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Currently, advancements in Rapid Prototyping (RP) technologies have led to considerable amount of research activities and has been playing a major role in the area of tooling development for which Rapid Tooling (RT) term was coined. While rapid prototyping techniques are employed to make prototype tools, the basic idea of the rapid tooling is to produce prototype and zero series parts by using prototype tools so the parts truly represent the future production. This paper will present an evaluation of a RP and RT technique in developing tools (punch and dies) for sheet metal forming, which had been manufactured and tested. Both punch and die have been manufactured by combining Stereolithography (SL), RP technique, with nickel electroforming process. The stereolithography technique that had been utilized in developing models for the tools had been built with modeling pattern called Accurate Clear Epoxy Solid (ACES).

Currently, advancements in Rapid Prototyping (RP) technologies have led to considerable amount of research activities and has been playing a major role in the area of tooling development for which Rapid Tooling (RT) term was coined. Rapid prototyping techniques are employed to make prototype tools. While, the basic idea of the rapid tooling is to produce prototype and zero series parts by using prototype tools so the parts truly represent the future production. This paper will present an evaluation of a RP & RT technique in developing tools (punch and dies) for sheet metal forming, which had been manufactured and tested. Both punch and die have been manufactured directly from Stereolithography (SL). The stereolithography technique that had been utilized in developing models for the tools had been built with modeling pattern called QuickCast infiltrated with Aluminum-Filled Epoxy, designated as Quick Tool.

COMVEC™ conference is the only North American event that addresses vehicles and equipment spanning on-highway, off-highway, agricultural, construction, industrial, military, and mining sectors.

Thermal Management Systems Symposium industry discusses latest regulatory impacts, applications to reduce engine emissions, conserve energy, reduce noise, improve the cabin environment, increase overall vehicle performance passenger, commercial vehicle industry.

To optimize the tyre contact patch in a sports car, Ferrari has developed an active camber and toe (ACT) system comprising of 4 actuators for the rear axle. This complex and completely new system is difficult to model accurately and for this reason, it was decided to combine a physical prototype with a full vehicle model to carry out the functional tests. The method of combining a virtual model with a physical test is known as hybrid simulation. This functional testing of both the actuators and the vehicle dynamics logic will be performed on an MTS 6DOF bench test prior to physical track testing on a prototype vehicle using Ferrari facility in Maranello, Italy. In support of this functional testing, we will use hybrid simulation techniques with software and methods specifically developed. The planned hybrid test system described in the paper will allow dynamic coupling between the physical bench test and a modified full vehicle simulation model.

Safety is a requirement concerning an increasing number of automotive applications. Recent safety standards set requirements for designing safety-critical systems. Among others, these specifications include a comprehensive detection and handling of hardware faults. Currently emerging dual-core microcontrollers provide a cost-effective opportunity to fulfill these requirements. In this paper we analyze a safety-critical application example and discuss two different approaches, an application-specific approach and a generic approach for implementing functional safety requirements on a dual-core microcontroller. An investigation of the associated concepts called function monitoring architectures and generic architectures reveals their differences and at the same time advantages and disadvantages. Besides effects on safety, effects on reliability, modifiability and costs are evaluated and presented graphically.

Hazard analysis plays an important role in the development of safety-critical systems. Hazard analysis techniques have been used in the development of conventional automotive systems. However, as future automotive systems become more sophisticated in functionality, design, and applied technology, the need for a more comprehensive hazard analysis approach has arisen. In this paper, we describe a comprehensive hazard analysis approach for system safety programs. This comprehensive approach involves applying a number of hazard analysis techniques and then integrating their results. This comprehensive approach attempts to overcome the narrower scope of individual techniques while obtaining the benefits of all of them.

