Effect of tumble-home on roof strength of a vehicle

This study reports on the effect of vehicle tumble-home (side body inclination) on roof strength. The steep inclination of the side body of a vehicle increases its roof strength. Comprehensive analysis of the impact of high roof strength driven by the steep inclination on dynamic roof strength in rollover is described. Here, we have developed a numerical model using the ADAMS, which is capable of characterizing both of the static and the dynamic roof strength. According to the FMVSS 216 protocol, we achieve the strength to weight ratio (SWR; static roof strength) by applying loading plates to the roof of a vehicle. The Controlled Rollover Impact System (CRIS) allows us to quantitatively characterize the displacements of the top end of A-pillar and B-pillar, thus determining the dynamic roof strength by comparing the results. We demonstrated that the roof intrusion was one of the most critical causes which lead to injuries of occupants fastening seat belts. Our analysis revealed that the increase of the side body inclination of vehicles enhanced the static roof strength whereas it could not reduce the roof displacement (intrusion) in the dynamic rollover.     

Loosening analysis for fastening screw of automotive door trim parts

While a screw is a fastening element that can tighten the two parts at low cost, the loosening of the screw is generated due to external forces such as repetitive load, vibration, and thermal stress. This phenomenon decreases the initial clamping force, and this can be a serious problem to the safety of the product. However, while fastening parts are handled through experiment and experience, there is a lack of research on the screw loosening of plastic fastening parts. For example, vehicles have various fastening parts. Among the fastening elements, screws are typically used for tightening parts of the vehicle door trim. Vehicle interior materials are mainly composed of plastic parts. Especially, the temperature of the vehicle interior changes from a sub-zero temperature to 100 degrees (°C) due to solar radiation. Unlike metals, plastic materials are commonly susceptible to the environment. In this study, the fastening screw of automotive door trim parts is selected. First, a screw loosening mechanism is implemented through Computer Aided Engineering (CAE) analysis and the influences of degradation are then analyzed. Secondly, the selecting method of clamping force is suggested through the analysis result of reduction according to the tightening torque.     

Automotive window seal design considering external aerodynamic load and surrogate constraint modeling

Installed between metallic DIW (Door in White) panel and nonmetallic door glass, automotive window seals has great influence on customers’ perception of NVH (Noise-Vibration-Harshness) performance. Recently, aerodynamic effect on ride comfort attracts increasing research interest. The external load causes unsteady pressure on glass, which is finally transferred to window seals and leads to complicated vibration and increases interior noise level. However, non-linearities of hyper-elastic material, rubber-glass contact and large deformation behavior make the construction of window seals constraint model much more difficult, thus impeding further analysis and optimization. A new window seal design method is proposed featuring in considering aerodynamics-induced load and nonlinear constraint. Firstly, by SST ? k ? ε (Shear Stress Transport) turbulence model, external flow field of full-scale automotive is established by solving three-dimensional, steady and uncompressible Navier-Stokes equation. With re-exploited mapping algorithm, the overall aerodynamic pressure is extracted and matched to local window as external loads for seals, thus taking into account high speed fluid-structure interaction. Secondly, based on functional equivalence and mathematical fitting, new surrogate constraint model is presented. The unitedseal CLD (Compression Load Deflection) curve is synthesized after translations and transformations from two semi-seal CLD experimental measurements of inner and outer lips. It is then fit to complex exponential function, making seal constraint equivalent to a surrogate elastic constraint with variable stiffness. Experiment is performed to verify the constraint surrogation effectiveness. Finally, case study of window seal design under high speed is investigated. After seal optimization based on the new method, windows seals’ maximal displacements have decreased. The improved seal-glass fitting status shows better NVH quality of window seal in high-speed condition.     

