Stochastic analysis of the variation in injury numbers of automobile frontal crash tests

Although automobile crash test data have a comparatively large variation because of the complexity of the tests, only a limited number of crash tests are usually conducted due to monetary and time limitations. Thus, it is necessary to control input variables that cause the variation in test data to obtain consistent crash test results and to correctly assess the safety performance of an automobile under development. In this study, a MADYMO model was validated deterministically to yield the head, chest, pelvis deceleration pulses of anthropomorphic test devices and the belt load pulses similar to those from actual tests, and it was also validated stochastically to yield means and standard deviations of the head and chest injury numbers, i.e., HIC ₁₅ and 3 msec clip similar to those from actual tests. A stochastic analysis was conducted using the validated MADYMO model to calculate the sensitivity of the standard deviations of the injury numbers to the standard deviations of influential input variables to determine the most influential input variable that makes the largest contribution to the variation in the injury numbers. Moreover, the Taguchi approach was used to determine the optimal values of the influential input variables to improve safety performance.     

Traffic-balancing algorithm for can systems with dual communication channels to enhance the network capacity

The controller area network (CAN) is the dominant protocol for in-vehicle network (IVN) systems because it provides bounded transmission delay among electronic control units (ECUs) at data rates between 100 Kbps and 1 Mbps. Many automotive companies have chosen the CAN protocol for their chassis network system of intelligent vehicles. However, the increasing number of ECUs in intelligent vehicles and the need for more intelligent functions require a network system with more network capacity and real-time capability. As one approach to enhance the network capacity of a CAN system, this paper introduces a CAN system with dual communication channels. This paper also presents a traffic-balancing algorithm that predicts the traffic of each channel and allocates frames to the most appropriate channel. An experimental testbed using commercial off-the-shelf microcontrollers with two CAN controllers was used to demonstrate the feasibility of the traffic-balancing algorithm.     

Robust design optimization of suspension system by using target cascading method

This study presents the robust design optimization process of suspension system for improving vehicle dynamic performance (ride comfort, handling stability). The proposed design method is so called target cascading method where the design target of the system is cascaded from a vehicle level to a suspension system level. To formalize the proposed method in the view of design process, the design problem structure of suspension system is defined as a (hierarchical) multilevel design optimization, and the design problem for each level is solved using the robust design optimization technique based on a meta-model. Then, In order to verify the proposed design concept, it designed suspension system. For the vehicle level, 44 random variables with 3% of coefficient of variance (COV) were selected and the proposed design process solved the problem by using only 88 exact analyses that included 49 analyses for the initial meta-model and 39 analyses for SAO. For the suspension level, 54 random variables with 10% of COV were selected and the optimal designs solved the problem by using only 168 exact analyses for the front suspension system. Furthermore, 73 random variables with 10% of COV were selected and optimal designs solved the problem by using only 252 exact analyses for the rear suspension system. In order to compare the vehicle dynamic performance between the optimal design model and the initial design model, the ride comfort and the handling stability was analyzed and found to be improved by 16% and by 37%, respectively. This result proves that the suggested design method of suspension system is effective and systematic.     

Numerical investigation on the dynamic characteristics of an automotive A/C hose

The objective of this study is to investigate the dynamic deformation characteristics of an automotive A/C hose assembly using the finite element method and experimentation. The finite element analysis consisted of two analyses, specifically, a modal and a transient analysis. The dynamic modal analysis was conducted to assess the dynamic characteristics of the A/C hose structure, and the dynamic transient analysis was performed to investigate the dynamic stresses of an automotive A/C hose by dynamic loading with particular emphasis on the reinforced braid. Furthermore, the analyses results are expected to provide useful reference data in the design optimization of the hose layout related to the constrained design space. Modal testing was undertaken to verify the FE model. The FE result was in good agreement with the experimental results. The modal analysis result showed that the bending and swing modes of the hose occurred in the first six natural frequencies. The dynamic transient result showed that the maximum stress in the hose components occurred in the reinforced braid layers, which are particularly damage-prone.     

Thermal anaysis of an electric water pump for internal combustion engine vehicles

An electric water pump for engine cooling system has an advantage which particularly in the cold start, the use of the electric water pump saves fuel and leads to a corresponding reduction in emissions. However, the electric water pump for internal combustion engine generates much more heat loss than that for hybrid electric vehicle or electric vehicle since it is operated by electric power of high current and low voltage. In this study, the fluid flow and thermal characteristics of the canned type electric water pump with an inverter integrated has been investigated under the effects of heat generation. The analysis conditions such as outdoor air temperature of 125°C, water pump speed of 6000 rpm, coolant temperature of 106°C and coolant flow rate of 120 L/min were used as a standard condition. Therefore, the thermal performance of the canned type electric water pump’s motor and inverter was evaluated by comparison with that of mechanical seal type. In the motor, the temperature reduced by over 10°C, and in the inverter, the amount of temperature decrease equaled to the maximum temperature difference, about 18.7°C. Also, canned type electric water pumps of variable materials were compared for the evaluation of thermal transfer performance for variable thermal conductivity of a can. The motor and inverter were cooled lower to 42°C at motor and about 40°C at inverter for reasonable selection of can’s thermal conductivity.     

Highly reliable driving workload analysis using driver electroencephalogram (EEG) activities during driving

Traffic accidents are caused by various factors, which can be classified into human factors, vehicle factors and environmental factors. Recently, human factors have been drawing particular attention as efforts are being made to enhance the safety performance of vehicles and improve road conditions. Driving distraction caused by an increased driving workload is a representative human factor. Various studies in the past have attempted to quantify the driving workload by using EEG activities. However, they have failed to consider vibration properties generated from vehicle engines. A number of noise signals were included in brainwave signal processing, which resulted in a failure to obtain reliable outcomes. Thus, this study suggests driver EEG activities free of vehicle engine secondary vibration in order to develop a method that analyzes the driving workload with high statistical reliability. By using the analytical method developed in this study, standard values of driving workload for straight and left-turn driving that has statistical significance could be calculated. The analytical method for driving workload created by this study can be applied to HVI and road design.     

Design of 2-speed transmission for electric commercial vehicle

As environmental and economic interests increase, the need for eco-friendly vehicle such as an electric vehicle (EV) has increased rapidly. Various research of enhancing EV powertrain efficiency and relibility have been studied. In this study, 2-speed shift gears mechanism is designed by using simpson type planetary gear train. This transmission has two planetary gear unit. Gear position is determinded by which ring gear is fixed. Internal components of the transmission are designed for satisfying the required specification of EV. We analyze gear strength, gear mesh efficiency, and transmission efficiency. By manufacturing the transmission prototype and performing some experiments, we verify the application suitability of this transmission.