bluuebunny/crossref_metadata_2025 huggingface dataset:
Light Weight and High Strength Load Floor with Paper Honeycomb Technology
Authors: D Anantha , Ritesh Kakade , Sriperumbudur Srivatsa , Kakani Phani Kumar , Raj Hemant
Published: April 2023

In order to sustain in automobile industry, fuel economy and robustness are playing vital role in vehicle. Every gram of weight will have an impact on fuel economy, thus burning a hole in consumers pocket and contributing heavily to the carbon footprint. Composite material development plays important role in meeting the stringent self-imposed targets of the automotive manufacturers and light weighting is becoming a prime option for improving Fuel Economy. The main objective of this paper is to optimize the weight of the luggage lid floor and reduce its cost without compromising on the strength by changing the raw material and manufacturing process. This part is in trunk compartment of the vehicle. Main function of this part is to withstand the luggage load under various user loading patterns at varied temperature and while driving on different road conditions.
Electromagnetic-Thermo-Mechanical Performance Management of Power Losses from 1 KW Traction Motor System
Authors: Benny Bineesh , Bala Harinivas , Abraham Gerin , GANIGER Mallikarjun
Published: April 2023

With increasing fuel demands and environmental issues, electric vehicles are more important in reaching a bearable solution. The driving motor is a vital component of electric vehicles defining the design of electric propulsion, and it has small volume, high efficiency with sufficient power for torque and speed with precise control. To ensure a satisfactory life span of the motor, temperature rise must be controlled within safe operating zone. The sizing parameters, design with magnetism, thermal and mechanical calculations are carried out for a 1016-Watt traction motor system. Effects of variation of torque and speed for the 1016-W Brushless Direct Current (BLDC) motor was performed. Power losses calculated included Winding, Stator & Rotor core losses of around 220Watt from the input power of 1236Watt. BLDC motor with air gap between cores and multi-rotational frames are selected for the above calculations. Finally motor system of 1016W was designed and analysed with electromagnetic-thermal-structural coupling simulations and results were verified for the functional requirements. Study of various input parameters with magnetic force distribution (due to current, voltage for stator winding and permanent magnetism) with system efficiency (losses), temperatures, power and its stress fields performances across the motor components verified with the help of commercial codes which meet capacity requirements.
Electrical Driven Compressor – Vibration Correlation for PCB & Electronic Components
Authors: Duraipandi Arumuga Pandian , RAJA Antony vinoth , LEON Renan , RIBOT Herve , SAAD Sofiane , BENCIVENGA Marco
Published: April 2023

Electrical driven compressors (EDC) are mounted on the automotive driveline to compress refrigerants in an automotive air conditioning system. The electrical power delivered by the battery is converted to mechanical power by an inverter and an electrical motor. The inverter is composed of a printed circuit board (PCB) with assembled electronic components. For the inverter part of the EDC, the vibration failures are predominant followed by thermal failures on electronic components. Hence robust methodology is necessary to improve the strength of the design under vibration environment through Finite Element Analysis. In this paper, a multi-fidelity methodology to validate automotive electronic components under harmonic loading through Finite Element Analysis is presented. This multi-fidelity methodology allows the risk of failure to be assessed at the earliest stages of product design, when changes are easy to make and have a low financial impact. The main focus is on the last stage of this methodology, which corresponds to the high fidelity model. The main features of this high-fidelity model are reviewed: from the modeling of the Printed Circuit Board which is considered as a composite material, to the glue modeling, through meshing and numerical method used, up to the loading applied to the model. The discussion will mention the main multi-fidelity results up to a vibration fatigue analysis to validate the life of components to check whether it meets the customer requirement. Next, the accuracy of the high-fidelity simulation results are discussed in comparison with the vibration test results. Finally, this robust methodology supports us to minimize the proto samples and quick evaluation of products.
Research on Control Strategy of Plug-in Hybrid Electric Vehicle Based on Improved Dynamic Programming
Authors: He Zixuan , Yu Qinghua
Published: April 2023

Because of the long driving range and good power performance, plug-in hybrid electric vehicles (PHEV) have drawn much attention. And the current fuel-saving effect of PHEV still has a lot of room for improvement. The complex powertrain structure of PHEV makes the requirements for control strategy be increasing. Therefore, it is crucial to develop an efficient control strategy to ensure that the PHEV operates at optimal performance with an improved driving range. This paper establishes a mathematical model for fuel economy control of PHEV, by treating the torque distribution problem as a multi-stage decision optimization problem, and establishes a global energy management strategy based on a dynamic programming (DP) algorithm. Based on the actual physical model, this paper creatively solves the correction range of battery SOC value according to the charge and discharge power of the motor, which greatly reduces the calculation time of the DP algorithm. Through further simulation study, it is found that the energy management strategy based on the improved DP algorithm can significantly improve the fuel economy of the whole vehicle compared with the rule-based energy management strategy. By comparing the working interval diagrams of the motor and the engine under the two strategies, it can be concluded that the higher the frequency of the engine working in the high efficiency zone, the more likely to get better fuel economy. This study provides the theoretical basis and essential guidance for the establishment and optimization of online energy management strategy.
Nonlinear, Concave, Constrained Optimization in Six-Dimensional Space for Hybrid-Electric Powertrains
Authors: Sovenyi Szabolcs , Weslati Feisel
Published: April 2023

