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With the growing prosperity of the long-distance freight and urban logistics industry, the demand for cargo trucks is gradually increasing. The connecting bracket is the critical connecting part of the truck chassis, which bears the load transmitted by the road excitation and reduces the damage to the frame caused by the load. However, the occurrence of rough road conditions is inevitable in heavy-duty transportation. In this paper, road durability tests and fatigue life analysis are carried out on the original structure to ensure the safety of the vehicle. Based on the known boundary and load constraints, a lightweight and high-performance structure is obtained through size optimization, as the original structure cannot meet the performance requirements. Firstly, the road test was conducted on the truck where the original bracket structure is located.

Based on the emergency lane change cases extracted from the China naturalistic driving data, the driving steering behavior divides into three phases: collision avoidance, lateral movement and steering stabilization. Using the steering primitive fitting by Gaussian function, the distribution of the duration time, the relationship between steering wheel rate and deflection were analyzed in three phases. It is shown that the steering behavior essentially is composed of steering primitives during the emergency lane-change. However, the combination of the steering primitives is different according to the specific steering constraints in three phases. In the collision avoidance phase, a single steering primitive with high peak is used for the fast steering; in the lateral movement and stabilization phase, a combination of two or even more steering primitives is built to a more accurate steering.

A driver steering model for emergency lane change based on the China naturalistic driving data is proposed in this paper. The steering characteristic of three phases is analyzed. Using the steering primitive fitting by Gaussian function, the steering behaviors in collision avoidance and lateral movement phases can be described, and the stabilization steering principle of yaw rate null is found. Based on the steering characteristic, the near and far aim point used in steering phases is analyzed. Using the near and far aim point correction model, a driver steering model for emergency lane change is established. The research results show that the driver emergency steering model proposed in this paper performs well when explaining realistic steering behavior, and this model can be used in developing the ADAS system.

The frame of a low-speed electric vehicle was treated as the research object in the paper. The fatigue load of the frame was analyzed with multi-body dynamics method and the fatigue life of frame was analyzed with the nominal stress method. Firstly, the multi-body dynamics model of the vehicle was established and the multi-body dynamics simulation was carried out to simulate the condition where the vehicle used to travel. The fatigue load history of the frame was obtained from the simulation. Secondly, the amplitude-frequency characteristic of the fatigue load was analyzed. The frequency of the fatigue load mainly focused on 0~20HZ from the analysis. Thirdly, the modal of frame was analyzed. As the frequency of the fatigue load was less than the natural frequency of the frame, the quasi-static method was selected to calculate the stress history of the frame. Next, the fatigue life of the frame was analyzed based on S-N curve.

This paper constructs the Accident Crash Scenarios(ACSs) classification system based on the traffic accident data collected by the traffic management department in a Chinses city from 2013 to 2015. The classification system selects four influenced variables on the basis of Critical Driving Scenarios(CDSs) in Naturalistic Driving Data. The proportions of each variable are analyzed, and all ACSs are divided into 48 scenarios. The highest proportion of nine ACSs are extracted from all 10596 ACSs, and the result shows the ACSs involved Car-Pedalcyclist occupy the top four scenarios, and the scenarios involved intersection situations are worth attention. Pedalcyclists include bicyclists, motorcyclists, tri-cyclists and electric bicyclists. Multivariate Logistic Regression(MLR) analysis is then used to study the ACSs involved the type of Car-Pedalcyclist.

Millimeter-wave automotive radars can prevent traffic accidents and save human lives as they can detect vehicles and pedestrians even in night and in bad weather. Various types of automotive radars operating at 24 and 77 GHz bands are developed for various applications, like adaptive cruise control, blind-spot detection and lane change assistance. In each year, millions of millimeter-wave radar are sold worldwide. Millimeter-wave radar is composed of radar hardware and radar signal processing software, which detects the targets among noise, measures the distance, longitudinal speed and the azimuth angle of the targets, tracks the targets continuously, and controls the ego vehicle to brake or accelerate. Performance of the radar signal processing software is closely related with the radar hardware properties and radar measurement conditions.

Battery management system (BMS) is the core component of the new energy vehicle battery system. With the increase of energy density of new energy vehicle battery, its control algorithm becomes more and more complex, and the work of the battery management system will be heavier. In order to solve the limits, the hardware, software and control strategy model of battery management system are developed based on AURIX multi-core microcontroller. The microprocessor control unit is developed by using dual-core chip, which meets the functional safety requirements. Dual-core processing of control strategy and individual information acquisition are realized, and the processing efficiency is improved. A four-tier software architecture of battery management system is developed to handle the Dual-core processing. The graphical development of battery management system strategy model is realized by using MATLAB / Simulink.

