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Often components or subsystems are attached to other systems through multiple fasteners at multiple locations. Examples may include things like compressors, alternators, engine cradles, powertrain mounting systems, suspension systems, body structures or almost any other interface between components or subsystems. Often during early design stages, alternative component or subsystem configurations are being considered that can have very different interface characteristics, such as alternators with different number of mounting fasteners, or suspension systems with different number of body structure interface attachments. Given these different mounting configurations, it can be difficult to meaningfully compare the interface performance of the two components or subsystems.

The concept of product or system function is considered as described in the Taguchi System of Quality Engineering. The importance of transfer functions is also discussed and a review of conventional value analysis techniques is given. This paper proposes a combination of the principles of robust design and value methodology to enable on-target functionality and direct cost allocation early in the product development process. The discussion on integration of value analysis principles in robust design methodology is provided considering the six sigma environment.

In the last years, increasing concerns about environmental pollution and fossil sources depletion led transport sectors research and development towards the study of new technologies capable to reduce vehicles emissions and fuel consumption. Direct-injection systems (DI) for internal combustion engines propose as an effective way to achieve these goals. This technology has already been adopted in Gasoline Direct Injection (GDI) engines and, lately, a great interest is growing for its use in natural gas fueling, so increasing efficiency with respect to port-fuel injection ones. Alone or in combination with other fuels, compressed natural gas (CNG) represents an attractive way to reduce exhaust emission (high H/C ratio), can be produced in renewable ways, and is more widespread and cheaper than gasoline or diesel fuels. Gas direct-injection process involves the occurrence of under-expanded jets in the combustion chamber.

Since 1985, the Body Division of the Automotive Corrosion and Prevention Committee of SAE (ACAP) has conducted biannual surveys of automotive body corrosion in the Detroit area. The purpose of these surveys is to track industry wide corrosion protection improvements and to make this information available for public consumption. The survey consists of a closed car parking lot survey checking for perforations, blisters, and surface rust. This paper reports the results of the five surveys conducted to date.

This study aims at building efficient and robust artificial neural networks (ANN) able to reconstruct the in-cylinder pressure of Diesel engines and to identify engine conditions starting from the signal of a low-cost accelerometer placed on the engine block. The accelerometer is a perfect non-intrusive replacement for expensive probes and is prospectively suitable for production vehicles. In this view, the artificial neural network is meant to be efficient in terms of response time, i.e. fast enough for on-line use. In addition, robustness is sought in order to provide flexibility in terms of operation parameters. Here we consider a feed-forward neural network based on radial basis functions (RBF) for signal reconstruction, and a feed-forward multi-layer perceptron network with tan-sigmoid transfer function for signal classification. The networks are trained using measurements from a three-cylinder real engine for various operating conditions.

In this paper the investigation with X-ray Tomography on the structure of a gasoline spray from a GDI injector for automotive applications based on polycapillary optics is reported. Table-top experiment using a microfocus Cu Kα X-ray source for radiography and tomography has been used in combination with a polycapillary halflens and a CCD detector. The GDI injector is inserted in a high-pressure rotating device actuated with angular steps Δθ = 1° at the injection pressure of 8.0 MPa. The sinogram reconstruction of the jets by slices permits a 360° spray access to the fuel downstream the nozzle tip. A spatial distribution of the fuel is reported along the direction of six jets giving a measure of the droplet concentration in a circle of 16 mm2 below the nozzle tip at atmospheric backpressure and ambient temperature.

Future automobiles are required to support an increasing number of complex, distributed functions such as active safety and X-by-wire. Because of safety concerns and the need to deliver correct designs in a short time, system properties should be verified in advance on function models, by simulation or model checking. To ensure that the properties still hold for the final deployed system, the implementation of the models into tasks and communication messages should preserve properties of the model, or in general, its semantics. FlexRay offers the possibility of deterministic communication and can be used to define distributed implementations that are provably equivalent to synchronous reactive models like those created from Simulink. However, the low level communication layers and the FlexRay schedule must be carefully designed to ensure the preservation of communication flows and functional outputs.