One of the building blocks of the Stellantis hybrid powertrain embedded control software computes the maximum and minimum values of objective functions, such as output torque, as a function of engine torque, hybrid motor torque and other variables. To test such embedded software, an offline reference function was created. The reference function calculates the ideal minimum and maximum values to be compared with the output of the embedded software. This article presents the offline reference function with an emphasis on mathematical novelties. The reference function computes the minimum and maximum points of a linear objective function as a function of six independent variables, subject to 42 linear and two nonlinear constraints. Concave domains, curved surfaces, disjoint domains and multiple local extremum points challenge the algorithm. As a theorem, the conditions and methods for running trigonometric calculations in 6D Euclidean space are presented. More complex geometric structures can be built by joining multiple triangles, adding one triangle at a time. Extensions to 4D, 5D, 7D, etc. are shown to be straightforward. Based on the rules of 6D trigonometry, a probing straight line is constructed. The overlap zone of the constraints is determined along a 6D probing straight line. The optimum point is found within the overlap zone. The algorithm iteratively changes the location and orientation of the straight line to find the optimum point. A formula for rotating any straight line by a given angle in 6D space is derived. The iteration with the probing straight line runs with 2.1 million starting points. In any iteration algorithm, the number of starting points must be determined. This is usually done based on intuition and experience. In this article, the minimum number of required iteration starting points is determined as a function of the required probability of finding the global optimum.
Development and Testing of a Hybrid Vehicle Energy Management Strategy
Authors: Wu Justin Quach , Nelson Douglas
Published: April 2023

An energy management strategy for a prototype P4 parallel hybrid Chevrolet Blazer is developed for the EcoCAR Mobility Challenge. The objective of the energy management strategy is to reduce energy consumption while maintaining the drive quality targets of a conventional vehicle. A comprehensive model of the hybrid powertrain and vehicle physics is constructed to aid in the development of the control strategy. To improve fuel efficiency, a Willans line model is developed for the conventional powertrain and used to develop a rule-based torque split strategy. The strategy maximizes high efficiency engine operation while reducing round trip losses. Calibratable parameters for the torque split operating regions allow for battery state of charge management. Torque request and filtering algorithms are also developed to ensure the hybrid powertrain can smoothly and reliably meet driver demand. Vehicle testing validates that the hybrid powertrain meets acceleration response targets while delivering an enjoyable driving experience. Simulation testing shows that the energy management strategy improved fuel economy in most drive cycles with improvements of 8.8% for US06, 9.8% for HWFET, and 0.1% for the EcoCAR Mobility Challenge Cycle. Battery state of charge management behavior is robust across a variety of drive cycles using inputs from both simulated and test drivers. The resulting energy management strategy delivers an efficient, responsive, and reliable hybrid electric vehicle.
Lifecycle Carbon Footprint Calculation of Hand-Held Tool Propulsion Concepts
Authors: Vogiatzis Dimitrios , Merschak Simon , Schacht Hans-Juergen , Schmidt Stephan , Arenz Martin
Published: April 2023

Following the recent trend in the automotive industry, hybrid and pure electric powertrain systems are more and more preferred over conventional combustion powertrain systems due to their significant potential to reduce greenhouse-gas emissions. Although electric powertrains do not produce direct emissions during their operational time, the indirect emissions over their whole life cycle have to be taken into consideration. In this direction, the carbon footprint due to the electrification of the hand-held power tool industry needs to be examined in the preliminary design phase. In this paper, after defining the carbon footprint calculation framework, assumptions and simplifications used for the calculations, a direct comparison of the total carbon dioxide equivalent (CO2eq) emissions of three equivalent power and range powertrain systems - a combustion-driven, a hybrid-driven, and a cordless electric-driven - is presented. The relative comparison of their life cycle CO2eq emissions delivers important insights for the future design considerations of hand-held power tools. Furthermore. as the energy storage system has the leading influence on CO2eq emissions for the hybrid and electric powertrains, a sensitivity analysis by examining different battery charging conditions and scenarios is presented. The aim of this study is to introduce useful knowledge of life cycle assessment for these small powertrains and forward an argumentation for different powertrain alternatives in the hand-held tool industry.
Impact of the 2022 European Energy Crisis on its Transportation Decarbonization Ambition: Life Cycle Techno-Economic Analysis
Authors: Garcia Antonio , Martinez Santiago , Monsalve-Serrano Javier , Tripathi Shashwat
Published: April 2023