In this paper, it was researched the degradation characteristics of catalytic performance of three kinds of DPFs (C1, C2 and C3, with precious metal concentrations being 15, 25 and 35 g/ft3 respectively) after diesel truck aging. It is found out that the crystallinity of three kinds of DPF samples (Used) in full vehicle aging was higher than that of fresh samples (Fresh) and aged samples (Aged) in the laboratory. Compared with Fresh samples, the concentration of Pt atom in precious metal on the surface of Aged and Used samples tends to decrease in most cases. Activities to CO and C3H8 of Aged and Used samples of three kinds of DPFs had all been degraded, and activity degradation showed a substantial correlation with concentration reduction rate of precious metal on the carrier surface. NO2 productivity of Used samples all rose. Crystallinity of DPF samples after full vehicle aging in Inlet, Middle and Outlet areas successively increased.

Electric vehicles are considered as one of the most popular way to decrease the consumption of petroleum resources and reduce environmental pollutions. Motor control system is one of the most important part of electric vehicles. It includes power supply module, IGBT driver, digital signal processing (DSP) controller, protection adjustment module, and resolver to digital convertor. To implement the control strategies on motor control system, a lot of practical aspects need to be taken into accounts. It includes setup of the initial excitation current, consistency of current between motor and program code, over-modulation, field weakening control, current protection, and so on. In this paper, an induction motor control system for electric vehicles is developed based on DSP. The control strategy is based on the field-oriented control (FOC) and space vector pulse width modulation (SVPWM).

Battery state estimation is one of the most important decision parameters for lithium battery energy management. It plays an important role in improving battery energy utilization, ensuring battery safety and enhancing system reliability. This paper is proposed to provide a dynamic correction of SOC in the full working condition, including static condition and dynamic condition. Based on the Coulomb-counting method, the current SOC value of the battery is calculated. Under the static conditions, the open circuit voltage of the battery is used to directly collect the initial SOC. Under the dynamic working conditions, the open circuit voltage of the battery is estimated by the sliding mode observer. Based on the deviation between the calculated and estimated values of the open circuit voltage, the current coefficient of the Coulomb-counting method is dynamically corrected by PI strategy.

Durability performance prediction is a critical issue in fuel cell research. During the demonstration operation of fuel cell commercial vehicles in China, this issue has attracted more attention. In this article, the long short-term memory neural network (LSTMNN), which is an improved recurrent neural network (RNN), and the demonstration operation data are used to establish the prediction model to predict the durability performance of the fuel cell stack. Then, a model based on a back-propagation neural network (BPNN) is established to be a control group. The demonstration operation data is divided into training group and validation group. The former is used to train the prediction model, and the latter is used to verify the validity and accuracy of the prediction model. The outputs of the prediction model, as the durability performance evaluation indexes of the fuel cell, are the polarization curve (current-voltage curve) and the voltage decay curve (time-voltage curve).

There are a large number of uncertainties in engineering design, and the accumulated uncertainties will enlarge the overall failure probability of the structure system. Therefore, structural design considering uncertainties has good guiding significance for improving the reliability of engineering structures. To address this issue, the dynamic-static structural topology optimization is established and reliability-based topology optimization with decoupling format is conducted in this study. The design point which satisfying the constraint of the target reliability indicator is obtained according to the reliability indicators of the first-order reliability method, and the uncertain design variables are modified into a deterministic variable according to the sensitivity information.

Lightweight design is a key factor in general engineering design practice, however, it often conflicts with fatigue durability. This paper presents a way for improving the effectiveness of fatigue performance dominated optimization, demonstrated through a case study on suspension brackets for heavy-duty vehicles. This case study is based on random load data collected from fatigue durability tests in proving grounds, and fatigue failures of the heavy-duty vehicle suspension brackets were observed and recorded during the tests. Multi-objective fatigue optimization was introduced by employing multiaxial time-domain fatigue analysis under random loads combined with the non-dominated sorting genetic algorithm II with archives.

