Model-based design of a variable nozzle turbocharger controller

Variable Nozzle Turbocharger (VNT) was invented to solve the problem of matching an ordinary turbocharger with an engine. VNT can harness exhaust energy more efficiently, enhance intake airflow response and reduce engine emissions, especially during transient operating conditions. The difficulty of VNT control lies in how to regulate the position of the nozzle at different engine working conditions. The control strategy designed in this study is a combination of a closed-loop feedback controller and an open-loop feed-forward controller. The gain-scheduled proportional-integral-derivative (PID) controller was implemented as the feedback controller to overcome the nonlinear characteristic. As it is difficult to tune the parameters of the gain-scheduled PID controller on an engine test bench, system identification was used to identify the plant model properties at different working points for a WP10 diesel engine on the test bench. The PID controller parameters were calculated based on the identified first-order-plus-dead-time (FOPDT) plant model. The joint simulation of the controller and the plant model was performed in Matlab/Simulink. The time-domain and frequency-domain performances of the entire system were evaluated. The designed VNT control system was verified with engine tests. The results indicated that the real boosting pressure traced the target boosting pressure well at different working conditions.     

Off-set crack propagation analysis under mixed mode loadings

An assessment was carried out herein to study the eccentricity of cracks subjected to mixed-mode loadings. Several loading locations relative to a central line were selected to induce mixed-mode loadings, which were computed using a finite element method. An adaptive meshing technique was adopted during the simulation of crack propagation to ensure the singularity of stress at the tip of the crack. The stress intensity failure criterion was used and programmed, and the node splitting technique was used when the stress intensity factor reached the fracture toughness of the material to simulate crack propagations. It was found that large variations in the stress intensity factor were observed when off-set cracks were used, and that K _II decreased when loading distance increased, but increased when the off-set crack distance was increased. Both crack eccentricity and loading distance played important roles in producing mixed-mode loading, compared to the influence of central cracks. Correction factors were introduced to modify the calculation of stress intensity factors under mixed-mode loadings. Simulations of crack propagation were also conducted to study the effects of crack eccentricities and loading distances. It was found that the crack length, the loading distance relative to the central crack and the crack eccentricity dominated calculations of the integrity of cracked structures.     

Design framework for FlexRay network parameter optimization

Because the FlexRay protocol has more than 70 configuration parameters and these parameters correlate with each other, designing a FlexRay network is a complex and difficult task. In this study, we propose a design framework that optimizes the two main FlexRay network parameters that are highly relevant to the application algorithm. The design process is composed of two steps for optimizing parameters. In the first step, the static slot length is optimized using a frame-packing algorithm. This algorithm binds network signals into static frames based on their periods and signal groups. In the second step, the communication cycle length is optimally designed with frame-scheduling algorithm and worst-case reponse time analysis. Based on the frame-scheduling algorithm, the response times are analyzed. The proposed design framework was applied to a unified chassis control system as a case study, and the analytical results were verified.     

Finite element modeling of static tire enveloping characteristics

To investigate static tire enveloping characteristics, a three dimensional (3-D) finite element model is proposed. The vertical stiffness of the tire is studied on a flat surface with and without cleat. Tire rubber materials and cord layers are represented independently using “rebar” elements available in MSC Marc Mentat. Comparisons of numerical and experimental results are given to show the validity of the proposed model. It is shown that after a certain displacement, the results of the proposed model agree well with experimental results. In addition, the model results show that regardless of the type of the cleat placed under the rim center (hub center), all vertical force curves intersect after a certain displacement, which indicates typical static enveloping characteristics. Moreover, another typical characteristic of the radial tires that is unlike those of bias-ply constructions confirms that the contact patch does not expand laterally after a level vertical load is applied to the tire, which is directly related to fuel consumption and tire tread life.     

Development of hot stamped center pillar using form die with channel type indirect blank holder

The hot stamping process has been used in the automotive industry to reduce the weight of the body-in-white and to increase passenger safety via improved crashworthiness. However, defects such as fracture and wrinkle occur when hot stamping is performed using a conventional drawing or forming method. In this study, a channel-type indirect blank holder (CIBH) is proposed to develop a high-strength center pillar in form-type hot stamping, so that the aforementioned drawbacks are overcome. This type of blank holder plays an important role in reducing severe wrinkling at the flange; such wrinkling leads to folding after the completion of form-type hot-stamping. First, we investigated the effect of the channel shape on the indirect blank holding force by using a simplified two-dimensional plane-strain stamping process. Second, we selected the slope angle and corner radius of the channel as the main shape parameters by finite element analysis and artificial neural network (ANN). It is known that fracture at the hot formed wall and wrinkle at the flange are significantly affected by the slope angle of the channel, and the appropriate value for eliminating fracture and wrinkle is determined to be 99°. By performing hot stamping using a form die with the selected channel, we can manufacture a high-strength center pillar without wrinkle and fracture.     

