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In this paper, we present a design and control methodology of an innovated structure of switching synchronous motor. This control strategy is based on the pulse width modulation technique imposing currents sum of a continuous value and a value having a shape varying in phase opposition with respect to the variation of the inductances. This control technology can greatly reduce vibration of the entire system due to the strong fluctuation of the torque developed by the engine, generally characterizing switching synchronous motors. A systemic design and modelling program is developed. This program is validated following the implementation and the simulation of the control model in the simulation environment Matlab-Simulink. Simulation results are with good scientific level and encourage subsequently the industrialization of the global system.

Inverters are solid state devices which change DC to 120VAC electricity. They are sufficiently rugged and reliable to make them practical for use on utility vehicles for operating thumpers, tools, lights and induction motor loads. The SCR type rather than the transistor type inverter is generally required for inductive and reactive loads. Static inverters operate from battery input. They provide power without running an engine, but are limited by battery capacity so work best in intermittent load applications. Dynamic inverters operate from alternator input and will handle continuous loads to 7200 watts with truck engine running.

Transfer path analysis is a powerful tool to support the vehicle NVH development. On the one hand it is a fast method to gain an overview of the complex interplay in the vehicle noise generation process. On the other hand it can be used to identify critical noise paths and vehicle components responsible for specific noise phenomena. FEV has developed several tools, which are adapted to the considered noise phenomena: Powertrain induced interior noise and vibration is analyzed by VINS (Vehicle Interior Noise Simulation), which allows the deduction of improvement measures fast enough for application in the accelerated vehicle development process. Further on vehicle/powertrain combinations not realized in hardware can be evaluated by virtual installation of the powertrain in the vehicle, which is especially interesting in the context of engine downsizing from four to three or six to four cylinders.

This paper describes the concept, design, and options of a new power shift transmission family for industrial equipment in the 50-100 hp range. The converter, clutch, and gearing arrangements provide the basis for various transmission configurations with both a drop and straight through output. The designs allow multiple usage of components within a transmission and between different sizes of transmissions. The various gearing, bearing, and clutch designs are based on proved experience factors, and as such will provide a new reliable family of transmissions.

In a running engine, various impacts are excitation sources for structural vibrations and engine noises. Engine noises are classified, depending on their excitation sources, into the combustion noise, the combustion induced mechanical noise and the mechanical noise. It is difficult to measure such noises separately because some impacts occur closely in time and space. In this paper, a transient noise generation model of an engine was proposed considering vibration and its damping of engine structure. The present model was verified through the single explosion excitation experiment for a stationary engine. Using the noise generation model, the combustion noise was separated from the total noise radiating from a running four-stroke gasoline engine for motorcycles. It was found that the combustion noise had larger power at lower frequencies than higher frequencies. However, its contribution to the total engine noise was relatively small.

The phenomenal success of the small car is leading to many engineering changes in the automobile industry. It has brought increased emphasis on weight reduction on both small and full-size cars. Improving reliability and designing to eliminate grease fittings have also become important objectives.

This paper describes Programmed Ride Control (PRC), the automatic adjustable shock absorber system designed and patented by Ford Motor Company. The system utilizes low shock absorber damping under normal driving conditions to provide soft boulevard ride, automatically switching to firm damping when required for improved handling. The system's microprocessor control module “learns” where the straight ahead steering wheel position is, allowing the system to respond to absolute steering wheel angle. A closed loop control strategy is used to improve system reliability and to notify the driver in the event of a system malfunction. Fast acting rotary solenoids control the damping rate of the shock absorbers.

This paper presents a summary of body structural analysis applied to the 1989 Suzuki Sidekick/Geo Tracker at various stages of development and design. The structure analysis techniques were applied previously to rigidity, vibration, strength, crashworthiness and optimization. The studies confirm that the CAE technique for body structure analysis is more beneficial if it is utilized in the earlier structure development stages particularly for vibration and crashworthiness. Through the extensive use of the structural analysis technique in conjunction with the experiment, the design concept of the Sidekick/Tracker body has been optimized to a most extent.

