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Abstract The use of appropriate loads and regulations is of great importance in weld fatigue assessment of rail on-track maintenance equipment and similar vehicles for optimized design. The regulations and available loads, however, are often generalized for several categories, which proves to be overly conservative for some specific categories of machines. EN (European Norm) and AAR (Association of American Railroads) regulations play a pivotal role in determining the applicable loads and acceptance criteria within this study. The availability of track-induced fatigue load data for the cumulative damage approach in track maintenance machines is often limited. Consequently, the FEA-based validation of rail track maintenance equipment often resorts to the infinite life approach rather than cumulative damage approach for track-induced travel loads, resulting in overly conservative designs.

Abstract Automated driving as one of the most anticipated technologies is approaching its market release in the near future. Since several years, the research in the automotive industry is largely focused on its development and presents well-engineered prototypes. The many aspects of this development do not only concern the function and its components itself, but also the proof of safety and assessment for its market release. It is clear that previous methods used for the release of Advanced Driver Assistance Systems are not applicable. In contrast to already released systems, automated driving is not restricted to a certain field of application in terms of driving scenarios it has to take action in. This results in an infeasible amount of required testing and unforeseeable scenarios the function can face throughout its lifetime. In this article, we show a scenario-based approach that promises to overcome those challenges.

Abstract This article introduces a methodology for conducting comparative evaluations of vibration-induced discomfort. The aim is to outline a procedure specifically focused on assessing and comparing the discomfort caused by vibrations. The article emphasizes the metrics that can effectively quantify vibration-induced discomfort and provides insights on utilizing available information to facilitate the assessment of differences observed during the comparisons. The study also addresses the selection of appropriate target scenarios and test environments within the context of the comparative evaluation procedure. A practical case study is presented, highlighting the comparison of wheel corner concepts in the development of new vehicle architectures. Currently, the evaluation criteria and difference thresholds available allow for comparative evaluations within a limited range of vehicle vibration characteristics.

Abstract This article investigates the dynamics of non-smooth and nonlinear oscillations of a bicycle-car model, considering the tire-road separation. Road contact applies a non-holonomic constrain on the dynamics system that makes the equations of motion to be different under in-contact and off-contact conditions. The set of nonlinear equations of the system has been formulated based on nondimensionalization to minimize the number of parameters and generalize the results. To compare the quality of different suspensions in reducing the unpleasant no-contact conditions, we define a contact-free fraction indicator to measure the separation fraction time during a cycle of steady-state oscillation. An observation of frequency responses including vertical displacements, the pitch mode, and the domain of contact-free fraction of time has been investigated to clarify engineering design directions.

Abstract Advanced passenger vehicles are complex dynamic systems that are equipped with several actuators, possibly including differential braking, active steering, and semi-active or active suspensions. The simultaneous use of several actuators for integrated vehicle motion control has been a topic of great interest in literature. To facilitate this, a technique known as control allocation (CA) has been employed. CA is a technique that enables the coordination of various actuators of a system. One of the main challenges in the study of CA has been the representation of actuator dynamics in the optimal CA problem (OCAP). Using model predictive control allocation (MPCA), this problem has been addressed. Furthermore, the actual dynamics of actuators may vary over the lifespan of the system due to factors such as wear, lack of maintenance, etc. Therefore, it is further required to compensate for any mismatches between the actual actuator parameters and those used in the OCAP.

Abstract In this study, a computer-aided design (CAD) geometry system that is linked to each other to create a parametric form of the side rear door’s inner frame sheet piece on a passenger vehicle body in a Siemens NX environment was developed. The system was created in the NX CAD environment, using the program’s unique product development structure. The system was designed and modified for time-consuming parts. At the end of the study, the parameterized vehicle door geometries worked in the NX environment standardized the design process and accelerated the design works.

Abstract This article presents a workflow for aerodynamic optimization of vehicles that for the first time combines the adjoint method and the efficient global optimization (EGO) algorithm in order to take advantage of both the gradient-based and gradient-free methods for aerodynamic optimization problems. In the workflow, the adjoint method is first applied to locate the sensitive surface regions of the baseline vehicle with respect to the objective functions and define a proper design space with reasonable design variables. Then the EGO algorithm is applied to search for the optimal site in the design space based on the expected improvement (EI) function. Such workflow has been applied to minimize the aerodynamic drag for a mass-produced electric vehicle. With the help of STAR-CCM+ and its adjoint solver, sensitive surface regions with respect to the aerodynamic drag are first located on the vehicle.