Nouveaux entrants, structure du réseau ferré et qualité des infrastructures ferroviaires en France : des stratégies d’itinéraires contrariées

The structure of the French rail network is highly centralized. It complies with the strategy of use of the incumbent operator, SNCF: the long-term trend has been rather towards the concentration of traffic on a limited number of well-equipped routes. The experience of freight market liberalization shows that seven newcomers have entered the market. They haul approximately 16% of the total volume in 2010. But they have neither the same vision of the network, nor the same use of it. They run point-to-point long-distance trains, so they try to travel via lines that are as direct as possible, thereby saving several kilometres and avoiding problematic bottlenecks. Their strategies are counteracted by the current state of the infrastructures when they try to avoid the main radial lines: limited capacity, speed and axle load restrictions, etc. Upgrading works are now in progress, under the direction of RFF, the network manager. They add perturbations to the existing restriction of use, without any satisfying alternative train path. This paper tries to emphasize the strategic divergences between operators confronted with a time-consuming (or insufficiently anticipated) network.     

Quasi steady-state aerodynamic model development for race vehicle simulations

Presented in this paper is a procedure to develop a high fidelity quasi steady-state aerodynamic model for use in race car vehicle dynamic simulations. Developed to fit quasi steady-state wind tunnel data, the aerodynamic model is regressed against three independent variables: front ground clearance, rear ride height, and yaw angle. An initial dual range model is presented and then further refined to reduce the model complexity while maintaining a high level of predictive accuracy. The model complexity reduction decreases the required amount of wind tunnel data thereby reducing wind tunnel testing time and cost. The quasi steady-state aerodynamic model for the pitch moment degree of freedom is systematically developed in this paper. This same procedure can be extended to the other five aerodynamic degrees of freedom to develop a complete six degree of freedom quasi steady-state aerodynamic model for any vehicle.     

Hybrid neural network model for history-dependent automotive shock absorbers

The method of numerical multi-body simulation is an often used and well-understood development tool in the automotive industry. In order to reproduce the ride comfort or handling behaviour of vehicles, mathematical models have to be built up. To achieve accurate simulation results, highly detailed component models are required. However, the formulation of appropriate physically-based model equations of complex automotive components (e.g. air springs, shock absorbers, rubber bearings, tyres, etc.) can be very difficult. To handle this, empirical modelling methods have been developed. Simple algebraic equations are used to describe complex system behaviour. This simplification is very effective, although it largely ignores the natural laws of mechanics and thermodynamics but is still capable to predict the component response. This article illustrates how to take advantage of this approach in numerical simulations. We describe the development of a hybrid automotive shock absorber model based on both spline and neural network (NN) approaches. By combining these different approaches, an accurate model is achieved without loss of variability. Non-isothermal laboratory force-displacement measurements of an automotive shock absorber are being used to estimate the parameters of the NN. As shown, the model replicates the measured data with sufficient accuracy, especially the hysteresis. Finally, we present a set of quarter-car simulations with a built-in hybrid NN shock absorber.     

Review on characterization of nano-particle emissions and PM morphology from internal combustion engines: Part 1

This paper is review of the characterization of exhaust particles from state-of-the-art internal combustion engines. We primarily focus on identifying the physical and chemical properties of nano-particles, i.e., the concentration, size distribution, and particulate matter (PM) morphology. Stringent emissions regulations of the Euro 6 and the LEV III require a substantial reduction in the PM emissions from vehicles, and improvements in human health effects. Advances in powertrains with sophisticated engine control strategies and engine after-treatment technologies have significantly improved PM emission levels, motivating the development of new particle measurement instruments and chemical analysis procedures. In this paper, recent research trends are reviewed for physical and chemical PM characterization methods for gasoline and diesel fueled engines under various vehicle certification cycles and real-world driving conditions. The effects of engine technologies, fuels, and engine lubricant oils on exhaust PM morphology and compositions are also discussed.     

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.