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.     

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.     

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.     

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.     

Durability prediction for automobile aluminum front subframe using nonlinear models in virtual test simulations

This research work presents fatigue life evaluation techniques for an automotive vehicle aluminum front subframe using virtual test simulation technology with nonlinear suspension components model. The technology was used for improving the accuracy of the polynomial model used in conventional analysis. The proposed nonlinear suspension components models were developed using direct approach. The effects of the nonlinear elements on the prediction of the fatigue life were also analyzed. Actual aluminum front subframe was tested using half-car road test simulator to verify the accuracy of the models. It was found that the proposed nonlinear models yield more accurate results than conventional polynomial models. The proposed virtual test simulation technology with nonlinear suspension components model can be used to predict fatigue life for vehicle chassis structures more accurately.     

Comparison study on characteristics of nano-sized particle number distribution by using condensation particle counter calibrated with spray and soot type particle generation methods

In the year 2011, the Particle Measurement Program (PMP) in Europe started the regulation of the diesel vehicle’s nano-sized particle number density (PN) due to its high degree of harm to the human body. Concretely, the standard level of PN emission was introduced in the Euro 5+ and 6 emissions regulation with a limit (<6.0 × 10¹¹#/km) for diesel light-duty vehicle. Therefore, the determination of suitable and sophisticated instruments for reliable particle sampling and analysis was essential in taking exact experimental data. Now, among the PN emission measuring devices suggested by the PMP, condensation particle counter (CPC) is a key equipment for measuring the particle number density in real time and it has been used extensively. However, CPC can cause different results depending on operating conditions of the saturator and condensation that induce different rates of particle growth. This study was conducted to analyze the effect of CPC calibrated by a two-particle generator with spray and soot type methods applied on the nano-sized particle distribution’s parameters such as number concentration and linearity. Also, in order to ensure the reliability for particle sensor system named as PPS, which had emerged as a useful diagnostic to making spatially and temporally resolved quantitative measurements of diesel PN concentration, it was compared with calibrated CPC system. As a result, nano-sized particle measuring system with CPC calibrated by spray type particle generator had a much higher counting efficiency, indicating a larger nano size available than soot type particle generator. And, comparative experimental results on the correlation between the particle number of CPC to a reflectance PPS system showed that above 5,000 #/cm ³ in number concentrations measured by CPC as well as PPS were found to be similar with good linear relationship.     

Experimental research of the EQ6110HEV hybrid electric bus using an on-line debugging system

This paper describes the on-line debugging software developed by our research team. The software has five functions and can be helpful in achieving rapid development for hybrid electric buses. In addition, the software can monitor system states continuously and also modify parametric maps or update control programs using its on-line programming function. Based on the on-line debugging system, the hybrid propulsion control system is designed, and all the working modes of the hybrid electric bus are tested. Finally, experiments are carried out that verify that the debugging system is feasible and reliable. The test results show that the hybrid electric bus can reduce fuel consumption by about 19.1 percent, in comparison with conventional buses.     

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.     

3D brush model to predict longitudinal tyre characteristics

A 3D tyre brush model, which aims to predict the longitudinal tyre characteristic under steady-state conditions by modelling the occurring physical effects in the tyre–road contact patch, is presented. The model includes an analytical method to describe the tyre footprint geometry, the pressure distribution, the slip due to the lateral tyre contour, the slip due to braking or traction and the longitudinal as well as the lateral shear stresses on a flattened tyre. The presented development tool offers a method to investigate different rubber friction data (caused by different tread compounds and/or surface textures) and to analyse its influence on longitudinal tyre characteristics. The tyre design is fixed (same casing, dimension and pattern). The results include the shear stresses as well as the different sliding velocities in the contact patch for different slip conditions. The model was developed for a standard summer pattern design and a standard tyre dimension (205/55R16). It can also be adapted to other tread designs and tyre dimensions. To offer a good comparability between model results and test bench measurements, the surface curvature of an internal test rig is considered.     

Artificial neural network approach to study the effect of injection pressure and timing on diesel engine performance fueled with biodiesel

This study intends to predict the influence of injection pressure and injection timing on performance, emission and combustion characteristics of a diesel engine fuelled with waste cooking palm oil based biodiesel using the artificial neural network (ANN) model. To acquire data for training and testing in the proposed ANN, experiments were carried out in a single cylinder, four stroke direct injection diesel engine at a constant speed of 1500 rpm and at full load (100%) condition. From the experimental results, it was observed that waste cooking palm oil methyl ester provided better engine performance and improved emission and combustion characteristics at injection pressure of 280 bar and timing of 25.5° bTDC. An ANN model was developed using the data acquired from the experiments. Training of ANN was performed based on back propagation learning algorithm. Multilayer perceptron (MLP) network was used for non-linear mapping of the input and output parameters. Among the various networks tested the network with two hidden layers and 11 neurons gave better correlation coefficient for the prediction of engine performance, emission and combustion characteristics. The ANN model was validated with the test data which was not used for training and was found to be very well correlated.