沥青层应变传感器数据采集及处理方法研究

介绍了沥青路面电阻应变传感器的基本原理,分析了数据采集过程中初始电压达到极限状态的原因和调整方法,通过试验分析确定了高速车轮荷载和FWD荷载作用下应变传感器数据采集系统的合理采集频率,最后结合应力应变传感器在动态荷载作用下的响应规律,总结了将电阻应变传感器电压信号转换为应变信号的数据处理方法.     

Diesel hybrid electric vehicle hardware system

A controller for a diesel hybrid electric vehicle based on a V-cycle development approach is investigated in this paper. The hardware and infra program of the Hybrid Control Unit (HCU) are discussed in detail. The hardware system is designed based on circuit simulation; while the infra system is written with assemble language. Time sharing mode, buffer sharing mode and multi-task schedule method are used to ensure real-time communication in the infra program design. Based on multi-thread technology, hardware in loop test system is also designed. The hardware in loop and bench tests show that the controller could meet the requirements of the hybrid electric vehicle (HEV) and communicate in real-time. Circuit simulation, HCU, infra program and hardware in loop test form the effective V-cycle development platform to design a hardware system for a diesel HEV controller.     

Effects of end coils on the natural frequency of automotive engine valve springs

In this paper, we present a method for estimating the natural frequencies of various engine valve springs such as constant pitch, two-step variable pitch, three-step variable pitch, and progressive springs. Since a valve spring’s surging amplitude is magnified when the spring’s natural frequency coincides with the frequency of the cam profile harmonic components, estimating the natural frequency of the spring is the first step in predicting valve spring surging phenomena. A new method for calculating the valve spring’s natural frequency is proposed in this paper that considers the end coil effect. This method predicts not only the natural frequency of a helical spring at a fixed number of active turns, but also the change in the natural frequency as the spring is compressed. The experimental results demonstrate that nonlinear characteristics of engine valve springs can be predicted from the given initial pitch curves.     

Prediction of vibrating forces on meshing gears for a gear rattle using a new multi-body dynamic model

An efficient multibody dynamic model was developed to predict the vibrating transmitted gear forces of loaded and unloaded pairs of helical gears simultaneously at all speeds. The model can also calculate the bearing forces of a manual transmission that, in turn, may be converted to rattling noises. The bending of meshing gear teeth and torsional flexibility of transmission shafts were considered and embodied effectively in the multibody dynamic model by calculating the tooth bending stiffness and adding a torsion spring on a shaft section between two gears, respectively. The reactive forces on teeth and bearings were calculated and compared using three different models that were developed for this study — an equivalent model, a rigid-body model, and a frequency-based model. The equivalent model took only 58% computation time, compared to the frequency-based method, even though the two showed very similar results.     

Dependence of fatigue limit of high-tension bolts on mean stress and ultimate tensile strength

High tension bolts in critical joints in internal combustion engines are susceptible to fatigue failure. Computeraided bolted joint design procedures require knowledge of the dependence of bolt fatigue limit on the mean stress and ultimate tensile strength. This dependence is investigated with staircase fatigue limit tests. The test results show that when the bolt fatigue limit is estimated with the nominal stress of the bolt, it decreases with increasing tensile strength and nominal mean stress. However, there is a range of the nominal mean stress where the bolt fatigue limit is almost constant. The test results are interpreted with finite element analysis.     

Design of conformal cooling channels for an automotive part

The cooling system plays a crucial role in determining the productivity and quality of an injection molding process. With the current growth of Solid Freeform Fabrication (SFF) techniques, mold designers have been striving for not only improvement in cooling system performance but also for a method to do so automatically. In this paper, a method is proposed for developing a conformal cooling system that facilitates uniform cooling over the entire mold surface with minimum cycle time. Based on the temperature distribution after the filling stage, the mold surface is split into zones which will be cooled by optimized subconformal channels obtained from the optimization process. The optimization process in which the objective function is stated as minimization of the cooling time with boundaries ensuring a realistic design will optimize the cooling system layout in terms of cooling channel size and location. Finally, all subcooling channels are combined to generate the entire conformal cooling system for the injection mold.     

