Torque characteristics analysis for optimal design of a copper-layered eddy current brake system

An enhanced parametric model for a copper-layered eddy current electric machine (retarder) is introduced in this paper. The modeled torque characteristics of the copper-layered electromagnetic retarders are based on the results from a detailed electromagnetic finite element analysis (FEA) of these eddy current machines. The model uses a parameterized double-exponential function to model the steady state speed-torque characteristics of the retarder. The parameters are adjusted for optimal braking performance in conjunction with predicted speed-torque characteristics of a copper-layered retarder. A full vehicle model, along with the proposed retarder speed-torque model has been used to simulate a series braking events. The simulation results show that the peaks of the retarder speed-torque curves must be designed to occur within a specific range of speeds for optimal braking performance.     

Quality evaluation of car window motors using sound quality metrics

In this paper, a method to establish a decision criterion to evaluate the quality of small window motors using sound quality (SQ) metrics is suggested. Although the sound level radiated from the motor is relatively small compared to other sounds in a car, the sound from an abnormal motor gives an uncomfortable feeling and the impression of abnormal operation, which can lead to customer complaints. To construct an objective decision criterion, the correlation between the SQ metrics and the subjective decision on the passing or failure of the motor were investigated. Four representative SQ metrics, viz., loudness, sharpness, roughness, and fluctuation strength, were calculated for the collected samples. It was observed that the loudness and roughness of the motor sample group classified as abnormal was higher than those of the normal motors. For a single figure rating for motor quality, an evaluation index for the motor sound was generated by combining the correlated SQ metrics with proper weightings. Evaluation results on the specimens that were not employed in generating the quality evaluation index showed a reasonable agreement with the subjective test at 73%. The suggested quality check method can replace the current subjective decision procedure to identify the faulty motors.     

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.     

Piston-temperature measuring system using electromagnetic induction with verification by a telemetry system

The development of an inner-piston-chamber temperature measurement system is a necessary step in engine development or when solving other fundamental problems related to automotive engines. There are various pre-existing measurement methods available, e.g., the linkage method, piston telemetry, templog, and the electromagnetic induction method. In this study, we first redesigned the coil sensor used in the electromagnetic induction method using PEEK and then used Taguchi methods to reduce the number of experiments in the development process and finally utilized piston telemetry via Bluetooth to verify the precision and accuracy of the redesigned PEEK coil sensor and electromagnetic induction method. The results displayed a reproducibility within 0.5 degrees and an accuracy within 2 degrees Celsius.     

Performance optimization of CVT for two-wheeled vehicles

Continuously Variable Transmission (CVT) is one of the most promising automotive transmission technologies because of its continuously variable gear ratio and reduced shift shock. CVT is different from Manual Transmission and Automatic Transmission, and it is possible to operate the power source in its high efficiency region with CVT in the drive train. Several types of CVT exist that can be categorized based on the mechanism of power transmission, such as the belt pulley, traction drive, and hydrostatic types. This paper investigates the belt pulley CVT, which consists of a thrust actuator, driver pulley, belt, driven pulley, and preload spring of the output shaft. A complete CVT is constructed, and based on that a simulation program that analyzes the static performance of a CVT is implemented in Matlab/Simulink. From these simulation results, methods for improving the efficiency of the CVT are discussed. The coefficient of the torque capacity factor is proposed as affecting the matching between a power source and a CVT, and methods for improving the matching effect are also investigated.     

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.     

Nonlinear three-dimensional wagon-track model for the investigation of rail corrugation initiation on curved track

A nonlinear wagon-track model on curved track has been developed to characterize rail corrugation formation due to self-excitation of the wheel-rail stick-slip process. In this model, wagon movements were described using up to 78 degrees of freedom (DOFs) to model a three-piece freight bogie. Innovatively, the wheelset movements are described using nine DOFs, including torsional and bending modes about the longitudinal and vertical directions. The track modelling is considered as a one-layer structure (two rail beams on discrete spring and damper elements). The wheel sliding after creepage saturation is considered in the wheel-rail interface modelling. Simulation of a case study shows that the frequencies of the wheel stick-slip process are composed of the basic frequency, which might come from the combined effect of sleeper-passing frequency and one-third of the combined torsional and bending frequency of the wheelset, and the double and triple basic frequencies, which form the wavelengths of rail corrugation at different situations.     

Analysis of the shifting behavior of a novel clutchless geared smart transmission

Conventional geared transmissions use some kinds of clutches to control the power flow from an internal combustion engine to the driveline while shifting gears. However, the shifting performance is seriously affected by the clutch engagement and an unavoidable drop in the torque may occur when the clutch is disconnected. Moreover, wear of the clutch, the need for hydraulic equipment, and the load limit may together aggravate the limits of the clutch system. For this reason, as a novel transmission without a clutch, the clutchless geared smart transmission (henceforth CGST) is proposed by our research team. The CGST controls the power flow in a multiple-input gear-train by controlling the electric motor attached to the planetary gear system. However, no CGST has been realized in an actual vehicle thus far, and the performance has been predicted only theoretically. In this research, we analyzed the achievable performance based on a developed CGST dynamic model with a typical CGST structure. In addition, a CGST gear-shifting algorithm is proposed for use with the dynamic model. From the simulation results, the CGST does not show an abrupt drop in its torque or oscillation while shifting gears due to the absence of a discontinuous power flow. The developed dynamic model can serve as a performance reference for the CGST. Moreover, it can be used as a simulation tool for developing a gear-shifting control logic scheme.     

Review on characterization of nano-particle emissions and PM morphology from internal combustion engines: Part 1

This paper is review of the characterization of exhaust particles from state-of-the-art internal combustion engines. We primarily focus on identifying the physical and chemical properties of nano-particles, i.e., the concentration, size distribution, and particulate matter (PM) morphology. Stringent emissions regulations of the Euro 6 and the LEV III require a substantial reduction in the PM emissions from vehicles, and improvements in human health effects. Advances in powertrains with sophisticated engine control strategies and engine after-treatment technologies have significantly improved PM emission levels, motivating the development of new particle measurement instruments and chemical analysis procedures. In this paper, recent research trends are reviewed for physical and chemical PM characterization methods for gasoline and diesel fueled engines under various vehicle certification cycles and real-world driving conditions. The effects of engine technologies, fuels, and engine lubricant oils on exhaust PM morphology and compositions are also discussed.     

Approach to functional safety-compliant ECU design for electro-mechanical brake systems

In this paper, we propose a design approach to a functional safety-compliant ECU for an electro-mechanical brake (EMB) control system or an electronic wedge brake (EWB) control system. Brake actuators in a brake-by-wire (BBW) system such as EMB or EWB are characterized by the safety-critical functions which are now executed by using many electric and electronic devices with application software. Based on hazard analysis and risk assessments of the automotive functional safety standard ISO 26262, the proposed EMB control system should be ASIL-D-compliant, which is the highest ASIL level. To this end, a hardware and a software design method is introduced to implement functionl safety-oriented monitoring functions which are based on an asymmetric dual-core architecture with an external watchdog processor. It is shown by using EMB hardware-In-the-Loop-Simulation (HILS) that the proposed ECU design approach is very effective when a hardware fault or software execution faults occur in the EMB ECU, moreover, this functional safety-compliant design can be well combiled with the sensor fault-tolerant control logic.