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.     

Air Dam对整车气动性能的影响

为进一步提高整车气动性能,降低油耗,通过风洞气动试验,研究了air dam不同安装位置、高度和结构对整车风阻系数和前端进气的影响。结果表明:1在满足整车造型要求的基础上,air dam的安装位置应尽可能前移;2Air dam在拐角处的结构很关键,需要精心设计;3相对于安装位置而言,air dam的高度对前端进气量的影响较大,故在满足路阶和接近角要求的条件下,应尽量取较大值。     

封闭式桅杆内的电磁干扰试验研究

针对所设计的一种封闭式射频集成桅杆,首先测试桅杆内部两个天线一发一收状态下接收天线射频端口的信号电平,从而判断是否会受到发射天线的电磁干扰。与传统的单纯观察设备的后端显示部分来进行干扰判断不同,射频信号测试与电子设备的后端信号处理能力无关,通过定量评估耦合能量的大小,进而可以总结通用的封闭桅杆的电磁干扰规律。试验结果表明,在封闭桅杆内同层、同面且上下布置的两副板阵天线间存在谐波干扰现象。然后,通过对天线特性、复合带通滤波层板特性、测试数据和桅杆内的电磁干扰路径进行大量、详细的理论分析来判断干扰来源。最终发现,电磁干扰很大程度上是由封闭桅杆内部发射天线的谐波通过天线边缘单元的直接辐射及内壁反射从而耦合到接收天线所造成,这是由于桅杆的封闭特性导致天线发射的带外能量无法射出,从而造成内部设备之间的电磁干扰。最后,针对此现象提出电磁干扰的一些控制措施,例如天线间敷设吸波材料、天线分层布置等。     

复合地层中盾构滚刀磨损原因分析及对策

通过系统地总结和分析约40台次混合式盾构机在复合地层中掘进近100 km的滚刀磨损情况,对滚刀磨损做了定性分类,并根据滚刀磨损的影响因素,提出滚刀磨损的对策,以期指导今后复合地层施工中盾构机刀盘刀具选择、配置及盾构掘进。     

Method to simplify ship outfitting and offshore plant equipment three-dimensional (3-D) computer-aided design (CAD) data for construction of an equipment catalog

The construction of an equipment catalog is necessary in ship outfitting and offshore plant design. We investigated the present status of equipment catalogs in shipyards and revealed several requirements for the catalogs, which are manually created and time-consuming. We defined the requirements by analyzing the construction procedure of the equipment catalog and conducted interviews with shipyard employees. In addition, problems with conventional equipment catalog construction are described, and a new procedure for the construction of an equipment catalog is introduced. By analyzing shipyard requirements, criteria for simplification (including volume, ports, and the outer boundary) are defined. Further analysis of technological factors for simplification is performed, and the results of implementing the simplification system are described. The proposed system is verified using three test cases used on site.     

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.     

Improved hot-stamping analysis of tubular boron steel with direct measurement of heat convection coefficient

There are two types of hot-stamping processes, direct and indirect, depending on the sequence of the heating, forming, and quenching steps and the method used for each step. In this study, an indirect hot-stamping process consisting of forming at room temperature, heating, and water quenching was applied to develop a coupled torsion beam axle. The analysis results indicated that the application of the heat convection coefficient is critical in the simulations and must take into account the temperature and specific location in the model to ensure the accuracy of the heating and quenching analysis. The heat convection coefficients used in the analysis were directly measured at various positions of the tube (e.g., outside, inside, and bending region) using thermocouples, and the final values were determined through correlation between the actual tests and numerical analysis. The experimental and simulated final deformed shape and temperature distribution were in good agreement.     

Fatigue life estimation of injection mold core using simulation-based approach

The purpose of this study is to present a simulation-based approach capable of predicting the fatigue life of a mold core with the help of CAE technology based on injection molding simulation, core stress analysis and fatigue life prediction. Injection molding simulation is performed in order to obtain the non-uniform pressure acting on a mold core due to the polymer melt flow during injection molding process. Subsequently, the melt pressure profile is used as loading condition for core stress analysis via one-way coupling technique. The lifetime of a mold core is then predicted by fatigue analysis with stress-life approach. For verification of simulation-based approach to the fatigue life prediction, tests were also performed.     

Development of estimation algorithms for vehicle’s mass and road grade

In controlling the longitudinal motion of electrified vehicles such as hybrid vehicles and PHEV (Plug-in Hybrid Electric Vehicles), the variation of the driving resistance loads (or driving loads) such as road grade and actual vehicle mass, is the most influential factor which limits the control performance. Measuring the driving load is not impossible, but it is costly since additional sensors have to be mounted on the vehicle. In this study, methods for estimating vehicle mass and road grade are designed to compensate for the driving loads. The proposed methods are verified using simulation tools and then evaluated experimentally.     

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.