In several regions, such as Europe, California, among others, the switch to Electric Vehicles (EVs) has been heavily pushed by policymakers for their high powertrain efficiency and zero tailpipe emissions compared to conventional Internal Combustion Engine Vehicles (ICEVs). Consequently, only zero tailpipe emission vehicles will be sold in Europe from 2035 for the passenger cars and vans segment. But an EV does emit CO2 emissions across its life cycle, mainly during production, and the Well-to-Tank (WTT) phase, i.e., from the electricity generation used to charge the batteries. Nonetheless, due to the high efficiency of the electric powertrain, the energy consumption is significantly less, making the cost of operation significantly low for EVs. Thus, clean electricity grid and cheap energy costs can make EVs one of the best options for decarbonizing transportation systems. Unfortunately, these two factors have been severely affected in Europe due to the ongoing energy crisis post-Russia's invasion of Ukraine. Europe’s electricity grid is around 20% powered by natural gas, out of which 40% was being imported from Russia, and is almost completely cut off now. Europe is restarting its coal-fired plants to meet the electricity demands, which will increase the electricity grid emissions. Moreover, European electricity prices have reached an all-time high in 2021. Since Russia’s invasion, electricity prices have risen further. Also, while the European Commission is appealing to its citizens to save up to 15% of energy to lower the demand and survive the winter, it must be noted that the electricity demand is expected to rise year-by-year due to higher electric vehicle sales, as targeted by the European Union earlier. Hence, this work highlights the increase in the life cycle emissions and total cost of ownership associated with EVs in the current European scenario, which is belying its ambition to decarbonize the transportation sector. The main results obtained shows that EV’s decarbonization potential will be the same as in 2020, i.e., emitting 0.13 kg/km, if fossil-based energy sources like coal are used to replace the Russian natural gas. While, in terms of total cost of ownership, EVs will continue to be the most expensive option and become even more expensive in the future. While it may also become the most expensive option in terms of operating cost.
ES2re, WS50M, and Human Body Models in Far-Side Pole Impacts
Authors: El-Jawahri Raed E.
Published: April 2023

Driver oblique far-side sled impacts were simulated with three surrogates. The EuroSID side impact dummy with rib extension (ES2re), the WorldSID side impact 50th percentile male dummy (WS50M), and the Global Human Body Modeling Consortium’s 50th percentile male human body (GHBM) models. The versions of the surrogates’ models were 7.0, 7.5.1, and 5.0, respectively. Surrogates were seated in the front left driver seat in a virtual generic crossover sled environment. The Finite Element (FE) based environment consisted of a driver seat, a center console, and a passenger seat. Two restraint systems were considered for each surrogate: belt only (BO) and belt plus a generic seat-mounted far-side impact airbag (BB). Surrogates were restrained using a 3-point belt that has a digressive shoulder force load limiter, and retractor, and anchor pretensioners. The far-side airbag used was a 37-liter in volume and has two chambers. Surrogate head excursions and injury indices for each surrogate were compared. The WS50M kinematics were closer to the GHBM than those of the ES2re. The WS50M predicted 4.7 and 0.5% probability of AIS3+ neck injuries in the BO and BB, respectively. ES2re predicted 48 and 30% probability of AIS3+ thoracic injuries, respectively. Whereas the WS50M predicted 0.5 and 0.0%, respectively. The GHBM had 12 fractures in 8 ribs and no fracture, respectively.
Thermomechanical Fatigue Life Predictions of Cast Aluminum Cylinder Heads Considering Defect Distribution
Authors: Hazime Radwan , Chang Cherng-Chi , Wang Qigui , Sochor Scott
Published: April 2023

Semi-Permanent Mold (SPM) cast aluminum alloy cylinder heads are commonly used in gasoline and diesel internal combustion engines. The cast aluminum cylinder heads must withstand severe cyclic mechanical and thermal loads throughout their lifetime. The casting process is inherently prone to introducing casting defects and microstructural heterogeneity. Porosity, which is one of the most dominant volumetric defects in such castings, has a significant detrimental effect on the fatigue life of these components since it acts as a crack initiation site. A reliable analytical model for Thermo-Mechanical Fatigue (TMF) life prediction must take into account the presence of these defects. In previous publications, it has been shown that the mechanism-based TMF damage model (DTMF) is able to predict with good accuracy crack locations and the number of cycles to propagate an initial defect into a critical crack size in aluminum cylinder heads considering ageing effects. In the current work, the model has been extended to also include the effect of porosity which is treated as the initial defect size. It is shown that the model can explain the difference in the fatigue lives of Low-Cycle Fatigue (LCF) samples taken from chilled and non-chilled regions of the heads made of an A356-T6 alloy and tested at different temperatures. On the component level, a non-linear transient elasto-viscoplastic finite element analysis is performed to simulate the thermal cycle that the cylinder head experiences during engine testing including ageing effects. A casting simulation of the head is carried out to provide pore size distribution throughout the casting. The pore sizes are then treated as the initial crack sizes at each node in the mechanism-based short-crack growth model. The TMF life prediction results are compared with zone-based analysis and with engine dyno tests.
Full Aluminum Body Design Considering Part-Specific Requirements
Authors: An Byeongdo , Cha Munsoo , An Yongdok , Kim Heeju , Oh Heedae , Kim Kyungbo , Jang Younghoon , Nam Byeunggun , Chun Yunbae , Lee Hunky
Published: April 2023

