Angular position error detection of variable reluctance resolver using simulation-based approach

The variable reluctance type resolver is widely used in an electric motor for hybrid electric vehicles as a rotor position sensor. The purpose of this paper is to present a simulation-based approach capable of determining a more accurate rotor shape of variable reluctance resolver in order to cut the time and cost of its development before testing a physical prototype. For the verification of the simulation-based approach to the position error detection of rotor, experiments for 8XVR resolver were conducted. Based on this approach, an optimal salient-pole rotor shape of 4X-VR resolver is proposed.     

Fatigue life reliability prediction of a stub axle using Monte Carlo simulation

A stub axle is a part of a vehicle constant-velocity system that transfers engine power from the transaxle to the wheels. The stub axle is subjected to fatigue failures due to cyclic loads arising from various driving conditions. The aim of this paper was to introduce a probabilistic framework for fatigue life reliability analysis that addresses uncertainties that appear in the mechanical properties. Service loads in terms of response-time history signal of a Belgian pave were replicated on a multi-axial spindle-coupled road simulator. The stress-life method was used to estimate the fatigue life of the component. A fatigue life probabilistic model of a stub axle was developed using Monte Carlo simulation where the stress range intercept and slope of the fatigue life curve were selected as random variables. Applying the goodness-of-fit analysis, lognormal was found to be the most suitable distribution for the fatigue life estimates. The fatigue life of the stub axle was found to have the highest reliability between 8000–9000 cycles. Because of uncertainties associated with the size effect and machining and manufacturing conditions, the method described in this paper can be effectively applied to determine the probability of failure for mass-produced parts.     

Design optimization of an injection mold for minimizing temperature deviation

The quality of an injection molded part is largely affected by the mold cooling. Consequently, this makes it necessary to optimize the mold cooling circuit when designing the part but prior to designing the mold. Various approaches of optimizing the mold cooling circuit have been proposed previously. In this work, optimization of the mold cooling circuit was automated by a commercial process integration and design optimization tool called Process Integration, Automation and Optimization (PIAnO), which is often used for large automotive parts such as bumpers and instrument panels. The cooling channels and baffle tubes were located on the offset profile equidistant from the part surface. The locations of the cooling channels and the baffle tubes were automatically generated and input into the mold cooling computer-aided engineering program, Autodesk Moldflow Insight 2010. The objective function was the deviation of the mold surface temperature from a given design temperature. Design variables in the optimization were the depths, distances and diameters of the cooling channels and the baffle tubes. For a more practical analysis, the pressure drop and temperature drop were considered the limited values. Optimization was performed using the progressive quadratic response surface method. The optimization resulted in a more uniform temperature distribution when compared to the initial design, and utilizing the proposed optimization method, a satisfactory solution could be made at a lower cost.     

Suspension parameter estimation in the frequency domain using a matrix inversion approach

The dynamic lumped parameter models used to optimise the ride and handling of a vehicle require base values of the suspension parameters. These parameters are generally experimentally identified. The accuracy of identified parameters can depend on the measurement noise and the validity of the model used. The existing publications on suspension parameter identification are generally based on the time domain and use a limited degree of freedom. Further, the data used are either from a simulated ‘experiment’ or from a laboratory test on an idealised quarter or a half-car model. In this paper, a method is developed in the frequency domain which effectively accounts for the measurement noise. Additional dynamic constraining equations are incorporated and the proposed formulation results in a matrix inversion approach. The nonlinearities in damping are estimated, however, using a time-domain approach. Full-scale 4-post rig test data of a vehicle are used. The variations in the results are discussed using the modal resonant behaviour. Further, a method is implemented to show how the results can be improved when the matrix inverted is ill-conditioned. The case study shows a good agreement between the estimates based on the proposed frequency-domain approach and measurable physical parameters.     

