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The focus of this paper is to develop an innovative vehicle layout and optimize vehicle body structure with the latest lightweight steel technologies, such as hydro-forming and hot stamping. Our BIW structure achieved a mass savings of 28 kg (−10%) compared to the mass of baseline BIW structure. (Base BIW : MD_Elantra)

NVH analysis based on numerical simulations before actual test vehicle is available becomes common process in the automotive industry. Furthermore, the latest work scope is extending even to conceptual study in the very early design stage, beyond traditional numerical simulations simply using 3-D CAD data. In case when reasonable information is provided at this very early vehicle development stage, a better decision on the design concept would be possible, and subsequent design process can be carried out in more efficient manner. The core of this trend is that it allows us to predict vehicle performance at the conceptual design stage without 3-D CAD data, and then, with this prediction, to suggest meaningful design directions for next stage. From this point of view, FRF-Based Substructuring (FBS) methodology has potential to be used as an appropriate tool for this purpose.

Today, many automakers are using LED lamp sources in exterior lamps to establish brand awareness and introduce specialized lamp designs. These eye-catching LED lamp source solutions require many control functions as the lamp functions are diversified and advanced, and accordingly the requirements for standardization and optimization of controllers are increasing. In particular, our LED rear combination lamps have a variety of LED loads according to the design of the lamp model, the installation position, and the diagnostic regulations, so that the design complexity and the number of specifications of the controller are increased [4]. In recent years, more and more aesthetic designs and new technologies are used by various automakers to optimize their controllers in cooperation with global partners to optimize costs [1].

Electric Power Steering (EPS) needs to meet both functional and stability requirements, it plays significant role in controlling vehicle motion. In the meantime, customers emphasizes natural steering feel which can reflect vehicle motion and road surface information while isolate unwanted external disturbances. In general, conventional EPS control algorithms exert assist torque according to driver torque measured from torque sensor, while maintaining stability using stabilizing compensator. However, there exist significant trade-off between steering feel and stability, because the performances of assist torque control and stabilizing compensator are strongly coupled. In this paper a torque feedback control algorithm for EPS system is proposed in order to overcome the trade-off, and to achieve more natural, robust steering feel.

In this paper, a reconfigurable object-oriented simulator is proposed to analyze the performance of Bluetooth Voice Communication Package (VCP) for telecom purposes like hands-free vehicular communication. It consists of a graphical user interface (GUI) for research or validation engineers to investigate system specific performance. For example, a research engineer can utilize this GUI to analyze a system performance using different noise reduction filtering techniques in vehicular hands-free applications. Also, a validation engineer can utilize this GUI to evaluate vehicular Bluetooth audio quality for different vehicles at different driving conditions (e.g. speeds, fan levels, etc.). The proposed Bluetooth VCP model consists of modules like Audio Equalization (EQ), Acoustic Echo Canceller (AEC), and Noise Suppression (NS). This dynamic GUI platform provides the scope to add and analyze new proposed filtering techniques.

Shudder vibration of a hydraulic power steering system during parking maneuver was studied with numerical and experimental methods. To quantify vibration performance of the system and recognize important stimuli for drivers, a shudder metric was derived by correlation between objective measurements and subjective ratings. A CAE model for steering wheel vibration analysis was developed and compared with measured data. In order to describe steering input dependency of shudder, a new dynamic friction modeling method, in which the magnitude of effective damping is determined by average velocity, was proposed. The developed model was validated using the measured steering wheel acceleration and the pressure change at inlet of the steering gear box. It was shown that the developed model successfully describes major modes by comparing the calculated FRF of the hydraulic system with measured one from the hydraulic excitation test.

The software must be verified and optimized from time to time to ensure system performance quality from the development process. Because the later you discover performance issues, the greater the cost of performance improvements, along with the extent to which they are fixed in the source code. In particular, performance problems due to poor system design should be identified and corrected as soon as possible. Also, as development progresses, source code added for new features and modified by bugs can potentially increase system resource usage or worsen responsiveness. Therefore, the development process needs to periodically measure, analyze, and improve system performance. This paper introduces the system-wide performance analyzer and explains how to use it to measure and analyze the performance of the infotainment system for performance management and improvement.

The need for a voice recognition system in the automotive industry is growing day by day. In our current voice recognition system, Hyundai's ‘Blue-Link’ and KIA's ‘UVO’ are developed with Microsoft which is a global software company. The system launched domestic market recently. Since usage of voice recognition system are increasing, research and development of Voice Recognition system also increase very fast. Research is mostly focus on increase recognition rate of speech. However there is no research of interior layout considering voice recognition usability. So in this research, we discover interior design factors for maximizing voice recognition usability.

This paper presents the research related to the self-driving system that has been actively carried out recently. Previous studies have been limited to ensure the path following performance in linear and steady state-alike handling region with small lateral acceleration. However, in the high speed driving, the vehicle cornering response is extended to nonlinear region where tire grips are saturated. This requires a technology to create the driving path for minimum time maneuvering while grasping the tire grip limits of the vehicle in real time. The entire controller consists of three stages-hierarchy: The target motion is determined in the supervisor phase, and the target force to follow the target behavior is calculated in the upper stage controller. Finally, the lower stage controller calculates the actuator phase control input corresponding to the target force.

Suspension is a system which operates dynamically according to road condition unlike other system statically mounted to the body. Especially this is more remarkable in high performance vehicle because there are more high inputs from road to suspension than normal vehicle. For this reason, the tightening torque of suspension system of high performance vehicle is more important than other systems and normal vehicle. To support the clamping between parts against force from road when cornering, optimized tightening torque is required to maximize R&H performance. For this optimization, it should be conducted first to comprehend how much performance effects on vehicle by tightening torque. This paper presents relationship between tightening torque of suspension parts hardware and R&H performance.