In the era of electric vehicles(EVs), the need for weight reduction of the vehicle body is increasing in order to maximize the driving distance of the EV. Accordingly, there is an increasing need for research to efficiently apply lightweight materials, such as aluminum and CFRP, to the EV body parts. In this study, design methodologies and optimization measures to increase lightweight efficiency when applying lightweight materials to EVs will be discussed. Based on theoretical basis and basic performance of each part of the EV, the “Material Substitution Method” of replacing existing parts of a steel body with aluminum materials will be defined, and the optimal design process on how to overcome performance trade-off caused by material characteristics will be addressed. In applying the “Material Substitution Method” to the actual EV body design process, it was possible to convert 93% of the components from steel to aluminum and reduce the overall weight of the body by 23%. Based on these results, the “Material Substitution Method” helps secure basic performance for each part with relative ease when changing the material of the body part from steel material to lightweight material (AL, CFRP, etc.). In addition, it is verified that the optimal design process defined in this paper is effective in maximizing the weight reduction efficiency of the lightweight body.
Side Door Closing Velocity Reduction Parameters in a SUV
Authors: Bhosale Mukund , Askari Hasan , Selvan Veera , Kale Sanjay , Unadkat Siddharth , Pandurangan Venugopal , Chavan Shailesh
Published: April 2023

Side Door closing velocity is one of the key customer touch points which depicts the build quality of the vehicle. Side door closing velocity results from the interaction of different parts like door and body seals, door check arm, door hinge, latch, and alignment of door hinge axis. In this paper, a high door closing velocity issue in a sports utility vehicle is discussed. Physical studies are carried out to understand each parameter in door closing velocity and its contribution is defined in terms of velocity. Many physical trials are conducted to conclude the contribution of each parameter. Studies revealed that the body and door seal are contributing around 70% of door closing velocity. Check arm and hinge axis deviation are contributing around 10% of the door closing velocity. Physical trials are conducted by reducing the compression distance of the body seal. Around 13.5 to 20 % reduction in door closing velocity is observed with a 3mm reduction in compression distance of the seal. Side door flushness adjustment on the positive side by 0.5mm reduced the door closing velocity by around 1.5 to 6%. These changes are implemented on the vehicle without affecting the vehicle development cycle time.
A Comprehensive Methodology to Design and Develop Suspension System Bolted Joints using Vehicle Test Loads and CAE Simulation
Authors: Vellandi Vikraman , Namani Prasad , Nair Sharad , Nayak Bhargav A. , Chaudhari Varun , Patnala Avinash , Senthil Raja T. , Arunachalam M
Published: April 2023

The bolted joints in suspension systems are subjected to severe external service loads during vehicle operation. To prevent the loaded joint from loosening and allowing it to retain its potential energy stored during assembly, a holistic design approach is needed. This paper explains the methodology to design and optimize bolted joints for the suspension systems of a modern 7-seater sports utility vehicle. The optimization technique consists of -

1
Extensive benchmarking of global benchmark vehicles with similar suspension architecture and gross vehicle weights to derive preliminary torque and joint preloads.

2
Measuring external loads acting in x, y and z directions using a wheel force transducer on various durability tracks.

3
Performing Multi body dynamic simulations to obtain the loads at various bolted joint locations.

4
Taking the input of the external loads acting on the individual joints and perform a simulation to evaluate slip at joinery for a given preload.

5
Bolt characterization measurements to establish the torque to be applied to achieve the required preload at the joint.

Based on the results, joinery design approaches are discussed which focus on increasing the resistance against slip and utilizing the optimum preload applied during assembly. For critical joints experiencing high service loads, the torque to yield (torque plus angle) method is prescribed instead of the elastic tightening method along with reduction of the axial gap. For double shear joints having steel sleeve and sheet metal interface, improvements seen with the addition of serrations/knurling on the contact surface of the sleeve are discussed. The stiffness of mating parts is increased for proper bolt load transfer. With the incorporation of these design modifications in the joinery, extensive vehicle durability tests are performed in the vehicle, and no incidences of joinery loosening/slipping are observed. The efficacy of the design improvement was reflected in the residual torque values which showed no reduction after the test compared to the start of the test.
Accuracy and Repeatability of Mobile Phone LiDAR Capture
Authors: Miller Seth Higgins , Hashemian Alireza , Gillihan Robert , Benes Saylor
Published: April 2023

