Synchronized Production and Transportation Planning Using Subcontracted Vehicles in a Production-Distribution Network

Abstract

Effective management of interfaces between procurement, supply, production and distribution for higher efficiency in the supply chain is an important issue in global manufacturing, where the synchronization of production and transportation planning represents important savings in operational costs. This paper focuses on the synchronization of production planning and transportation planning in a production distribution network, where transportation is subcontracted to a professional transportation enterprise (PTE) for vehicle-hiring. Dynamic and flexible numbers of vehicles are used to cater for fast changing market demands. Thus, the number of vehicles to be hired is viewed from the planning point of view as an operational decision considered simultaneously with production and transportation planning. A mathematical model – SPTP/MTDS – for synchronized production and transportation planning under multiple times and direct shipping strategy (MTDS) is discussed, and a Lagrange relaxation decomposition-based two layer decision procedure (LRD-TLDP) is developed. By introducing artificial decision variables and Lagrange multipliers, SPTP/MTDS is decomposed into a production decision sub-problem (SPTP-PD), and a distribution decision sub-problem (SPTP-DD). A priority-based assignment heuristic and a partial chain-based genetic algorithm are developed to solve SPTP-PD and SPTP-DD, respectively. An illustration of the application of the model in an electronic appliance manufacturing enterprise in China is presented.     

A multinomial logit car use model for a megacity of the developing world: Istanbul

The increase in motor vehicle use is one of the important factors that cause traffic congestion, especially in megacities. Thus, the reasons behind this increase require serious attention. This paper offers an analysis of this kind, for a megacity from the developing world, Istanbul. A stratified multinomial logit model accounting for the availability of a second vehicle in the household is estimated for a sample drawn from a questionnaire to gather information of actual car use in Istanbul. This estimation is only possible through a unique data generation process that converts actual preferences into a choice study setting. In addition, a simulation study, generally utilized in the analyses of discrimination between certain layers of society, and a scenario analysis related to changes in income are also included in the paper for a better understanding of the nature of the topic. The results show that the behavior of households with a second vehicle available and not available varies significantly due to household, individual and professional-related characteristics.     

Approach to functional safety-compliant ECU design for electro-mechanical brake systems

In this paper, we propose a design approach to a functional safety-compliant ECU for an electro-mechanical brake (EMB) control system or an electronic wedge brake (EWB) control system. Brake actuators in a brake-by-wire (BBW) system such as EMB or EWB are characterized by the safety-critical functions which are now executed by using many electric and electronic devices with application software. Based on hazard analysis and risk assessments of the automotive functional safety standard ISO 26262, the proposed EMB control system should be ASIL-D-compliant, which is the highest ASIL level. To this end, a hardware and a software design method is introduced to implement functionl safety-oriented monitoring functions which are based on an asymmetric dual-core architecture with an external watchdog processor. It is shown by using EMB hardware-In-the-Loop-Simulation (HILS) that the proposed ECU design approach is very effective when a hardware fault or software execution faults occur in the EMB ECU, moreover, this functional safety-compliant design can be well combiled with the sensor fault-tolerant control logic.     

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.     

Node-based scheduling method for easy migration from CAN to FlexRay in in-vehicle networking systems

As vehicles become more intelligent, in-vehicle networking (IVN) systems such as controller area network (CAN) are essential for the convenience and safety of drivers. To expand the applicability of IVN systems, attention is currently being focused on chassis networking systems that require increased network capacity and real-time capabilities. FlexRay was developed to replace CAN protocol in chassis networking systems, to remedy the shortage of transmission capacity and unsatisfactory real-time transmission delay of conventional CAN. However, FlexRay network systems require a complex scheduling method, which is a barrier to their implementation as chassis networking systems. In particular, if we want to migrate from a CAN network to a FlexRay network using the well-defined CAN message database, which has been specifically constructed for chassis networking systems by automotive vendors, a new type of scheduling method is necessary to reduce scheduling efforts during the software development process. This paper presents a node-based scheduling method for easy migration from a CAN network to a FlexRay network system. To demonstrate the feasibility of the technique, its performance is evaluated in terms of various software complexity indices.     

Vehicle velocity estimation using effective inertia for an in-wheel electric vehicle

In this study, a vehicle velocity estimation algorithm for an in-wheel electric vehicle is proposed. This algorithm estimates the vehicle velocity using the concept of effective inertia, which is based on the motor torque, the angular velocity of each wheel and vehicle acceleration. Effective inertia is a virtual mass that changes according to the state of a vehicle, such as acceleration, deceleration, turning or driving on a low friction road. The performance of the proposed vehicle velocity estimation algorithm was verified in various conditions that included straight driving, circle driving and low friction road driving using the in-wheel electric vehicle that was equipped with an in-wheel system in each of its rear wheels.     

