Effect of nozzle orifice diameter on diesel spray tip penetration according to various spray models for CFD simulation with widely varying back pressure

CFD simulations of spray tip penetration with the standard KIVA3V, ‘original gas jet’ and ‘Normal gas jet profile with breakup length formula’ (NGJBL) spray models were performed to investigate the effects of nozzle orifice size and ambient gas density combinations on the spray penetration. The accuracy of the CFD simulation results was estimated by comparing them with available experimental data. The ambient gas density was varied in 12 kg/m³ intervals from 12 to 69 kg/m³ for each nozzle orifice diameter. The nozzle orifice diameters used were 119, 140, 183 and 206 mm. A total of 20 cases in the CFD simulations were considered with combinations of the 4 nozzle orifice diameters and 5 ambient gas densities. CFD simulations with the NGJBL spray model were more accurate than those with either the standard KIVA3V or gas jet spray models as the nozzle orifice diameter and ambient gas density was increased. The NGJBL and original gas jet model is more effective in predicting the spray tip penetration near the nozzle tip region.     

Special issue: Importance of public transport

The transport demand in most major cities around the world can only be met with a high‐quality public transport system. The requirements on bus, rail, underground and tram systems are manifold with reliability and efficiency as the key factors. The service operating hours and the size of the network are often extended in order to serve the needs better. Further, most metropolitan areas are trying to provide more incentives for citizens to leave the car at home and use the local transit systems instead. The reasons are well known. Not only does a public transport system only make economical sense if it is well used, but most urban areas with a high car‐dependency face at least three major problems; safety, congestion, and pollution (noise and air pollution, land separation, etc.). It is generally recognised that to decrease car usage and to increase public transport usage a stick & carrot approach is needed. The London congestion‐charging scheme is an example since all revenues collected by the scheme are put into the improvement of bus and underground services.     

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.     

Deflection test and transmission error measurement to identify hypoid gear whine noise

T-Hypoid gears are commonly used in rear-drive and 4WD (4 Wheel Drive) vehicle axles. Investigating their sensitivity to deflections is one of the most important aspects of their design and optimization procedures. Therefore, a deflection test was performed in this study in the actual gear mounting using completely processed gear. This test covered the full operating range of gear loads from “no load” to “peak load”. Under peak load, the contact pattern extended to the tooth boundaries without showing a concentration of the contact pattern at any point on the tooth surface. The transmission error was tested under an axle assembly triaxial-real-car-load condition.     

Development of a navigation algorithm with dead reckoning for unmanned ground vehicles

A navigation algorithm is indispensable for Unmanned Ground Vehicles (UGVs). During driving, UGVs follow a global path. In this study, we propose a navigation algorithm using Real Time Kinematic (RTK)-Differential Global Positioning System (DGPS) units and encoders to complement global path planning. Sometimes GPS systems lose their signals and receive inaccurate position data due to many factors, such as edifice and barrier obstructions. This paper shows that GPS deviations can be solved using a Dead Reckoning (DR) navigation method with encoders and that position errors can be decreased through the use of RTK-DGPS units. In addition to this method, we will introduce a new waypoint update algorithm and a steering algorithm using RTK-DGPS units.     

License plate extraction method for identification of vehicle violations at a railway level crossing

The primary cause of most railroad accidents is vehicle entry into railway level crossings despite warning messages. To identify drivers who violate railway level crossing regulations, vehicle license plate recognition can be applied at railway level crossings. The purpose of this paper is to present an effective method for extracting the license plate region from vehicle images taken at railway level crossings. The method proposed in this paper uses the variation in the gray-level values across the image of a license plate. For license plate region extraction, the character region is first recognized by identifying the character width and the difference between the background region and the character region. The license plate region is then extracted by finding the inter-character distance in the plate region. In addition, the license plate type is identified by the difference in the gray-level value between the background region and the character region. The proposed method is effective in solving the current challenges in extracting the license plate region from the damaged frames of license plates issued for domestic use, including new types of license plates. According to the experimental results, the proposed method yields a high extraction rate of 99.5% for vehicle license plates.     

Performance optimization of CVT for two-wheeled vehicles

Continuously Variable Transmission (CVT) is one of the most promising automotive transmission technologies because of its continuously variable gear ratio and reduced shift shock. CVT is different from Manual Transmission and Automatic Transmission, and it is possible to operate the power source in its high efficiency region with CVT in the drive train. Several types of CVT exist that can be categorized based on the mechanism of power transmission, such as the belt pulley, traction drive, and hydrostatic types. This paper investigates the belt pulley CVT, which consists of a thrust actuator, driver pulley, belt, driven pulley, and preload spring of the output shaft. A complete CVT is constructed, and based on that a simulation program that analyzes the static performance of a CVT is implemented in Matlab/Simulink. From these simulation results, methods for improving the efficiency of the CVT are discussed. The coefficient of the torque capacity factor is proposed as affecting the matching between a power source and a CVT, and methods for improving the matching effect are also investigated.     

Piston-temperature measuring system using electromagnetic induction with verification by a telemetry system

The development of an inner-piston-chamber temperature measurement system is a necessary step in engine development or when solving other fundamental problems related to automotive engines. There are various pre-existing measurement methods available, e.g., the linkage method, piston telemetry, templog, and the electromagnetic induction method. In this study, we first redesigned the coil sensor used in the electromagnetic induction method using PEEK and then used Taguchi methods to reduce the number of experiments in the development process and finally utilized piston telemetry via Bluetooth to verify the precision and accuracy of the redesigned PEEK coil sensor and electromagnetic induction method. The results displayed a reproducibility within 0.5 degrees and an accuracy within 2 degrees Celsius.     

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.     

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.