An expansion tank is an integral part of an automotive engine cooling system. The primary function of the expansion tank is to allow the thermal expansion of the coolant. The expansion tank will be referred as hot bottle in this paper. In the System level modeling of the engine internal flow, it is imperative to accurately model and characterize the components in the system. It is often challenging to define the hot bottle accurately with limited parameters in the 1D modeling. Currently it is very difficult to optimize the system by testing. Since testing consumes a lot of time and changes in development stage. If the hot bottle component is not defined properly in the system network, then the system flow balancing cannot be predicted accurately. In this paper, the approach of creating a 1D modeling tool for hot bottle flow prediction is discussed and the simulation results are compared with the physical test data.

The demands for comfort and a cleaner environment have been increasing for the past years for motorcycle as well as car manufacturers. With the need to decrease the time-to-market, there is a clear drive to apply CAE-based methods in order to evaluate new designs and to propose design changes that solve any identified problems. More specifically, the demands on the comfort of the rider are not only related to ride & handling and vibration levels(1), but also to the noise levels generated by the motorcycle. This paper presents the virtual modeling of one-cylinder engine of a motorcycle that identifies the mechanism behind the generation of an annoying noise. Furthermore, different possible design changes were evaluated in order to solve the problem. A combined experimental and numerical approach was followed to achieve this. Experiments were used to identify important parameters that determine the engine behavior and thus are critical for the modeling of such an engine.

To effectively utilize larger trucks (85 ton and up), open-pit mines and quarries need a larger front-end loader with high reliability and performance. This paper describes the design approach and tests carried out to design 21 cubic yard 580 PAY® loader to meet these requirements. Long fatigue life of structures was obtained by use of full penetration welds. New concept for power control was designed to effectively distribute power between hydraulics and drive train. Spring applied - pressure released brakes were designed into the axle. Tests were carried out in our laboratory and proving grounds to determine performance and reliability.

Durability tests have been initiated on olefinic and production painted fascias. Both 2D and 3D tests have provided insights into Friction Induced Damage (FID) failure mechanics. Full scale, 3D tests of automotive fascia mimic the parking lot rubbing contact between cars with friction forces exceeding 5000. N. 2D tests provide the cost effective approach to materials research by isolating the failure mechanics in the upper 250 μm of the decorated TPO where the cosmetic damage is initiated. Initial findings show some olefinic paint, TPO combinations to be more damage resistant for realistic frictional contact scenarios.

2k clearcoat is the progressive step that is keeping coatings for elastomeric fascia in pace with the current automobile design, performance, and durability demands. Initially, rigid 2k coatings were applied over plastic for low temperature cure. Over metal, 2k rigid clearcoat produced a dramatic improvement in appearance and durability. Flexibility is the key attribute that a 2k clearcoat engineered for use over fascias must posses. Utilizing the same basecoat and primer, 2k flexible clearcoats are being successfully applied to flexible fascia, generating excellent appearance and outstanding durability.

Challenges surrounding OEM′s go far beyond to manufacture and delivery high quality vehicles. A perfect design and performance in the lowest cost possible is extremely essential to delivery to the customer the best vehicles. In order to guarantee all these targets, a robust process must be set to developed and implemented. It is known all process limitations, which faces the emergent markets and the lack of infrastructure considering the developed countries. All this limitations can deeply affect the robustness of the process. Some innovative solutions are becoming common from the engineering development combined with the manufacturing team to work out these limitations and provide excellent process stability. In this present paper it will be discussed the Bi component structural adhesive (2K PU epoxy) utilization to establish the process in the assembly line, mainly in order to improve parts dimensionally.

In order to reproduce heavy bass with a small diameter loudspeaker for automotive use similar to the intensity and low distortion of a home-use Hi-Fi system, a large volume velocity must be obtained. This is done by lowering the minimum resonant frequency of system and by linearly expanding the amplitude range of diaphragm. We have developed a 3-D woofer system using a centering suspension that consists of four tubes of square cross-section continuously laid in the circumferential direction and a cone suspension that has V-shaped pleats in both of the circumferential and diameter directions for the vibration system. The results are good acoustic characteristics in an automotive cabin that are low in distortion with high output in the low frequency range up to 100Hz.

