Fatigue life prediction of a rubber material based on dynamic crack growth considering shear effect

This paper suggests a fatigue life calculation method (A fatigue life calculation method is suggested) for rubber components based on the dynamic crack growth considering shear effect. Dynamic tearing tests were carried out, and the crack length was measured using an optical microscope to calculate the dynamic crack growth rate which characterizes and determines the fatigue life. The algorithm was numerically implemented in finite element code, ABAQUS standard, by using the user subroutine and applied to several rubber components. In the finite element analysis, deformation mode of an element was classified into tension and shear, and a weighting factor was multiplied to a strain energy density according to the degree of shear strain. Tension and compression of an elliptic dumbbell specimen was simulated in order to verify the material parameters of the suggested fatigue life prediction equation and to enhance the reliability of the algorithm. Finally, the fatigue life of a vehicle suspension bushing was calculated and compared with test. There were good agreements in the failure location and the magnitude of the fatigue life.     

Evaluation and visualization of stratified ultra-lean combustion characteristics in a spray-guided type gasoline direct-injection engine

To comply with reinforced emission regulations for harmful exhaust gases, including carbon dioxide (CO₂) emitted as a greenhouse gas, improved technologies for reducing CO₂ and fuel consumption are being developed. Stable lean combustion, which has the advantage of improved fuel economy and reduced emission levels, can be achieved using a sprayguided-type direct-injection (DI) combustion system. The system comprises a centrally mounted injector and closely positioned spark plugs, which ensure the combustion reliability of a stratified mixture under ultra-lean conditions. The aim of this study is to investigate the combustion and emission characteristics of a lean-burn gasoline DI engine. At an excess air ratio of 4.0, approximately 23% improvement in fuel economy was achieved through optimal event timing, which was delayed for injection and advanced for ignition, compared to that under stoichiometric conditions, while NO_x and HC emissions increased. The combustion characteristics of a stratified mixture in a spray-guided-type DI system were similar to those in DI diesel engines, resulting in smoke generation and difficulty in three-way catalystutilization. Although a different operating strategy might decrease fuel consumption, it will not be helpful in reducing NO_x and smoke emissions; therefore, alternatives should be pursued to achieve compliance with emission regulations.     

Durability prediction for automobile aluminum front subframe using nonlinear models in virtual test simulations

This research work presents fatigue life evaluation techniques for an automotive vehicle aluminum front subframe using virtual test simulation technology with nonlinear suspension components model. The technology was used for improving the accuracy of the polynomial model used in conventional analysis. The proposed nonlinear suspension components models were developed using direct approach. The effects of the nonlinear elements on the prediction of the fatigue life were also analyzed. Actual aluminum front subframe was tested using half-car road test simulator to verify the accuracy of the models. It was found that the proposed nonlinear models yield more accurate results than conventional polynomial models. The proposed virtual test simulation technology with nonlinear suspension components model can be used to predict fatigue life for vehicle chassis structures more accurately.     

Realization of pmp-based control for hybrid electric vehicles in a backward-looking simulation

Optimal control is generally not possible without information about the future coming up, and it is not easy to obtain an optimal solution even though the information is given a priori. In this paper, a control concept based on Pontryagin’s Minimum Principle (PMP) is introduced as an efficient solution to generate an optimal control trajectory for Hybrid Electric Vehicles (HVEs) when the performance of the vehicles is evaluated on scheduled driving cycles at a simulation level. The main idea of the control concept is to minimize Hamiltonian, which is interpreted as equivalent fuel consumption, and the Hamiltonian is characterized by a co-state, which is interpreted as a weighting factor for the electrical usage. A key aspect of the control problem is that an appropriate initial condition of the co-state is required to satisfy the boundary condition of the problem. In this study, techniques to calculate the Hamiltonian in different hybrid configurations are introduced, and a methodology to look for the initial condition of the co-state is studied, so that the controller is able to realize a desired State Of Charge (SOC) trajectory. To address the issue, we utilize a shooting method with multiple initial conditions based on the concept of the Newton-Raphson method, and all these techniques are realized in a backward looking simulator. The simulation results show that the PMP-based control is a very efficient approach to produce the optimal control trajectory, and the performance is compared to the optimal solution solved by Dynamic Programming (DP).     

Vehicle velocity estimation using effective inertia for an in-wheel electric vehicle

In this study, a vehicle velocity estimation algorithm for an in-wheel electric vehicle is proposed. This algorithm estimates the vehicle velocity using the concept of effective inertia, which is based on the motor torque, the angular velocity of each wheel and vehicle acceleration. Effective inertia is a virtual mass that changes according to the state of a vehicle, such as acceleration, deceleration, turning or driving on a low friction road. The performance of the proposed vehicle velocity estimation algorithm was verified in various conditions that included straight driving, circle driving and low friction road driving using the in-wheel electric vehicle that was equipped with an in-wheel system in each of its rear wheels.     

