Crashworthiness of chromium plated plastic radiator grille

The use of plastic in vehicle development has increased. In particular, a design trend has resulted in chromiumplated plastics being used in exterior panels. Recently, as the appearance has become more important in design, the plastic radiator grille has become larger, to where it can become the primary member when a front collision happens. The radiator grille should be designed with considerations of the geometric structure, such as delamination, and material characteristics, when plastics are plated with chromium. The enlarged grille has to pass regulations like FMVSS Part 581. Although the material property of plastic has been studied before, what seems to be lacking is study on the crashworthiness of plastic radiator grilles that are plated using chromium. In this paper, in order to evaluate the crashworthiness, tensile test and front collision analysis using finite element method are performed. Tensile test is conducted with 4 types of materials, and then material properties of chromium-plated plastics are obtained. Meanwhile radiator grille’s crashworthiness is evaluated using finite element analysis method. Analysis result is evaluated according to failure criterion. Through this study, method of the assessment of plastic radiator grille’s crashworthiness considered material properties of chromium plated plastics is proposed, and it can be predicted the delamination and the failure point of radiator grille at the design step.     

Effect of radial interference on torque capacity of press- and shrink-fit gears

Some gears in an automobile transmission have to be mounted by being press-fitted on a shaft instead of splines. The torque capacity of the press-fitted gear will be proportional to the radial interference. The excessive interference, however, will increase the gear radial deformation. In this paper, the press- and shrink-fit and the subsequent torque capacity test were investigated by finite element analysis, theoretically and experimentally. The static and dynamic coefficient of friction were determined.     

Fault-tolerant braking control with integerated EMBs and regenerative in-wheel motors

This paper presents a fault-tolerant brake torque controller for four-wheel-distributed braking systems with in-wheel motors and Electro-Mechanical Brakes (EMB). Mechanical and electrical faults can degrade the performance of the EMB actuators and, thus, their effects need to be compensated in vehicle dynamics level. In this study, the faults are identified as performance degradation and expressed by the gains of each actuator. Assuming the brake force distribution and the regenerative braking ratios, the over-actuated braking system is simplified into a two-input system. A sliding mode controller is designed to track the driver’s braking and steering commands, even if there exist faults in EMBs. In addition, adaptive schemes are constructed to achieve the fault-tolerant control in braking. The proposed controller and strategies are verified in the EMB HILS (Hardware-in-loop-simulation) unit for various conditions.     

Idle speed controller based on active disturbance rejection control in diesel engines

This study proposes a design for an idle speed controller to compensate for varying engine load and friction torque in passenger car diesel engines. An active disturbance rejection control (ADRC) framework, comprised of a disturbance compensator and a feedback controller, is applied to an idle speed controller to compensate for disturbances such as engine load and friction torque. In addition, a feedforward compensator is designed into the ADRC framework to improve disturbance rejection performance. The proposed controller is validated by engine and vehicle experiments and the experiment results are compared with a commercial controller.     

Grille design for passenger car to improve aerodynamic and cooling performance using CFD technique

Grille opening shape for small passenger car is designed numerically by using parametric study. Key geometric parameters to design a grille opening configuration are represented by vertical height, horizontal width, size, linear deformation, position, and blockage. Numerical study investigates the effects of those key parameters on the aerodynamic drag and the grille inlet flow rate, which are very important to the aerodynamic performance as well as the powertrain cooling performance of the car. Flow simulations are performed at the velocity of 110 km/h inflow condition. The outflow boundary condition is implemented by pressure outlet condition of atmospheric pressure. Moving wall condition of 110 km/h is set on the ground.     

New tension mechanism for high-speed tensile testing machine

As concerns of dynamic tensile measuring, a new tension mechanism driven by liner motor in high-speed tensile testing machine is presented. It satisfies the requirements for testing the dynamic tensile properties of plastic materials with strain rates from 1 to 100 s^-1, which is relatively difficult to test for currently available machines. For this purpose the idle stroke principle is used to realize the dynamic load of plastic material with static grip. Computer aided engineering is used: i) to analyze and optimize the tension mechanism thus allowing reducing the system shock caused by collisions. ii) to avoid the influence of plastic materials specimen stress and strain uniformity on the measuring system. The analysis results agreed well with the established empirical relationships based on experimental evidence. Two sets of experiments for different strain rate tensile were conducted thus allowing proving the reliability and credibility of the designed tension mechanism.     

