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Based on the success of the second-generation Genesis G80 model, Hyundai Motor has declared the independence of Genesis as a luxury car brand in 2015. The third-generation G80 is the representative model of the Genesis brand and has a unique identity of Genesis that can surpass its competitors. In addition, it was necessary to develop seats that were considered not only for ICE but also for the scalability of electric vehicles. A newly formed Genesis organization established the Genesis design philosophy of its own. Four key elements of the design philosophy were comfort, aesthetics, usability and safety. The third-generation Genesis seats incorporate its design philosophy of seat design and new technologies based on comfort, aesthetics, usability, and safety. This paper describes the seat development of the Ergo Motion seat, Rear Seat Relaxtion(Relax + Position), Seat Syling, AVN switch display and PSS(pre-active safety seat )system, which are representative technologies.

As environmental problems such as global warming are emerging, regulations on automobile exhaust gas are strengthened and various exhaust gas reduction technologies are being developed in various countries in order to satisfy exhaust emission regulations. Exhaust gas recirculation (EGR) technology is a very effective way to reduce nitrogen oxides (NOx) at high combustion temperatures by using EGR coolers to lower the combustion temperature. This EGR cooler has been mass-produced in stainless steel, but it is expensive and heavy. Recently, high efficiency and compactness are required for the EGR cooler to meet the new emission regulation. If aluminum material is applied to the EGR cooler, heat transfer efficiency and light weight can be improved due to high heat transfer coefficient of aluminum compared to conventional stainless steel, but durability is insufficient. Therefore, the aluminum EGR cooler has been developed to enhance performance and durability.

Premature failure in lead-acid batteries used in starting, lighting, and ignition applications has led to warranty issues which can be resolved by predicting the contributing factors of battery aging and evaluating different design alternatives. Battery degradation in real vehicles is accelerated by dark currents from an integrated dashboard camera which are drawn while the ignition is turned off, high ambient temperatures, a shortage of the battery charge rate, and the intermittent occurrence of bad starts during idle-stop-and-go operation. Existing battery durability verification requires a long period of more than 4 months using experimental deep discharge testing and does not reflect the various actual vehicle driving conditions of the customer. In order to improve this, the present work aims to develop a battery aging prediction model that reflects the various operating conditions of actual vehicle driving patterns.

The existing FCEV have been developed with only a few vehicle models. With the diversification of both passenger and commercial FCEV lineups, as well as the increasing demand for vehicle trailer towing, there is a growing need for high-capacity fuel cell stacks to be applied in vehicles. However, at the current level, there are limitations and issues that arise, such as insufficient power output and reduced driving speed. As a results, the importance of thermal energy management has been increasing along with the increase in required power. Traditional cooling performance enhancement methods have mainly focused on developing increased hardware specifications, but even this approach has reached its limitation due to package, cost and weight problem. Therefore, it is essential to develop a new cooling system to solve the increases in heat dissipation.

The engine indicated torque is not delivered entirely to the wheels, because it is lowered by losses, such as the pumping, mechanical friction and front auxiliary power consumption. The front auxiliary belt drive system is a big power consumer-fueling and operating the various accessory devices, such as air conditioning compressor, electric alternator, and power steering pump. The standard fuel economy test does not consider the auxiliary driving torque when it is activated during the actual driving condition and it is considered a five-cycle correction factor only. Therefore, research on improving the front end auxiliary drive (FEAD) system is still relevant in the immediate future, particularly regarding the air conditioning compressor and the electric alternator. An exertion to minimize the auxiliary loss is much smaller than the sustained effort required to reduce engine friction loss.

As the AVN display in the car interior becomes larger and located above the center fascia, the driver's visual visibility is becoming important. In addition, since an expensive touch sensor is installed, a transparent electrode cost reduction technology for a display touch sensor that can replace an indium material, which is an expensive rare metal, is required. In this paper, we developed new transparent electrode materials and manufacturing methods for the touch sensor film which light reflectance is low and flexible without a separate low-reflection multi-layer, so that the design freedom is high and the material cost is low. By optimizing the amount of fluorine doping ratio in tin oxide, excellent electrical conductivity and high optical transmittance are secured, and the surface reflectance is reduced by adjusting the diameter and length of the silver nanowire. As a result, it was shown that the AVN display image and font readability was improved.

