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2014-04-01
Technical Paper
2014-01-1057
Daewon Jang, Sungbae Jang
Abstract Today, all manufacturers of vehicle are up for the challenge to abide in automobile emission control laws. Weight reduction is one of the best solutions to reduce both fuel consumption and emissions. The most effective method for the said idea is to have lightweight materials to some of parts of vehicle using the FRP(Fiber Reinforced Plastics). In order to obtain good mechanical properties of FRP, continuous fiber should be used. But it is difficult to design and manufacture of FRP parts using continuous fiber because of material properties and molding process. In this paper, it is used CF(carbon Fiber) and Epoxy to make a composite material Properties of this CFRP can be predicted through analysis. Tests and simulations of specimen are performed as every steps progress for correlation. And spring can be designed to meet all requirements for specific performance. The CFRP spring is made by new devices and methods and can be applied to vehicle for practical using.
2014-04-01
Technical Paper
2014-01-1050
Massimiliana Carello, Andrea Giancarlo Airale, Alessandro Ferraris
Abstract The use of composite materials is very important in automotive field to meet the European emission and consumption standards set for 2020. The most important challenge is to apply composite materials in structural applications not only in racing vehicles or supercars, but also in mass-production vehicles. In this paper is presented a real case study, that is the suspension wishbone arm (with convergence tie and pull-rod system) of the XAM 2.0 urban vehicle prototype, that it has the particular characteristics that the front and rear, and left and right suspension system has the same geometry. The starting point has been an existing solution made in aluminum to manufacture a composite one.
2014-04-01
Technical Paper
2014-01-0999
Klaus Greven, Manikandan Loganathan
Abstract The Counter Pressure Casting (CPC) process is particularly suited for the production of aluminum suspension components like wheel carriers or steering knuckles. Using a typical AlSi7Mg alloy such as A356 or EN AC-42100, yield strength above 260 MPa and elongation rates above 8% are possible in a high volume production. Although these are very good values for aluminum castings, the yield strength has to be improved to increase the light weight potential of such components. The present work shows how this goal can be achieved by the development of a new aluminum casting alloy. Besides the modification of Si and Mg content, the addition of Cr leads to an additional dispersion hardening effect. In this way, yield strength above 310 MPa combined with an elongation of 7% can be assured in the CPC process after a T6 heat treatment.
2014-04-01
Technical Paper
2014-01-1009
Yoon Cheol Kim, Seong Jin Kim, Jaeyoung Lee, Jeongkyu Kim, SooHyuk Lee, Kyoungdon Yi, KiJeong Kim
Abstract Reducing unsprung mass of the car is a representative method to enhance the ride & handling performance and fuel efficiency. In this study, brake disc weight is reduced 15∼20% using a hybrid type material. The basis for this study is the separation of the friction surface and HAT(mounting part). Aluminum material is applied in the HAT for a light weight effect. Gray iron is applied in the friction surface section to maintain braking performance. Two types of joining between aluminum and cast iron are developed. One is the aluminum casting method utilizing a gray iron insert and the other is a bolted assembly method. Detailed structure, process and material are optimized using try-out & dynamometer experiments. The Reliability of this development is proved through durability (dynamometer and vehicle) testing.
2014-04-01
Technical Paper
2014-01-1242
Jonathan M. S. Mattson, Michael Mangus, Christopher Depcik
Abstract A timing sweep to correlate the location of Maximum Brake Torque (MBT) was completed on a single-cylinder, direct injected compression ignition engine that was recently upgraded to a high-pressure rail injection system for better engine control. This sweep included emissions monitoring for carbon dioxide, carbon monoxide, particulate matter, hydrocarbons, and oxides of nitrogen for the calibration of a heat release model, as well as the opportunity to relate MBT timing to brake-specific emissions production. The result of this timing sweep was a relatively linear correlation between injection delay and peak pressure timing. In addition, a number of other MBT timing methodologies were tested indicating their applicability for immediate feedback upon engine testing, particularly mass fraction burned correlations. Emissions were either strongly correlated to MBT timing (with emissions being minimized in the vicinity of MBT), or were completely independent of MBT.
