Sensitivity analysis for reducing critical responses at the axle shaft of a lightweight vehicle

Critical responses are frequently detected at the coupled torsional beam axle (CTBA) of a lightweight vehicle. However, the freedom to modify the design of the axle shaft is limited because the suspension system must satisfy other vehicle requirements such as steering performance. Conventional sensitivity analysis cannot provide practical information about the resonant behavior because the analysis only identifies the contribution of the axle shaft to the behavior. This paper presents a novel sensitivity analysis based on transmissibility ratios (TRs). The vehicle components other than the axle shaft that can be modified to control the critical spectra are identified using acceleration responses. A multi-body vehicle model is constructed to simulate the proposed design modifications, and the simulation results show that the vibration of the axle shaft is considerably reduced by the modifications. Because the TRs on the CTBA are effectively minimized through the modified design strategy, the resonant response from the axle shaft can be controlled efficiently.     

A comparative study on the power characteristics and control strategies for plug-in hybrid electric vehicles

A comparative study was performed on two types of plug-in hybrid electric vehicles (PHEVs): the GM Volt and the Toyota Prius Plug-in Hybrid. First, the powertrain models of the two vehicles were derived. Based on the dynamic models, a detailed component control algorithm was developed for each PHEV. Specifically, a control algorithm was proposed for motor generator 1 (MG1) and MG2 to achieve optimal engine operation. Additionally, an energy management strategy for selecting the operation mode was developed from the viewpoint of fuel economy, battery state of charge and vehicle velocity. Using the dynamic model of the control algorithm for each PHEV, simulations were performed, and the simulation results were verified by comparing them with those obtained using the Powertrain System Analysis Toolkit simulator for the plug-in Prius. Based on the simulation results, a comparative study was performed, and it was found that the role and capacity of MG1 and MG2 and the mode selection algorithm must be determined depending on the configuration of the PHEV.     

Numerical investigation of a DI diesel spray flame using a detailed chemical reaction mechanism

Emission standards have grown increasingly stricter, consequently triggering greater interest in issues surrounding environmental pollution. In particular, soot and NOx released from DI diesel vehicles is considered to be the main source of air pollution in urban environments. However, the mechanics of fuel spray formation and the influence of the operating parameters on the resulting spray flame are not yet fully understood. In this study, the original KIVA code was modified to incorporate a detailed chemical reaction mechanism involving various species and multiple reaction steps to better understand the spray characteristics. n-Heptane, C₇H₁₆, was used as the representative fuel for diesel fuel, and the reaction mechanism for this fuel was composed of 66 species and 274 elementary reaction steps. The accuracy of the predicted results was demonstrated primarily by a comparison with experimental results. The numerical prediction of a specific operating condition for the parametric investigation correlates well with the experimental results.     

Simulation of a powertrain system for the diesel hybrid electric bus

The plug-in hybrid electric bus (HEB) is designed to overcome the vulnerable driving range and performance limitations of a purely electric vehicle (EV) and have an improved fuel economy and lower exhaust emissions than those of a conventional bus and convention HEBs. The control strategy of the plug-in parallel HEB??s complicated connected propulsion system is one of the most significant factors for achieving a higher fuel economy and lower exhaust emissions than those of the HEV. The proposed powertrain control strategy has flexibility in adapting to the battery??s state of charge (SOC), exhaust emissions, classified driving patterns, driving conditions, and engine temperature. Simulation is required to model hybrid powertrain systems and test and develop powertrain control strategies for the plug-in parallel HEB. This paper describes the simulation analysis tools, powertrain components?? models and modifications, simulation procedure, and simulation results.     

Roof strength performance improvement enablers

Before 2009, rollover in vehicle accidents had not been significantly studied not only because its rate is lower than other types of accidents but also because it had been easy to meet the rollover regulation, the FMVSS 216 Roof Crush Resistance target. The regulation only requires that the strength-to-weight ratio (SWR) be 1.5, i.e., it was acceptable when the roof could withstand a force of only 1.5 times the vehicle??s weight. In other words, rollover is not considered an important safety factor. However, presently, the situation has completely changed. Rollover is now considered a key safety factor. Recently, the number of rollover incidences has been increasing, reaching as much as the number of front, side and rear accidents. Furthermore, the IIHS has begun to require that the roof must withstand a force of 4.0 times the vehicle??s weight, a more severe restriction than FMVSS. To satisfy this requirement, many manufacturers, universities and institutes are studying the topic. This paper focuses on changing the body structure to minimize injury to the occupant when rollover occurs and help rollover safety performance become excellent. This paper draws on a simple analysis that is based on general factors: changes in the material, the addition of welds and additional reinforcements. The best result will be determined, as described by this paper.     