Fatigue design approach for the spot-welded T-type member using a simulated single spot-welded joint

In order to develop a fatigue design method for actual railroad car and commercial vehicle body structures using the fatigue data of simulated single spot-welded lap joints, we first analyzed the stress distribution and evaluated fatigue strength of spot-welded T-type members that are the components of actual railroad car and commercial vehicle body structures. Next, fatigue design approach of these members using the fatigue data of single spot-welded lap joints was investigated. From our results, we found that, even though there was a quantitative difference of fatigue strength between the single spot-welded joint and the actual members over the same number of fatigue cycles, through the use of appropriate correction, the fatigue design criterion of actual spot-welded members, such as those used in railroad car and commercial vehicle body, can be predicted using the fatigue strength of single spot-welded joint.     

Shockwave-based queue estimation approach for undersaturated and oversaturated signalized intersections using multi-source detection data

With the progress of information and sensing technologies, estimating vehicular queue length at signalized intersections becomes feasible and has attracted considerable attention. The existing studies provided a solid theoretical foundation for the estimation; however, the studies have some restrictions or limitations more or less. This paper presents a new methodology for estimating vehicular queue length at signalized intersections using multi-source detection data under both undersaturated and oversaturated conditions. The methodology applies the shockwave theory to model queue dynamics. Using data from probe vehicles and point detectors, analytical formulations for calculating the maximum and minimum (residual) queue lengths of each cycle are developed. Ground truth data were collected from numerical experiments conducted at two intersections in Shanghai, China, to verify the proposed methodology. It is found that the methodology has mean absolute percentage errors of 17.09% and 12.28%, respectively, for maximum queue length estimation in two tests, which are reasonably effective. However, the methodology is unsatisfactory in estimating the residual queue length. Other limitations of the proposed models and algorithms are also discussed in the paper.     

Study on pilot injection of DI diesel engine using common-rail injection system

In recent DI diesel engines designed to achieve high output and meet future exhaust regulation, the pilot injection control using a common-rail injection system is adopted. In this research, we developed visualization equipment for pilot combustion behavior of non-luminous flame to clarify the influence of pilot injection parameters (timing and quantity) on engine performance. As a result of this analysis, we clarified the influence of pilot injection parameters on pilot-main combustion and found the optimum pilot injection controlling method.     

半挂车车架多轴疲劳寿命研究

根据半挂车车架结构特点,建立了半挂车车架的有限元模型及多体动力学模型,对车架进行了静力学分析和以H级路面的路面载荷作为边界条件的动力学分析,得到了车架静态应力分布和载荷谱。并以此数据为依据,采用Wang-Brown多轴疲劳损伤模型预测了半挂车车架的多轴疲劳寿命,针对其疲劳薄弱部分提出了结构和工艺优化方案。优化后的车架满足使用寿命要求,且比原设计减重20%。     

Fatigue features extraction of road load time data using the S-transform

This paper presents the algorithm development of a new fatigue data editing technique using S-T approach. In general, the S-transform (S-T) is a time-frequency spectral localization method which performs a multi-resolution analysis on signal. This method represents a better time-frequency resolution especially for non-stationary signal analysis. This technique was developed to produce shortened fatigue data for fatigue durability testing. The S-T method was applied to detect the damaging events contained in the fatigue signals due to high S-T spectrum location. The damaging events were extracted from an original fatigue signal to produce the shortened edited signal which has equivalent fatigue damage. Three types of road load fatigue data were used for simulation purpose, pave track, highway and country road. In this study, an algorithm was developed, to detect the damaging events in the original fatigue signal. The algorithm can be used to extract the fatigue damaging events and these events were combined in order to produce a new edited signal which neglect the low amplitude cycles. The edited signal consists of the majority of the original fatigue damage in the shortened signal with 15–25% time reduction. Thus, it has been suggested that this shortened signal can then be used in the laboratory fatigue testing for the purpose of accelerated fatigue testing.     

