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In automotive body manufacturing the dies for blanking/trimming/piercing are under most severe loading condition involving high contact stress at high impact loading and large number of cycles. With continuous increase in sheet metal strength, the trim die service life becomes a great concern for industries. In this study, competing trim die manufacturing routes were compared, including die raw materials produced by hot-working (wrought) vs. casting, edge-welding (as repaired condition) vs. bulk base metals (representing new tools), and the heat treatment method by induction hardening vs. furnace through-heating. CaldieTM, a Uddeholm trademarked grade was used as trim die material. The mechanical tests are performed using a WSU developed trimming simulator, with fatigue loading applied at cubic die specimen’s cutting edges through a tungsten carbide rod to accelerate the trim edge damage. The tests are periodically interrupted at specified cycles for measurement of die edge damage.

Contemporary manufacturing systems are still evolving. The system elements, layouts, and integration methods are changing continuously, and ‘collaborative robots’ (CoBots) are now being considered as practical industrial solutions. CoBots, unlike traditional CoBots, are safe and flexible enough to work with humans. Although CoBots have the potential to become standard in production systems, there is no strong foundation for systems design and development. The focus of this research is to provide a foundation and four tier framework to facilitate the design, development and integration of CoBots. The framework consists of the system level, work-cell level, machine level, and worker level. Sixty-five percent of traditional robots are installed in the automobile industry and it takes 200 hours to program (and reprogram) them.

Research of Adaptive Cruise Control (ACC) is an important issue of intelligent vehicle (IV). As we all known, a real and experienced driver can control vehicle's speed very well under every traffic environment of ACC working. So a direct and feasible way for establishing ACC controller is to build a human-like longitudinal control algorithm with the simulation of driver behavior of speed control. In this paper, a novel fuzzy self-tuning control algorithm of ACC is established and this controller's parameters can be tuned on-line based on the evaluation indexes that can describe how the driver consider the quality of dynamical characteristic of vehicle longitudinal dynamics. With the advantage of the controller's parameter on-line self-tuning, the computational workload from matching design of ACC controller is also efficiently reduced.

A HIL simulator for developing vehicle adaptive cruise control systems is presented in this paper. The xPC target is used to establish real-time simulation environment. The simulator is composed of a virtual vehicle model, real components of an ACC system like ECU, electronic throttle and braking modulator, a user interface to facilitate simulation, and brake and accelerator pedals to make interactive driver inputs easier. The vehicle model is validated against data from field test. Tests of an ACC controller in the real-time are conducted on the simulator.

Microprocessors and microcontrollers are now widely used in automobiles. Microprocessor systems contain sources of interrupt and interrupt service routines, which are software components executed in response to the assertion of an interrupt in hardware. A major problem in designing the software of microprocessor systems is the analytical treatment of interrupt latency. Because multiple interrupt service routines are executed on the same CPU, they compete for the CPU and interfere with each other's latency requirements. Here, interrupt latency is defined as the delay between the assertion of the interrupt in hardware and the start of execution of the associated interrupt service routine. It is estimated that 80% of intermittent bugs in small microprocessor software loads are due to improper treatment of interrupts. Until this work, there is no analytic method for analyzing a particular system to determine if it may violate interrupt latency requirements.

Taking full advantage of available traffic environment information, making control decisions, and then planning trajectory systematically under structured roads conditions is a critical part of intelligent vehicle. In this article, a lane-changing decision-making method for intelligent vehicle is proposed based on acceleration field. Firstly, an acceleration field related to relative velocity and relative distance was built based on the analysis of braking process, and acceleration was taken as an indicator of safety evaluation. Then, a lane-changing decision method was set up with acceleration field while considering driver’s habits, traffic efficiency and safety. Furthermore, velocity regulation was also introduced in the lane-changing decision method to make it more flexible.

A new formulation is developed for the ignition delay (ID) in diesel engines to account for the effect of piston motion on the global autoignition reaction rates. A differentiation is made between the IDe measured in engines and IDv, measured in constant volume vessels. In addition, a method is presented to determine the coefficients of the IDe correlation from actual engine experimental data. The new formulation for IDe is applied to predict the misfiring cycles during the cold starting of diesel engines at different low ambient temperatures. The predictions are compared with experimental results obtained on a multi-cylinder heavy-duty diesel engine.