Vehicle dynamics control by using a three-dimensional stabilizer pendulum system

Active safety systems of a vehicle normally work well on tyre–road interactions, however, these systems deteriorate in performance on low-friction road conditions. To combat this effect, an innovative idea for the yaw moment and roll dynamic control is presented in this paper. This idea was inspired by the chase and run dynamics animals like cheetahs in the nature; cheetahs have the ability to swerve while running at very high speeds. A cheetah controls its dynamics by rotating its long tail. A three-dimensional stabilizer pendulum system (3D-SPS) resembles the rotational motion of the tail of a cheetah to improve the stability and safety of a vehicle. The idea has been developed in a stand-alone 3D stabilizer pendulum system as well as in an integrated control system, which consists of an ordinary differential braking direct yaw control (DYC) and active steering control that is assisted by the 3D-SPS. The performance of the proposed 3D-SPS has been evaluated over a wide range of handling manoeuvres by using a comprehensive numerical simulation. The results show the advantage of 3D-SPS over conventional control approaches, which are ineffective on low-friction road conditions and high lateral acceleration manoeuvres. It should however be noted that the best vehicle dynamics performance is obtained when an integrated 3D-SPS and DYC and AFS is utilised.     

Cluster-based correlation of severe driving events with time and location

In this article, a systematic strategy is proposed to identify severe driving events occurrence correlation with time and location. The proposed approach, which is constructed based on batch clustering and real-time clustering techniques, incorporates historical and real-time data to predict the time and location of severe driving events. Batch clustering is implemented with the combination of subtractive clustering and fuzzy c-means clustering to generate clusters representing the initial correlation patterns. Real-time clustering is then developed to create and update real-time correlation patterns on the foundation of the batch clustering using the evolving Gustafson–Kessel like (eGKL) algorithm. In both clustering processes, the correlation of the events within time domain is identified first, and then two different levels of accurate correlations are conducted for the location domain. Real-time data of operating vehicles each equipped with a data acquisition and wireless communication platform are used to validate the proposed strategy. Batch clustering results reveal the severe braking events distribution and concentration at daytime and nighttime. Real-time clustering provides and updates the variation of the correlations/intercorrelation of different regions. Drivers can be notified of the potential severe driving locations through maps showing the driving routes. Through the variation of the correlations, drivers can recognize the events occurrence at different times and locations. The generated time series can be potentially used to develop spatial-time models for regions to model and forecast the events occurrence.     

High fidelity quasi steady-state aerodynamic model effects on race vehicle performance predictions using multi-body simulation

We described in this paper the development of a high fidelity vehicle aerodynamic model to fit wind tunnel test data over a wide range of vehicle orientations. We also present a comparison between the effects of this proposed model and a conventional quasi steady-state aerodynamic model on race vehicle simulation results. This is done by implementing both of these models independently in multi-body quasi steady-state simulations to determine the effects of the high fidelity aerodynamic model on race vehicle performance metrics. The quasi steady state vehicle simulation is developed with a multi-body NASCAR Truck vehicle model, and simulations are conducted for three different types of NASCAR race tracks, a short track, a one and a half mile intermediate track, and a higher speed, two mile intermediate race track. For each track simulation, the effects of the aerodynamic model on handling, maximum corner speed, and drive force metrics are analysed. The accuracy of the high-fidelity model is shown to reduce the aerodynamic model error relative to the conventional aerodynamic model, and the increased accuracy of the high fidelity aerodynamic model is found to have realisable effects on the performance metric predictions on the intermediate tracks resulting from the quasi steady-state simulation.     

Railway vehicle performance optimisation using virtual homologation

Unlike regular automotive vehicles, which are designed to travel in different types of roads, railway vehicles travel mostly in the same route during their life cycle. To accept the operation of a railway vehicle in a particular network, a homologation process is required according to local standard regulations. In Europe, the standards EN 14363 and UIC 518, which are used for railway vehicle acceptance, require on-track tests and/or numerical simulations. An important advantage of using virtual homologation is the reduction of the high costs associated with on-track tests by studying the railway vehicle performance in different operation conditions. This work proposes a methodology for the improvement of railway vehicle design with the objective of its operation in selected railway tracks by using optimisation. The analyses required for the vehicle improvement are performed under control of the optimisation method global and local optimisation using direct search. To quantify the performance of the vehicle, a new objective function is proposed, which includes: a Dynamic Performance Index, defined as a weighted sum of the indices obtained from the virtual homologation process; the non-compensated acceleration, which is related to the operational velocity; and a penalty associated with cases where the vehicle presents an unacceptable dynamic behaviour according to the standards. Thus, the optimisation process intends not only to improve the quality of the vehicle in terms of running safety and ride quality, but also to increase the vehicle availability via the reduction of the time for a journey while ensuring its operational acceptance under the standards. The design variables include the suspension characteristics and the operational velocity of the vehicle, which are allowed to vary in an acceptable range of variation. The results of the optimisation lead to a global minimum of the objective function in which the suspensions characteristics of the vehicle are optimal for the track, the maximum operational velocity is increased while the safety and ride quality measures of the vehicle, as defined by homologation standards, are either maintained in acceptable values or improved.     

