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Abstract In this work, a three-phase integrated onboard battery charger is investigated and implemented for electric vehicle (EV) applications. A three-switch add-on interface is introduced to connect with the inverter and the motor windings, such that a two-channel interleaved boost converter is formed for the battery charging. The detailed system analysis, design methodology, and control strategy are discussed. Moreover, a simulation study is carried out to validate the effectiveness of the proposed integrated charger. As verification, a 5 kW liquid-cooled prototype is built and tested. The proposed integrated charging system achieves a power factor of 0.99, and total harmonic distortion (THD) of 4.82% at 5 kW with an efficiency of 93.2%.

Abstract Modern Automated Driving (AD) systems rely on safety measures to handle faults and to bring the vehicle to a safe state. To eradicate lethal road accidents, car manufacturers are constantly introducing new perception as well as control systems. Contemporary automotive design and safety engineering best practices are suitable for analyzing system components in isolation, whereas today’s highly complex and interdependent AD systems require a novel approach to ensure resilience to multiple-point failures. We present a holistic and cost-effective safety concept unifying advanced safety measures for handling multiple-point faults. Our proposed approach enables designers to focus on more pressing issues such as handling fault-free hazardous behavior associated with system performance limitations. To verify our approach, we developed an executable model of the safety concept in the formal specification language mCRL2.

Abstract An efficient vehicle thermal management is essential to fulfil the requirements of fuel consumption and passenger comfort. Therefore, the design and dimensioning of the cooling system is under high scrutiny in new vehicle architectures. With increasing electrification, no longer just the load peaks define the design frame but also the dynamics of thermal loading and recovery. Consequently, electrified vehicle architectures such as plug-in hybrid fuel cell vehicles demand for alternative approaches regarding the design of cooling systems and the definition of the decisive criteria. This article presents a new methodology for designing the cooling system related to its demands in customer operation. The recorded fleet data is first filtered for high load driving, using the so-called thermal load integral (LI) as a filter criterion.

Abstract Automotive interior coatings for flexible and rigid substrates represent an important segment within automotive coating space. These coatings are used to protect plastic substrates from mechanical and chemical damage, in addition to providing colour and design aesthetics. These coatings are expected to resist aggressive chemicals, fluids, and stains while maintaining their long-term physical appearance and mechanical integrity. Designing such coatings, therefore, poses significant challenges to the formulators in effectively balancing these properties. Among many factors affecting coating properties, the cross-link density (XLD) and solubility parameter (δ) of coatings are the most predominant factors.

Abstract Maximum lifetime and minimum manufacturing cost for new products are the primary goals of companies for competitiveness. These two objectives are contradictory and the geometric dimensions of the products directly control them. In addition, the earlier design errors of new products are predicted, the easier and more inexpensive their rectification becomes. To achieve these objectives, we propose in this article a novel model that makes it possible to solve the problem of optimizing the lifespan and the manufacturing cost of new products during the phase of their design. The prediction of the life of the products is carried out by an energy damage method implemented on the finite element (FE) calculation by using the ABAQUS software. The manufacturing cost prediction is carried out by applying the ABC cost estimation analytical method. In addition, the optimization problem is solved by the method of genetic algorithms.

Abstract In this study, a parametric thoracic spine (T-spine) model was developed to account for morphological variations among the adult population. A total of 84 CT scans were collected, and the subjects were evenly distributed among age groups and both sexes. CT segmentation, landmarking, and mesh morphing were performed to map a template mesh onto the T-spine vertebrae for each sampled subject. Generalized procrustes analysis (GPA), principal component analysis (PCA), and linear regression analysis were then performed to investigate the morphological variations and develop prediction models. A total of 13 statistical models, including 12 T-spine vertebrae and a spinal curvature model, were combined to predict a full T-spine 3D geometry with any combination of age, sex, stature, and body mass index (BMI). A leave-one-out root mean square error (RMSE) analysis was conducted for each node of the mesh predicted by the statistical model for every T-spine vertebra.

Abstract A major contributor to fatal vehicle crashes is hydroplaning, which has traditionally been reported at a specific vehicle speed for a given operating condition. However, hydroplaning is a complex phenomenon requiring a holistic, probabilistic, and multidisciplinary approach. The objective of this article is to develop a probabilistic approach to predict Hydroplaning Potential and Risk that integrates fundamental understanding of the interdependent factors: hydrology, fluid-solid interactions, tire mechanics, and vehicle dynamics. A novel theoretical treatment of Hydroplaning Potential and Risk is developed, and simulation results for the prediction of water film thickness and Hydroplaning Potential are presented. The results show the advantages of the current approach which could enable the improvement of road, vehicle, and tire design, resulting in greater safety of the traveling public.

