Prediction of fatigue life and estimation of its reliability on the parts of an air suspension system

Air suspension systems have been implemented in various commercial vehicles, such as buses and special purpose trucks, because of the comfortable ride and easy height control. An evaluation of the durability of vehicle parts has been required for service life and safety starting in the early stages of design. The cyclic load applied to the vehicle can cause fatigue failure of parts, such as the suspension frame. This paper presents a method to predict the fatigue life of the suspension frame at the design stage of the air suspension system used in a heavy-duty vehicle. To estimate the fatigue life using the SN method, the Dynamic Stress Time History (DSTH) is necessary for the part of interest. DSTH can be obtained from the results of the flexible body dynamic analysis using the Belgian road simulation and the Modal Stress Recovery (MSR) method. Furthermore, the reliability of the predicted fatigue life can be evaluated by considering the variations in material properties. The probability and distribution of the expected life cycle can be obtained using experimental design with a minimum number of simulations. The advantage of using statistical methods to evaluate the life cycle is the ability to predict replacement time and the probability of failure of mass-produced parts. This paper proposes a rapid and simple method that can be effectively applied to the design of vehicle parts.     

Auto-ignition and micro-explosion behaviors of droplet arrays of water-in-fuel emulsion

The characteristics of auto-ignition and micro-explosion behaviors of one-dimensional arrays of fuel droplets suspended in a chamber with high surrounding temperature were investigated experimentally with various droplet spacings, numbers of droplet and surrounding temperatures. The fuels used were pure n-decane and emulsified n-decane with varied water contents ranging from 10 to 30%. All experiments were performed under atmospheric conditions with high surrounding temperatures. An imaging technique using a high-speed camera was adopted to measure ignition delay, flame lifetime, and flame spread speed. The camera was also used to observe micro-explosion behaviors. As the droplet array spacing increased, the ignition delay also increased, regardless of water content. However, the lifetime of the droplet array decreased as the droplet spacing increased. The micro-explosion starting time remained unchanged regardless of the number of the droplets or the droplet spacing; however, it tended to be delayed slightly as the water percentage and droplet spacing increased.     

3-D numerical and experimental analysis for airflow within a passenger compartment

People use cars so frequently that they always consider the air-conditioning, and thermal comfort of the driver and passenger when buying a new car. Therefore accurate simulation of the thermal performance of automobile air conditioners to improve human comfort has become increasingly important. In order to improve the thermal comfort of passengers, 3-D flow motion and thermal behavior within vehicles must be analyzed. In this paper, a numerical simulation was used to investigate thermal behavior in a vehicle. Because air temperature at an air vent is related to the cooling capacity of the air conditioner, the cooling capacity was calculated using ɛ-NTU (effective number of transfer unit) theoretical equations. Using the air temperature relationship between inlet and outlet vents as boundary conditions, a 3-D unsteady κ-ɛ turbulent model was used to give a transient analysis simulation of the temperature field and flow conditions in a vehicle’s passenger cabin. Cooling cycle analysis and conjugate heat transfer analysis at the inside surface of the cabin’s ceiling, floor and sides were also considered. The predicted temperature distributions in the vehicles passenger cabin were in good agreement with those obtained experimentally.     

Effect on friction of engine oil seal with engine oil viscosity

Low viscosity engine oil can improve a vehicle’s fuel economy by decreasing the friction between the engine components. Frictional torque varies with the velocity change due to different viscosity characteristics of SAE grade 5W-20, 5W-30 and 5W-40 engine oils. The viscosity for each of these grades was measured to outline the effect low viscosity engine oils have on engine friction, which may lead to improved fuel economy. Engine oil seal frictional torque increases with the shaft rotational speed for all three engine oil grades. A decrease in engine oil seal frictional torque was confirmed when low viscosity engine oil was used. Also, the leak-free performance of the engine oil with the seal satisfied the life limit durability test criteria. Thus, low viscosity engine oil may be used to improve fuel economy by decreasing the frictional loss of the engine oil seal while having no negative impact on performance due to leak-free functioning.     