2014-04-01
Technical Paper
2014-01-0030
Kun Diao, Lijun Zhang, Dejian Meng
Abstract Brake squeal shows a significant uncertainty characteristic. In this paper, a series of bench tests were carried out to study the uncertainty of brake squeal on a multi-function brake inertia dynamometer test bench. Then based on time-frequency analysis results, a creative squeal confirmation and determination method was presented, which can show the squeal variations in the domains of time, frequency and amplitude together. An uncertainty analysis method was also established, in which the statistical parameters of squeal frequency and sound pressure level (SPL), and probability density evaluation of frequency based on Quantile-Quantile Plot (QQ plot) were given. And a judgment method of the frequency doubling was devised based on numerical multiple and occurrence concurrence, as well as the uncertainty statistical analysis method considering frequency doubling. All the methods established were applied to the uncertainty analysis of brake squeal.
2014-04-01
Technical Paper
2014-01-0017
Masashi Terada, Takashi Kondo, Yukihiro Kunitake, Kunitomo Miyahara
Abstract In automobile development, steering vibrations caused by engine excitation force and suspension vibration input from the road surface are a problem. The conventional method of reducing vibrations and thereby securing marketability has been to dispose a dynamic damper inside the steering wheel. The resonance frequency of a steering system varies for each vehicle developed (as a result of the vehicle size, the arrangement of the stiff members of the vehicle body, and the like). As a result, the individual values of dynamic dampers that are used with vehicles must be adjusted for each developed vehicle type. To address this problem, we have developed a new structure in which, rather than using a conventional dynamic damper, we disposed a floating bush on the Supplemental Restraint System (SRS) module attachment section and used the SRS module itself as the weight for the dynamic damper.
2014-04-01
Technical Paper
2014-01-0130
Donald F. Tandy, Steven Beane, Robert Pascarella
Abstract There have been many articles published in the last decade or so concerning the components of an electronic stability control (ESC) system, as well as numerous statistical studies that attempt to predict the effectiveness of such systems relative to crash involvement. The literature however is free from papers that discuss how engineers might develop such systems in order to achieve desired steering, handling, and stability performance. This task is complicated by the fact that stability control systems are very complex and their designs and what they can do have changed considerably over the years. These systems also differ from manufacturer to manufacturer and from vehicle to vehicle in a given maker of automobiles. In terms of ESC hardware, differences can include all the components as well as the addition or absence of roll rate sensors or active steering gears to name a few.
2014-04-01
Journal Article
2014-01-0118
Ryan M. Ashby, JongYun Jeong, Shreesha Y. Rao, Gary J. Heydinger, Dennis A. Guenther
This research was to model a 6×4 tractor-trailer rig using TruckSim and simulate severe braking maneuvers with hardware in the loop and software in the loop simulations. For the hardware in the loop simulation (HIL), the tractor model was integrated with a 4s4m anti-lock braking system (ABS) and straight line braking tests were conducted. In developing the model, over 100 vehicle parameters were acquired from a real production tractor and entered into TruckSim. For the HIL simulation, the hardware consisted of a 4s4m ABS braking system with six brake chambers, four modulators, a treadle and an electronic control unit (ECU). A dSPACE simulator was used as the “interface” between the TruckSim computer model and the hardware.
2014-04-01
Technical Paper
2014-01-0123
Mingyuan Bian, Long Chen, Yugong Luo, Keqiang Li
Abstract A new dynamic tire model for estimating the longitudinal/lateral road-tire friction force was derived in this paper. The model was based on the previous Dugoff tire model, in consideration of its drawback that it does not reflect the actual change trend that the tire friction force decreases with the increment of wheel slip ratio when it enters into the nonlinear region. The Dugoff model was modified by fitting a series of tire force data and compared with the commonly used Magic Formula model. This new dynamic friction model is able to capture accurately the transient behavior of the friction force observed during pure longitudinal wheel slip, lateral sideslip and combined slip situation. Simulation has been done under different situations, while the results validate the accuracy of the new tire friction model in predicting tire/road friction force during transient vehicle motion.