The conventional radar modeling methods for automotive applications were either function-based or physics-based. The former approach was mainly abstracted as a solution of the intersection between geometric representations of radar beam and targets, while the latter one took radar detection mechanism into consideration by means of “ray tracing”. Although they each has its unique advantages, they were often unrealistic or time-consuming to meet actual simulation requirements. This paper presents a combined geometric and physical modeling method on millimeter-wave radar systems for Frequency Modulated Continuous Wave (FMCW) modulation format under a 3D simulation environment. With the geometric approach, a link between the virtual radar and 3D environment is established. With the physical approach, on the other hand, the ideal target detection and measurement are contaminated with noise and clutters aimed to produce the signals as close to the real ones as possible.

The goal of optimization in vehicle design is often blurred by the myriads of requirements belonging to attributes that may not be quite related. If solutions are sought by optimizing attribute performance-related objectives separately starting with a common baseline design configuration as in a traditional design environment, it becomes an arduous task to integrate the potentially conflicting solutions into one satisfactory design. It may be thus more desirable to carry out a combined multi-disciplinary design optimization (MDO) with vehicle weight as an objective function and cross-functional attribute performance targets as constraints. For the particular case of vehicle body structure design, the initial design is likely to be arrived at taking into account styling, packaging and market-driven requirements.

The current extensive revisitation of the application of gasoline direct-injection to automotive, four-stroke, spark-ignition engines has been prompted by the availability of technological capabilities that did not exist in the late 1970s, and that can now be utilized in the engine development process. The availability of new engine hardware that permits an enhanced level of computer control and dynamic optimization has alleviated many of the system limitations that were encountered in the time period from 1976 to 1984, when the capabilities of direct-injection, stratified-charge, spark-ignition engines were thoroughly researched. This paper incorporates a critical review of the current worldwide research and development activities in the gasoline direct-injection field, and provides insight into new areas of technology that are being applied to the development of both production and prototype engines.

To satisfy the power and energy requirement of the systems, such as electrical vehicles, the battery packs are constructed with hundreds of single cells connected in series and parallel connection. The most significant difference between a single cell and a battery pack is cell-to-cell variation. Not only does cell-to-cell variation have a big effect on the available energy and power of the battery packs, but also it causes early degradation of battery and potential safety issues. The cell variation effects on battery packs are widely studied because it is of great significance for battery sorting and management scheme. In this paper, battery pack inconsistency is clearly defined and the resulting battery capacity loss and aging acceleration problems are analyzed in detail. A comprehensive LiFePO4 battery pack model was established, which has taken into account cell-to-cell variation, thermal model, capacity degradation, resistance increasing and different battery topologies.

Autonomous driving technology is more and more important nowadays, it has been changing the living style of our society. As for autonomous driving planning and control, vehicle dynamics has strong nonlinearity and uncertainty, so vehicle dynamics and control is one of the most challenging parts. At present, many kinds of specific vehicle dynamics models have been proposed, this review attempts to give an overview of the state of the art of vehicle dynamics models for autonomous driving. Firstly, this review starts from the simple geometric model, vehicle kinematics model, dynamic bicycle model, double-track vehicle model and multi degree of freedom (DOF) dynamics model, and discusses the specific use of these classical models for autonomous driving state estimation, trajectory prediction, motion planning, motion control and so on.

This paper proposed a path coordination strategy for autonomous parking based on independently designed parking lot topological map. The strategy merges two types of paths at the three stages of path planning, to determinate mode switching timing between low-speed automated driving and automated parking. Firstly, based on the principle that parking spaces should be parallel or vertical to a corresponding path, a topological parking lot map is designed by using the point cloud data collected by LiDAR sensor. This map is consist of road node coordinates, adjacent matrix and parking space information. Secondly, the direction and lateral distance of the parking space to the last node of global path are used to decide parking type and direction at parking planning stage. Finally, the parking space node is used to connect global path and parking path at path coordination stage.

High-speed video of combustion processes and cylinder pressure traces were obtained from a single-cylinder optical-accessible engine with a production four-valve cylinder head to study the mixture formation and flame propagation characteristics at near-stoichiometric start condition. Laser-sheet Mie-scattering images were collected for liquid droplet distributions inside the cylinder to correlate the mixture formation process with the combustion results. A dual-stream (DS) injector and a quad-stream (QS) injector were used to study the spray dispersion effect on engine starting, under different injection timings, throttle valve positions, engine speeds, and intake temperatures. It was found that most of the fuel under open-valve injection (OVI) conditions entered the cylinder as droplet mist. A significant part of the fuel droplets hit the far end of the cylinder wall at the exhaust-valve side.

