Optimisation of active suspension control inputs for improved vehicle handling performance

Active suspension is commonly considered under the framework of vertical vehicle dynamics control aimed at improvements in ride comfort. This paper uses a collocation-type control variable optimisation tool to investigate to which extent the fully active suspension (FAS) application can be broaden to the task of vehicle handling/cornering control. The optimisation approach is firstly applied to solely FAS actuator configurations and three types of double lane-change manoeuvres. The obtained optimisation results are used to gain insights into different control mechanisms that are used by FAS to improve the handling performance in terms of path following error reduction. For the same manoeuvres the FAS performance is compared with the performance of different active steering and active differential actuators. The optimisation study is finally extended to combined FAS and active front- and/or rear-steering configurations to investigate if they can use their complementary control authorities (over the vertical and lateral vehicle dynamics, respectively) to further improve the handling performance.     

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.     

Crashworthiness of chromium plated plastic radiator grille

The use of plastic in vehicle development has increased. In particular, a design trend has resulted in chromiumplated plastics being used in exterior panels. Recently, as the appearance has become more important in design, the plastic radiator grille has become larger, to where it can become the primary member when a front collision happens. The radiator grille should be designed with considerations of the geometric structure, such as delamination, and material characteristics, when plastics are plated with chromium. The enlarged grille has to pass regulations like FMVSS Part 581. Although the material property of plastic has been studied before, what seems to be lacking is study on the crashworthiness of plastic radiator grilles that are plated using chromium. In this paper, in order to evaluate the crashworthiness, tensile test and front collision analysis using finite element method are performed. Tensile test is conducted with 4 types of materials, and then material properties of chromium-plated plastics are obtained. Meanwhile radiator grille’s crashworthiness is evaluated using finite element analysis method. Analysis result is evaluated according to failure criterion. Through this study, method of the assessment of plastic radiator grille’s crashworthiness considered material properties of chromium plated plastics is proposed, and it can be predicted the delamination and the failure point of radiator grille at the design step.     

Effect of radial interference on torque capacity of press- and shrink-fit gears

Some gears in an automobile transmission have to be mounted by being press-fitted on a shaft instead of splines. The torque capacity of the press-fitted gear will be proportional to the radial interference. The excessive interference, however, will increase the gear radial deformation. In this paper, the press- and shrink-fit and the subsequent torque capacity test were investigated by finite element analysis, theoretically and experimentally. The static and dynamic coefficient of friction were determined.     

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.     

Application of rack type motor driven power steering control system for heavy vehicles

The Electric Power Steering (EPS) or Motor Driven Power Steering (MDPS) mechanism proves to be a bright prospect among passenger vehicles ensuring better vehicle safety and fuel economy. The car manufacturers are focusing on the production of Rack type EPS system (REPS). This paper describes the development of concurrent simulation technique using TruckSim and control strategy for analysing RMDPS control system with a dynamic vehicle system. A full Truck vehicle model interacting with RMDPS control algorithm was concurrently simulated on a sinusoidal steering input. The dynamic responses of vehicle chassis and steering system resulting were evaluated and compared with proving ground experimental data. The comparisons show reasonable agreement on steering wheel torque, lateral acceleration and yaw rate. This concurrent simulation research leads the possibility of RMDPS performance evaluation of Truck and Semi-bonnet cars.     

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 steering system preferences evaluated using a driving simulator

The automotive steering system is the primary channel through which road and vehicle behavior feedback is transmitted to the driver. While the driver provides directional platform control through the steering wheel, perceptions of the vehicle’s handling responsiveness are simultaneously transmitted back to the driver allowing for correction of any instabilities the vehicle may encounter. Based on these factors, drivers often pay special attention to the steering system when deciding what vehicle to purchase. Therefore, a significant amount of effort and time is invested in attempting to determine the optimal design of steering system components and configurations. In this study, the determination of an optimal steering configuration was attempted based on responses obtained from questionnaires that subjects answered. The questions were designed to evaluate the degree of satisfaction regarding the “control”, “ease of operation”, and “fun” participants experienced after each driving run. During the study, human subjects drove a driving simulator for 15 combinations of 3 different roadway environments and 5 different steering configurations, filling out a questionnaire after each scenario. The subjects were also classified as a type of driver (“utility”, “enthusiast”, and/or “performance”). The study attempted to determine if the mean values of questionnaire responses for “control”, “ease”, and “fun” type of questions changed as the scenario and/or driver type changed. Analysis of Variance (ANOVA) was used to determine if the mean values of the three types of questions were statistically different. The overall results suggest that the average responses for vehicle “control”, “ease”, and the “fun” type of questions were dependent on the type of roadway environment; however, only the responses for “fun” type of questions were influenced by the given steering configurations. Indeed, the steering system can impact the driver’s perceptions of the vehicle’s operational experience.     

Network reliability‐based optimal toll design

Optimal toll design from a network reliability point of view is addressed in this paper. Improving network reliability is proposed as a policy objective of road pricing. A reliability‐based optimal toll design model, where on the upper level network performance including travel time reliability is optimized, while on the lower level a dynamic user‐equilibrium is achieved, is presented. Road authorities aim to optimize network travel time reliability by setting tolls in a network design problem. Travelers are influenced by these tolls and make route and trip decisions by considering travel times and tolls. Network performance reliability is analyzed for a degradable network with elastic and fluctuated travel demand, which integrates reliability and uncertainty, dynamic network equilibrium models, and Monte Carlo methods. The proposed model is applied to a small hypothesized network for which optimal tolls are derived. The network travel time reliability is indeed improved after implementing optimal tolling system. Trips may have a somewhat higher, but more reliable, travel time.