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.

Environmental and fuel economy regulations (Eu 6d and WLTP RDE) on automobiles have been tightened recently. To counter this regulation, the global automobile industry is focusing on weight reduction, fuel efficient turbo charger, cooled EGR, thermal management, low friction and so on. However, the high-speed turbocharger makes turbulence, and resulting in airflow noise. This noise is transmitted indoor through the air intake system, which adversely affects the vehicle's competitiveness. Therefore, for turbo engine, it is essential to reduce the noise of the air intake system. The air intake system consists of air cleaner, air filter, air intake hose and air duct. The air flow noise of turbo-engine is mainly the emission noise emitted from the walls of air intake system. And the transfer path of turbo noise is in order of air intake hose, air cleaner and air duct. Therefore, it is effective to reduce the noise of the air intake hose located at the beginning of noise transfer path.

In this study, an optimized structure for opening the headlining considering the deployment of the face-to-face roof airbag was studied. It was confirmed that the deployment performance differs depending on the skin of the headlining, and a standardized structure with mass production was proposed. Non-woven fabric and Tricot skin, which are economical and high-end specifications, satisfy the performance of PVC fusion application specifications after cutting 80% of the skin. The structure that satisfies the entire body including the knit specifications is a type that separates the roof airbag area piece, the corresponding soft piece is separated, and the deployment performance is satisfied with safety. Therefore, the structure is proposed as a standardized structure. This structure is expected to be applicable to roof DAB (Driver Airbag), PAB (Passenger Airbag), and Sunroof Airbag, which will be necessary technologies to secure indoor space.

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.

The FMVSS 208 advanced air bag rule has brought new technologies into the automotive industry. Low Risk Deployment, Suppression, or a combination of both, have prevailed in the industry to meet the right front passenger requirements for FMVSS 208 compliance. This rule provides the options to conduct low risk deployment (LRD) airbag tests with a 12-months-old infant dummy riding in a rear facing child seat and child dummies representing 3 years and 6 years old children. If the LRD tests do not meet the injury criteria set by NHTSA, vehicle manufacturers have to choose the another option for the suppressing airbag system when infants or children are present at the passenger seat. But this suppressing systems is not the cost effective method, also, contains potential quality problem such as misrecognition passenger age. Thus, the car makers start to choose LRD requirement option and develop new LRD passenger airbag system.

Generally, the HVAC system of a vehicle is composed of Blower unit assembly and Heater unit assembly, and is located on the driver’s side of the dash panel. However, electric vehicles have far fewer parts than conventional internal combustion engine vehicles, so electric vehicles have large space in the engine room. This allows HVAC, which occupies large volume in the interior side, to be pushed in the direction of the engine room altogether, or by placing a part inside the engine room to make a slim cockpit and expand the interior space. However, this new structure, called the Split HVAC System, is mounted through the dash, allowing noise to pass through relatively easily. Since this adversely affects the NVH of an electric vehicle, it needs to be developed in terms of noise transmission. Therefore, in this paper, a study was conducted to predict the sound transmission loss of Split HVAC through an analytical method.

In this paper, an application process is studied at which the insertion loss (IL) test data of sound insulating parts or noise control treatments are utilized for the sound transmission loss (STL) simulation of the trimmed dash structure. The considered sound barrier assemblies were composed of a felt layer, a mass layer, and a decoupler layer. Flat samples of sound barrier assemblies with several different thicknesses were prepared, and ILs of them were measured by using a sound transmission loss facility. Flat samples were assumed to have mass-spring-mass resonance frequencies. The mass was set as the area mass of the sound barrier layer of the felt layer and the mass layer. The spring constant of the decoupler layer was assumed as the multiplication of that of an air spring and a spring correction factor.

To achieve a mass goal and minimize the bell mouthing phenomenon of Passenger Air Bag Housing which takes place when the air bag is in explosive action and detrimental to the safety of passenger side because excessive canister bell mouthing may distort and crash the top surface of instrument panel, a study on the replacing process of a PAB housing to a different material and process was performed. The explosive action of current steel PAB housing was firstly analized to evaluate the reaction forces transferred through the PAB and find out the adaptable material for replacing process. Due to the properties among the die casting alloys, the AM60B alloy was chosen for our new material for PAB housing. Then, stress analysis by the finite element method was performed for a design modification of magnesium one piece housing.