Transient characteristics of emissions during engine start/stop operation employing a conventional gasoline engine for HEV application

In this paper, we investigate the transient characteristics of combustion and emissions during engine start/stop operations in hybrid electric vehicle (HEV) applications. Hydrocarbon (HC) emissions during the initial 2^nd∼9^th cycles are found to be significantly greater when the engine is quickly started under the original engine calibration mode. Lower intake manifold absolute pressure (MAP) was also found to cause larger residual gas dilution and poor combustion, resulting in a higher HC concentration when the cranking speed was increased. The post-catalyst HC concentration was found in the way of initially decrease and then to increase again as the cranking speed was increased. A lowest concentration value was achieved at a cranking speed of 1000 r/min. Engine shut-down by fuel cut-off was shown to produce lower emissions than shut-down by ignition cut-off as one can avoid misfire of the last fuel injection cycle. The fuel deposited during the stop process seems to impact engine restart enrichment mostly during the initial 0.7 s for this engine, whose performance is dominated by the MAP transition characteristic and the time coefficient for fuel vaporization in this time period     

Optimized design for a MacPherson strut suspension with side load springs

Undesired lateral force inevitably exists in a MacPherson suspension system, which is liable to damper rod’s side wear and promotes the damper’s inner friction decreasing the ride performance from the suspension system. Substituting a new side load spring with curved centerline for the conventional coil spring has been proven able to solve these problems and Multi-body Dynamics combining with Finite Elements Analysis may be an efficient method in optimizing its design. Therefore, taking a passenger car as example, a detailed multi-body dynamics model for the suspension system is built to simulate forces exerted on the damper and the minimization of its lateral component is selected as the design target for the spring. When the structure optimization of the side load spring is performed using FEA software ANSYS, its vertical and lateral elastic characteristics, supported by test data, are analyzed. After importing FEA results back to the suspension system, the dynamics simulation can be performed to validate the optimization result.     

Analysis process of a steering system using a concept model for idle vibration

This paper describes the development of an optimal design process for a steering column system and supporting system. A design guide is proposed at the initial concept stage of the development process to obtain sufficient stiffness of the steering system while reducing the idle vibration sensitivity of the system. Case studies on resonance isolation are summarized, where vibration modes among the systems are separated by applying a vibration mode map at the initial stage of the design process. This study also provides design guidelines for an optimal dynamic damper system using a CAE (computer aided engineering) analysis. The damper FE (finite element) model is added to the vehicle model to analyze the relation between the frequency and the sensitivity of the steering column system. This analysis methodology makes it possible to achieve target performance in the early design stage and reduction of damper tuning activity after the proto car test stage. Through the proposed steering column system development process, a lightweight vehicle with high stiffness is possible prior to the proto build stage. Furthermore, the improved process is expected to contribute to reducing the overall development period and the number of proto car tests necessary to achieve the desired steering system performance.     

Effect of fuel stratification on initial flame development: Part 2-low swirl condition

This paper is the second invstigation on the effect of fuel stratification on flame propagation. In the previous work, the characteristics under the no port-generated swirl condition, i.e., the conventional case was studied. In this work, the flame development under the low swirl condition was considered. For this purpose, the initial flame development and propagation were visualized under different axially stratified states in a modified optical single cylinder SI engine. The images were captured by an intensified CCD camera through the quartz window mounted in the piston. Stratification was controlled by the combination of the port swirl ratio and injection timing. These were averaged and processed to characterize the flame propagation. The flame stability was estimated by the weighted average of flame area and luminosity. The stability was also evaluated through the standard deviation of flame area and propagation distance and through the mean absolute deviation of the propagating direction. The results show that the flame-flow interaction determines the direction of flame propagation and that the governing roles of the two factors vary according to the stratified state and the location in the cylinder. In addition, the flame development and the initial flame stability are strongly dependent on the stratified conditions, and the initial flame stability is closely related to the engine stability and lean misfire limit. Lastly, there is no essential difference in gasoline and CNG flame propagation characteristics.     

Automotive structure vibration with component mode synthesis on a multi-level

The recursive component mode synthesis method (RCMS) has been implemented for the finite element analysis model of an automobile structure as an efficient free vibration analysis tool. The RCMS method is intended to obtain a better performance relative to the block Lanczos method, which is a traditional method in the industry of obtaining eigenvalues, while obtaining the acceptable accuracy. A numerical example of the automobile finite element model demonstrates the outstanding performance of RCMS compared to the block Lanczos method.     

Public perceptions of the use of dynamic message signs

Intelligent transportation systems have been promoted as a means to improve both the efficiency and safety of the road network. The effectiveness of advanced technologies in improving road safety has been an area of research which has thus far yielded mixed results. In order to ensure that advanced technologies deliver on their intended outcomes, more research has to be devoted to understanding road users' perceptions and reactions to these systems. This study examines drivers' perceptions of the use of dynamic message signs and their self‐reported reactions to the messages displayed. In general, drivers support the use of highway electronic boards for traffic incident reports and weather information which have an impact on traffic delays and level of service. They also think that it is a good idea to display road safety messages and to remind drivers to drive safely and be courteous on the roads. Moreover, most drivers reported that they do read and think about the messages displayed and react positively to some of the road safety messages.