In the design and development of modern cars with respect to comfort, silence and safety, state of the art experimental modal analysis is one of the essential development tools. Due to the large amount of degrees of freedom of such a large and complex system like a car with all its components, a complete simulation by FEM can not be realised easily and requires an enormous expenditure of work and calculations. In addition the simulations are based on assumed system parameters and thus the vibration behaviour of the resulting prototypes often is not completely identical to the simulated model. In contrast to conventional measurements with accelerometers, the 3-D Scanning Vibrometer enables fast and efficient non-contact measurements of the in-plane and out-of-plane vibration behaviour at all optical accessible surfaces. The method easily allows to increase the number of measured points to obtain a high measurement point density.

In order to use modeling as a predictive tool for real-world particulate filter designs (segmented filters, non-axisymmetric designs), it is necessary to develop reliable 3-dimensional models. This paper presents a 3 d modeling approach, which is validated against engine-bench measurements with both FBC and CDPF systems. Special emphasis is given to the prediction of the transient inlet flow distribution, which is realized without resorting to external CFD software. The experimental and modeling results illustrate the 3-d nature of the problem, induced by the heat capacity and conductivity effects of the cement layers. It is possible to predict the localization of regeneration in certain areas of the filter (partial regeneration), as a result of poor heat transfer to thermally isolated regions in the filter. The accuracy of the model was validated by extensive comparisons with temperature measurements in 30 positions inside the filters and at various operating conditions.

The present study deals with the reduction of fluid vibrations by dissipating the kinetic energy in a closed vibrating container partly filled using vertical slotted obstacles. The effect of the barriers on the liquid vibration inside a closed container exposed to a harmonic excitation is numerically studied. A single vertical slotted barrier (SVSB) and multivertical slotted barrier (MVSB) systems are considered for different liquid levels. The 3D liquid domain with the tank and the barrier as boundaries is modelled and solved numerically using ANSYS-CFX software. The reduction in pressures on the walls and the ceiling of the tank due to the influences of the slot size and numbers were evaluated to optimize the size and the numbers of the slots. The numerical approach shows an ability to simulate the nonlinear behavior of the liquid vibration when using vertical slotted barriers (VSB).

The continuous pursuit of higher combustion efficiencies, as well as the possible usage of synthetic fuels with different properties than fossil-ones, require reliable and low-cost numerical approaches to support and speed-up engines industrial design. In this context, SI engines operated with homogeneous ultra-lean mixtures both characterized by a classical ignition configuration or equipped with an active prechamber represent the most promising solutions. In this work, for the classical ignition arrangement, a 3DCFD strategy to model the impact of the ignition system type on the CCV is developed using the RANS approach for turbulence modelling. The spark-discharge is modelled through a set of Lagrangian particles, whose velocity is modified with a zero-divergence perturbation at each discharge event, then evolved according to the Simplified Langevin Model (SLM) to simulate stochastic interactions with the surrounding gas flow.

Crankshafts of motorcycles require high strength, high reliability and low manufacturing cost. Recently, a reduction of Pb content in the free-cutting steel, which is harmful substance, is required. In order to satisfy such requirements, we started the development of Pb-free free-cutting steel which simultaneously enabled the omission of the normalizing process. For the omission of normalizing process, we adjusted the content of Carbon, Manganese and Nitrogen of the steel. This developed steel can obtain adequate hardness and fine microstructure by air-cooling after forging. Pb-free free-cutting steel was developed based on Calcium-sulfur free-cutting steel. Pb free-cutting steel is excellent in cutting chips frangibility in lathe process. We thought that it was necessary that cutting chips frangibility of developed steel was equal to Pb free-cutting steel. It was found that cutting chips frangibility depend on a non-metallic inclusion's composition, shape and dispersion.