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.     

Integrated approach to an optimal automotive timing chain system design

Ensuring engine efficiency is a crucial issue for automotive manufacturers. Several manufacturers focus on reducing the time taken to develop and introduce brand new vehicles to the market. Thus, a synergic approach including various simulations is generally adopted to achieve a development schedule and to reduce the cost of physical tests. This study involved proposing a design process that is very useful in the preliminary development stage through effective support from simulations. This type of simulation-based design process is effective in developing timing chain drives; the use of this process, based on results from multiple trials, showed improvements in performance including low friction and vibration, improved durability, and cost-effective part design when compared to conventional processes. This study proposes an integrated approach to the preliminary design of an automotive timing chain system. The approach involves structural and dynamic analyses. The details of the design process are described by using the case of a virtual engine. This study conducted and summarized a dynamic and structural analysis as well as topological optimization to describe a process to obtain optimal results. The results of this study indicated the following improvements in overall performance factors: 12.1 % improvement in transmission error, 10.1 % reduction in chain tension, 46 % reduction in tensioner arm weight, and 11 % reduction in transversal displacement.     

Optimum design of tilting bogie frame in consideration of fatigue strength and weight

This paper addresses the use of finite-element (FE) analysis to calculate the fatigue strength of a bogie frame, for the development of tilting trains in Korea. A multi-body dynamic analysis was performed to extract the load condition by tilting on curves. Using the results of the multi-body dynamic analysis and the load scenario setout in the UIC standard, FE analysis was performed to obtain the stress distribution and to calculate the fatigue strength. An attempt was made to minimize the weight of the bogie frame using a back-propagation artificial neural network (ANN). The results of this study reveal that the stresses at some nodes are near the fatigue limit in the Goodman diagram and by using back-propagation ANN, the weight of the bogie frame could be reduced by 4.7%.     

License plate extraction method for identification of vehicle violations at a railway level crossing

The primary cause of most railroad accidents is vehicle entry into railway level crossings despite warning messages. To identify drivers who violate railway level crossing regulations, vehicle license plate recognition can be applied at railway level crossings. The purpose of this paper is to present an effective method for extracting the license plate region from vehicle images taken at railway level crossings. The method proposed in this paper uses the variation in the gray-level values across the image of a license plate. For license plate region extraction, the character region is first recognized by identifying the character width and the difference between the background region and the character region. The license plate region is then extracted by finding the inter-character distance in the plate region. In addition, the license plate type is identified by the difference in the gray-level value between the background region and the character region. The proposed method is effective in solving the current challenges in extracting the license plate region from the damaged frames of license plates issued for domestic use, including new types of license plates. According to the experimental results, the proposed method yields a high extraction rate of 99.5% for vehicle license plates.     

Prediction of fatigue life and estimation of its reliability on the parts of an air suspension system

Air suspension systems have been implemented in various commercial vehicles, such as buses and special purpose trucks, because of the comfortable ride and easy height control. An evaluation of the durability of vehicle parts has been required for service life and safety starting in the early stages of design. The cyclic load applied to the vehicle can cause fatigue failure of parts, such as the suspension frame. This paper presents a method to predict the fatigue life of the suspension frame at the design stage of the air suspension system used in a heavy-duty vehicle. To estimate the fatigue life using the SN method, the Dynamic Stress Time History (DSTH) is necessary for the part of interest. DSTH can be obtained from the results of the flexible body dynamic analysis using the Belgian road simulation and the Modal Stress Recovery (MSR) method. Furthermore, the reliability of the predicted fatigue life can be evaluated by considering the variations in material properties. The probability and distribution of the expected life cycle can be obtained using experimental design with a minimum number of simulations. The advantage of using statistical methods to evaluate the life cycle is the ability to predict replacement time and the probability of failure of mass-produced parts. This paper proposes a rapid and simple method that can be effectively applied to the design of vehicle parts.     

Desired yaw rate and steering control method during cornering for a six-wheeled vehicle

This paper proposes a steering control method based on optimal control theory to improve the maneuverability of a six-wheeled vehicle during cornering. The six-wheeled vehicle is believed to have better performance than a four-wheeled vehicle in terms of its capability for crossing obstacles, off-road maneuvering and fail-safe handling when one or two of the tires are punctured. Although many methods to improve the four-wheeled vehicle’s lateral stability have been studied and developed, there have only been a few studies on the six-wheeled vehicle’s lateral stability. Some studies of the six-wheeled vehicle have been reported recently, but they are related to the desired yaw rate of a four-wheeled vehicle to control the six-wheeled vehicle’s maneuvering during corning. In this paper, the sideslip angle and yaw rate are controlled to improve the maneuverability during cornering by independent control of the steering angles of the six wheels. The desired yaw rate that is suitable for a six-wheeled vehicle is proposed as a control target. In addition, a scaled-down vehicle with six drive motors and six steering motors that can be controlled independently is designed. The performance of the proposed control methods is verified using a full model vehicle simulation and scaled-down vehicle experiment.     

Automotive structure vibration with component mode synthesis on a multi-level

The recursive component mode synthesis method (RCMS) has been implemented for the finite element analysis model of an automobile structure as an efficient free vibration analysis tool. The RCMS method is intended to obtain a better performance relative to the block Lanczos method, which is a traditional method in the industry of obtaining eigenvalues, while obtaining the acceptable accuracy. A numerical example of the automobile finite element model demonstrates the outstanding performance of RCMS compared to the block Lanczos method.     

An approach to estimating the hull girder response of a ship due to springing

This article describes an estimation method for the hull girder response of a ship due to springing. The linear and nonlinear springing effects on the hull girder are evaluated. Previous studies on the springing response focused mainly on the symmetric response, or vertical response. In this article, however, the springing analysis is extended to asymmetric responses, or horizontal and torsional responses. The Timoshenko beam model was used to calculate the hull girder response and the quadratic strip method was employed to calculate hydrodynamic forces and moments on the hull. To remove irregular frequencies, a rigid lid was adopted on the hull free surface level and hydrodynamic coefficients were interpolated for asymptotic values. Applications to two ships for the symmetric and asymmetric responses were carried out and the effect of springing responses is also discussed.     

Dynamic analysis of a pantograph-catenary system using absolute nodal coordinates

The dynamic interaction between the catenary and the pantographs of high-speed trains is a very important factor that affects the stable electric power supply. In order to design a reliable current collection system, a multibody simulation model can provide an efficient and economical method to analyze the dynamic behavior of the catenary and pantograph. In this article, a dynamic analysis method for a pantograph-catenary system for a high-speed train is presented, employing absolute nodal coordinates and rigid body reference coordinates. The highly flexible catenary is modeled using a nonlinear continuous beam element, which is based on an absolute nodal coordinate formulation. The pantograph is modeled as a rigid multibody system. The analysis results are compared with experimental data obtained from a running high-speed train. In addition, using a derived system equation of motion, the calculation method for the dynamic stress in the catenary conductor is presented. This study may have significance in providing an example that a structural and multibody dynamics model can be unified into one numerical system.     

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.