New nonlinear bushing model for general excitations using Bouc-Wen hysteretic model

Because the characteristics of rubber bushing significantly affect the accuracy of vehicle dynamics simulations, they should be accurately modeled in the vehicle suspension model. In this paper, a new nonlinear bushing model for automotive bushing components is developed to improve the accuracy of vehicle dynamics analysis. Bushing components were first tested to capture the nonlinear and hysteretic behavior of typical elements by using a MTS 3-axis elastomer tester. A simple Bouc-Wen hysteretic differential model was modified to generate a more precise rubber bushing model. A sine wave, step input, and random excitations are imposed on the bushing. The ADAMS program is used to calculate sensitivity and the VisualDOC program is employed to find the optimal parameters for the bushing model. An error function is designed to find optimal parameters of the model. Parameter identification is carried out to satisfy the static and dynamic characteristics due to sine and step excitation inputs. It was proved that the proposed model could predict the bushing forces under sine, step, and random inputs well. The errors are within 10% in the overall range. To show the validity of the proposed model, a numerical example was also carried out. Because the bushing forces due to random excitation input show good agreement with experiments, the proposed bushing model is available in the vehicle dynamics simulation.     

Fatigue life prediction based on the rainflow cycle counting method for the end beam of a freight car bogie

This paper presents a system for treating of the actual measured data for load histories. The approach consists of two steps: stress analysis and fatigue damage prediction. Finite element analysis is conducted for the component in question to obtain detailed stress-strain responses. A significant number of failures occurred in a brake end beam which led to economic losses and disruption of service. The cracks appeared to be fatigue cracks caused by the dynamic load produced in the loaded bogie frame. Strain gauge data were analyzed, and fatigue cycles were calculated from this data. Rainflow cycle counting was used to estimate cumulative damage of the end beam under in-service loading conditions. The fatigue life calculated with the rainflow cycle counting method, the P-S-N curve, and the modified Miner’s rule agreed well with actual fatigue life within an error range of 2.7%~31%.     

Measurement of hydrocarbon and carbon monoxide emissions during the starting of automotive DI Diesel engines

Most of hydrocarbon (HC) and carbon monoxide (CO) emissions from automotive DI Diesel engines are produced during the engine warm-up period and are primarily caused by difficulties in obtaining stable and efficient combustion under these conditions. Furthermore, the contribution of engine starting to these emissions is not negligible; since this operating condition is highly unfavorable for the combustion progress. Additionally, the catalytic converter is ineffective due to the low engine temperature. In conjunction with adequate engine settings (fuel injection and fresh air control), either the glow plugs or the intake air heater are activated during a portion of the engine warm-up period, so that a nominal engine temperatures is reached faster, and the impact of these difficulties is minimized. Measurement of gaseous pollutants during engine warm-up is currently possible with detectors used in standard exhaust gas analyzers (EGA), which have response times well-suited for sampling at such transient conditions. However, these devices are not suitable for the measurement of exhaust emissions produced during extremely short time intervals, such as engine starting. Herein, we present a methodology for the measurement of the cumulative pollutant emissions during the starting phase of passenger car DI Diesel engines, with the goal of overcoming this limitation by taking advantage of standard detectors. In the proposed method, a warm canister is filled with an exhaust gas sample at constant volumetric flow, during a time period that depends on the engine starting time; the gas concentration in the canister is later evaluated with a standard EGA. When compared with direct pollutant measurements performed with a state-of-art EGA, the proposed procedure was found to be more sensitive to combustion changes and provided more reliable data.     

Two- and three-dimensional hydroelastic modelling of a bulker in regular waves

The relatively high rates of bulk carrier casualties in recent years, as well as structural features such as large deck openings, make this vessel type a suitable example for investigating the influence of hydroelastic modelling on predicting wave-induced loads and responses. Two- and three-dimensional fluid–flexible structure interaction models, due to their different degree of complexity and associated data requirements, can be used at different stages of the design process when estimating wave-induced loads, namely preliminary and detailed design stages, respectively.

In this paper, therefore, two- and three-dimensional hydroelasticity theories are applied to predict and compare the dynamic behaviour of a bulk carrier hull, based on OBO MV Derbyshire, in waves. Both symmetric and antisymmetric motions and distortions are incorporated in these investigations. The three-dimensional structural model consists entirely of shell finite elements, representing all major external and internal structural components, whilst the two-dimensional model is generated using Timoshenko beam finite element and finite difference discretisations. Issues relevant to the structural modelling stage, for both idealisations, are discussed. The in vacuo dynamic characteristics are compared for all models, with particular emphasis on the influence of hatch openings, shear centre and warping on the antisymmetric dynamics of the structure. For the wet analysis the fluid–flexible structure interaction is carried out using two-dimensional (Timoshenko beam and strip theory) and three-dimensional (beam and shell finite element idealisations combined with potential flow analysis based on pulsating source distribution over the mean wetted surface) analyses. Comparisons are made between steady-state responses predicted by two- and three-dimensional models in bow quartering regular waves.

It is shown that whereas the predicted symmetric dynamic responses obtained from two- and three-dimensional models are in good agreement, differences are observed for the antisymmetric dynamic characteristics. It is thought that this may be due to inadequacies in the beam models employed when simulating the global dynamic behaviour of this highly non-prismatic hull girder whilst allowing for the effects of warping.     