Apple’s mobile phone LiDAR capabilities were previously evaluated to obtain geometry from multiple exemplar vehicles, but results were inconsistent and less accurate than traditional ground-based LiDAR (SAE Technical Paper 2022-01-0832. Miller, Hashemian, Gillihan, Helms). This paper builds upon existing research by utilizing the newest version of the mobile LiDAR hardware and software previously studied, as well as evaluating additional objects of varying sizes and a newly released software not yet studied. To better explore the accuracy achievable with Apple mobile phone LiDAR, multiple objects with varied surface textures, colors, and sizes were scanned. These objects included exemplar passenger vehicles (including a motorcycle), a fuel tank, and a spare tire mounted on a chrome wheel. To test the repeatability of the presented methodologies, four participants scanned each object multiple times and created three individual data sets per software. The accuracy for each data set was then evaluated against each other and established terrestrial LiDAR methods, including FARO scanners, and the repeatability and accuracy of presented methodologies reported. The authors found that the Recon-3D software presented significant improvements when compared to other software and believe the accident reconstruction community, and other forensic disciplines, will find utility in the accessibility, portability, and accuracy of this methodology.
Dynamic Testing and Modeling of a Variable Stiffness Seatback
Authors: Warner Wyatt , Warner Mark
Published: April 2023

The concept of a seat with an active adjustable seatback stiffness for enhanced safety during a rear impact was published previously. Static testing of a demonstrative prototype is supplemented with repeated dynamic tests at various velocity / acceleration levels. These tests were performed with a Hybrid III Anthropomorphic Test Device (ATD) and demonstrate that the occupant response can be modified by engagement of the device based on the severity of the crash pulse and other factors. A mathematical model for the dynamic response of the seat and the correlated occupant response is in development. Refinement of this technology is complemented by results of the dynamic testing.
Drivers’ Perceived Sensitivity to Crosswinds and to Low-Frequency Aerodynamic Lift Fluctuations
Authors: Brandt Adam , Jacobson Bengt , Sebben Simone
Published: April 2023

The automotive industry continues to increase the utilization of computer-aided engineering. This put demands on finding reliable objective measures that correlate to subjective driver assessments on driving stability performance. However, the drivers’ subjective perception of driving stability can be difficult to quantify objectively, especially on test tracks where the wind conditions cannot be controlled. The advancement in driving simulator technology may enable evaluation of driving stability with high repeatability. The purpose of this study is to correlate the subjective assessment of driving stability to reliable objective measures and to evaluate the usefulness of a driving simulator for the subjective assessment. Two different driver clinic studies were performed in a state-of-the-art driving simulator. The first study included 38 drivers (professional, experienced and common drivers) and focused on crosswind gust sensitivity. The second study focused on straight-line driving stability at constant crosswinds, where the influence of unsteady aerodynamic wake fluctuations was assessed. This study involved three of these professional drivers. It was found that the subjective assessment of crosswind sensitivity can be correlated with the sensory motion response of the vehicle (lateral acceleration and yaw velocity), and also with vehicle path curvature (visual feedback). The assessment of fluctuating CFD loads showed that blind-tested professional drivers could differentiate vehicle configurations in agreement with their on-road subjective ratings. Based on the results of this study, a new aerodynamic lift target for high speed straight-line stability, which also accounts for the fluctuating loads of the wake, is proposed.
Modeling of Gas Charging and Discharging for Airbag Suspension System and Control of Height Adjustment
Authors: Deng Lin , Lv Hui , Shangguan Wenbin
Published: April 2023

Taking a closed airbag suspension system as studying objects, the nonlinear dynamic model of the reservoir, compressor, solenoid valve, pipeline and air spring is established. The compressor exhaust volume, solenoid valve flow rate and air spring charging and discharging rate are calculated and compared with experiment to validate the model. Taking pressure difference and height adjustment rate under different working conditions of an airbag suspension as control measures, a control strategy is developed based on the established nonlinear dynamic model. The result indicates that when the vehicle is in curb weight, design weight and GVW (gross vehicle weight), the working time of the compressor can be reduced by 13.6%, 15.1% and 46.5%, respectively, compared with the conventional mode, during a height adjustment cycle. Then a state observer is proposed to estimate the steady-height for reducing the disturbance of measured height from road excitation. According to the required height error and pipeline pressure, a method for adjusting compressor speed to reduce the influence of pipeline pressure on height adjustment accuracy is proposed.
Path Planning and Tracking Control of Car-like Robot Based on Improved NSGA-III and Fuzzy Sliding Mode Control
Authors: Zhu Haotian , Pang Chenghui , Zhou liang
Published: April 2023

