New nonlinear bushing model for general excitations using Bouc-Wen hysteretic model

Because the characteristics of rubber bushing significantly affect the accuracy of vehicle dynamics simulations, they should be accurately modeled in the vehicle suspension model. In this paper, a new nonlinear bushing model for automotive bushing components is developed to improve the accuracy of vehicle dynamics analysis. Bushing components were first tested to capture the nonlinear and hysteretic behavior of typical elements by using a MTS 3-axis elastomer tester. A simple Bouc-Wen hysteretic differential model was modified to generate a more precise rubber bushing model. A sine wave, step input, and random excitations are imposed on the bushing. The ADAMS program is used to calculate sensitivity and the VisualDOC program is employed to find the optimal parameters for the bushing model. An error function is designed to find optimal parameters of the model. Parameter identification is carried out to satisfy the static and dynamic characteristics due to sine and step excitation inputs. It was proved that the proposed model could predict the bushing forces under sine, step, and random inputs well. The errors are within 10% in the overall range. To show the validity of the proposed model, a numerical example was also carried out. Because the bushing forces due to random excitation input show good agreement with experiments, the proposed bushing model is available in the vehicle dynamics simulation.     

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%.     

Measurement of hydrocarbon and carbon monoxide emissions during the starting of automotive DI Diesel engines

Most of hydrocarbon (HC) and carbon monoxide (CO) emissions from automotive DI Diesel engines are produced during the engine warm-up period and are primarily caused by difficulties in obtaining stable and efficient combustion under these conditions. Furthermore, the contribution of engine starting to these emissions is not negligible; since this operating condition is highly unfavorable for the combustion progress. Additionally, the catalytic converter is ineffective due to the low engine temperature. In conjunction with adequate engine settings (fuel injection and fresh air control), either the glow plugs or the intake air heater are activated during a portion of the engine warm-up period, so that a nominal engine temperatures is reached faster, and the impact of these difficulties is minimized. Measurement of gaseous pollutants during engine warm-up is currently possible with detectors used in standard exhaust gas analyzers (EGA), which have response times well-suited for sampling at such transient conditions. However, these devices are not suitable for the measurement of exhaust emissions produced during extremely short time intervals, such as engine starting. Herein, we present a methodology for the measurement of the cumulative pollutant emissions during the starting phase of passenger car DI Diesel engines, with the goal of overcoming this limitation by taking advantage of standard detectors. In the proposed method, a warm canister is filled with an exhaust gas sample at constant volumetric flow, during a time period that depends on the engine starting time; the gas concentration in the canister is later evaluated with a standard EGA. When compared with direct pollutant measurements performed with a state-of-art EGA, the proposed procedure was found to be more sensitive to combustion changes and provided more reliable data.     

Influence of shock absorber wearing on vehicle brake performance

In order to safely maintain a vehicle, it is necessary to verify the most important systems that affect safety during Periodic Motor Vehicle Inspections (PMVIs). In a previous paper, a test method and validation criteria were suggested by the authors to verify shock absorber status during PMVIs, as they are a fundamental component that may wear out during a vehicle’s life. In this paper, variations of the performance of the vehicle’s brakes resulting from shock absorber wearing have been analyzed, in order to confirm whether the suggested criteria is valid for taking into account longitudinal forces and pitch movement on the vehicle. A simulation-based study was conducted with several configurations of a worn damper on a vehicle driving on two virtual roads: smooth and undulating. The results confirmed that the damping coefficient established as an acceptable value to verify the shock absorber status in PMVIs is also valid considering the forces involved in a braking maneuver.     

Driver propensity characterization for different forward collision warning times

The forward collision warning system, which warns danger to the driver after sensing possibility of crash in advance, has been actively studied recently. Such systems developed until now give a warning, regardless of driver’s driving propensity. However, it’s not reasonable to give a warning to every driver at the same time because drivers are different in driving propensity. In this study, to give a warning to each driver differently, three metrics classifying driver’s driving propensity were developed by using the driving data on a testing ground. These three metrics are the predicted time headway, required deceleration divided by the deceleration of the leading vehicle, and the resultant acceleration divided by the deceleration of the leading vehicle. Driving propensity was divided into 3 groups by using these metrics for braking and steering cases. In addition, these metrics were verified by making sure that braking propensity could be classified on public roads as well.     

