Urban driving cycle for performance evaluation of electric vehicles

Nowadays, a number of environmental issues have seriously come to the fore. For this reason, the R & D spending on eco-friendly vehicles that use electric power has been gradually increasing. In general, fuel economy and pollutant emissions of both conventional and eco-friendly vehicles are measured through chassis dynamometer tests that are performed on a variety of driving cycles before an actual driving test. There are a number of driving cycles that have been developed for the for performance evaluation of conventional vehicles. However, there is a lack of research into driving cycle for EV. Because large differences exist between the drive system and driving charateristics of EV and that of CV, a study on driving cycle for EV should be conducted. In this study, the necessity of an urban driving cycle for the performance evaluation of electric vehicles is confirmed by developing the driving cycle. First, the Gwacheon-city Urban Driving Cycle for Electric Vehicles (GUDC-EV) is developed by using driving data obtained through actual driving experiments and statistical analysis. Second, GUDC-EV is verified by constructing EV simulators and performing simulations that use the actual driving data. The simulation results are then compared against existing urban driving cycles, such as FTP-72, NEDC, and Japan 10–15. These results confirm that GUDC-EV can be used as an urban driving cycle to evaluate the performance of electric vehicles and validate the necessity of development of the driving cycle for electric vehicles.     

Micro deformation of automobile hood in dipping process using stiffness

Technicians have been going through trial-and-error processes to solve very small or micro deformation on automobile hood during the painting process. In order to establish a systematic improvement procedure which can replace the time-consuming trial-and-error method to reduce defects, an accurate analysis of how micro deformation occurs during the painting process is needed. We have utilized a stiffness scanning method in automobile hood and reverse engineering to build up a reliable and accurate structural analysis and measurement procedures. We measured the load-stroke data at critical locations on automobile hood through stiffness scanning to determine material constants closest to the measurement by assuming several critical hood parts, such as sealer inside the hood, hemming part, spot weld part, and other uncertain joints, as virtual elastic materials. After setting the difference between analytical and measured load-stroke data as an objective function, we computed and minimized it by using the response surface method and partial differentiation of the object function. As a result, by obtaining the reliability was over 91%, which showed a strong correlation between analysis and measured results. By comparing the actual strain measured in real painting lines with calculated strain, we confirmed the validity of our structural analysis method. It was concluded that the proper analysis tool could be utilized in determination of optimal locations of supports during the painting process.     

Semi-Active Suspension with Preview Using a Frequency-Shaped Performance Index

The objective of this study is to develop a control law for a semi-active suspension for the purpose of ride quality improvement. The semi-active control law is determined by reproducing the control force of an optimally controlled active suspension while suppressing its damping coefficient variation. The performance index of the optimal control for the active suspension is modified to include frequency-shaping by use of Parseval's theorem, which allows us to de-emphasize the effects of particular variables over specific frequency bands.

Through the numerical simulations, it was found that the semi-active suspension may reduce the vertical acceleration of the driver's seat and the sprung mass motions significantly. The road-holding and tire deflections were not affected much.     

Sequential Approximate Optimization of MacPherson Strut Suspension for Minimizing Side Load by Using Progressive Meta-Model Method

In a MacPherson strut suspension, the side load is inevitably generated and it causes friction at the damper reducing riding comfort. In this paper, to solve this problem, progressive meta-model based sequential approximate optimization (SAO) is performed to minimize the side load. To calculate the side load, a wheel travel analysis is performed by using flexible multi-body dynamics (FMBD) model of suspension, which can consider both finite element method (FEM) and multi-body dynamics (MBD). In the optimal design process, meta-model is generated by using extracted sampling points and radial basis function (RBF) method. As a result of optimal design, spring setting positions that minimize the side load are obtained and by using optimal spring setting positions, the suspension FMBD model was constructed.     