In recent years, research on car-like robots has received more attention due to the rapid development of artificial intelligence from diverse disciplines. As essential parts, path planning and lateral path tracking control are the basis for car-like robots to complete automation tasks. Based on the two-degree-of-freedom vehicle dynamic model, this study profoundly analyzes the car-like robots’ path planning and lateral path tracking control. Three objectives: path length, path smoothness, and path safety, are defined and used to construct a multi-objective path planning model. By introducing an adaptive factor, redefining the selection of reference points, and using the cubic spline interpolation for path determination, an improved NGSA-III is proposed, which is mostly adapted in solving the multi-objective path planning problem. Furthermore, the chattering problem of sliding mode control is eliminated by introducing fuzzy control, and a sliding mode controller with fuzzy control is also applied for the lateral path tracking control of car-like robots. To verify the effectiveness of the proposed methods, simulation experiments are carried out for the planning and control layers, respectively. Comparing the improved NSGA-III with NSGA-III, HV decreased by 12.47%, SP increased by 1.17%, and the number of iterations decreased by 20.59% on average. The results show that the improved NSGA-III sacrifices part of the population diversity but has a more significant improvement in the convergence and accurate path predictions. Furthermore, the lateral path tracking controller effectively solved the chattering problem and reduced the lateral deviation by 29.35% and 52.53%, under the standard double-line-change working condition with road adhesion coefficients of 0.8 and 0.2. In addition, the proposed planning and control methods in this study can cooperate under medium and low speed conditions which is suitable for most application scenarios of car-like robots.
Utilizing Speed Information Forecast in Energy Optimization of an Electric Vehicle with Adaptive Cruise Controller
Authors: Shahram Shahriar , Pourmohammadi Fallah Yaser
Published: April 2023

The efficiency in energy consumption of an electric vehicle (EV) has significant value to both vehicle manufacturers and vehicle owners. Such efficiency will directly impact the cost of energy and vehicle range while relieving the stringent requirements on the DC motor and battery specs. Nowadays, with the development of advanced driver assistance systems (ADAS), such as adaptive cruise control (ACC) or cooperative adaptive cruise control (CACC), drivers enjoy a much safer driving experience. ADAS capabilities in sensory, computing and communication can be leveraged in EVs for the purpose of optimizing energy consumption.

This paper introduces an energy-optimized ACC platform, which utilizes a forecast of the speed profile of the host vehicle in a short (few seconds) horizon. Such speed information can be available through ADAS or similar systems. This paper focuses on optimization in longitudinal tracks. We consider ten different drive-cycles in several driving scenarios, such as highways, urban areas, and test tracks with multiple stops. We study the average energy consumption and performance in all the scenarios through simulation experiments. Our results show significant improvement in the overall energy consumption in a drive-cycle compared with a baseline vehicle that only uses ACC.

We can optimize the energy consumption by 2.30% on average in a random driving scenario (Highway, Urban area, or test tracks with multiple stops) utilizing the proposed method compared to only using ACC.
Automotive Applications Multiaxial Proving Grounds and Road Test Simulator: Durability Prediction Methodology Development and Correlation for Rubber Components
Authors: Zarrin-Ghalami Touhid , Datta Sandip
Published: April 2023

Many chassis and powertrain components in the transportation and automotive industry experience multi-axial cyclic service loading. A thorough load-history leading to durability damage should be considered in the early vehicle production steps.

The key feature of rubber fatigue analysis discussed in this study is how to define local critical location strain time history based on nominal and complex load time histories. Material coupon characterization used here is the crack growth approach, based on fracture mechanics parameters. This methodology was utilized and presented for a truck engine mount. Temperature effects are not considered since proving ground (PG) loads are generated under isothermal high temperature and low frequency conditions without high amounts of self-heating.

This novel methodology for fatigue life calculation involves finding independent load channels and mapping all load history through converting single or multichannel load-displacement history into stress-strain history for a nonlinear elastic finite element model. After finding strain history, a critical plane approach, based on crack energy density, is used for life predictions. Rainflow cycle counting methodology and linear damage rules are used for load cycle characterization and damage accumulation, respectively.

This methodology is correlated with component proving ground vehicle testing under complete service conditions for the vehicle. Predictions are validated through analysis of hot spot high stress locations, life regime, and strain states. Comparative results of numerical predictions show reasonable correlation with experimental data.
Friction and Wear Studies on Jute Fiber and SS 304 Wire Mesh Reinforced Hybrid Polymer Composites for Automotive Applications
Authors: Salve Aniket Vinayak , Mache Ashok
Published: April 2023