Fatigue life prediction of a rubber material based on dynamic crack growth considering shear effect

This paper suggests a fatigue life calculation method (A fatigue life calculation method is suggested) for rubber components based on the dynamic crack growth considering shear effect. Dynamic tearing tests were carried out, and the crack length was measured using an optical microscope to calculate the dynamic crack growth rate which characterizes and determines the fatigue life. The algorithm was numerically implemented in finite element code, ABAQUS standard, by using the user subroutine and applied to several rubber components. In the finite element analysis, deformation mode of an element was classified into tension and shear, and a weighting factor was multiplied to a strain energy density according to the degree of shear strain. Tension and compression of an elliptic dumbbell specimen was simulated in order to verify the material parameters of the suggested fatigue life prediction equation and to enhance the reliability of the algorithm. Finally, the fatigue life of a vehicle suspension bushing was calculated and compared with test. There were good agreements in the failure location and the magnitude of the fatigue life.     

Development of a generalised equivalent estimation approach for multi-axle vehicle handling dynamics

This paper devotes analytical effort in developing the 2M equivalent approach to analyse both the effect of vehicle body roll and n-axle handling on vehicle dynamics. The 1M equivalent vehicle 2DOF equation including an equivalent roll effect was derived from the conventional two-axle 3DOF vehicle model. And the 1M equivalent dynamics concepts were calculated to evaluate the steady-state steering, frequency characteristics, and root locus of the two-axle vehicle with only the effect of body roll. This 1M equivalent approach is extended to a three-axle 3DOF model to derive similar 1M equivalent mathematical identities including an equivalent roll effect. The 1M equivalent wheelbases and stability factor with the effect of the third axle or body roll, and 2M equivalent wheelbase and stability factor including both the effect of body roll and the third-axle handling were derived to evaluate the steady-state steering, frequency characteristics, and root locus of the three-axle vehicle. By using the recursive method, the generalised 1M equivalent wheelbase and stability factor with the effect of n-axle handling and 2M equivalent generalised wheelbase and stability factor including both the effect of body roll and n-axle handling were derived to evaluate the steady-state steering, frequency characteristics, and root locus of the n-axle vehicle. The 2M equivalent approach and developed generalised mathematical handling concepts were validated to be useful and could serve as an important tool for estimating both the effect of vehicle body roll and n-axle handling on multi-axle vehicle dynamics.     

Comparison of two injection systems in an HSDI diesel engine using split injection and different injector nozzles

The demand for reduced pollutant emissions has motivated various technological advances in passenger car diesel engines. This paper presents a study comparing two fuel injection systems and analyzing their combustion noise and pollutant emissions. The abilities of different injection strategies to meet strict regulations were evaluated. The difficult task of maintaining a constant specific fuel consumption while trying to reduce pollutant emissions was the aim of this study. The engine being tested was a 0.287-liter single-cylinder engine equipped with a common-rail injection system. A solenoid and a piezoelectric injector were tested in the engine. The engine was operated under low load conditions using two injection events, high EGR rates, no swirl, three injection pressures and eight different dwell times. Four injector nozzles with approximately the same fuel injection rate were tested using the solenoid injection system (10 and 12 orifice configuration) and piezoelectric system (6 and 12 orifice design). The injection system had a significant influence on pollutant emissions and combustion noise. The piezoelectric injector presented the best characteristics for future studies since it allows for shorter injection durations and greater precision, which means smaller fuel mass deliveries with faster responses.     

Analysis of injection rate characteristics of fuel injection systems in IDI diesel engines using an enhanced numerical simulation code

A fuel injection simulation code was developed with an approximate lumped-parameter network scheme. This code has many improvements for obtaining better computational accuracy. These include a new iteration approach, a nonuniform dividing method of injection pipe, a large number of injection system elements and consideration of kinematic viscosity of the fuel and its flow resistance through the injector during the throttling period. This simulation code was used to evaluate various control systems of injection rate for IDI diesel engines. Based on the results, a comparison was carried out among control characteristics of fuel injection rate of these systems, and clear correlation was shown between operating conditions of the injection pump and injection rates.     

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.     