2014-04-01
Technical Paper
2014-01-0098
Anthony Barkman, Kelvin Tan, Arin McIntosh, Peter Hylton, Wendy Otoupal-Hylton
This paper discusses a project intended as a design study for a team of college students preparing for careers in motorsports. The project's objective was to conduct a design study on the possible redesign of the suspension for a dirt-track sprint car. The car examined was typical of those which race on one-quarter to one-half mile dirt oval tracks across the United States. The mission of this concept study was to develop a different configuration from the traditional torsion bar spring system, for the front end. The design included moving the dampers inboard with the addition of a rocker to relate the movement through the front suspension system. For the rear end, components were designed to allow the radius rod to be adjustable from the cockpit, thus providing the driver with adjustability to changing track conditions.
2014-04-01
Technical Paper
2014-01-0093
Xiaomin Lin, Nenggen Ding, Guoyan Xu, Feng Gao
Abstract Most tractor-semitrailers are fitted with multi-axle trailers which cannot be actively steered, and such vehicles with an articulated configuration are inclined to exhibit instability such as trailer swing, jack-knifing, and rollover at high speed. Proposed in this paper is an optimal control of the yaw stability of tractor-semitrailers at high speed by applying an active trailer's steering angle. An optimal control algorithm is designed by employing a 3-DOF vehicle model in the yaw plane. The optimal linear quadratic regulator (LQR) approach is used with a cost function including sideslip angles, yaw rates of both tractor and trailer, and trailer's steering angle. The yaw stability at the high speed is also quantified by the dynamic performance measurements of lateral path deviation, hitch angle and rearward amplification (RA). The algorithm is evaluated by co-simulations using TruckSim and Matlab/Simulink softwares.
2014-04-01
Technical Paper
2014-01-0115
Jie Ni, Lifu Wang
Abstract In this paper, a torsion-eliminating Hydraulically Interconnected Suspension (THIS) is proposed for the first time to reduce the undesired articulation (warp) stiffness of a two-axis vehicle. The dynamic characteristics of a typical sport utility vehicle (SUV) fitted with the THIS is investigated in the frequency domain. The equations of motion of the coupled mechanical and hydraulic sub-systems are presented. The vehicle basic mechanical sub-system is modeled as a 7 degrees of freedom (DOF) mass-spring-damper system. The hydraulic impedance method is employed to model the fluid sub-system. The relationships between the dynamic fluid states, i.e. pressures and flows, are determined by transfer matrices. Then the mechanical and hydraulic sub-systems are coupled through the mechanical-fluid boundary conditions.
2014-04-01
Technical Paper
2014-01-0117
Yang Liu, Zechang Sun, Wenbin JI
Abstract A brake pedal stroke simulator for Electro-hydraulic Braking System (EHBS) was developed to ensure the comfort braking pedal feel for the brake-by-wire system. An EHBS with an integrated master cylinder was proposed, and a composite brake pedal stroke simulator was designed for the EHBS, which was comprised of two inline springs and a third parallel one. A normally closed solenoid valve was used to connect the master cylinder booster chamber and the stroke simulator. The suitable brake pedal stroke was achieved by three stages of these springs' compression, whereas the solenoid valve was shutdown to enable mechanical control of the service brakes when electrical faults appeared.
2014-04-01
Technical Paper
2014-01-0109
Prashanth KR. Vaddi, Sandeep Vinjamuri, Kumar Cheruvu
Abstract Advanced research in ABS (Anti-lock Braking System), traction control, electronic LSD's (Limited Slip Differential) and electrical powertrains have led to an architecture development which can be used to provide a controlled yaw moment to stabilize a vehicle. A steer assistance mechanism that uses the same architecture and aims at improving the vehicle response to the driver steering inputs is proposed. In this paper a feed-forward approach where the steering wheel angle is used as the main input is developed. An optimal control system is designed to improve vehicle response to steering input while minimizing the H2 performance of the body slip angle. The control strategy developed was simulated on a 14 DOF full vehicle model to analyze the response and handling performance.