The electrochemical performance of a lithium-ion battery is strongly affected by the temperature. During charge and discharge cycles, batteries are subjected to an increment of temperature that can accelerate aging and loss of efficiency if critical values are reached. Knowing the thermal parameters that affect the heat exchange between the battery surface and the surrounding environment (air, cooling fins, plates, etc…) is fundamental to their thermal management. In this work, thermal imaging is applied to a laminated lithium-polymers battery as a non-invasive temperature-indication method. Measurements are taken during the discharge phase and the following cooling down until the battery reaches the ambient temperature. The 2d images are used to analyze the homogeneity of the temperature distribution on the battery surface. Then, experimental results are coupled with mathematical correlations.

There are now a wide variety of Hybrid and Electric Vehicles in or near production. They reduce or displace petroleum consumption with of various combinations of conventional IC engine, mechanical transmission, liquid fuel storage, electrical energy storage, electrical and electro-mechanical energy conversion, and vehicle-to-grid energy interface. These Electrified types of vehicles include Mild Hybrid, Full Hybrid, Plug-In Hybrid, Extended Range Electric, and Battery Electric. Some types differ in their actual usability for the real mixes of driving trips, and further that differ in their effectiveness to reduce or displace fuel in actual real world driving use. Vehicle size is also a factor in total vehicle utility in transporting people. If we may segment drivers by their driving needs, in each segment, we see a particular type of electrified vehicle that is better suited than others at minimizing fuel cost and petroleum consumption for the purposes of transporting people.

For the assessment of vehicle acoustics in the early design stages of a vehicle program, the use of full vehicle SEA models is becoming the standard analysis method in the US automotive industry. One benefit is that OEM's and Tier 1 suppliers are able to cascade lower level acoustic performance targets for NVH systems and components. Detailed SEA system level models can be used to assess the performance of systems such as dash panels, floors and doors, however, the results will be questionable until test data Is available. Correlation can be accomplished with buck testing, which is a common practice in the automotive industry for assessing the STL (sound transmission loss) of vehicle level components. The opportunity to conduct buck testing can be limited by the availability of representative bodies to be cut into bucks and the availability of a transmission loss suite with a suitably large opening.

The Chevrolet Volt is an electric vehicle (EV) with extended-range (ER) that is capable of operation on battery power alone, and on power generated by an on-board gasoline engine after depletion of the battery charge. For 2016, GM has developed the next generation of the Volt vehicle and “Voltec” propulsion system. Building on the experience of the first generation Volt, the second generation targeted improved all-electric range, improved charge sustaining fuel economy, and improved performance. All of this was to be accomplished while maintaining the EV character of the first generation Volt which customers clearly valued. This paper describes the next generation “Voltec” system and the realized improvements in efficiency and performance. The features of the propulsion system components, including energy storage, transaxle, electric motors and power electronics, on-board charging, and engine are described and compared with the previous generation.

The so-called Modified Martempering discussed in this work differs from the standard martempering by that the temperature of the quenching bath is below the Ms point. In spite of the fact the lower temperature increases the severity of quenching, this also usually avoids the bainite formation, and by this reason, it is possible to make a fair comparison between different processes, which result in different microstructures. The present study shows the results in terms of mechanical properties, impact resistance in special of a cold work tool steel class, after being heat treated by the isothermal modified martempering process, as well as a comparison with the conventional quenching and tempering process and the austempering as well.

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.

It has the aim to discuss the evolution of electronics components, integrated circuits, new transistors concepts and associate its importance in the automotive modules. Today, the challenge is to have devices which consume less power, suitable for high-energy radiation environment, less parasitic capacitances, high speed, easier device isolation, high gain, easier scale-down of threshold voltage, no latch-up and higher integration density. The improvement of those characteristics mentioned and others in the electronic devices enable the automotive industry to have a more robust product and give the possibility to integrate new features in comfort, safety, infotainment and telematics modules. Finally, the intention is to discuss advanced structures, such as the silicon-on-insulator (SOI) and show how it affects the electronics modules applied for the automotive area.