基于模糊神经网络的信号交叉口交通量预测方法研究

提出了基于模糊神经网络技术的信号交叉口交通量滚动预测模型。该模型的主要特点地交叉口交通量变化的规律可以利用模糊神经网络在线学习得到，因此该模型具有计算简单，能够不断积累经验的优点。通过仿真算例研究了该模型的实用性。     

Wear rate estimation of train wheels using dynamic simulations and field measurements

Wheel–rail wear is one of the important problems in the railway industry, especially from the point of safety, maintenance, and replacement cost. To investigate this phenomenon, it is necessary to simulate the wheel–rail interaction. The simulation results and in particular the wear number is not tangible enough to explain the wear condition of the system. For one set of simulation performed on two different railway systems one could obtain the same wear numbers, of say 100, while having two completely different wear rates. In order to have a better understanding of the wear condition, it is proposed to convert the wear numbers to wear rates. In doing so by measuring the wear rate, one determines the rate at which the wheel flange thickness is reduced. In this research, a new approach has been proposed to determine the wheel wear rate through multi-body dynamic analysis and simulation and the field measurements carried out on the fleet of one of Tehran's subway lines. This procedure could also be expanded to determine a wear criterion for specific lines and their fleets. Having this wear criterion would provide a better understanding of the simulation results either prior to the construction of railway lines or for the presently used ones. In other words, designers can simulate a railway line, not being constructed yet, and with a good approximation determine the critical points along the line with high wear rates, and make necessary modifications to decrease the wear.     

Fatigue life prediction based on the rainflow cycle counting method for the end beam of a freight car bogie

This paper presents a system for treating of the actual measured data for load histories. The approach consists of two steps: stress analysis and fatigue damage prediction. Finite element analysis is conducted for the component in question to obtain detailed stress-strain responses. A significant number of failures occurred in a brake end beam which led to economic losses and disruption of service. The cracks appeared to be fatigue cracks caused by the dynamic load produced in the loaded bogie frame. Strain gauge data were analyzed, and fatigue cycles were calculated from this data. Rainflow cycle counting was used to estimate cumulative damage of the end beam under in-service loading conditions. The fatigue life calculated with the rainflow cycle counting method, the P-S-N curve, and the modified Miner’s rule agreed well with actual fatigue life within an error range of 2.7%~31%.     

Numerical study of the early injection parameters on wall wetting characteristics of an HCCI diesel engine using early injection strategy

Wall wetting in the early injection period has been proved to be unavoidable in the HCCI (Homogeneous charge compression ignition) diesel engine using early injection strategy, which directly affects in-cylinder fuel-air mixture formation. In this study, the effects of the early injection parameters (injection timing, injection angle and injection pressure) on wall wetting characteristics of an HCCI diesel engine using early injection strategy have been numerically investigated. The variations of maximum wall film mass, evaporated wall film mass and residual wall film mass have been summarized. The concept of MHI (Mixture Homogenous Index) is introduced to evaluate the homogeneity of fuel-air mixture in the wall wetting region. In additions, the effects of the early injection parameters on the HC (Hydrocarbon Compounds) and CO (Carbon Monoxide) emissions have also been discussed. Results showed that in order to decrease the HC and CO emission caused by wall wetting as low as possible, it was better to increase the injection pressure and to advance the injection timing. The most effective method was to narrow the injection angle, In addition, the impingement target should be considered for choosing the injection timing and injection angle, and the impingement target of the piston bowl lip was recommended due to the enhancement of the atomization and the higher surface temperature.     

Hydroplaning simulation of a tire in thin water using fem and an estimation method and its application to skid number estimation

To simulate the hydroplaning of a tire, many analytical studies have been performed using commercial explicit FE (Finite Element) codes such as MSC.DYTRAN and LS-DYNA. However, most previous studies on this subject have addressed simulation of hydroplaning for water more than 5 mm deep. Additionally, because a great number of Eulerian elements and Lagrangian elements are typically used to analyze hydroplaning and because multiple analyses should be performed for various water depths, long CPU times are required. In this study, it was found that the traction force and the lift and drag forces between the tire and the road surface could be easily estimated for water shallower than 5 mm using an exponential function based on tire rolling FE simulation results. Furthermore, changes in skid resistance, expressed as SN (skid number), could be estimated for various water depths and vehicle speeds using the method proposed in this study, and the results were proven to be in good agreement with results obtained using the ASTM E274 Pavement Friction Tester.