2014-04-01
Technical Paper
2014-01-0076
Jongchol Han, Zong Changfu, Zhao Weiqiang
Abstract This article focuses on the research of control algorithm and control logic for the pneumatic EBS (Electronic Braking System) of commercial vehicle. An overall technical program was proposed which develops conventional braking and emergency braking for commercial vehicle EBS. According to the overall scheme, the methods of vehicle state estimation and driver's braking intention were determined, modeling and simulation for key components of commercial vehicle EBS were then carried out. This lead to the development of deceleration control, braking force distribution, brake assist and ABS control. Simulation models for key components of EBS and control strategy were validated through hardware-in-the-loop simulation tests. Simulation results show that the control strategy improves vehicle braking stability and vehicle active safety.
2014-04-01
Technical Paper
2014-01-0073
Ken Archibald, William Schnaidt, Rick Wallace, Kyle Archibald
Abstract SAE J2562 defines the background, apparatus and the directions for modifying the Scaled Base Load Sequence for a given a wheel rated load for a wheel design. This practice has been conducted on multiple wheel designs and over one hundred wheel specimens. All of the wheels were tested to fracture. Concurrently, some of the wheel designs were found to be unserviceable in prior or subsequent proving grounds on-vehicle testing. The remainder of the wheel designs have sufficient fatigue strength to sustain the intended service for the life of the vehicle. This is termed serviceable. Using the empirical data with industry accepted statistics a minimum requirement can be projected, below which a wheel design will likely have samples unserviceable in its intended service. The projections of serviceability result in a recommendation of a minimum cycle requirement for SAE J2562 Ballasted Passenger Vehicle Load Sequence.
2014-04-01
Technical Paper
2014-01-0070
Ralph S. Shoberg, Jeff Drumheller
Abstract Reliable wheel attachment must start with proper tightening of the lug nuts in order to achieve the clamping force necessary to hold the vehicle's wheels securely for all operating conditions. It is the purpose of this paper to provide a complete overview of the theory and practice of using torque-angle signature analysis methods to examine the installation and audits of wheel lug nuts. An accurate estimate of clamp load can be determined without actually measuring the clamp load. The torque-angle signature analysis, known as “M-Alpha”, performed on tightening and loosening curves provides a powerful tool to understand the integrity of a bolted joint when clamp load data is not available. This analysis technique gives insight into the frictional effects, material properties, and geometric factors that can affect the clamp load attained during the installation process.
2014-04-01
Technical Paper
2014-01-0069
Andrew Nevin, Eric Daoud
Abstract Traditional tread depth measurements require manual utilization of a mechanical device to acquire measurements at each location of interest on a tire. Drive-over machine-vision sensors are becoming available as a means for measuring tread depth. These sensors typically consist of a laser and a camera contained in an environmentally-sealed sensor housing. Tires approach the sensor over the supporting surface, while a laser projects an illuminating line across the tread surface for capture in a digital image. This scan is evaluated to provide a single 2D contour of tread depth at the illuminated line. Advanced machine-vision sensors acquire a sequence of images, which results in a multitude of data points over a 3D region of the tread surface. Post-processing of the acquired images illustrates the observed tread pattern and establishes multiple tread depth measurements.
2014-04-01
Technical Paper
2014-01-0066
Ben Wen, Gregory Rogerson, Alan Hartke
Abstract Tire rolling resistance is one of tire performance indicator that represents a force needed to maintain the constant rolling of a tire. There are quite few methods and standards to measure tire rolling resistance, such as ISO-28585, ISO-18164, SAE-J1269, SAE-J2452, …. These tests have been used by tire companies, vehicle manufactures, and government agencies to evaluate tire rolling resistance performance. SAE-J1269 and SAE-J2452 are two popularly used multi-condition rolling resistance tests for passenger and light truck tires. Examining the test conditions and procedures of these two test standards showed that some key procedures and conditions from both standards are similar although there are many difference as well. The study presented here is to analyze test results from both tests and their correlation under certain conditions. If the correlation exists, one test may provide test results for both test conditions, therefore, test efficiency can be improved.