Simulation Study on Thermal Management Strategy to Achieve 99 % SCR Efficiency of a Heavy-Duty Diesel Engine over a Transient Cycle

In this study, NOx conversion characteristics of a urea selective catalytic reduction (SCR) system equipped on a heavy-duty diesel engine were evaluated through engine dynamometer bench tests over a scheduled world harmonized transient cycle (WHTC). Also, based on transient SCR simulations, the thermal management strategy to improve SCR NOx conversion efficiency was investigated. As a result, it was found that a selective increase in exhaust temperature at low temperature period would be a useful measure to increase SCR efficiency on WHTC mode. From the baseline SCR efficiency of around 98 % on WHTC mode, the current simulation results have shown that around 99 % level of SCR efficiency would be achievable by increasing exhaust temperatures with modifying diesel exhaust fluid (DEF) dosage. Another valuable contribution of this study is that the design guidelines for controlling exhaust temperature and DEF injection to obtain a target NOx conversion efficiency are presented for SCR systems of heavy-duty diesel engines on transient operating conditions.     

Wheel Slip Control in Traction Control System for Vehicle Stability

Traction control systems are used to prevent wheel slippage and to maximize traction forces. This paper proposes a new scheme to enhance vehicle lateral stability with a traction control system during cornering and lane changes. This scheme controls wheel slip during cornering by varying the slip ratio as a function of the slip angle. It assumes that a traction control system with the engine throttle angle is used. The scheme is dynamically simulated with a model of front-wheel-driven passenger vehicles. Simulation results show that the proposed scheme is robust and superior to a conventional one, which is based upon fixed slip ratios, during cornering and lane changes.     

Multimodal route choice in maritime transportation: the case of Korean auto-parts exporters

Global offshoring has increased the need for transport of half-finished goods and components, along with finished goods. The auto-parts industry in Korea has also entered the global market as Korean car manufacturers have started to build overseas factories. Maintaining cost competitiveness by minimising total logistics costs will thus be a critical strategy for the industry. This research compares the total annual costs of four feasible transport routes from Korea to the US using the inventory-theoretic model, which encompasses direct transport costs, in-transit carrying costs, and warehouse inventory costs. We apply this model to real transport data collected from a Korean auto-parts company. A static analysis shows that inventory costs can play a decisive role in altering the cost competitiveness of different routes. In addition, sensitivity and scenario analyses with changes in variables and the market situations reveal that the cost structure of each route plays an important role in determining their relative cost competitiveness in varying market conditions.     

A study of fatigue crack propagation at a web stiffener on a longitudinal stiffener

Predicting fatigue crack growth after its detection during in-service inspection is necessary to prevent a loss of serviceability, such as the oil and/or water tightness of critical compartments. This paper focuses on the most typical fatigue cracks that start at the weld joint between a flat bar stiffener on a transverse web frame and the flange of a longitudinal stiffener on a bottom plate or inner bottom plate. An experiment is carried out to observe the fatigue crack propagation for two kinds of flat bars at the abovementioned connection. The experimental results, especially the surface crack growth on the flange (which dominates during the total fatigue life of the longitudinal stiffener), are compared with crack growth curves predicted using a few existing formulas. Based on the comparative study, a formula that shows the best agreement with the experiment results is selected. Weld toe magnification factors for the web stiffener are computed from the crack propagation rates measured in the experiment, and two equations for the magnification factors versus crack depth are developed for two types of web stiffeners. The selected existing formula and the proposed equations are applied to two connections at the inner bottom and side longitudinal bulkhead of an LNG carrier. The equivalent stress approach based on a long-term distribution is employed to avoid the complexity involved in dealing with the actual stress history. Using this prediction, the remaining service life until an oil or water leakage occurs at a tank boundary can be estimated when a fatigue crack at the connection is detected.     

Sheet metal forming simulation considering die deformation

Due to environmental concerns and safety regulations in the automotive industry, the development of strong and lightweight cars has been a hot issue in the last decade. One solution for this purpose would be to use high-strength steel (HSS) and advanced high-strength steel (AHSS). These materials can make the car lighter while maintaining the crash resistance of the vehicle. HSS and AHSS have more resistance force in the die structure compared with conventional steel due to their higher yield and tensile strength and thus, these materials have a greater effect on die deformation during the sheet metal forming process. As a result, die deformation can affect the blank sheet’s drawn pattern, strain, and stress as well as springback. This study presents a sheet metal forming simulation that considers die deformation. The simulation process was compared with conventional simulation methods. Our results indicate that the sheet metal forming simulation with die deformation consideration provides useful information on the die structure as well as formability and springback.