This study has been conducted to analyze microbial diversity and its community by using a method of NGS(Next generation sequencing) technique that is not rely on cultivation for microbial community in an core evaporator causing odor of car air conditioner. The NGS without any cultivation method of cultivation, has been developed recently and widely. This method is able to research a microorganism that has not been cultivated. Differently with others, it can get a result that is closer to fact, also can acquire more base sequence with larger volume in relatively shorter time. According to bacteria population analysis of 23 samples, It can be known limited number of bacteria can inhabit in Evaporator core, due to small exposure between bacteria and evaporate, as well as its environmental characteristics. With the population analysis, only certain group of it is forming biofilm in proportion.

It is known that SEA is a rapid and simple methodology for analyzing complex vibroacoustic systems. However, the SEA principle is not always valid and one has to be careful about the physical conditions at which the SEA principle is acceptable. In this study, the appropriate damping loss factor of the vehicle interior cavity is studied in the viewpoint of the modal overlap factor of the cavity and the decay per mean free path (DMFP) of the cavity. Virtual SEA tests are performed with an FE model combination, which is suggested by a previous study of Stelzer et al. for the simulation of the sound transmission loss (STL) of vehicle panel structure. The FE model combination is consisting of the body in white (BIW), an acoustical-excited hemisphere-shaped exterior cavity, and the interior cavity. It is found that the DMFP of the interior cavity is appropriate between 0.5 ~ 1 dB for applying SEA principle.

Some CO2-reducing technologies have real-world benefits not captured by regulatory testing methods. This paper documents a two-layer heating, ventilation, and air-conditioning (HVAC) system that facilitates faster engine warmup through strategic increased air recirculation. The performance of this technology was assessed on a 2020 Hyundai Sonata. Empirical performance of the technology was obtained through dynamometer tests at Argonne National Laboratory. Performance of the vehicle across multiple cycles and cell ambient temperatures with the two-layer technology active and inactive indicated fuel consumption reduction in nearly all cases. A thermally sensitive powertrain model, the National Renewable Energy Laboratory’s FASTSim Hot, was calibrated and validated against vehicle testing data. The developed model included the engine, cabin, and HVAC system controls.

Coconut shell and torrefied wood are bio-sourced and renewable materials that can be used as fillers in various polymer matrices. Torrefied wood material can be produced from numerous cellulose based materials, such as wood, sunflower hulls, flax shive, hemp and oat hulls. These bio-fillers would replace talc and glass bubbles which are not a renewable resource. Additionally, the implementation of torrefied wood and coconut would reduce the carbon footprint and improve sustainability of Hyundai and Kia vehicles, improving customer perception of our product line. In this study, coconut and torrefied wood filled polypropylene properties are tested for a HVAC Case application.

This paper presents the design, implementation, and performance evaluation of a reduced complexity algorithm for a predictive control which is based on our previously published SAE paper (2021-01-0225) titled, “Model Predictive Control for Engine Thermal Management System.” That paper presented a model predictive control (MPC) design concept and demonstrated energy efficiency improvements by enabling engine pre-cooling based on GPS/Navigation data to recognize future vehicle speed limit and road grade in anticipation of high engine load demand. When compared to conventional control, the predictive control demonstrated considerable energy and fuel savings due to delayed timing of both knock mitigation and activation of radiator cooling fan during high engine load demand. However, this predictive control strategy is much more complicated due to its highly coupled nonlinear behavior.

Hyundai-Kia Motor Company recently developed a multi-way, electrical coolant valve for engine thermal management module (TMM). The main purposes of the TMM are to boost fuel economy by accelerating engine warm-up and also to enhance engine thermal efficiency by actively controlling the operating temperature. In addition to those, the system can improve vehicle heating and cooling performance as well. The electrical coolant valve is a key component in the TMM as it modulates the amount of coolant flow to individual components in cooling system such as engine oil heat exchanger, heater core, and radiator. The coolant flow modulation is done by controlling the electric valve’s position with using an electric motor attached to the valve. The objective of the valve control is to manage coolant temperature at a desired level that varies depending on vehicle’s operating condition. This paper discusses the control algorithm developed for controlling electrical coolant valve.