The unscented Kalman filter (UKF) is applied to estimate the real vehicle velocity. The velocity estimation algorithm uses lateral acceleration, longitudinal acceleration and yaw rate as inputs. The non-linear vehicle model and Dugoff tire model are built as the estimation model of UKF. Some parameters of Dugoff tire model and vehicle, which can't be measured directly, are identified by the particle swarm optimization (PSO). For the purpose of evaluating the algorithm, the estimation values of UKF are compared with measurements of the Inertial and GPS Navigation system. Besides, the real time property of UKF is tested by xPC Target, which is a real-time software environment from MathWorks. The result of the real vehicle experiment demonstrates the availability of the UKF and PSO in vehicle velocity estimation.

In order to satisfy design requirements of Lane Keeping Assistance System (LKAS), a Driver Steering Override (DSO) strategy is necessary for driver’s interaction with the assistance system. The assistance system can be overridden by the strategy in case of lane change, obstacle avoidance and other emergency situations. However, evaluation and optimization of the DSO strategy for LKAS cannot easily be completed quantitatively considering driver’s acceptability. In this research, firstly subjective and objective evaluation experiment is designed. Secondly, correlations between the subjective and the objective evaluation results are established by using regression analysis. Finally, based on the correlations established previously, the optimal performance of DSO strategy is obtained by setting the desired comprehensive evaluation ratings as the optimized goal.

Proton exchange membrane fuel cell (PEMFC) system is considered as one of the most popular power sources because of its high energy density, fast dynamic response and zero pollution. However, the start-up at low temperature (e.g. - 30 °C) is still a major challenge for its wide application due to water freezing in Membrane Electrode Assembly (MEA). In this paper, a cold start test process in an environment cabin with auxiliary heat was carried out for a full power automotive PEMFC system, including normal operation, shutdown purge and cold start processes analysis from -30°C. Rated power of this stack is 100kW at the current density of 1.4A/cm2 and relevant maximum output power can reach to 120kW. In order to reduce the damage of high potential to MEA, on-load purge with a current of 30A is conducted to removing extra water in stack for improving cold start ability. Based on corresponding control strategy, cold start was realized successfully within 110s.

As the international community strengthens the control of carbon dioxide emissions, electric vehicles have gradually become a substitute for internal combustion engine vehicles. The battery pack is one of the most important components of electric vehicles. The strength and fatigue performance of the battery support plate not only affect the performance of the vehicle but also concern the safety of the driver. In the present study, the finite element model of a battery pack for fatigue analysis is completely established. The random vibration stress response analysis and acceleration power spectral density response analysis of the support plate for the battery pack are carried out, and the accuracy of the finite element model is verified by a random vibration test.

Fatigue behavior of aluminum alloys under multiaxial loading was investigated with both cast aluminum A356-T6 and wrought alloy 6063-T6. The dominant multiaxial fatigue crack preferentially nucleates from flaws like porosity and oxide films located near the free surface of the material. In the absence of the flaws, the cracking/debonding of the second phase particles dominates the crack initiation and propagation. The number of cracked/debonded particles increases with the number of cycles, but the damage rate depends on loading paths. Among various loading paths studied, the circle loading path shows the shortest fatigue life due to the development of complex dislocation substructures and severe stress concentration near grain/cell boundaries and second phase particles.

Fatigue defect and failure of rubber element widely used in mechanical systems could seriously affect the safety and reliability of systems in practical operation. Because rubber element is considered as hyperelastic material, traditional σ - N curve which is usually used in metal material for fatigue life analysis can not be used here. The fatigue life of rubber bushing in automobile engine cradle was analyzed by using the energy method. The Yeoh model coefficients were given by tensile test of natural rubber, and the estimating formula for fatigue life of natural rubber was obtained by finite element calculation and fatigue test. Maximum strain energy density was treated as the parameter of fatigue damage, then the rubber bushing fatigue life was calculated by the estimating formula. The results were verified by test of rubber bushing, which indicated that the model mentioned in this paper is accuracy enough.

Sealing system is an important subsystem of modern high-performance engine. Sealing system reliability directly affects the engine operating conditions. Cylinder head gaskets(CHG) sealing system is of the most importance to the engine sealing system, which is not only responsible for sealing chamber, the cooling fluid and lubricating oil passage, for preventing gas leakage, water leakage and oil leakage, but also responsible for force transferring between cylinder head and cylinder body. Basing on nonlinear solution method, the sealing performance of multi-layer-steel cylinder head gaskets to a gasoline engine is studied with the finite element software ABAQUS. The deformations of the cylinder liners and engine block are also considered.