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Fault diagnosis for automotive systems is driven by government regulations, vehicle repairability, and customer satisfaction. Several methods have been developed to detect and isolate faults in automotive systems, subsystems and components with special emphasis on those faults that affect the exhaust gas emission levels. Limit checks, model-based, and knowledge-based methods are applied for diagnosing malfunctions in emission control systems. Incipient and partial faults may be hard to detect when using a detection scheme that implements any of the previously mentioned methods individually; the integration of model-based and knowledge-based diagnostic methods may provide a more robust approach. In the present paper, use is made of fuzzy residual evaluation and of a fuzzy expert system to improve the performance of a fault detection method based on a mathematical model of the engine.

As vehicle development timelines continue to shorten, it is necessary for the full vehicle NVH engineer to be able to predict performance without actual prototypes. There has been significant advancement in the accuracy of finite element modeling techniques of trimmed bodies; however accuracy is still low in the road noise mid frequency range from 150-400Hz. Also, calculation times for these frequencies are long, with very large results files in some cases. To alleviate these limitations, a Hybrid approach has been used, where a finite element suspension and drive train model is coupled with a test based Frequency Response Function (FRF) model of the trimmed body. The predicted road noise level was compared to actual vehicle tests and exhibited excellent correlation.

This research was to model a 6×4 tractor-trailer rig using TruckSim and simulate severe braking maneuvers with hardware in the loop and software in the loop simulations. For the hardware in the loop simulation (HIL), the tractor model was integrated with a 4s4m anti-lock braking system (ABS) and straight line braking tests were conducted. In developing the model, over 100 vehicle parameters were acquired from a real production tractor and entered into TruckSim. For the HIL simulation, the hardware consisted of a 4s4m ABS braking system with six brake chambers, four modulators, a treadle and an electronic control unit (ECU). A dSPACE simulator was used as the “interface” between the TruckSim computer model and the hardware.

This study investigated the jackknife stability of Class VIII double tractor-trailer combination vehicles that had mixed braking configurations between the tractor and trailers and dolly (e.g. ECBS disc brakes on the tractor and pneumatic drum brakes on the trailers and dolly). Brake-in-turn maneuvers were performed with varying vehicle loads and surface conditions. Conditions with ABS ON for the entire vehicle (and select-high control algorithm on the trailers and dolly) found that instabilities (i.e. lane excursions and/or jackknifes) were exhibited under conditions when the surface friction coefficient was 0.3. It was demonstrated that these instabilities could be avoided while utilizing a select-low control algorithm on the trailers and dolly. Simulation results with the ABS OFF for the tractor showed that a tractor equipped with disc brakes had greater jackknife stability.

During Phase VI of the National Highway Traffic Safety Administration's (NHTSA) Light Vehicle Rollover Research Program, three of the twenty-six light vehicles tested exhibited significant response asymmetries with respect to left versus right steer maneuvers. This paper investigates possible vehicle asymmetric characteristics and unintended inputs that may cause vehicle asymmetric response. An analysis of the field test data, results from suspension and steering parameter measurements, and a summary of a computer simulation study are also given.

The acoustic characteristics of a hybrid silencer consisting of two dissipative chambers and a Helmholtz resonator are investigated first computationally and experimentally. Complex wave number and characteristic impedance are used for the dissipative chambers to account for the wave propagation through absorbing material. Three-dimensional boundary element method (BEM) is employed to predict the transmission loss in the absence of mean flow and the predictions are compared with the experimental results obtained from an impedance tube setup. Noting that the long connecting tube between acoustic elements may reduce the transmission loss near the resonance frequency, two alternative hybrid silencers with short connecting tubes are also investigated by BEM. The present study shows the effectiveness of hybrid silencers over a wide frequency range and demonstrates the importance of understanding each acoustic element, as well as their interaction in designing silencers.