2014-04-01
Technical Paper
2014-01-0087
Shinhoon Kim, John McPhee, Nasser Lashgarian Azad
Abstract A compact sized vehicle that has a narrow track could solve problems caused by vehicle congestion and limited parking spaces in a mega city. Having a smaller footprint reduces the vehicle's total weight which would decrease overall vehicle power consumption. Also a smaller and narrower vehicle could travel easily through tight and congested roads that would speed up the traffic flow and hence decrease the overall traffic volume in urban areas. As an additional benefit of having a narrow track length, a driver can experience similar motorcycle riding experience without worrying about bad weather conditions since a driver sits in a weather protected cabin. However, reducing the vehicle's track causes instability in vehicle dynamics, which leads to higher possibility of rollovers if the vehicle is not controlled properly. A three wheel personal vehicle with an active tilting system is designed in MapleSim.
2014-04-01
Technical Paper
2014-01-0084
Mario Milanese, Ilario Gerlero, Carlo Novara
Abstract The vehicle sideslip angle is one of the most important variables for evaluating vehicle dynamics. The potential value of such a variable for obtaining significant improvements over current stability control systems is widely recognized. However, its direct measurement requires the use of complex and expensive devices which cannot be used in production cars. Large research efforts has been devoted to the problem of estimating the sideslip angle from other variables currently measured by standard Electronic Stability Control (ESC) sensors. However, at the best of author's knowledge, until now no application to production cars is known. In this paper, a new sideslip angle estimation technology is presented.
2014-04-01
Technical Paper
2014-01-0082
Yang Qi, Nenggen Ding, Feng Gao, Guoyan Xu
Abstract This paper develops a control strategy for tractor semi-trailers by active trailer steering, aiming at minimizing the sweep width of the vehicle at low speeds. The metric of sweep width is defined to evaluate the maneuverability of tractor semi-trailers under a circular motion with constant speeds. The active steering angle of the trailer for each given front wheel steering angle of the tractor is determined to minimize the sweep width, based on solution of equilibrium equations of both the tractor and the trailer in the yaw plane at a very low speed such as 5 km/h. The two steering angles of the tractor and the trailer are fitted to form an open-loop active-steering control algorithm. A nonlinear tractor semi-trailer system model is built for co-simulation purpose by using TruckSim and MATLAB/SIMULINK to evaluate the active trailer steering algorithm.
2014-04-01
Technical Paper
2014-01-0045
Swapnil S. Kulkarni, Muragendra Magdum, Ravi B.
Abstract Automotive shock absorber shims are subjected to deformation while generating the pressure differential across the rebound and compression chambers. Considering the contact, large deflection, and material this shim stack deformation will be nonlinear throughout the working velocity of shock absorbers. The deformation of shim stack mainly depends on number and geometry of deflection disk, number and geometry of ports, and clamping disk geometry on which shims are rested. During the rebound and compression stroke of the shock absorber, the oil flows through the piston and base valve ports. High pressure oil developed during mid and high velocity of shock absorber results in deflection of shim stack in piston and base valve assembly. This deflection leads to oil leakage through the shim stack which results in change in damping force by the shock absorber.
2014-04-01
Technical Paper
2014-01-0043
Manchi Venkateswara Rao, Jos Frank, Mohit Kohli
Abstract Brake groan noise is resolved without any major change in the design of brake system and vehicle sub-system components in the development phase of a utility vehicle. The groan noise is observed during the end of the stopping of the vehicle under moderate braking. The concerned NVH issue is perceived as unacceptable noise in the passenger compartment. Groan induced vibration is subjectively felt on steering and seat frame. A typical process is established to successfully reproduce the groan which helped in precisely evaluating the effect of modifications proposed. The temperature range of the disc which has the highest probability to produce the groan noise is found out experimentally. The transfer path analysis is carried out to find the path contributions from suspension. Acoustic transfer functions from considered paths are measured with the suspension removed from vehicle.
