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.     

Lane-following method for high speed autonomous vehicles

This paper presents a steering control method for lane-following in a vehicle using an image sensor. With each image frame acquired from the sensor, the steering control method determines target position and direction, and constructs a travel path from the current position to the target position either as an Arc-path or S-path. The steering angle is calculated from the travel path thus generated, and the vehicle follows the travel path via motor-control. The method was tested using a vehicle dubbed as KAV (Korea Autonomous Vehicle) along an expressway (Seoul Inner Beltway) trajectory with a variety of radii (50 m ∼ 300 m) while traveling at a speed of 60 km/h to 80 km/h. Compared with an experienced human driver, the method showed little much difference in performance in terms of lane-center deviation. The proposed method is currently employed for high speed autonomous driving as well as for stop and go traffic.     

Fault detection method for electric parking brake (EPB) systems with sensorless estimation using current ripples

A fault detection method with parity equations is proposed in this paper. Due to its low cost implementation, the velocity of the motor is not measurable in electric parking brake (EPB) systems. Therefore, residuals are not reliable when estimating the motor velocity with a low-resolution encoder. In this paper, we propose a fault detection method with sensorless estimation using current ripples that estimates the position and velocity of the motor by detecting periodical oscillations of the armature current caused by rotor slots. In addition, this method can estimate the position and velocity of the motor with less computational effort than a state observer. Moreover, the method is less sensitive to motor parameters than model-based estimation methods. The effectiveness of this method is validated with experimental data, and the simulation results show that various faults have their own residual patterns. Therefore, we can detect the presence of faults by monitoring the residual signals.     

Development of electrostatic diesel particulate matter filtration systems combined with a metallic Flow-Through Filter and electrostatic methods

A 3000 cc diesel engine attached to an engine dynamo was used to test three newly developed electrostatic Diesel Particulate matter filtration Systems (DPS 1, 2, and 3) under four steady-state engine operating conditions: idle, 2000 rpm with no load, and 2000 rpm under 25% and 50% loads. Of the two developed alternatives, DPS 1 and DPS 2, DPS 2 comprises an ionization section, electrostatic field additional section and Flow-Through Filter (FTF), which achieved almost 90% removal of particulate matter (PM) under the engine’s operating conditions, and the efficiency of the FTF was maintained between 20% and 50%. Comparing the long-term performance of DPS 2 and DPS 3 (effectively a serial combination of two DPS 2s) with a commercially-available Diesel Particulate Filter (DPF), the DPS 2 and DPS 3 achieved almost the same efficiency for removing PM as the DPF but had significantly improved (75%∼90% lower) differential pressure drops.     

Design and optimization of an LPG roller vane pump for suppressing cavitation

A roller vane type liquefied petroleum gas (LPG) pump was developed for a liquid phase LPG injection (LPLi) engine. Most of the LPG pumps used in the current LPLi engines are installed inside of the LPG tank, but this pump is intended to be installed outside of the LPG tank to overcome the difficulty of fixing an in-tank pump. Because LPG has a low boiling point and high vapor pressure, it usually causes cavitation in the pump and consequently deteriorates the flow rate of the pump. The purpose of this work is to optimize the design of the roller vane pump in order to suppress cavitation and increase the fuel flow rate by using a computational fluid dynamics (CFD) analysis. In order to achieve these goals, the intake port configuration and the rotor of the roller vane pump were redesigned and simulated using STAR-CD code. Computation was performed for six different models to obtain the optimized design of the roller vane pump at a constant speed of 2600 rpm and a constant pressure difference between the inlet and outlet of 5 bar. The computation results show that an increased intake port cross-section area can suppress cavitation, and the pump can achieve a higher flow rate when the rotor configuration is changed to increase its chamber volume. When the inlet pressure difference is 0.1 bar higher than the fluid saturation pressure, the pump reaches its maximum flow rate.     