This paper presents the development of a CarSim model of an All-Terrain Vehicle (ATV) that can be used to predict the handling and stability characteristic of the vehicle. The inertia and suspension characteristics of a subject ATV are measured and a model of the ATV is built in CarSim based on the measurements. A simplified suspension model is developed to convert the suspension compliance measurements into parameters suitable to a CarSim model. Procedures used to apply vehicle mass, inertia and suspension kinematics data in CarSim are also shown. The model is evaluated using predictions of vehicle response during a constant radius circle test. The simulation results of the maneuver are compared with the field test results shown in a recent CPSC report on ATV’s. Similar cornering characteristics are found in both results. Modifications are made to the model to study how changes to the ATV affect performance.

The single-parameter, in-process monitor and automatic control systems for the resistance spot welding process have been studied by many investigators. Some of these have already been commercialized and used by sheet metal fabricators. These control systems operate primarily on one of the three process parameters: maximum voltage or voltage drop, dynamic resistance, or thermal expansion between electrodes during nugget formation. Control systems based on voltage or dynamic resistance have been successfully implemented for industrial applications. A great amount of experience on these two control methods has been accumulated through trial-and-error approaches. The expansion-based control system is not commonly utilized due to lack of experience and understanding of the process. Since the expansion displacement between electrodes during welding responds directly to the weld nugget formation, this control parameter provides a better means to produce more precise spot welds.

The component response synthesis approach utilizing frequency response function (FRF) has been used to analyze the dynamic interaction of two or more vehicle components coupled at discrete interface points. This method is somewhat suitable for computing higher frequency response because experimental component FRFs can be incorporated into the formulation directly. However its calculations are quite sensitive to measurement errors in the FRFs due to the several matrix inversion steps involved. In the past, researchers have essentially used a combined direct inverse and truncated singular valued decomposition (TSVD) technique to ensure a stable calculation, which is typically applied semi-empirically due to the lack of understanding of the influence of measurement error.

Model-based design is a collection of practices in which a system model is at the center of the development process, from requirements definition and system design to implementation and testing. This approach provides a number of benefits such as reducing development time and cost, improving product quality, and generating a more reliable final product through the use of computer models for system verification and testing. Model-based design is particularly useful in automotive control applications where ease of calibration and reliability are critical parameters. A novel application of the model-based design approach is demonstrated by The Ohio State University (OSU) student team as part of the Challenge X advanced vehicle development competition. In 2008, the team participated in the final year of the competition with a highly refined hybrid-electric vehicle (HEV) that uses a through-the-road parallel architecture.

Recent studies in sheet metal forming, conducted at universities world wide, emphasize the development of computer aided techniques for process simulation. To be practical and acceptable in a production environment, these codes must be easy to use and allow relatively quick solutions. Often, it is not necessary to make exact predictions but rather to establish the influence of process variables upon part quality, tool stresses, material flow, and material thickness variation. In cooperation with its industrial partners, the ERC for Net Shape Manufacturing of the Ohio State University has applied a number of computer codes for analysis and design of sheet metal forming operations. This paper gives a few selected examples taken from automotive applications and illustrates practical uses of computer simulations to improve productivity and reduce tool development and manufacturing costs.

Because of the need to safely vent exhaust gases, most engine dynamometer facilities are not well suited to measuring engine exhaust orifice noise. Depending on the location of the dyno facility within the building, the exhaust system may need to be extended in order to properly vent the exhaust fumes. This additional ducting changes the acoustic modes of the exhaust system which will change the measured orifice noise. Duct additions downstream of the original orifice location also alter the termination impedance such that in-duct pressure measurements with and without the extended exhaust system can vary significantly. In order to minimize the effect of the building's exhaust system on the desired engine exhaust system measurements, the present approach terminates the engine exhaust into a large enclosed volume or surge tank before venting the gases into the building's ventilation system.

Autonomous vehicles are expected to change our lives with significant applications like on-demand, shared autonomous taxi operations. Considering that most vehicles in a fleet are parked and hence idle resources when they are not used, shared on-demand services can utilize them much more efficiently. While ride hailing of autonomous vehicles is still very costly due to the initial investment, a shared autonomous vehicle fleet can lower its long-term cost such that it becomes economically feasible. This requires the Shared Autonomous Vehicles (SAV) in the fleet to be in operation as much as possible. Motivated by these applications, this paper presents a simulation environment to model and simulate shared autonomous vehicles in a geo-fenced urban setting.