Technology analysis and low-cost design of automotive radar for adaptive cruise control system

Recently, the advanced driver assistance system (ADAS), which helps mitigate car accidents, has been developed using environmental detection sensors, such as long and short range radar, lidar, wide dynamic range cameras, ultrasonic sensors and laser scanners. Among these detection sensors, radars can quickly provide drivers with reliable information about the velocity, distance and direction of a target obstacle, as well as information about the vehicle in changing weather conditions. In the adaptive cruise control system (ACCS), three radar sensors are usually needed because two short range radars are used to detect objects in the adjacent lane and one long range radar is used to detect objects in-path. In this paper, low-cost radar based on a single sensor, which can detect objects in both the adjacent lane and in-path, is proposed for use in the ACCS. Before designing the proposed radar, we analyzed the world-wide radar technology and market trends for ACCS. Based on this analysis, we designed a novel radar sensor for the ACCS using radar components, such as an antenna, transceiver module, transceiver control module and signal processing algorithm. Finally, target detection experiments were conducted. In the experimental results, the proposed single radar can successfully complete the detection required for the ACCS. In the conclusion, the perspective and issues in the future development of the ACCS radar are described.     

Capacity estimation of torque converters with piston holes using the response surface method and an artificial neural network

In new slim torque converters, lock-up clutches are used to provide high fuel efficiency at low speed. However, the slimness of the converters causes difficulty in heat dissipation, which may damage the friction material and shorten its life span. A cooling hole in the lock-up piston reduces the heat but also reduces the torque because oil flows through the hole due to the pressure difference between the two faces of the piston. In the early stages of the development of this type of torque converter, designers must consider the minimum flow rate required to cool the friction material and the minimum torque capacity required to transmit the engine torque. This research explored two methods of estimating these parameters. In the first method, an estimation equation was derived by combining the response surface method with physical properties such as the centrifugal force, a sudden expansion, a sudden contraction, and the steady flow energy equation. The second method involved the use of an artificial neural network. The feasibility of the estimates based on statistics and on the artificial neural network were confirmed in the design stage by comparing experimental and estimated data. An estimation program was created using the C#.Net language and has been used for actual torque converter designs by the Korea Powertrain Company.     

Effect of a 2-stage injection strategy on the combustion and flame characteristics in a PCCI engine

Recently, to reduce environmental pollution and the waste of limited energy resources, there is an increasing requirement for higher engine efficiency and lower levels of harmful emissions. A premixed charge compression ignition (PCCI) engine, which uses a 2-stage type injection, has drawn attention because this combustion system can simultaneously reduce the amount of NOx and PM exhausted from diesel engines. It is well known that the fuel injection timing and the spray angle in a PCCI engine affect the mixture formation and the combustion. To acquire two optimal injection timings, the combustion and emission characteristics of the PCCI engine were analyzed with various injection conditions. The flame visualization was performed to validate the result obtained from the engine test. This study reveals that the optimum injection timings are BTDC 60° for the first injection and ATDC 5° for the second injection. In addition, the injection ratio of 3 to 7 showed the best NOx and PM emission results.     

Investigation of engine restart stability after idle stop for a mild type HEV powertrain

Stringent regulations on exhaust emissions and fuel economy for vehicles have become major issues in the automotive industry. Hybrid electric vehicles (HEV) are one of the crucial alternative plans to current conventional vehicles, but they have drawbacks, which include increases in total hydrocarbon (THC) emission from the engine and deterioration of the combustion stability with frequent stopping and restarting of the engine. Intake port fuel film is evaporated up during the deceleration state due to the fuel-cut. The λ (relative A/F ratio) at engine restart is lean because part of injected fuel is used to form the fuel film in the intake port. This study revealed the behavior of a fuel film in engine stop with fuel-cut and in engine restart with a simulation model. To investigate the fuel film characteristics, a simulation model was applied and validated with a single-cylinder engine. The simulation result shows that λ of at least 1.2 is required for a stable engine restart. The minimum injection quantity of the first cycle for stable combustion is suggested to be at least 240% of the steady-state idle condition.     

Design methodology of component design environment for PHEV

In this study, the design methodology for PHEV component design environment is proposed, which consists of power evaluation, component evaluation, component analysis and vehicle performance evaluation environments. First, PHEV simulators were developed based on the dynamic model of the target PHEV powertrain, and a PHEV control algorithm was designed based on the general power-split type PHEV using MATLAB/Simulink. Experimental results were used to validate the constructed PHEV simulators. The power evaluation environment provides the magnitude and direction of the power between components at the vehicle level at any selected time that the user wants to evaluate. The component evaluation environment is designed to evaluate the parameter behaviors of a component using the effort-flow causality relationship. The component analysis environment is designed to investigate component performance according to the variations of component parameters. The vehicle evaluation environment is designed to evaluate equivalent fuel economy at any selected time. It is expected that the design methodology of the PHEV component design environment proposed in this study can be extended to other x-EVs for evaluating and designing vehicle components.