Fatigue strength assessment including welding residual stress of spot welded joints subjected to cross-tension loads

This paper presents a method to assess of fatigue strength for resistance spot welded joints, which incorporates welding residual stress effects. To achieve this, first, a non-linear finite element analysis (FEA) was performed to simulate the spot-welding process. To validate the FEA results, the numerically calculated welding residual stresses of spot welds were then compared with experimental results measured by X-ray diffraction method. The residual stress distributions showed good agreement between calculations and experiments. To evaluate the effects of welding residual stress on the fatigue design criterion of resistance spot welded joints subjected to cross-tension load, the stress amplitude (σ_a-res) taking into account welding residual stress at a spot weld was proposed based on a modified Goodman equation incorporating the residual stress effect. Using the stress amplitude σ_a-res at the nugget edge of a spot weld, the ΔP ? N_f relations obtained as the fatigue test results for spot welded joints were systematically rearranged to the σ_a-res ? N_f relation. It was found that the proposed stress amplitude (σ_a-res) provides more reasonable and accurate fatigue design criterion of spot welded joints subjected to cross-tension load.     

Evaluation and visualization of stratified ultra-lean combustion characteristics in a spray-guided type gasoline direct-injection engine

To comply with reinforced emission regulations for harmful exhaust gases, including carbon dioxide (CO₂) emitted as a greenhouse gas, improved technologies for reducing CO₂ and fuel consumption are being developed. Stable lean combustion, which has the advantage of improved fuel economy and reduced emission levels, can be achieved using a sprayguided-type direct-injection (DI) combustion system. The system comprises a centrally mounted injector and closely positioned spark plugs, which ensure the combustion reliability of a stratified mixture under ultra-lean conditions. The aim of this study is to investigate the combustion and emission characteristics of a lean-burn gasoline DI engine. At an excess air ratio of 4.0, approximately 23% improvement in fuel economy was achieved through optimal event timing, which was delayed for injection and advanced for ignition, compared to that under stoichiometric conditions, while NO_x and HC emissions increased. The combustion characteristics of a stratified mixture in a spray-guided-type DI system were similar to those in DI diesel engines, resulting in smoke generation and difficulty in three-way catalystutilization. Although a different operating strategy might decrease fuel consumption, it will not be helpful in reducing NO_x and smoke emissions; therefore, alternatives should be pursued to achieve compliance with emission regulations.     

Preview suspension control for a full tracked vehicle

In this study, preview control algorithms for the active and semi-active suspension systems of a full tracked vehicle (FTV) are designed based on a 3-D.O.F model and evaluated. The main issue of this study is to make the ride comfort characteristics of a fast moving tracked vehicle better to keep an operator’s driving capability. Since road wheels almost trace the profiles of the road surface as long as the track doesn’t depart from the ground, the preview information can be obtained by measuring only the absolute position or velocity of the first road wheel. Simulation results show that the performance of the sky-hook suspension system almost follows that of full state feedback suspension system and the on-off semi-active system carries out remarkable performance with the combination of 12 on-off semi-active suspension units. The results simulated with 1^st and 2^nd weighting sets mean that the suspension system combined with the soft type of inner suspension and hard type of outer suspension can carry out better ride comfort characteristics than that with identical suspensions. The full tracked vehicle (FTV) system is uncontrollable and the system is split into controllable and uncontrollable subspace using singular value decomposition transformation. Frequency response curves to four types of inputs, such as heaving, pitching, rolling, and warping inputs, also demonstrate the merits of preview control in ride comfort. All the frequency characteristic responses confirm the continuous time results.     

Simulation of flow in diesel particulate filter system using metal fiber filter media

Metal fiber is introduced as a new filter media in wall-flow Diesel Particulate Filter (DPF) system. This technology has high temperature durability which is required for filter regeneration, and can maintain the mechanical strength even in the extreme exhaust-related vibrations of vehicles. However, the regeneration near the wall (outer layer) is more difficult because of the heat loss and reduced gas flow near the wall. In this study, a flow is simulated to determine the flow control method for the more uniform flow in all filter layer. By using Star CCM+ commercial software, we obtain local velocity, streamline, and pressure distributions in the filter, which are typically difficult to obtain from measurements. The major control factors are the filter porosity, size and location of the distribution plate, and the number of blades of the swirler. By placing the distribution plate in front of the filter, the flow velocity near the wall was increased. The optimum location and size of the flat plate were chosen. By attaching the blade on the plate the flow velocity near the wall was increased more. Therefore, the regeneration efficiency is increased by using the swirler-type metal fiber DPF system.