Abstract Safety is always a crucial aspect of developing autonomous systems, and the motivation behind this project comes from the need to address the traffic crashes occurring globally on a daily basis. The present work studies the coexistence of the novel rule-based behavioral planning framework with the five key advanced driver assistance system (ADAS) features as proposed in this article to fulfill the safety requirements and enhance the comfort of the driver/passengers to achieve a receding-horizon autopilot. This architecture utilizes data from the sensor fusion and the prediction module for the prediction time horizon of 2 s iteratively, which is continuously moving forward (hence, the receding horizon), and helps the behavior planner understand the intent of other vehicles on the road in advance.

Abstract Tailored blanks offer great lightweighting opportunities for automotive industry and were applied on the front rails of a sedan in this research. To achieve the most efficient material usage, all the front rail parts were tailored into multiple sheets with the gauge of each sheet defined as a design variable for optimization. The equivalent static loads (ESL) method was adopted for linear optimization and the Insurance Institute for Highway Safety (IIHS) moderate overlap frontal crash as the nonlinear analysis load case. The torsion and bending stiffness of the sedan body in white (BIW) were set as design constraints. The occupant compartment intrusion in IIHS moderate overlap front crash was set as design objective to be minimized. The optimal thickness configuration for the tailored front rail designs was obtained through ESL optimization for multiple mass saving targets.

Abstract The advancement in vision sensors and embedded technology created the opportunity in autonomous vehicles to look ahead in the future to avoid potential obstacles and steep regions to reach the target location as soon as possible and yet maintain vehicle safety from rollover. The present work focuses on developing a nonlinear model predictive controller (NMPC) for a high-speed off-road autonomous vehicle, which avoids undesirable conditions including stationary obstacles, moving obstacles, and steep regions while maintaining the vehicle safety from rollover. The NMPC controller is developed using CasADi tools in the MATLAB environment. The CasADi tool provides a platform to formulate the NMPC problem using symbolic expressions, which is an easy and efficient way of solving the optimization problem. In the present work, the vehicle lateral dynamics are modeled using the Pacejka nonlinear tire model.

Abstract An improved control method of automatic emergency braking (AEB) for rear-end collision avoidance is proposed, which combines the advantages of a time-to-collision (TTC) control algorithm and professional driver emergency braking behavior. The TTC control algorithm mostly adopts phased braking, and although it can avoid collision effectively, the braking process is radical and brake comfort is poor. The emergency braking system with professional driver fitting (PDF) has good comfort and can also avoid collision successfully. However, its brake trigger time is too early, which leads to the stopping distance being too large under high-speed conditions and affects the road utilization. By combining the advantages of the two control methods, an improved control algorithm for AEB is proposed. When the TTC value is not greater than a predetermined limit, the PDF control switch will be closed to avoid collision.

Abstract Advanced Driver Assistance Systems (ADAS) are playing a significant role in enhancing driver safety and occupant comfort in modern vehicles. The primary research focus in this domain includes the precise perception of the current state and the prediction of the future states of dynamic agents. To perform these tasks an intelligent agent capable of operating in the stochastic environment is implemented in the form of various ADAS features. A trajectory prediction problem can be defined using either a model-based or data-driven approach. The current article addresses the problem of trajectory prediction in the stochastic environment using a model-based approach with a quintic polynomial as a function approximator to ensure smooth acceleration trajectory for the left and right lane-change maneuvers. The task of trajectory prediction also considers the information about the vehicle dynamics, the concept of Receding Time Horizon (RTH), and the variable curvature model of the road.

Abstract We model neck loading as a function of impact severity in aligned rear impacts. Neck loading is understood and expected to vary as a function of factors including crash severity, occupant compartment design, and occupant metrics. Within occupant compartment design, seat and restraint characteristics are expected to influence the biomechanical response and occupant kinematics. We investigated the relationship between biomechanical neck-loading metrics and impact severity expressed as speed change (delta-V) by examining 47 low to moderate speed rear-impact crash and sled tests utilizing the Hybrid III (HIII) 50th male Anthropomorphic Test Device (ATD). Our hypothesis was that the relationship between severity expressed as delta-V and the neck metrics examined could be modeled as linear consistent with an understanding that neck loading in a rear impact results from the acceleration of the vehicle.