Development of a new sound metric for impact sound in a passenger car using the wavelet transform

Vehicles can experience impacts due to harsh road conditions. Contact with an uneven road surface causes vehicles to vibrate, which generates a loud impact sound. The attenuation of such noise is important because car passengers may complain about the impact noise. However, perfect removal of impact noise is not possible because most of it is caused by external conditions. More research is needed on the objective attributes of impact noise; however, the problem of impact noise is not a simple matter because impact noise is transient in nature and reaches a high level instantaneously. In this paper, a new objective attribute of impact noise is designed using the wavelet transform, which is appropriate for analyzing nonstationary signals, such as an impact signal. The usefulness of the new objective attribute, which is a sound metric, is examined by comparing the mean subjective ratings for real impact noise in passenger cars. The new sound metric has better correlation with the mean subjective rating than currently existing sound metrics.     

Effects of injection parameters on the spray characteristics of swirl and slit injectors using the Mie-scattering method

We investigated the effects of injection parameters such as injection pressure, ambient pressure, and ambient temperature on spray characteristics. We calculated the turbulence occurring point (t _c ), defined as the time required to generate a vortex, and the deceleration point (t _b ), defined as the time when spray penetration begins to decelerate, to elucidate the breakup mechanism of the test injectors. The spray velocity coefficient (C_v) was obtained to evaluate the spray characteristics. As the ambient pressure increases in the case of a slit injector, C_v decreases. We investigated the effects of nozzle tip shape according to injection pressure, ambient pressure, and fuel properties on spray characteristics and provide a C_v value of 0.38 for the swirl injector with a spray angle of 60° and the slit injector under atmospheric conditions. The value of C_v in the case of a slit injector was reduced by increasing the ambient pressure. Our results suggest that C_v of a swirl injector is constant regardless of changes in ambient pressure, injection pressure, and fuel properties. On the other hand, C_v of a slit injector is altered by changes in ambient pressure.     

Development of a navigation algorithm with dead reckoning for unmanned ground vehicles

A navigation algorithm is indispensable for Unmanned Ground Vehicles (UGVs). During driving, UGVs follow a global path. In this study, we propose a navigation algorithm using Real Time Kinematic (RTK)-Differential Global Positioning System (DGPS) units and encoders to complement global path planning. Sometimes GPS systems lose their signals and receive inaccurate position data due to many factors, such as edifice and barrier obstructions. This paper shows that GPS deviations can be solved using a Dead Reckoning (DR) navigation method with encoders and that position errors can be decreased through the use of RTK-DGPS units. In addition to this method, we will introduce a new waypoint update algorithm and a steering algorithm using RTK-DGPS units.     

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.     

Improving the predictiveness of the quasi-d combustion model for spark ignition engines with flexible intake systems

Fast and predictive simulation tools are prerequisites for pursuing simulation based engine control development. A particularly attractive tradeoff between speed and fidelity is achieved with a co-simulation approach that marries a commercial gas dynamic code WAVE™ with an in-house quasi-dimensional combustion model. Gas dynamics are critical for predicting the effect of wave action in intake and exhaust systems, while the quasi-D turbulent flame entrainment model provides sensitivity to variations of composition and turbulence in the cylinder. This paper proposes a calibration procedure for such a tool that maximizes its range of validity and therefore achieves a fully predictive combustion model for the analysis of a high degree of freedom (HDOF) engines. Inclusion of a charge motion control device in the intake runner presented a particular challenge, since anything altering the flow upstream of the intake valve remains “invisible” to the zero-D turbulence model applied to the cylinder control volume. The solution is based on the use of turbulence multiplier and scheduling of its value. Consequently, proposed calibration procedure considers two scalar variables (dissipation constant C _β and turbulence multiplier C _M ), and the refinements of flame front area maps to capture details of the spark-plug design, i.e. the actual distance between the spark and the surface of the cylinder head. The procedure is demonstrated using an SI engine system with dual-independent cam phasing and charge motion control valves (CMCV) in the intake runner. A limited number of iterations led to convergence, thanks to a small number of adjustable constants. After calibrating constants at the reference operating point, the predictions are validated for a range of engine speeds, loads and residual fractions.