Application of rack type motor driven power steering control system for heavy vehicles

The Electric Power Steering (EPS) or Motor Driven Power Steering (MDPS) mechanism proves to be a bright prospect among passenger vehicles ensuring better vehicle safety and fuel economy. The car manufacturers are focusing on the production of Rack type EPS system (REPS). This paper describes the development of concurrent simulation technique using TruckSim and control strategy for analysing RMDPS control system with a dynamic vehicle system. A full Truck vehicle model interacting with RMDPS control algorithm was concurrently simulated on a sinusoidal steering input. The dynamic responses of vehicle chassis and steering system resulting were evaluated and compared with proving ground experimental data. The comparisons show reasonable agreement on steering wheel torque, lateral acceleration and yaw rate. This concurrent simulation research leads the possibility of RMDPS performance evaluation of Truck and Semi-bonnet cars.     

Modelling and controlling of car-following behavior in real traffic flow using ARMAX identification and Model Predictive Control

Nowadays, car following models, as the most popular microscopic traffic flow modeling, are increasingly being used by transportation experts to evaluate new Intelligent Transportation System (ITS) and Advanced Driver Assistance Systems (ADAS) applications. The control of car following is essential due to its safety and its operational efficiency. For this purpose, this paper builds a model of car following behavior based on ARMAX structure from a real traffic data set and presents a Model Predictive Control (MPC) controller. An important advantage of this type of control is its ability to cope with constraints on controls. Since safety and operational efficiency are constraints for car following, therefore we have recruited this type of controller in this study to deal with these constraints. Based on the relative distance and relative acceleration of each instant, the MPC predicts the future behavior of the leader vehicle (LV) and according to this behavior, the acceleration of the follower vehicle (FV) is controlled. The MPC tries to control this acceleration in a way to keep the relative distance at a safe region. To investigate the performance of the designed controller, the result of the system is compared with the behavior of human drivers with similar initial conditions. Also, some other test performances were accomplished to investigate other features such as robustness and the stability of the designed MPC. The simulation results show that the MPC controller has a behavior much safer than that of real drivers and it can provide a pleasant trip for passengers.     

Loosening analysis for fastening screw of automotive door trim parts

While a screw is a fastening element that can tighten the two parts at low cost, the loosening of the screw is generated due to external forces such as repetitive load, vibration, and thermal stress. This phenomenon decreases the initial clamping force, and this can be a serious problem to the safety of the product. However, while fastening parts are handled through experiment and experience, there is a lack of research on the screw loosening of plastic fastening parts. For example, vehicles have various fastening parts. Among the fastening elements, screws are typically used for tightening parts of the vehicle door trim. Vehicle interior materials are mainly composed of plastic parts. Especially, the temperature of the vehicle interior changes from a sub-zero temperature to 100 degrees (°C) due to solar radiation. Unlike metals, plastic materials are commonly susceptible to the environment. In this study, the fastening screw of automotive door trim parts is selected. First, a screw loosening mechanism is implemented through Computer Aided Engineering (CAE) analysis and the influences of degradation are then analyzed. Secondly, the selecting method of clamping force is suggested through the analysis result of reduction according to the tightening torque.     

Comparative study between Korea and UK: relationship between driving style and real-world fuel consumption

It is known that differences in driving styles have a significant impact on fuel efficiency and driving styles are affected by various factors such as driver characteristics, street environment, traffic situation, vehicle performance, and weather conditions. However, existing knowledge about the relationship between driving style and fuel consumption is limited. Thus, the aim of this study was to analyze the relationship beteen driving style and fuel consumption. The analysis presented in this paper used data from three on-road experiments were conducted independently in two different countries, i.e. South Korea and the United Kingdom. In this study, 91 participants, consisting 44 UK drivers and 47 Korean drivers, were asked to drive approximately 28 km of UK road and 21 km of Korean road, respectively. Driving data, including real-time fuel consumption, vehicle speed, and acceleration pedal usage were collected. The results suggested that driving styles including average vehicle speed and average throttle position were highly correlated with the real-world fuel consumption, and the cultural factors, e.g. road environment, traffic design, and driver’s characteristics affected the driving styles and, consequently, fuel efficiency.