Driver propensity characterization for different forward collision warning times

The forward collision warning system, which warns danger to the driver after sensing possibility of crash in advance, has been actively studied recently. Such systems developed until now give a warning, regardless of driver’s driving propensity. However, it’s not reasonable to give a warning to every driver at the same time because drivers are different in driving propensity. In this study, to give a warning to each driver differently, three metrics classifying driver’s driving propensity were developed by using the driving data on a testing ground. These three metrics are the predicted time headway, required deceleration divided by the deceleration of the leading vehicle, and the resultant acceleration divided by the deceleration of the leading vehicle. Driving propensity was divided into 3 groups by using these metrics for braking and steering cases. In addition, these metrics were verified by making sure that braking propensity could be classified on public roads as well.     

Transient modeling and validation of lithium ion battery pack with air cooled thermal management system for electric vehicles

A transient numerical model of a lithium ion battery (LiB) pack with air cooled thermal management system is developed and validated for electric vehicle applications. In the battery model, the open circuit voltage and the internal resistance map based on experiments are used. The Butler-Volmer equation is directly considered for activation voltage loss estimation. The heat generation of cells and the heat transfer from cells are also calculated to estimate temperature distribution. Validations are conducted by comparison between experimental results at the cell level and the pack level. After validations, the effects of module arrangement in a battery pack are studied with different ambient temperature conditions. The configuration that more LiB cells are placed near the air flow inlet is more effective to reduce the temperature deviation between modules.     

Robustness analysis of ESC ECU to characteristic variation of vehicle chassis components using HILS technique

The ESC system, since its introduction in the mid 90s, has greatly contributed to prevention of vehicle accidents with its capability of maintaining vehicle stability in severe driving conditions. Due to its significant advantages, many nations are now adopting regulations that mandate installation of the ESC system in all classes of passenger vehicles — from mini to luxury. Accordingly it became important to know whether an ESC ECU can yield good performance on a wide range of vehicle parameter changes. In this paper, robustness analysis was conducted to study how characteristic variation of the main chassis components affect the performance of the ESC ECU. This analysis was carried out using a HILS system built on an actual ESC ECU. The variation range of each chassis component was carefully selected considering the component’s design criteria adopted in automotive industries. Based upon the robustness analysis results, the allowable variation ranges of the chassis components for ensuring sound performance of an ESC ECU were proposed.     

Development of an autonomous braking system using the predicted stopping distance

An autonomous braking system is designed using the prediction of the stopping distance. The stopping distance needs to be determined by considering several factors such as the desired deceleration and the speed of the hydraulic brake actuator. In particular, the actuator speed is very critical because it affects the shape of the deceleration response and it determines the accuracy of the predicted stopping distance. The autonomous braking control algorithm is designed based on the predicted stopping distance. The proposed autonomous braking system has been validated in autonomous vehicle tests and demonstrates that the subject vehicle can avoid the collision effectively.     

Robust design optimization of frontal structures for minimizing injury risks of Flex Pedestrian Legform Impactor

The Flexible Pedestrian Legform Impactor (Flex-PLI) consisting of a flexible femur and tibia will be tested for pedestrian protection by Euro NCAP within the next couple of years as a potential replacement for the Transport Research Laboratory (TRL) legform impactor. The injury risks that are measured when using Flex-PLI are the elongation of the anterior/posterior cruciate ligament (A/PCL), elongation of the medial collateral ligament (MCL), and tibia bending moment (TBM). In this study, we used a correlated computer-aided engineering (CAE) model to conduct a contribution analysis of each injury with regard to the changes in the location of the frontal structures based on the results of a design of experiments (DOE) and analysis of variance (ANOVA). The frontal structures that were selected as control factors were the energy absorber (EA), lower bumper stiffener (LBS), and hood angle. A kriging interpolation model was developed using the DOE results, and its results were compared with those of the CAE model. Furthermore, for robust design optimization, the speed and height of Flex-PLI were used as the noise factors. Finally, a robust design optimization was carried out using the optimal combination of the discrete control factors for minimizing MCL elongation.     

Experimental approach to developing human driver models considering driver’s human factors

A new approach to develop human driver models (HDMs) is proposed in accordance with the drivers’ generic human factors, i.e., gender, age, and experience, to develop more realistic vehicle simulations. The HDMs consist of three independent and stepwise models with functioning driver’s information processing stages based on the human factors: constructing drivers’ preview distance (PVD) models as a ‘cognition process’, implementing a finite preview optimal control algorithm as a ‘decision process’, and differentiating an ‘operation process’ according to neuromuscular efficiency. Eight different groups of 65 drivers with a 2 × 2 × 2 within-subject design participated in both the PVD estimates and neuromuscular efficiency tests to develop a set of statistically different HDMs. Regarding the preview distance models, an analysis of covariance (ANCOVA) procedure was adopted with two covariates (i.e., vehicle velocity and road curvature), while analyses of variance (ANOVAs) were performed on the neuromuscular efficiency parameters. The ANCOVA procedure produced eight significantly different cognition processes, whereas the ANOVAs revealed gender differences for the drivers’ neuromuscular systems. Moreover, an integrated vehicle simulation was configured with the HDMs using Carsim and Simulink software to observe the differential effects of both the cognition and operation processes on a double-lane-change (DLC) maneuver. During the simulations, gender differences in real-world DLC tests were also identified, especially between the male-oldexpert and the female-young-novice HDMs. The results presented in this study suggest that differentiating HDMs according to human factors is an essential process when utilizing vehicle simulations in the early stage of developing an intelligent vehicle system.