Development of knowledge based body structure concept design model

The purpose of this study is to propose a concept design process for an automotive body structure using technical information on the major joints and members of vehicles. First, in order to collect the technical information on major joints and members, 17 vehicles were selected using benchmark data. The collected technical information for the selected vehicles was the cross sectional shapes of each joint and member which were used for the analysis of joint stiffness, crashworthiness and static stiffness of the member to make a database along with cross section properties. This study applied a ‘What If Study’ technique to perform a concept design of an automotive body using the analyzed information and selected cross section meeting the design objectives. The criteria for the selection of the cross section were defined by subdividing the defined design objectives of an automotive body structure and constraints into members and joints. In order to configure an analysis model of an automotive body structure using the selected cross section, a shape parametric model was used and static stiffness, dynamic stiffness and crashworthiness were assessed to evaluate the configured automotive body structure. The evaluation result showed that the crashworthiness and static/dynamic stiffness were improved compared to an existing body structure. In addition, the weight of the body structure was reduced. Through this study, the process that can rapidly and effectively derive and evaluate the concept design of an automotive body structure was defined. It is expected that, henceforth, this process will be helpful for the study of automotive body structures.     

Bayesian estimation of multinomial probit models of work trip choice

In this paper, we estimate a multinomial probit model of work trip mode choice in Seoul, Korea, using the Bayesian approach with Gibbs sampling. This method constructs a Markov chain Gibbs sampler that can be used to draw directly from the exact posterior distribution and perform finite sample likelihood inference. We estimate direct and cross-elasticities with respect to travel cost and the value of time. Our results show that travel demands are more sensitive to travel time than travel cost. The cross-elasticity results show that the bus has a greater substitute relation to the subway than the auto (and vice versa) and that an increase in the cost of an auto will increase the demand for bus transport more so than that of the subway.     

Performance Design of an Exhaust Superheater for Waste Heat Recovery of Construction Equipment

Although fuel cost has been the largest portion of annual operating costs of construction equipment, it is possible to save the energy and reduce cost using fuel economy enhancement technology. In this study, an organic Rankine cycle is applied to an excavator in order to recover waste heat, reproduce it into electrical energy, and consequently reduce the fuel consumption by 10 %. A design process was carried out to develop an exhaust gas superheater that recovers the waste heat from exhaust gas through a composite-dimensional thermal flow analysis. A one-dimensional code was developed to perform a size design for the exhaust gas superheater. The ranges for the major design parameters were determined to satisfy the target of the heat recovery, as well as the pressure drop at both fluid sides. Performance analysis was done through onedimensional design code results, which were compared with three-dimensional CFD analysis. By utilizing a 3D commercial code, the arrangement of the tubes was selected and the working fluid pressure drop was reduced through a detailed layout design. The design procedure was verified by a performance evaluation of the prototype, which yielded only a 7 % tolerance in heat recovery.     

Vehicle distance estimation using a mono-camera for FCW/AEB systems

For robust vision-based forward collision warning (FCW) and autonomous emergency braking (AEB) systems, not only reliable detection performance including high detection rate and low false positives but also accurate measurement output of a target vehicle is required. Especially, in order to reduce false alarm or activation of FCW/AEB systems, the systems require the precise measurement output of a target object, such as position, velocity, acceleration, and time-to-collision (TTC). In this study, we developed a measurement estimation algorithm of a target vehicle using a monocular camera. This method estimates two cases of vehicle widths for a target vehicle by using the detected lane information and a pin-hole camera model. After that, the position, velocity, acceleration, and TTC of a target vehicle are estimated by using a Kalman filter for the each estimated vehicle width. To improve robustness, the both estimation results using the detected lane information and the pinhole camera model are fused. This estimation algorithm was evaluated and compared with the state-of-the-art technology. As a result, the proposed measurement output estimation method can improve the performance of the FCW/AEB systems.     

Robust design optimization of suspension system by using target cascading method

This study presents the robust design optimization process of suspension system for improving vehicle dynamic performance (ride comfort, handling stability). The proposed design method is so called target cascading method where the design target of the system is cascaded from a vehicle level to a suspension system level. To formalize the proposed method in the view of design process, the design problem structure of suspension system is defined as a (hierarchical) multilevel design optimization, and the design problem for each level is solved using the robust design optimization technique based on a meta-model. Then, In order to verify the proposed design concept, it designed suspension system. For the vehicle level, 44 random variables with 3% of coefficient of variance (COV) were selected and the proposed design process solved the problem by using only 88 exact analyses that included 49 analyses for the initial meta-model and 39 analyses for SAO. For the suspension level, 54 random variables with 10% of COV were selected and the optimal designs solved the problem by using only 168 exact analyses for the front suspension system. Furthermore, 73 random variables with 10% of COV were selected and optimal designs solved the problem by using only 252 exact analyses for the rear suspension system. In order to compare the vehicle dynamic performance between the optimal design model and the initial design model, the ride comfort and the handling stability was analyzed and found to be improved by 16% and by 37%, respectively. This result proves that the suggested design method of suspension system is effective and systematic.     