Nonlinear dynamic modeling of an electro-pneumatic pressure converter for VGT pneumatic actuator

This paper presents a detailed physical model of an electro-pneumatic system, used to control Variable Geometry Turbochargers (VGT). The VGT actuator system consists of two parts, a diaphragm based pneumatic actuator and a solenoid based Electro-pneumatic Pressure Converter (EPC). The proposed model copes with the pressure dynamics inside the pneumatic actuator, with special focus on the EPC. The dynamics of both parts have been modeled separately and combined into one model by parameterizing the effective flow area and the air mass flow through the pneumatic actuator. The variations in volume, temperature and air mass flow rate have been taken into account. The model so obtained serves mainly for studying the effect of actuator dynamics on the global engine system. For control purposes, the detailed model is simplified to reduce the calculation load. Both models are validated using experimental data obtained from an engine test bench.     

Cooling performance of 25 kW in-wheel motor for electric vehicles

The in-wheel motor used in electric vehicles was designed and constructed for an electric direct-drive traction system. It is difficult to connect cooling water piping to the in-wheel motor because the in-wheel motor is located within the wheel structure. In the air cooling structure for the in-wheel motor, an outer surface on the housing is provided with cooling grooves to increase the heat transfer area. In this study, we carried out the analysis on the fluid flow and thermal characteristics of the in-wheel motor for various motor speeds and heat generations. In order to resolve heat release, the analysis has been performed using conjugate heat transfer (conduction and convection). As a result, flow fields and temperature distribution inside the in-wheel motor were obtained for base speed condition (1250 rpm) and maximum speed condition (5000 rpm). The thermo-flow analysis of the in-wheel motor for vehicles was performed in consideration of ram air effect. Also, in order to improve cooling effect of the motor, we variously changed geometries of housing. Therefore, we confirmed the feasibility of the air cooling for the motors of 25 kW capacity with housing geometry having cooling grooves and investigated the cooling performance enhancement. We found that the cooling effect was most excellent, in case that cooling groove direction was same with air flow direction and arranged densely.     

Effect of fuel choice on nanoparticle emission factors in LPG-gasoline bi-fuel vehicles

Nanoparticle and gas-phase emission factors are presented for a liquefied petroleum gas (LPG) passenger vehicle and are compared to gasoline operation. A bi-fuel LPG-gasoline vehicle certified for use on either fuel was used as the test vehicle so that a direct comparison of the emissions could be made based on fuel choice. These values were considered along with previous studies to determine the relative change in particulate emissions due to fuel choice over a wide range of vehicles and operating conditions. The vehicle examined in this study was tested on a chassis dynamometer for both steadystate and transient conditions. Transient test cycles included the US FTP72 driving cycle, Japanese driving cycle and modified Indian driving cycle while steady-state tests were done at vehicle speeds ranging from 10–90 km/hr in various transmission gears. Exhaust particle size distributions were measured in real-time using a differential mobility spectrometer (DMS50), and particle number and particle mass emission factors were calculated. For both fuels, the majority of the particles ranged from 5 to 160 nm in terms of particle diameter, with typically more than 85% of the particles in the nucleation mode (between 5–50 nm). In most cases, the vehicle produced a greater fraction of larger (accumulation mode) particles when fuelled on LPG. Using the data in the literature as well as the data in the current study, gasoline fuel produces 4.6 times more particles in terms of number and 2.1 times more particles in terms of mass.