Interior sound field refinement of a passenger car using modified panel acoustic contribution analysis

Panel acoustic contribution analysis (PACA) is a practical engineering tool for the reduction of interior structure-borne noise in passenger cars. In this study, the current PACA method has been improved for sound field refinement of the entire interior. Two new parameters, the “acoustic contribution sum” and the “total sound field contribution”, are introduced to analyze the interior sound field characterized with multiple field points and sound pressure peaks, and to evaluate the integrated acoustic contributions of auto body panels. In addition, a systematic methodology for automotive interior sound field refinement is also proposed on the basis of the modified PACA method. An example of a passenger car model demonstrates the application of the sound-field-refinement methodology and shows the advantage of using damping layers at optimum locations on the auto body. The example also shows that the modified PACA method has practical significance for refining the interior sound field and decreasing added mass in accord with the trend towards lightweight auto bodies.     

Improved method for analyzing automotive transmission parts (shaft/gear) manufactured using the warm shrink fitting process

There are three sub-processes associated with the assembly of an automobile transmission: heat fitting, shrink fitting, and combination fitting. In the heat fitting stage, the gear is heated to a specified temperature and then squeezed towards the outer diameter of the shaft. The stress of the heat-fitted gear depends on the yield strength of the gear. In the shrink fitting process, the gear is typically squeezed towards the shaft at room temperature using a press. An alternate method, known as warm shrink fitting, heats the already warm gear and safely squeezes it toward the shaft. The warm shrink fitting process for automobile transmission parts is becoming more commonplace, but the additional heating can cause the dimensions of the assembled parts (shaft/gear) to change with respect to both the outer diameter and the profile of the gear. As a result, there may be additional noise and vibration between gears. To address these problems, we analyzed the warm shrink fitting process using the contact pressure caused by fitting interference between the outer diameter of the shaft and the inner diameter of the gear, fitting temperature, and the profile tolerance of the gear as design parameters. In this study, a closed form equation for predicting the contact pressure and fitting load is proposed. This equation is used to develop an optimization technique for the warm shrink fitting process. The reliability of the model was verified using experimental results measured in the field, and FEM with thermal-structural coupled field analysis. Actual loads measured in the field showed good agreement with the results obtained by theoretical and finite element analysis, and expansion of the outer diameters of the gears agreed well with the results.     

Motor control of input-split hybrid electric vehicles

A motor control strategy for an input-split hybrid electric vehicle (HEV) is proposed. From a power characteristic analysis, it is found that the powertrain efficiency decreases for speed ratios at which power circulation occurs. Using dynamic models of an input-split HEV powertrain, a motor-generator control algorithm for obtaining high system efficiency is designed by inversion-based control. The performance of the control algorithm is evaluated by the simulator which is developed based on PSAT, and simulation results are compared with the test results. It is found that, even if the engine thermal efficiency is sacrificed by moving the engine operation point from the OOL for the control strategy, improved overall powertrain system efficiency can be achieved by the engine operation that gives a relatively high efficiency from the viewpoint of the overall powertrain efficiency. The control algorithm developed can be used in design of future electric vehicles.     

Sensor fusion-based lane detection for LKS+ACC system

This paper discusses the market trends and advantages of a safety system integrating LKS (Lane Keeping System) and ACC (Adaptive Cruise Control), referred to as the LKS+ACC system, and proposes a method utilizing the range data from ACC for the sake of lane detection. The overall structure of lane detection is the same as the conventional method using monocular vision: EDF (Edge Distribution Function)-based initialization, sub-ROI (Region Of Interest) for left/right and distance-based layers, steerable filter-based feature extraction, and model fitting in each sub-ROI. The proposed method adds only the system for confining lane detection ROI to free space that is established by range data. Experimental results indicate that such a simple adaptive ROI can overcome occlusion of lane markings and disturbance of neighboring vehicles.