Ground vehicle dynamic stability, including spinout and rollover, is highly dependent on maneuvering conditions and the nonlinear force response characteristics of tires. Depending on vehicle configuration, unstable behavior requires high, sustained lateral acceleration, and some maneuver induced excitation of the roll and yaw mode dynamics. Dynamic instability in some vehicles can be induced by a steering reversal maneuver that involves sustained limit performance lateral acceleration. Using a validated vehicle dynamics simulation, analysis is presented to illustrate what constitutes a critical stability sensitive maneuver. Two example test cases are used to show that a critical stability sensitive maneuver must be more severe than a single lane change. Even reaching tire saturation limits during an aggressive single lane change does not give the sustained lateral acceleration required to provoke instability conditions.

This paper presents an overview of the connected controls and optimization system for vehicle dynamics and powertrain operation on a light-duty plug-in multi-mode hybrid electric vehicle developed as part of the DOE ARPA-E NEXTCAR program by Michigan Technological University in partnership with General Motors Co. The objective is to enable a 20% reduction in overall energy consumption and a 6% increase in electric vehicle range of a plug-in hybrid electric vehicle through the utilization of connected and automated vehicle technologies. Technologies developed to achieve this goal were developed in two categories, the vehicle control level and the powertrain control level. Tools at the vehicle control level include Eco Routing, Speed Harmonization, Eco Approach and Departure and in-situ vehicle parameter characterization.

Low-pressure cooled EGR (LP-cEGR) systems can provide significant improvements in spark-ignition engine efficiency and knock resistance. However, open-loop control of these systems is challenging due to low pressure differentials and the presence of pulsating flow at the EGR valve. This research describes a control structure for Low-pressure cooled EGR systems using closed loop feedback control along with internal model control. A Smith Predictor based PID controller is utilized in combination with an intake oxygen sensor for feedback control of EGR fraction. Gas transport delays are considered as dead-time delays and a Smith Predictor is one of the conventional methods to address stability concerns of such systems. However, this approach requires a plant model of the air-path from the EGR valve to the sensor.

This article describes how future Single-Chip ECU's can be debugged and calibrated using the new emerging debug standard known as GEPDIS informally named NEXUS. The paper explains why conventional debug and calibration methods no longer work with future ECU architectures. Infineon Technologies and some other leading semiconductor vendors and tool companies have worked on the development of a ‘global embedded processor debug interface standard’ called GEPDIS (1). Throughout this paper will use the GEPDIS short cut. The GEPDIS standard defines and implements a global, open, micro-controller development interface standard for embedded controller applications. The GEPDIS interface can be used for run-time Control, Code Execution and Data Trace, Calibration and Co-processor communication (for use in Rapid Prototyping).

Computer Aided Control System Design (CACSD) tools are widely used in the development of embedded control systems. Automatic code generation for CACSD models is the subject of increasing interest. In this study, Software-in-the-Loop Simulation (SILS) and Rapid Control Prototyping (RCP) are proposed as a development framework for the design of real-time control systems. SILS is a simulation environment to consider functional behavior as well as temporal behavior of control systems. RCP supports seamless development from design to implementation through automatic code generation. SILS/RCP environments make it possible to design and analysis control systems under conditions similar to real execution during off-line simulation and to realize controllers in the early design phase.

In this project, phenomena in a SCR catalyst, such as heat transfer and catalytic reactions, are modeled numerically. The model is simplified to be integrated on an electronic control unit. The calibration process for this model has been developed, which is performed on gas bench and validated on a vehicle equipped with a Urea-SCR system and a Rapid Prototype Control Unit. With this simplified SCR reaction model, it is possible to estimate NH3 consumption and properly control the urea injection quantity with less calibration efforts.

With the growing complexity and integration of systems as satellites, automobiles, aircrafts, turbines, power controls and traffic controls, as prescribed by SAE-ARP-4754A Standard, the time de-synchronization can cause serious or even catastrophic failures. Time synchronization is a very important aspect to achieve high performance, reliability and determinism in networked control systems. Such systems operate in a real time distributed environment which frequently requires a consistent time view among different devices, levels and granularities. So, to guarantee high performance, reliability and determinism it is required a performance evaluation of time synchronization of the overall system. This time synchronization performance evaluation can be done in different ways, as experiments and/or model and simulation.