Electrochemical models of lithium ion batteries are today a standard tool in the automotive industry for activities related to the computer-aided engineering design, analysis, and optimization of energy storage systems for electrified vehicles. One of the challenges in the development or use of such models is the need of detailed information on the cell and electrode geometry or properties of the electrode and electrolyte materials, which are typically unavailable or difficult to retrieve by end-users. This forces engineers to resort to “hand-tuning” of many physical and geometrical parameters, using standard cell-level characterization tests. This paper proposes a method to provide information and data on individual electrode performance that can be used to simplify the calibration process for electrochemical models.

Catalytic converters are typically constrained and cushioned by an intumescent mat material that is critical to the durability of the ceramic and metallic substrates. In an effort to reduce costs and improve designs, this work attempts to develop and verify a material model for the mat that can be utilized in predictive analysis. Test data are used in conjunction with the finite element program ABAQUS™ to create both a hyperfoam and a user-defined material model. These models will be verified and compared by modelling with ABAQUS the specimens and test conditions used to generate the data.

During a motor-vehicle collision, an occupant may interact with a variety of interior structures. The material properties and construction of these structures can directly affect the occupant's kinetic response. Simulation tools such as MADYMO (Mathematical Dynamical Models) can be used to estimate the forces imparted to an occupant for injury mechanism and causation evaluation relative to a particular event. Depending on the impact event and the specific injury mechanism being evaluated, the selection of proper material characteristics can be quite important. A comprehensive literature review of MADYMO studies illustrates the prevalent use of generic material characteristics and the need for improved property estimation and implementation methods.

This paper presents the details of the model for the physical steering system used on the National Advanced Driving Simulator. The system is basically a hardware-in-the-loop (steering feedback motor and controls) steering system coupled with the core vehicle dynamics of the simulator. The system's torque control uses cascaded position and velocity feedback and is controlled to provide steering feedback with variable stiffness and dynamic properties. The reference model, which calculates the desired value of the torque, is made of power steering torque, damping function torque, torque from tires, locking limit torque, and driver input torque. The model also provides a unique steering dead-band function that is important for on-center feel. A Simulink model of the hardware/software is presented and analysis of the simulator steering system is provided.

Plug-In Hybrid Vehicles (PHEVs) represent the middle point between Hybrid Electric Vehicles (HEVs) and Electric Vehicles (EVs), thus combining benefits of the two architectures. PHEVs can achieve very high fuel economy while preserving full functionality of hybrids - long driving range, easy refueling, lower emissions etc. These advantages come at an expense of added complexity in terms of available fuel. The PHEV battery is recharged both though regenerative braking and directly by the grid thus adding extra dimension to the control problem. Along with the minimization of the fuel consumption, the amount of electricity taken from the power grid should be also considered, therefore the electricity generation mix and price become additional parameters that should be included in the cost function.

A test procedure that rates brake performance must control variability so that measured differences between vehicles are real. Tests were conducted using standard brake test procedures with three drivers in three cars on wet and dry asphalt with the ABS working and disabled. The differences between vehicles were greater than differences due to ABS condition, surface condition, and drivers. The procedure measured differences between all the vehicles with statistical certainty but used many replications and drivers. If only large differences in performance need to be distinguished, fewer replications and drivers will be needed.

The influence of die corner geometry on the attainable draw depth of rectangular parts was investigated using 3-D FEM and optimum rectangular blanks. Axisymmetric cup analysis was not adequate because a corner assist effect promotes corner draw. Guidelines for selecting corner radius were developed and the sensitivities of the maximum part depth to other process variables, such as drawbead restraint force; die clearance gap; friction coefficient; strain rate sensitivity; material anisotropy; and strain hardening exponent, were simulated. The results are much more conservative than handbook rules, which to not to take into account the details of blank size, drawbead restraint, die geometry, material properties, and friction.