2014-04-01
Technical Paper
2014-01-0065
Hiroki Taniguchi, Takeshi Kimura, Yuya Takeda, Taku Suzuki, Akihiro Kaneko, Tomohiro Jinbo
Abstract This paper describes a control method to improve straight-line stability without sacrificing natural steering feel, utilizing a newly developed steering system controlling the steering force and the wheel angle independently. It cancels drifting by a road cant and suppresses the yaw angle induced by road surface irregularities or a side wind. Therefore drivers can keep the car straight with such a little steering input adjustment, thus reducing the driver's workload greatly. In this control method, a camera mounted behind the windshield recognizes the forward lane and calculate the discrepancy between the vehicle direction and the driving lane. This method has been applied to the test car, and the reduction of the driver's workload was confirmed. This paper presents an outline of the method and describes its advantages.
2014-04-01
Technical Paper
2014-01-0928
Daryl R. Poirier, Ravindra Patil, Robert Geisler, Joseph Schudt
Abstract The automotive industry is under great pressure to reduce vehicle mass for both cost and fuel economy gains. A significant contributor to body and suspension structure mass is peak vertical loads, primarily entering the body structure through the jounce bumper to body interface. This paper focuses on the successful development of “Loads Management Striker Caps” for the 2013 Cadillac ATS front and rear suspension. Component design and development of the striker caps was executed using explicit finite element analysis tools. Multi-body dynamics vehicle models were used to set component requirements and confirm striker cap performance for the vehicle during peak vertical events. The “Loads Management Striker Caps” ultimately reduced peak strut/shock tower loads by 40% in the front suspension and 25% in the rear suspension. This resulted in significant body and chassis mass savings, contributing to the Cadillac ATS's class leading curb weight.
2014-04-01
Technical Paper
2014-01-0944
Ovun Isın, Ilyas Istif, Deniz Uzunsoy, Feray Guleryuz
Abstract The brake friction materials in an automotive brake system play an important role in the overall braking performance of a vehicle. Metal Matrix Composites (MMCs) have been widely investigated and applied due to their advantages of improved strength, stiffness and increased wear resistance over the monolithic alloys in automobile industries. In this paper, Al/B4CP and Mg/B4CP composites were compared to find a suitable candidate material for automotive disk brake application, in terms of wear behavior results of the materials. In addition, the experimental data was also used to model this behavior by identification. The measured tangential force was considered as the input parameter, whereas the weight loss as the output parameter. Preliminary results of this work showed that B4CP addition improved wear resistance of both aluminum and magnesium matrix composites.
2014-04-01
Technical Paper
2014-01-0945
Romeo Sephyrin Fono-Tamo
Abstract The development of a non-asbestos automotive brake pad using palm kernel shell (PKS) as friction filler material is presented. This was with a view to exploiting the characteristics of PKS, which are otherwise largely deposited as waste from palm oil production, to make substitution for asbestos which has been found to be carcinogenic. Two sets of brake pads with identical ingredients but using either PKS or asbestos as base material were produced, following standard procedures employed by a commercial brake pad manufacturer. The physical, thermal, mechanical and the wear characteristics of the PKS-based brake pads were evaluated, compared with the values for the asbestos-based brake pads, and weighted against established recommendations for friction materials for road vehicle brake pads. The PKS based brake pad was characterized by 32.34 Brinell hardness number; 0.62%, swell and growth; 3375 N/s, bonding to back plate, and phase change at 689.5°C.
2014-04-01
Technical Paper
2014-01-0929
Changxin Wang, Wenku Shi, Qinghua Zu
Abstract Aiming at the difficulty of sovling the stiffness calculation of taper-leaf spring with variable stiffness, a combined method was proposed, which combine superposition method and finite difference method. Then the calculation results of different differential segments were compared with experimental results. The compared results show that the proposed method is effective and simple. So it has some practical significance in designing the taper-leaf spring. In addition, based on the stiffness test of the taper-leaf spring, the proper adjustments to the correction factor of the single parabolic leaf spring stiffness formula was recommended(ξ =0.92-0.96).
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