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.     

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.     

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.     

Influence of load and inflation pressure on the tyre rolling resistance

Tyre load and inflation pressure are important factors controlling rolling resistance of road vehicles. The article presents results obtained in the Technical University of Gdańsk during laboratory and road measurements of different car tyres rolling on different pavements. The knowledge of rolling resistance characteristics is important for modelling car dynamics as well as fuel consumption. It is also necessary to establish proper test conditions in the future standardized on-road method of measuring rolling resistance. The results indicate that while an increase of load always leads to the increase of rolling resistance force, the influence on Coefficient of Rolling Resistance is more complicated and unpredictable. They also indicate that tyres with high rolling resistance are more sensitive to inflation pressure changes than low rolling resistance tyres.     

Implementation of discharging/charging current sensorless state-of-charge estimator reflecting cell-to-cell variations in lithium-ion series battery packs

This paper offers novel insights to the design and implementation of an innovative state-of-charge (SOC) estimator for the lithium-ion (Li-Ion) series battery pack. The most interesting feature of this approach is that it can utilize information from each filtered terminal voltage of the Li-Ion cells connected in series for SOC estimation of the battery pack. Without actual sensing each discharging/charging current (DCC) applied to the Li-Ion cells, it is possible to extract each DCC estimation from the corresponding filtered terminal voltages with an equivalent electrical circuit model (EECM) identification of all Li-Ion cells in the battery pack. There are two advantages to SOC estimation of the battery pack with this approach. First, the proposal can be implemented simply and effectively, reducing the computational steps required for SOC estimation. By reducing computational steps, the proposal is expected to be more cost-effective. Second, the approach guarantees an improved SOC performance, even if the battery pack results in inevitable cell-to-cell variation among Li-Ion cells. Accordingly, there are fewer differences to previously estimated DCCs among Li-Ion cells. Specifically, all values from the estimated DCCs are properly compensated for by simultaneous parameter modification according to each cell’s electrochemical characteristics. Experimental results clearly demonstrate that our DCC sensorless SOC estimator provides robust SOC performance for the battery pack. This approach considered an experimental battery pack (12S1P) connected in series using 2.6 Ah LiCoO2 cells produced by Samsung SDI.     

Methodology for bus structure torsion stiffness and natural vibration frequency prediction based on a dimensional analysis approach

Engineering bus design requires testing of bus structures prototypes in order to guarantee a certain level of strength and an appropriate static and dynamic behavior of the bus superstructure when exposed to road loads. However, experimental testing of real bus structures is very expensive as it requires expensive resources and space. If testing is done on a scale bus model the previous required expenses are considerably reduced. Therefore, a novel methodology based on dimensional analysis applied to bus structure prediction to evaluate the bus structure static and dynamic performance is proposed. The static performance is evaluated attending to torsion stiffness and the dynamic in terms of the natural vibration frequencies and rollover threshold. A scale bus has been manufactured and dimensionless parameters have been defined in order to project the results obtained in the scale bus model to a larger model. Validation of the proposed methodology has been carried out under experimental and finite element analysis.     

Application of a modified thermostatic control strategy to parallel mild HEV for improving fuel economy in urban driving conditions

A modified thermostatic control strategy is applied to the powertrain control of a parallel mild hybrid electric vehicle (HEV) to improve fuel economy. This strategy can improve the fuel economy of a parallel mild HEV by operating internal combustion engine (ICE) in a high-efficiency region. Thus, in this study, experiments of a parallel mild HEV were conducted to analyze the characteristics of the hybrid electric powertrain and a numerical model is developed for the vehicle. Based on the results, the thermostatic control strategy was modified and applied to the vehicle model. Also, battery protection logic by using electrochemical battery model is applied because the active usage of battery by thermostatic control strategy can damage the battery. The simulation results of the vehicle under urban driving conditions show that the thermostatic control strategy can improve the vehicle’s fuel economy by 3.7 % compared with that of the conventional strategy. The results also suggest that the trade-off between the fuel economy improvement by efficient ICE operation and the battery life reduction by active battery usage should be carefully investigated when a thermostatic control strategy is applied to a parallel mild HEV.