resistances is difficult. We propose a method of determining thermal resistances, using both theoretical and experimental approaches.

The need for improved axle NVH integration has increased significantly in recent years with industry trends toward full-time and automatic four wheel drive (4wd) systems. Along with seamless 4wd operation, quiet performance has become a universal expectation. Axle gear-mesh noise can be transmitted to the vehicle passenger compartment through airborne paths (not discussed in this paper) and structure-borne paths (the focus of this paper.) A variety of mounting configurations are used in an attempt to provide improved axle isolation and reduce structure-borne transmission of gear-mesh noise. The configuration discussed in this paper is a 4-point vertical mount design for an Independent Front Drive Axle (IFDA). A significant benefit of this configuration is improved isolation in the range of drive torques where axle-related NVH issues typically exist.

In order to reduce the number of head injuries sustained by pedestrian accidents, safety engineers are developing pedestrian friendly hood systems through gauge optimization of the hood inner panel. In this study, the clinch method was employed to assemble a pedestrian friendly hood with a 0.5mm thick inner panel. Static and dynamic analyses were carried out to determine the clinch experiencing the highest loads and to understand the fatigue behavior of a clinched hood during a slam event. The macroscopic failure modes of clinched joints by hood slam were studied by means of a scanning electron microscope. A simple equation was derived to correlate the hexahedron spot weld model as a substitute for clinching in order to obtain an equivalent stiffness for a clinched joint within the linear region of an F-D curve. The F-D curve was obtained by lap shear testing.

Loss of power steering assist (LoA) is viewed as a potential hazard in certain vehicle operational scenarios. Despite the importance of this steering failure mode, few published test protocols for the objective or subjective evaluation of vehicle performance in a loss of assist situation exist. The first part of this paper examines five of the key steering failure modes that can result in LoA and discusses why LoA persists as a key industry challenge. The second part analyzes the situational dynamics affecting vehicle controllability during a LoA event and proposes a subjective evaluation driving course that facilitates evaluations in various LoA scenarios. A corresponding objective test procedure and metric is also proposed. These evaluation methods support consistent performance evaluation of physical vehicles while also enabling the prediction of vehicle characteristics early in the vehicle development process (VDP).

We demonstrate here an accounting of damage accrual under road loads for a filled natural rubber bushing. The accounting is useful to developers who wish to avoid the typical risks in development programs: either the risk of premature failure, or of costly overdesign. The accounting begins with characterization of the elastomer to quantify governing behaviors: stress-strain response, fatigue crack growth rate, crack precursor size, and strain crystallization. Finite Element Analysis is used to construct a nonlinear mapping between loads and strain components within each element. Multiaxial, variable amplitude strain histories are computed from road loads. Damage accrues in this reckoning via the growth of cracks. Crack growth is calculated via integration of a rate law from an initial size to a size marking end-of-life.

In the area of Human Factors and Usability research a desired output of many studies is identification of what value a specific Design Parameter should be set at to minimize customer dissatisfaction. A Customer Loss Function is a simple way to graphically display the probability customers will be dissatisfied at different levels of a given design parameter, due to a given failure mode. Many design parameters however, have two distinct but related Failure Modes (customer disatisfiers), typically representing two ends of the parameter (i.e. too much/too little; too hot/too cold; too fast/too slow). Each of these Failure modes is represented by its own unique Customer Loss Function. This paper will introduce a technique to combine these two One-Sided Loss Functions into a comprehensive Two Sided Loss Function. The mathematics behind the creation of both one sided and two sided loss functions is based on Binary Logistic Regression [1,2,3] Analysis Techniques.

The evolution toward the use of electrostatic painting processes has been driven primarily by environmental legislation and efforts to improve efficiencies in the painting process. The development of conductive substrate material compliments the industry trend toward a green environment through further reductions in emissions of volatile organic compounds during the painting process. Traditionally, electrostatic painting of thermoplastics requires that a conductive primer be applied to the substrate prior to topcoat application. The conductive polymer blend of polyphenylene ether and polyamide provides sufficient conductivity to eliminate usage of conductive primers. Additional benefits include improved transfer efficiencies of the primer and top coat systems, uniform film builds across the part, and improved painting of complex geometries.

The automotive system domain are in increasing motivation with benefits by using the x-by-wire technologies, which employ new electronic devices to provide for automobile system more facilities during processes at development, production, usability and maintenance. Considering at automobile user domain point of view, the next generation of automobiles can give users more comfort, safety and flexibility. However, for the safety critical applications at automobiles have as requirements the use of distributed embedded systems and fault tolerance methodologies where in communication infrastructure need to offer fault-tolerance communication services. Several researches regards fault tolerance communication systems for automotive domain are now in progress and a strong convergence in use of the Flexray technology is noted for the automotive community. The Flexray is one of the communication systems that had been proposed and available at AUTOSAR standard.

To support the market introduction of lithium ion energy storage systems for HEV and EREV applications, a process and tool was developed to expedite the verification of the lithium-ion cell balancing system across differing usage scenarios and cell imbalance rates. Presented is an overview of the cell imbalance analysis methodology and tool used in the development and verification of General Motors cell balancing systems. The use of this analysis methodology and tool has allowed for a cell balancing system optimization that would not have been possible with the use of actual energy storage systems because of the magnitude of lab or vehicle time required to execute the array of tests necessary to comprehend the large number of factors than can influence balancing.

The present work aims to characterize the microstructure of valvetrain camshaft lobes that are currently applied in the automotive industry, obtained by different processing routes. The cam lobe microstructure has been assessed by microscopy, whereas the mechanical properties by hardness profile measurements on the surface region. Microconstituents type and form, composing the final microstructure at the cam lobe work region, are defined by the casting route and/or post-heat treatment process other than alloy chemical composition, so that knowledge and control of processing route is vital to assure suitable valvetrain system assembly performance and durability. Most of the mechanical solicitations on the part occur at the interface between cam and follower; the actual contact area is significantly smaller than the apparent area. As a result, the microstructure at and near the surface performs a direct role on the performance of the valvetrain, cam lobe and its counterpart.

Highly automated driving systems have a responsibility to keep a vehicle safe even in abnormal conditions such as random or systematic failures. However, creating redundancy in a system to respond to failures increases the cost of the system, and simple redundancy cannot detect systematic failures because some systematic failures occur in each system at the same time. Systematic failures in automated driving systems cannot be verified sufficiently during the development phase due to numerous patterns of parameters input from outside the system. A safety concept based on a “safety sustainer” for highly automated driving systems is proposed. The safety sustainer is designed for keeping a vehicle in a safe state for several seconds if a failure occurs in the system and notifying the driver that the system is in failure mode and requesting the driver to take over control of the vehicle.