Bayesian kriging regression for the accuracy improvement of beam modeled T-junctions of buses and coaches structures with a methodology based on FEM behavioral analysis

This paper has been developed in the framework of the alternative beam T-junction solution previously propoused by the authors (Alcalá et al., 2013), with the scope of optimizing the behavior of buses and coaches upper structures modeled with beam type elements. The alternative beam T-junction model proposed by the authors, had a total of six elastic elements at the junction level allowing to modify the localized rigidity of any modeled T-junctions, therefore improving their behavior and avoiding the well known rigidity issue these elements have. A fundamental aspect behind the use of these alternative beam models is related to the necessity of correctly estimating the rigidity values of the elastic elements for each modeled T-junction. In this context, we propose applying a surrogate model for the reference calculations which is based on statistical Bayesian kriging predictors. Statistical predictions have the added value, with respect to deterministic solutions, of providing a quantification of uncertainty. The development of the kriging predictors has required the application of a statistical methodology including computer experiment design, computation of moments of inertia, graphical and ANOVA type sensitivity analysis and Monte Carlo computation of Bayesian inference. The results of the application have been a very satisfactory trade-off between accuracy of approximation (prediction) and computational cost. The surrogate kriging models also provide an useful tool for a better understanding of the input-output relationships involved in the reference computations.     

Worst-case scenario development based on Sine with Dwell test and evaluation for vehicle dynamics controller in UCC HILS

The current test methods are insufficient to evaluate and ensure the safety and reliability of vehicle systems for all possible dynamic situations, including the worst case scenarios such as rollover, spin-out and so on. Although the known NHTSA Sine with Dwell steering maneuvers have been applied for the vehicle performance assessment, they are not enough to estimate other possible worst case scenarios. Therefore, it is crucial for us to verify the various worst case scenarios, including the existing severe steering maneuvers. This paper includes useful worst case scenarios based upon the existing worst case scenarios mentioned above and worst case evaluation for the vehicle dynamic controller in a simulation basis and UCC HILS. The only human steering angle was selected as a design parameter here and optimized to maximize the index function to be expressed in terms of both yaw rate and side slip angle. The obtained scenarios were enough to generate the worst case scenario to meet NHTSA worst case definition. It has been concluded that the new procedure in this paper is adequate to create other feasible worst case scenarios for a vehicle dynamic control system.     

Meachanism and method of DPF regeneration by oxygen radical generated by NTP technology

By using a self-designed non-thermal plasma (NTP) injection system, an experimental study of the regeneration of DPF was conducted at different temperatures, where oxygen as the gas source. The results revealed that PM can be decomposed to generate CO and CO₂ by these active substances O₃, O which was generated through the discharge reaction of NTP reactor. With the increasing of test temperature, the mass of C₁ (C in CO) shows a overall downward trend while the mass of C₂ (C in CO₂) and C₁₂ (C₁ and C₂) increase firstly and then decrease. When the test temperature is 80°C, the backpressure of DPF decreases fastest and the regenerative effect is remarkable. DPF can be regenerated by NTP technology without any catalyst at a lower temperature. Compared with the traditional regeneration method, the NTP technology has its superiority.     

Transient modeling and validation of lithium ion battery pack with air cooled thermal management system for electric vehicles

A transient numerical model of a lithium ion battery (LiB) pack with air cooled thermal management system is developed and validated for electric vehicle applications. In the battery model, the open circuit voltage and the internal resistance map based on experiments are used. The Butler-Volmer equation is directly considered for activation voltage loss estimation. The heat generation of cells and the heat transfer from cells are also calculated to estimate temperature distribution. Validations are conducted by comparison between experimental results at the cell level and the pack level. After validations, the effects of module arrangement in a battery pack are studied with different ambient temperature conditions. The configuration that more LiB cells are placed near the air flow inlet is more effective to reduce the temperature deviation between modules.     

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.