Abstract Analysis of Kinetic Metrics in Submarining vs Non-Submarining Conditions for a 6YO Pediatric Human Body Model in Frontal Impacts

Abstract The Japanese population is aging rapidly, raising the number of traffic accidents involving elderly drivers. In Japan, single-vehicle accidents are a serious problem because they often result in fatalities. We analyzed these accidents by vehicle type, age group, and driving area. To examine the risk of accidents of the elderly drivers, their driving frequency needs to be considered, which is less. Moreover, it is difficult to know the actual distance driven by them. Therefore, in this paper, based on the assumption that the number of rear-end collisions is a proxy for the traffic volume, we used the number of such collisions as a control for the driving frequency. It was found that in single-vehicle accidents, elderly drivers were at higher risk than other age groups, especially when driving light motor vehicles (K-type vehicles) in non-urban areas.

Abstract Platform sharing is widely used for reducing time and cost of vehicle development. It has been believed that vehicles that employ the same platform show similar performances of noise and vibration. Recently, however, it is observed that two vehicles that share the same platform present a noticeable difference in road noise. The structural difference between the two vehicles is located only at the upperbody of a Body In White (BIW). In order to investigate the effects of the upperbody on the road noise, several analyses such as (1) input point stiffness, (2) noise transfer function (NTF), and (3) road noise are performed using finite element (FE) models of the vehicles. As a result, it is found that the upperbody affects the NTF of the trimmed body and the road noise, which explains the dissimilarity of the road noise for the two vehicles. A novel method based on equivalent radiated power (ERP) is proposed to assess the upperbody.

Abstract The critical intercepts used for the Neck Injury Criterion (Nij) have not been assessed in computational human body models. Under matched-pair conditions, the response of the head-neck complex was compared between the Livermore Software Technology Corporation (LSTC) Hybrid III (HIII) and Global Human Body Models Consortium’s (GHBMC) 50th percentile, detailed male occupant (M50-O) models. The head and neck of the M50-O and HIII were subjected to the dummy performance calibration test procedure for flexion and extension. As a nominal condition, the HIII model met all calibration specifications. Operationalization of the M50-O’s initial position was defined by equivalent head CG location to the HIII and subsequently compared at nominal, ±10%, ±20%, and ±30% of pendulum displacement. Kinematics of the head CG, forces and moments of the upper neck, and changes in neck angle were post processed and compared between the models.

Abstract In-phase rear-wheel steering, where rear wheels are steered in the same direction of front wheels, has been widely investigated in the literature for vehicle stability improvements along with stability control systems. Much faster response can be achieved by steering the rear wheels automatically during an obstacle avoidance maneuver without applying the brakes where safe stopping distance is not available. Sudden lane change movements still remain challenging for heavy articulated vehicles, such as tractor and semitrailer combinations, particularly on roads with low coefficient of adhesion. Different lateral accelerations acting on tractor and semi-trailer may cause loss of stability resulting in jackknifing, trailer-swing, rollover, or slip-off. Several attempts have been made in the literature to use active steering of semi-trailer’s rear wheels to prevent jackknifing and rollover.

Abstract Unstable articulated vehicles pose a serious threat to the occupants driving them as well as the occupants of the vehicles around them. Articulated vehicles typically experience three types of instability: snaking, jack-knifing, and rollover. An articulated vehicle subjected to any of these instabilities can result in major accidents. In this study a Nonlinear Model Predictive Control (NMPC) that applies brake-based torque vectoring on the trailer is developed to improve the articulated vehicle stability. The NMPC formulation includes tire saturation and applies constraints to prevent rollover. The controller output is a left and right brake force allowing the longitudinal velocity change to be incorporated into the model. Simulations were conducted to instigate snaking and jack-knifing and show the NMPC controller result compared to a simple proportional controller.

Abstract Compared to other age groups, older adults are at more significant risk of hip fracture when they fall. In addition to the higher risk of falls for the elderly, fear of falls can reduce this population’s outdoor activity. Various preventive solutions have been proposed to reduce the risk of hip fractures ranging from wearable hip protectors to indoor flooring systems. A previously developed rubberized asphalt mixture demonstrated the potential to reduce the risk of head injury. In the current study, the capability of the rubberized asphalt sample was evaluated for the risk of hip fracture for an average elderly male and an average elderly female. A previously developed human body model was positioned in a fall configuration that would give the highest impact forces toward regular asphalt.