Automotive industry is looking for high strength and durable lightweight material with resistance to wear and friction. To meet this requirement, a new hybrid polymer composite material has been developed using reinforcement as SS 304 wire mesh and jute fibre. Present paper explores the experimental findings of wear performance of hybrid polymer composite under dry condition. Four different laminates with configurations JJSJJSJJ, (JJSJJSJJ)450, GGSGGSGG and GJSJJSJG along with their virgin counterpart were developed by hand layup technique supported by compression moulding. These laminates were tested as per the ASTM standards to investigate its performance for friction and wear using pin on disc machine with steel as a counterpart. Testing parameters were sliding distance, applied load and sliding speed. Experimental results showed that, applied load have major influence on the friction and wear performance of developed hybrid composites. As load rises, friction force value increases with increased specific wear rate for entire composites. With hybridization of composite laminates, the frication and wear performance has improved as their virgin counterpart. The study demonstrates that wire mesh added to hybrid polymer composites during manufacturing increases the composite's wear resistance. This developed hybrid composite material has great potential to replace metal or alloy in automobile door trim panels where friction and wear are dominates.
Analysis of the Thermodynamic Effects of a Plate Based on Numerical Simulations
Authors: Azeem Naqash , Qaisar Abdul , Asary Abdul Rab , Khan Razi
Published: April 2023

Heat transfer is a common phenomenon in engineering applications, and selecting an appropriate material is vital. When the heat is exchanged between two mediums, the wall or material in-between them is exposed to extreme temperatures (high and low), commonly known as a cooling or heating plate. This article proposes a finite difference formulation to determine the temperature distribution of a plate for a 2D steady-state heat conduction equation. This formulation is then applied to a specific plate shape with particular boundary conditions. A MATLAB code is proposed to formulate the heat conduction equation using a finite difference approach. The proposed methodology can be used to determine the temperature distribution of a plate along with boundary conditions defined by the user, including plate size, size of the resolution in both axes (horizontal and vertical), heat flux, and thermal conductivity. Finally, the results of the proposed methodology are verified by modeling. The novel method allows a plate's optimal size, geometry, and appropriate material to be selected based on thermodynamic effects.
Sun Radiation Estimation on Display Screens through Virtual Simulation
Authors: Alonso Liliana , Saavedra Oscar
Published: April 2023

Currently the automotive industry has been under extremely important technological changes. Part of these changes are related to the way that users interact with the vehicle and fundamental components are the new digital cluster and screens. These devices have created a disruption in the way information is transmitted to the user, being essential for vehicle operation, including safety.

Due to new operating conditions, multiple evaluations need to be performed, one of them is the solar temperature Load to ensure correct operation without compromising user safety. This test is required to identify the thermal performance on the screens mounted on the instrument panel. The performance identification is performed on both sides, analytical and physical. In regards finite element simulation it represents the solar chamber as the main source of heat and being the main mechanism of transmission the radiation.

To model this boundary conditions, Taitherm® Software [1] is used, and it allows to evaluate several load cases such as thermal load variation, several exterior colors of the car because it has been identified a strong relationship between the colors and the thermal energy captured, finally incident angle determined by the windshield inclination/slope because the present assessment it is restricted to the clusters/screens mounted on the instrument panel

To identify the validity of the study, a correlation has been achieved, that means that a physical test was assessed by the use thermocouples instrumented and the temperature captured on the screen was correlated with the robustness of the CAE simulation (Computer-Aided Engineering) to apply this method on vehicle programs that are under design phase.
Research on Fatigue Damage of Independent Suspension Support Structure for a Commercial Vehicle Based on Load Spectrum of Basic Vehicle
Authors: Pan Ting , Gao De , Zhang Suo , Gao Yunkai , Wang Lei , Xie Furong , Tong Jiachi
Published: April 2023

In this paper, an equivalent conversion method is proposed to apply the six-dimensional force road spectrum of the four-axle vehicle on the same platform to the three-axle through the axle load comparison. Further, the feasibility of the devolved equivalent conversion method is verified, and the fatigue performance improvement of the wishbone support structure of a commercial vehicle is finally achieved. Specifically, firstly, the load spectrum at each attachment point of the suspension for the three-axle vehicle is obtained through the iteration of the multi-body dynamic model. Furthermore, the finite element model of the suspension for the three-axle vehicle is established; the analysis of fatigue life for the suspension structure is performed by extracting stress amplitude through the multi-axis cyclic counting method and calculating equivalent force amplitude through McDiarmid’s criterion, combined with the SN curve of the material. Finally, the prediction and optimization design of the fatigue weak position for the wishbone support are realized. The results of the three-axle vehicle after trial production show that the fatigue damage position of the control arm bracket is consistent with the simulation prediction, and the fatigue performance of the optimized suspension is significantly improved. Therefore, the developed method can be applied to the fatigue analysis of replacement vehicle components, which can shorten the design cycle and improve the efficiency under the premise of ensuring the accuracy and reliability of fatigue life prediction.
Comparison of Child Restraint System (CRS) Installation Methods and Misuse During Far-Side Impact Sled Testing
Authors: Mansfield Julie
Published: April 2023