GM Powertrain Europe and Istituto Motori CNR have undergone a research project aimed at studying the effects on engine performance, emissions and fuel consumption of alternative diesel fuels, from both first (FAME) and second (GTL) generation. The present paper reports some of the results achieved studying the impact on injection and spray behavior of rapeseed and soybean methyl-esters, as well as of GTL diesel blends. The test were performed on a Bosch second generation common rail solenoid-driven fuel injection system capable of 1600bar maximum injection pressure, fitted on GM 1.9L Euro4 diesel engine for passenger cars. The characterization of the injection process has been carried out in terms both of fuel injection rate, as well as of spatial and temporal fuel distribution in a quiescent non-evaporative optically accessible chamber.

Multiple automotive applications exist for small electric motors that are activated by vehicle occupants for various functions such as window lifts and seat adjusters. For such a motor to be described as high quality, not only should the sound it produces be low in amplitude, but it also needs to be free from pulsations and variations that might occur during its (otherwise) steady-state operation. If a motor’s sound contains pulsations or variations between 2 and 8 cycles per second, the variation is described as warble. To establish performance targets for warble noise at both the vehicle and component level a way to measure and quantify the warble noise must be established. Building on existing sound quality metrics such as loudness and pitch variation, a method is established by which processed sound data is put through a secondary operation of Fourier analysis.

This paper reports an experimental and numerical investigation on the spatial and temporal liquid- and vapor-phase distributions of diesel fuel spray under engine-like conditions. The high pressure diesel spray was investigated in an optically-accessible constant volume combustion vessel for studying the influence of the k-factor (0 and 1.5) of a single-hole axial-disposed injector (0.100 mm diameter and 10 L/d ratio). Measurements were carried out by a high-speed imaging system capable of acquiring Mie-scattering and schlieren in a nearly simultaneous fashion mode using a high-speed camera and a pulsed-wave LED system. The time resolved pair of schlieren and Mie-scattering images identifies the instantaneous position of both the vapor and liquid phases of the fuel spray, respectively. The studies were performed at three injection pressures (70, 120, and 180 MPa), 23.9 kg/m3 ambient gas density, and 900 K gas temperature in the vessel.

As the automobile industry is moving towards Electrical vehicles, it becomes very important to have low cost and robust solution to seal all the internal Battery sub systems. It’s a known fact that various IC engine Vehicles are already using Room temperature vulcanized rubber (RTV) for many metal and composite sealing interfaces. Nevertheless, it always needs a good structural design to have good sealing performance. For designing a robust RTV joint for composite structures, it becomes important to have standard RTV chamfers. Sometimes even with these standards, it becomes very costly in having warranty issues when we have weak structure around RTV chamfers. Any joint structure involves multiple design parameters which might impact the sealing performance. Some of the joint structural parameters should be well designed at the early phase of product development cycle, which otherwise will later add lot of cost in modifying the product with its integrated components.

This study aims at building an efficient and robust radial basis function (RBF) artificial neural network (ANN), to reconstruct the in-cylinder pressure of a diesel engine starting from the signal of a low-cost accelerometer placed on the engine block. The accelerometer is a perfect non-intrusive replacement for expensive probes and is prospectively suitable for production vehicles. The RBF network is trained using measurements from different engine operating conditions. Training data are composed of time series from the accelerometer and corresponding measured in-cylinder pressure signals. The RBF network is then validated using data not included in training and the results show good correspondence between measured and reconstructed pressure signal. Various network parameters are used to optimize the network quality.

Crash safety researchers have an increased concern regarding the decreased thoracic deflection and the contributing injury causation factors among the elderly population. Sternum fractures are categorized as moderate severity injuries, but can have long term effects depending on the fragility and frailty of the occupant. Current research has provided detail on rib morphology, but very little information on sternum morphology, sternum fracture locations, and mechanisms of injury. The objective of this study is two-fold (1) quantify sternum morphology and (2) document sternum fracture locations using computed tomography (CT) scans and crash data. Thoracic CT scans from the University of Michigan Hospital database were used to measure thoracic depth, manubriosternal joint, sternum thickness and bone density. The sternum fracture locations and descriptions were extracted from 63 International Center for Automotive Medicine (ICAM) crash cases, of which 22 cases had corresponding CT scans.