Numerical study on the gap flow of a semi-spade rudder to reduce gap cavitation

The flow around the gap of a semi-spade rudder was simulated as part of an effort to minimize gap cavitation. Simulations were performed for various devices aimed at controlling the gap flow in two-dimensional and three-dimensional domains using the Reynolds-averaged Navier–Stokes equations. A significant difference in the pressure field near the gap in two- and three-dimensional computations was found. In particular, the pressure field of the gap, where the local flow is dominant, and that of the main flow from the propeller were compared. Finally, a remedy for the gap cavitation that occurs between the horn and the rudder was introduced.     

Robustness analysis of ESC ECU to characteristic variation of vehicle chassis components using HILS technique

The ESC system, since its introduction in the mid 90s, has greatly contributed to prevention of vehicle accidents with its capability of maintaining vehicle stability in severe driving conditions. Due to its significant advantages, many nations are now adopting regulations that mandate installation of the ESC system in all classes of passenger vehicles — from mini to luxury. Accordingly it became important to know whether an ESC ECU can yield good performance on a wide range of vehicle parameter changes. In this paper, robustness analysis was conducted to study how characteristic variation of the main chassis components affect the performance of the ESC ECU. This analysis was carried out using a HILS system built on an actual ESC ECU. The variation range of each chassis component was carefully selected considering the component’s design criteria adopted in automotive industries. Based upon the robustness analysis results, the allowable variation ranges of the chassis components for ensuring sound performance of an ESC ECU were proposed.     

Abnormality detection via SVDD technique of motor-generator system in HEV

This paper introduces a method to detect abnormality of MGS (Motor-Generator System) in HEV (Hybrid Electric Vehicle) using its temperature. The MGS in HEV consists of two Motor-Generators (MG1, MG2), Compound Gear Unit, and etc. The MG1 is to act as a generator in conventional internal combustion engine. And the MG2 is an electric motor to rotate wheel of vehicle using saved electricity in battery or using produced electricity via the MG1. In case of overheating, the electric motors are easily damaged because resistance of wires in motor is abnormally changed. Therefore, detection of abnormally changed temperature in motors (MG1 and MG2) is essential. In this study, the temperature distribution of two Motor-Generators is observed simultaneously in 2-dimensional space. A boundary region of normal operation temperature of two motors is obtained via SVDD technique utilizing Gaussian kernel, one of the most widely being used Mercer kernels. Linear SVDD technique generates boundary of exact ball shape, however SVDD technique using Gaussian kernel can generate nonlinear boundary of distorted ball shape. Abnormality boundary comparison is made between the obtained boundary via SVDD technique and those obtained from conventional temperature range checking method. In order to compare the performance of proposed method, the actual vehicle operation data in excessive driving condition on mountain road is adopted. In verification, simulation shows that warning time due to proposed method is faster and more efficient than those due to conventional method. It is also shown that the reliability of the Motor-Generator System can be improved by using the proposed abnormality detection method.     

Optimizing the shape of a bumper beam section considering pedestrian protection

This paper presents a design technique to optimize the shape of a vehicle bumper beam that satisfies both the safety requirements for a front rigid-wall impact and the regulations protecting pedestrians from lower leg injuries caused by bumper impacts. An intermediate response surface modeling (IRSM) technique was introduced to approximate the non-linear force-displacement curves obtained from the front impact analysis of a vehicle bumper. The accuracy of the IRSM model was tested by comparing its results with those of the non-linear finite element analysis. The maximum displacement error between the two models did not exceed 3%. Using pedestrian impact analyses based on the experimental arrangement of the Plackett-Burman design, the approximate functions describing the response values acting on the lower legs were calculated. The shape of the bumper beam was optimized by integrating the IRSM with the force-displacement model and the approximate functions on lower leg impact. The optimization results satisfied safety regulations on the maximum allowable displacement of the vehicle bumper, and also the regulations protecting pedestrians from lower leg injuries caused by bumper impacts.