Child occupants have not been studied in far-side impacts as thoroughly as frontal or near side crash modes. The objective is to determine whether the installation method of child restraint systems (CRS) affects far-side crash performance. Twenty far-side impact sled tests were conducted with rear-facing (RF) CRS, forward-facing (FF) CRS, high-back boosters, and belt only. Each was installed on second row captain’s chairs from a recent model year minivan. Common CRS installation errors were tested, including using the seat belt in Emergency Locking Mode (ELR) instead of Automatic Locking Mode (ALR), not attaching the top tether, and using both the lower anchors (LA) and seat belt together. Correct installations were also tested as a baseline comparison. Q3s and Hybrid III 6-year-old (6yo) anthropomorphic test devices (ATDs) were used. Lateral displacements of the CRS and head were examined as well as injury metrics in the head, spine, and torso.

For RF CRS, the ELR belt installation resulted in a 91 mm (15%) increase in lateral head displacement compared to ALR belt, along with slight decreases in most other injury metrics. Results were similar between installations with LA only and LA + ALR belt together. For FF CRS, the ELR belt condition showed increased lateral CRS displacement compared to ALR belt: +66 mm (9%) without top tether, +93 mm (12%) with top tether. However, head displacements were similar between conditions (approximately 1% difference). Using the top tether decreased head displacements by 12 to 42 mm (2% to 7%, depending on installation method), which is a priority for children since head injuries due to head contact are the most frequent type of injury. Using the top tether slightly increased head injury criterion (HIC36) and neck loads compared to tests without tether. Booster displacement was less for boosters installed with LA and/or top tether compared to belt only installations, but head displacements were similar (<3% difference) regardless of booster installation method. The presence of side wings did not affect peak head displacement but HIC36 was lower in the booster with large side wings compared to the no-wing booster.
The Effect of Engine Parameters on In-Cylinder Pressure Reconstruction from Vibration Signals Based on a DNN Model in CNG-Diesel Dual-Fuel Engine
Authors: Kim Gyeonggon , Park Chansoo , Kim Wooyeong , Jeon Jeeyeon , Jeon Miyeon , Bae Choongsik , Kim Wooyeong
Published: April 2023

In marine or stationary engines, consistent engine performance must be guaranteed for long-haul operations. A dual-fuel combustion strategy was used to reduce the emissions of particulates and nitrogen oxides in marine engines. However, in this case, the combustion stability was highly affected by environmental factors. To ensure consistent engine performance, the in-cylinder pressure measured by piezoelectric pressure sensors is generally measured to analyze combustion characteristics. However, the vulnerability to thermal drift and breakage of sensors leads to additional maintenance costs. Therefore, an indirect measurement via a reconstruction model of the in-cylinder pressure from engine block vibrations was developed. The in-cylinder pressure variation is directly related to the block vibration; however, numerous noise sources exist (such as, valve impact, piston slap, and air flowage). A deep neural network (DNN) model is among the most feasible ways to reconstruct the in-cylinder pressure from engine block vibrations, minimizing the effect of noise or uncertainties. Vibration and in-cylinder pressure signals were measured on a natural gas (NG)/diesel dual-fuel engine using an accelerometer and a piezoelectric sensor. A parametric study was conducted to investigate the effects of the composition of the training conditions on the accuracy of the model. The main parameters, engine load, engine speed, diesel injection timing, and intake air pressure, were varied to investigate their effect on the model prediction. The results showed that the prediction accuracy was directly related to the amount of training data that had similar trends of in-cylinder pressure with the test conditions, irrespective of the total amount and types of engine parameters of the training data. With these investigations, we can identify the relationships between the training dataset and model performance that can be used in the development of a cylinder pressure reconstruction model for the real-time verification of performance in dual-fuel engines.
Exterior-Interior Interface Connection Design for Optimal Performance in Automotive Systems
Authors: Alonso Liliana , Alvarez Ezequiel
Published: April 2023

The vehicle instrument panel (IP) system has several interactions with the surrounding components such as the Dash, Cowl, Cross Car Beam (CCB), Floor, Body Side etc. With such interactions comes different loadings, usage scenarios, interfaces and design challenges to overcome. For the specific case of the IP to Cowl & Dash interfaces, the position and performance in different load cases, such as, but not limited to, vibration and heat expansion loading as well as the assembly process. A design solution is required to enhance the performance in all these scenarios while maintaining the cost, weight & complexity as low as possible. This paper describes the development process of an optimized solution with a multi-disciplinary approach using advanced computer aided engineering (CAE) optimization tools, which involved performance in multiple virtual evaluations and mass. The achieved enhanced solution provides of multiple alternatives from early design stages to allow flexibility in the manufacture stage, it also proved to be effective to reduce complexity by using few parts in the assembly. The enhanced method reduces time required to assemble and the weight while meeting the performance required.