Hydroforming process is an emerging manufacturing technology which allows engineers to use continuous closed section without flange for spot weld in a given package envelope. In this research, Hydroforming is applied to a front pillar and a roof side rail for improvement of obstruction angle, body stiffness and roof crush resistance. In addition, the joints of front / center pillar that were integrated into the hydroforming part and structure of package tray were improved. As a result, front pillar width is reduced by 23%, body torsional stiffness is increased by 45% and roof crush resistance is improved by 35%.

The driver’s seat in heavy trucks is designed for an upright driving posture with narrow back and cushion angles; thus, the seatback offers very little support. This makes the sitting posture prone to shifting during long trips, leading to loss of comfort and increase in fatigue. Sitting posture stability allows initial posture to be maintained during long drives, and the lack of stability causes fatigue and body pain during the drive. This study confirmed that enhancement of sitting posture stability of the driver’s seat in heavy trucks requires appropriate support from the cushion. The study also analyzed the support characteristics of each part of the cushion, and presented development guidelines of new cushion. Although subjective assessments of sitting posture stability have been performed, this study presented a method for quantitative and efficient assessment of sitting posture stability using the PAM-COMFORT simulation tool and virtual testing.

This paper focuses on the optimization of the cross-section of a panel type impact door beam. The key parameters of the cross-section of the beam were artificially changed by using a geometry morphing tool FCM (Fast Concept Modeler), which is plugged in to CATIA. Then, the metamodel of FE (Finite Element) analysis results was created and optimized using LS-OPT. The ANOVA (Analysis of Variance) analysis of results was carried out to find the factor of weight reduction. Finally, a new cross section concept was proposed to overcome the limitation of old structure. The optimization was carried out for the beam with the final cross-section to have 10 % or more reduction in total weight.

The multi-function drive plate used for a high performance engine was developed by optimizing its structure, material and design features. To do so, the investigation of the load characteristics was done in order to increase FEA reliability. DFSS was utilized for optimizing the design features and defining the effect of geometric parameters on the durability. The durability of the optimized drive plate was verified by comparing the FEA and test results with other drive plates which were already verified. Finally, the real powertrain test was done to confirm its durability for a high performance engine.

Broadband active noise control algorithms require high-performance so multi-channel control to ensure high performance, which results in very high computational power and expensive DSP. When the control filter update part need a huge computational power of the algorithm is separated and calculated by the server, it is possible to reduce cost by using a low-cost DSP in a local vehicle, and a performance improvement algorithm requiring a high computational power can be applied to the server. In order to achieve the above goal, this study analyzed the maximum delay time when communication speed is low and studied response measures to ensure data integrity at the receiving location considering situations where communication speed delay and data errors occur.

This paper describes the optimal design process of the steering column system and the supporting system. At the initial concept stage of development process, a design guide is proposed to obtain sufficient stiffness of the steering system while reducing idle vibration sensitivity of the system. Case studies on resonance isolation are summarized, in which separated vibration modes among systems by applying Vibration Mode Map at the initial stage of design process. This study also makes it possible to provide design guideline for optimal dynamic damper system using CAE (computer aided engineering) analysis. The damper FE (finite element) model is added to vehicle model to analyze the relation between the frequency and the sensitivity of steering column system. This analysis methodology enables target performance achievement in early design stage and reduction of damper tuning activity after proto car test stage.

Various optimization schemes have successfully been utilized to design mounting brackets of chassis components, especially suspension systems, in the large commercial vehicle development process. Depending on the design status, different optimization schemes, i.e. size, topology, and shape, are applied. There are two key elements that determine types of optimization schemes used, which are design freedom and available analysis time. First, in a case that the design is already frozen near the mass production, so that only minimal design change and time is allowed, the size optimization is attempted. Second, in the middle of the design process where relatively more room for the change is available, the topology optimization is adequate to carry out, based on the basic CAD model.

The characteristics of vibration in the seat system are presented using the analysis of Finite Element Method (FEM). The Noise, Vibration and Harshness (NVH) performance should be managed from the viewpoint of tactile, acoustic and visual sense. Tactile response is the response of sub-systems, which is induced when the human body contacts steering wheel, footrest and seats. The seat modeling techniques have been developed and correlated with the modal test. The main modes in the seat system were analyzed and these seat modes were used to set the mode map (seat target) at the stage of full vehicle level. The sensitive region on seat mountings was defined through the design sensitivity analysis. Weight down design studies were performed.

The electrification of the internal combustion engine is an important subject of future automotive technology. By using a motorized internal combustion engine, it is possible to recover waste energy by regeneration technology and to reduce various losses that deteriorate the efficiency of the internal combustion Engine. This paper summarizes the results of the development of an engine-integrated motor that can be applied to a 48V mild hybrid system for motorization of an internal combustion engine. Like the 48V MHSG-mounted mild hybrid system designed to replace the generator in the auxiliary belt system, the motorized internal combustion engine is designed with the scalability as the top priority to minimize the additional space for the vehicle and to mount the same engine in various models.

Design optimization of a vehicle is required to increase a product value for noise and vibration performances and for a fuel-efficient car. This paper describes the development process of a high stiffness and lightweight vehicle. A parameter study is carried out at the initial stage of design using the mother car, and a design guide with a good performance is achieved early prior to the development of the proto car. Influences of body stiffness based on the relative weight ratio of the floor and side structures are analyzed. Results show that bending and torsional stiffness has a significant effect on weight distribution ratio. Influences of the distribution of side joint stiffness are analyzed through numerical experiments. Results reveal that the stiffness difference between the upper and lower parts should be small to increase the stiffness of a body.