Abstract One of the key problems of battery electric vehicles is the risk of severe range reduction in winter conditions. Technologies such as heat pump systems can help to mitigate such effects, but finding adequate heat sources for the heat pump sometimes can be a problem, too. In cold ambient conditions below −10°C and for a cold-soaked vehicle this can become a limiting factor. Storing waste heat or excess cold when it is generated and releasing it to the vehicle thermal management system later can reduce peak thermal requirements to more manageable average levels. In related architectures it is not always necessary to replace existing electric heaters or conventional air-conditioning systems. Sometimes it is more efficient to keep them and support them, instead. Accordingly, we show, how latent heat storage can be used to increase the efficiency of existing, well-established heating and cooling technologies without replacing them.

Abstract Renewable energy sources provide an excellent opportunity for state departments of transportation (DOTs) to benefit from a dual use of land while providing flexible, resilient, affordable, and environmentally responsible modes of generation. Solar photovoltaic (PV) systems are particularly useful in this regard. This study presents a literature review on the types of solar project partnerships, application of solar PV systems by DOTs in the United States (U.S.), solar energy potential, energy policies, and incentives in Virginia. In addition, a feasibility assessment of installing solar PV systems at six (6) Virginia DOT (VDOT)-owned sites is presented. The review of the literature indicated that twenty state DOTs have implemented or are developing solar projects using their facilities. The feasibility assessment showed the benefits of installing solar PV systems at VDOT facilities.

Abstract As the automotive industry moves toward electrification, battery costs and vehicle range are two large issues that will delay this movement. These issues can be partially resolved through the use of series-hybrid vehicles, which can replace a portion of the batteries with a small engine that serves to recharge the battery. Given the size, weight, and operational constraints of this engine, a 2-stroke engine makes sense. Indeed, 2-stroke engines are currently being used for a number of applications including consumer products, small ground vehicles, boats, and drones. The technology has significantly improved to allow for reduced emissions and increased efficiency, especially through the use of direct injection. This article discusses the state of technology for 2-stroke engines and its application in series-hybrid vehicles. In particular, the use of a 2-stroke engine as a range extender provides significant benefit in range and cost over fully electric vehicles.

Abstract Advances in hybrid vehicles and electric vehicles (EV) are creating a need for a new generation of lubricants and new lubricant performance tests. Copper corrosion is one prominent concern for hybrid vehicles and EVs and is routinely assessed using a coupon test. This is characterized as metal dissolution, a surface tarnish, or a corrosion layer where a corrosion product remains on the surface and is characterized by a qualitative visual rating. This deficiency does not provide insight into the nature of the corrosion deposit. In an electric drive unit, there are multiple sources of the electric potential present, which can significantly alter the formation of a corrosion deposit which is not assessed in the coupon tests. The formation of a conductive corrosion deposit can result in catastrophic failure of the electric drive unit, either through direct shorting of the motor winding or failure of the power electronics.

Abstract This study evaluates the applicability of the Octane Index (OI) framework under conventional spark ignition (SI) and “beyond Research Octane Number (RON)” conditions using nine fuels operated under stoichiometric, knock-limited conditions in a direct injection spark ignition (DISI) engine, supported by Monte Carlo-type simulations which interrogate the effects of measurement uncertainty. Of the nine tested fuels, three fuels are “Tier III” fuel blends, meaning that they are blends of molecules which have passed two levels of screening, and have been evaluated to be ready for tests in research engines. These molecules have been blended into a four-component gasoline surrogate at varying volume fractions in order to achieve a RON rating of 98. The molecules under consideration are isobutanol, 2-butanol, and diisobutylene (which is a mixture of two isomers of octene). The remaining six fuels were research-grade gasolines of varying formulations.

Abstract The high-frequency noise issue is one of the most significant noise, vibration, and harshness problems, particularly in battery electric vehicles (BEVs). The sound package treatment is one of the most important approaches toward solving this problem. Owing to the limitations imposed by manufacturing error, assembly error, and the operating conditions, there is often a big difference between the actual values and the design values of the sound package components. Therefore, the sound package parameters include greater uncertainties. In this article, an uncertainty analysis method for BEV interior noise was developed based on an interval model to investigate the effect of sound package uncertainty on the interior noise of a BEV. An interval perturbation method was formulated to compute the uncertainty of the BEV’s interior noise.