This paper has designed a real time control algorithm to use ISG motor actively compensate the torque ripple produced by the engine, to reduce torsional vibration. This paper consists of 3 parts. In the first section, this paper has introduced the research object and its modification for experiments. Then the development of control strategy is presented. The engine dynamic model is built, and real-time control with a feedforward unit and a feedback unit is derived. Encoder and cylinder pressure is used for engine torque estimator. Then the ISG motor output the counter-waveform to make the overall output smooth. In order to verify the effectiveness of the control strategy, the final section has established a test bench, where two experiments are carried out. One of the experimental conditions is to set the engine at a constant operating point, while the other is to crank the engine from 0 rpm to idle speed with ISG motor.

The adoption of lithium-ion batteries in vehicle electrification is fast growing due to high power and energy demand on hybrid and electric vehicles. However, the battery overall performance changes with time through the vehicle life. This paper investigates the electric vehicle battery cell aging under different usages. Battery cell experimental data including open circuit voltage and internal resistance is utilized to build a typical electric vehicle model in the AVL-Cruise platform. Four driving cycles (WLTP, UDDS, HWFET, and US06) with different ambient temperatures are simulated to acquire the battery cell terminal currents. These battery cell terminal current data are inputs to the MATLAB/Simulink battery aging model. Simulation results show that battery degrades quickly in high ambient temperatures. After 15,000 hours usage in 50 degrees Celsius ambient temperature, the usable cell capacity is reduced up to 25%.

Vehicle lane keeping system is becoming a new research focus of drive assistant system except adaptive cruise control system. As we all known, vehicle lateral dynamics show strong nonlinear and time-varying with the variety of longitudinal velocity, especially tire’s mechanics characteristic will change from linear characteristic under low speed to strong nonlinear under high speed. For this reason, the traditional PID controller and even self-tuning PID controller, which need to know a precise vehicle lateral dynamics model to adjust the control parameter, are too difficult to get enough accuracy and the ideal control quality. Based on neural network’s ability of self-learning, adaptive and approximate to any nonlinear function, an adaptive PID control algorithm with BP neural network self-tuning online was proposed for vehicle lane keeping.

The vehicle pull problem is very important to driving safety. Major factors that may cause the pull problem related to tire include variations of geometric dimension (e.g. RPK) and stiffness (e.g. cornering stiffness, aligning stiffness), plysteer and conicity. In previous research, the influencing mechanism of these factors was well studied. But in fact, vehicle pull problem caused by tire is probabilistic. When we assemble four tires onto the car, there could be 384 different assembly arrangements. If there are significant differences among these four tires, there will also be significant differences in the influence of different tire assembly schemes on vehicle pull, which has not been systematically discussed in previous studies. If we want to evaluate the pull performance of all these arrangements by vehicle test, it will be a time consuming process which will take almost 24 working days, along with a high test expense.

Automated parking is an efficient way to solve parking difficulties and path planning is of great concern for parking maneuvers [1]. Meanwhile, the starting region of path planning greatly affects the parking process and efficiency. The present research of the starting region are mostly determined based on a single algorithm, which limits the flexibility and efficiency of planning feasible paths. This paper, taking parallel parking and vertical parking for example, proposes a method to calculate the starting region and select the most suitable path planning algorithm for parking, which can improve the parking efficiency and reduce the complexity. The collision situations of each path planning algorithm are analyzed under collision-free conditions based on parallel and vertical parking. The starting region for each algorithm can then be calculated under collision-free conditions.

To address the need of increasing fuel economy requirements, automotive Original Equipment Manufacturers (OEMs) are increasing the number of turbocharged engines in their powertrain line-ups. The turbine-driven technology uses a forced induction device, which increases engine performance by increasing the density of the air charge being drawn into the cylinder. Denser air allows more fuel to be introduced into the combustion chamber, thus increasing engine performance. During the inlet air compression process, the air is heated to temperatures that can result in pre-ignition resulting and reduced engine functionality. The introduction of the charge air cooler (CAC) is therefore, necessary to extract heat created during the compression process. The present research describes the physics and develops the optimized simulation method that defines the process and gives insight into the development of CACs.