Comparison study on characteristics of nano-sized particle number distribution by using condensation particle counter calibrated with spray and soot type particle generation methods

In the year 2011, the Particle Measurement Program (PMP) in Europe started the regulation of the diesel vehicle’s nano-sized particle number density (PN) due to its high degree of harm to the human body. Concretely, the standard level of PN emission was introduced in the Euro 5+ and 6 emissions regulation with a limit (<6.0 × 10¹¹#/km) for diesel light-duty vehicle. Therefore, the determination of suitable and sophisticated instruments for reliable particle sampling and analysis was essential in taking exact experimental data. Now, among the PN emission measuring devices suggested by the PMP, condensation particle counter (CPC) is a key equipment for measuring the particle number density in real time and it has been used extensively. However, CPC can cause different results depending on operating conditions of the saturator and condensation that induce different rates of particle growth. This study was conducted to analyze the effect of CPC calibrated by a two-particle generator with spray and soot type methods applied on the nano-sized particle distribution’s parameters such as number concentration and linearity. Also, in order to ensure the reliability for particle sensor system named as PPS, which had emerged as a useful diagnostic to making spatially and temporally resolved quantitative measurements of diesel PN concentration, it was compared with calibrated CPC system. As a result, nano-sized particle measuring system with CPC calibrated by spray type particle generator had a much higher counting efficiency, indicating a larger nano size available than soot type particle generator. And, comparative experimental results on the correlation between the particle number of CPC to a reflectance PPS system showed that above 5,000 #/cm ³ in number concentrations measured by CPC as well as PPS were found to be similar with good linear relationship.     

Fault detection method for electric parking brake (EPB) systems with sensorless estimation using current ripples

A fault detection method with parity equations is proposed in this paper. Due to its low cost implementation, the velocity of the motor is not measurable in electric parking brake (EPB) systems. Therefore, residuals are not reliable when estimating the motor velocity with a low-resolution encoder. In this paper, we propose a fault detection method with sensorless estimation using current ripples that estimates the position and velocity of the motor by detecting periodical oscillations of the armature current caused by rotor slots. In addition, this method can estimate the position and velocity of the motor with less computational effort than a state observer. Moreover, the method is less sensitive to motor parameters than model-based estimation methods. The effectiveness of this method is validated with experimental data, and the simulation results show that various faults have their own residual patterns. Therefore, we can detect the presence of faults by monitoring the residual signals.     

Development of electrostatic diesel particulate matter filtration systems combined with a metallic Flow-Through Filter and electrostatic methods

A 3000 cc diesel engine attached to an engine dynamo was used to test three newly developed electrostatic Diesel Particulate matter filtration Systems (DPS 1, 2, and 3) under four steady-state engine operating conditions: idle, 2000 rpm with no load, and 2000 rpm under 25% and 50% loads. Of the two developed alternatives, DPS 1 and DPS 2, DPS 2 comprises an ionization section, electrostatic field additional section and Flow-Through Filter (FTF), which achieved almost 90% removal of particulate matter (PM) under the engine’s operating conditions, and the efficiency of the FTF was maintained between 20% and 50%. Comparing the long-term performance of DPS 2 and DPS 3 (effectively a serial combination of two DPS 2s) with a commercially-available Diesel Particulate Filter (DPF), the DPS 2 and DPS 3 achieved almost the same efficiency for removing PM as the DPF but had significantly improved (75%∼90% lower) differential pressure drops.     

Development of a new sound metric for impact sound in a passenger car using the wavelet transform

Vehicles can experience impacts due to harsh road conditions. Contact with an uneven road surface causes vehicles to vibrate, which generates a loud impact sound. The attenuation of such noise is important because car passengers may complain about the impact noise. However, perfect removal of impact noise is not possible because most of it is caused by external conditions. More research is needed on the objective attributes of impact noise; however, the problem of impact noise is not a simple matter because impact noise is transient in nature and reaches a high level instantaneously. In this paper, a new objective attribute of impact noise is designed using the wavelet transform, which is appropriate for analyzing nonstationary signals, such as an impact signal. The usefulness of the new objective attribute, which is a sound metric, is examined by comparing the mean subjective ratings for real impact noise in passenger cars. The new sound metric has better correlation with the mean subjective rating than currently existing sound metrics.     

Research on control strategy for differential steering system based on H mixed sensitivity

The differential steering system (DSS) of electric wheel vehicle gets rid of the restrictions of traditional steering system completely. As an ideal steering technology, it not only realizes the perfect combination of the road feel and the steering portability, but also realizes the harmony and unification between the steering maneuverability and safety. The structure and basic theory of the DSS of electric wheel vehicle are discussed in this paper. Based on these, the dynamic model of the steering system is built. Considering of the uncertainties and disturbances existing in the model, the H_∞ mixed sensitivity control theory is applied to achieve better tracking performance and road feel in the process of steering. Then, a H_∞ mixed sensitivity controller is designed to restrain the effect of the road disturbance and model uncertainties. The simulation results indicate that the DSS with the designed controller can effectively restrain the effect of noises and disturbances caused by random motivation from road, torque sensor measurement and model parameter uncertainty, and enable the driver to obtain satisfactory road feel.