Abstract Sustainable practices are taking precedence across many industries, as evident from their shift towards the use of environmentally responsible materials, such as natural fiber-reinforced acrylated epoxidized soybean oil (NF-AESO). However, due to the lower reactivity of AESO, the curing reaction usually requires higher temperatures and longer curing time (e.g., 150°C for 6-12 h), thus making the entire process unsustainable. In this study, we demonstrate the potential power of photons towards manufacturing NF-AESO composites in a sustainable manner at room temperature (RT) within 10 min. Two photoinitiators, i.e., the 2,2-dimethoxy phenylacetophenone (DMPA) and 1-hydroxycyclohexyl phenyl ketone (HCPK), were evaluated and compared with the thermal initiator, i.e., tert-butyl perbenzoate (TBPB). Based on the mechanical performance of the AESOs, the photoinitiation system for NF-AESO was optimized.

Abstract Electric Vehicle (EV) equipped with two-speed transmission has benefit in improving dynamic performance and saving battery consumption. However, during gear shift process, torque interruption and shift impact may lead to a bad shift quality. This work investigates gear shift process in an Automated Manual Transmission (AMT) configuration-based two-speed transmission. First of all, a typical gear shift process is analyzed. Parameters like motor speed, shift force, motor torque change rate, and speed difference between synchronizer and target engage gear are all included to find the relationships with shift duration. Then vehicle jerk is introduced as a criterion to evaluate shift impact. Besides, a comprehensive shift control strategy is developed. While keeping the output torque at wheels unchanged, the shift strategy also improved motor working efficiency after gear shift.

Abstract Gasoline Particulate Filter (GPF) technology is the key method of meeting the new regulations for particulate matter emissions from gasoline cars. Computer-Aided Engineering is widely used for the design of such systems; thus the development of accurate models for GPFs is crucial. Most existing pressure loss models require experimental calibration of several parameters. These experiments are performed at room temperatures, or on an engine test bench, where gas properties cannot be fully controlled. This article presents pressure loss measurements for clean GPF cores performed with uniform airflow and temperatures up to 680°C. The flow regime in GPF is shown to be different to that in the Diesel Particulate Filters (DPF) due to high flow rates and temperatures. Therefore, most of the existing models are not suitable for design of the new generation of aftertreatment devices. To separate pressure loss contribution from different sources, unplugged filter cores are tested.

Abstract China is driving the transition away from internal combustion engine vehicles (ICEVs) to plug-in electric vehicles (PEVs, including plug-in hybrid electric vehicles (PHEVs) and battery electric vehicles (BEVs)) to address its pressing energy security and environmental pollution problems. The recent enactment of the dual-credit scheme mandate will compensate for the phase out of the subsidy program, while ostensibly shifting the burden of filling in the cost gap between PEVs and ICEVs from the government to the automakers (though in practice to car buyers).

Abstract The promise and potential for a future of automated vehicles (AVs) remains great, with safety and societal transformations that may rival the original introduction of the automobile. Yet an inability for industry and governments to define what it means for an AV to drive safely has tempered enthusiasm and risks causing a “winter of AV” just like the one that affected Artificial Intelligence technologies decades ago, which is only now being overcome. Towards this end, the Responsibility-Sensitive Safety (RSS) model was introduced as an open and transparent white-box, an interpretable and scalable formal model that defines minimum safety requirements based on reasonable assumptions of others, balancing safety and usefulness for automated driving vehicles.

Abstract Distributed drive electric vehicles can apply the four-wheel differential drive to change the vehicle handling performance, which can make the connected and automated vehicles (CAV) more controllable. This article proposes a hierarchical scheme of the torque-vectoring controller (TVC), whose key parameters affecting the control objective are optimized from the human-vehicle closed-loop simulation test. First, the radial basis function (RBF)-based adaptive second-order sliding mode control (RASOSMC) for additional yaw moment generation is designed in the upper layer of the controller. The lower layer is the torque distribution strategy that takes into consideration the minimization of the tire load and the control error of the additional yaw moment and yaw rate. Afterward, the longitudinal and lateral driver model with the adaptive correction of preview time is established.

Abstract Wheel loaders are widely used in construction projects. In order to reduce pollution and energy consumption, major wheel loader manufacturers are developing electric powertrain technology. Our main research goal is to reduce the energy consumption of a pure electric loader. This study is intended to build a vehicle simulation model of a multiple drive motor electric loader. According to the common working conditions and empirical formulas of the loader, the simulation data of the electric loader are calculated. The torque distribution control strategy based on the optimal efficiency of the motor is designed for the multiple drive motor electric loader and is compared with the equal proportion distribution control and the axle load ratio distribution control through simulation analysis. The simulation results show that the proposed torque distribution control strategy based on motor optimal efficiency can reduce energy consumption by 7–12%.