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2017-03-28
Technical Paper
2017-01-0167
Steven Lambert, William Jamo, Mike Kurtz
Purpose: Determine the effectiveness of flushing a contaminated automotive A/C system with a refrigerant recovery and recharge machine, using refrigerant as a flushing agent. The current flushing method uses solvent flushing. Methodology: Introduce contamination into the vehicle A/C system to induce a compressor failure. Run the vehicle A/C system at various speeds and engine RPM’s until the compressor fails. Certified Arizona Dust is the contaminant chosen for this study. Flush contaminated components using various manufactures A/C recovery and recharge machines using refrigerant as a flush agent. Flush components at different time intervals of 15, 30, 40 and 60 minutes for each machine being tested. Machines that were used for this test had continuous loop flushing capability. The current solvent flush time is 15 minutes flushing and 30 minutes purge for a total time of 45 minutes. Flushed components are evaluated to determine the amount of contamination removal.
2017-03-28
Technical Paper
2017-01-1685
Gopal K. Chamarthi, Andrew Sarkar, Paul Baltusis, Mark Laleman
An average luxury car contains more than 50 sensors connected, to over 28 microprocessors, through multiple communication networks. What makes these complex machines diagnosable at a dealership, is the ability of sophisticated diagnostics algorithms. Besides use of diagnostics in service, diagnosing a failure is also key for functional safety and vehicle availability. Safety functions such as loss of Brake fluid and leaky fuel system are essential. Once a failure is detected, Vehicle availability functions allow vehicle to operate, so that one could reach the dealership without being stranded. The number of failure modes in a car could far exceed tens of thousands, thereby identifying key failure modes for developing diagnostics can be a challenge.
2017-03-28
Technical Paper
2017-01-1686
Muhammad Askar
A vehicle's electrical system is one of the top sources of problems requiring service. Electronic means of service documentation have been replacing static documents as a way of speeding vehicle troubleshooting. The next step on this path of evolution is to turn those into smart maintenance systems, capable of offering technicians true data insights, and highly-efficient diagnostic procedures. This paper briefly summarizes the technologies underpinning the evolution in electrical system diagnosis and repair; which include schematic layout automation using prototypes and rule-based styling, instant language translation, 2D/3D view links with schematics, interactive diagnostic procedures, and dynamically-generated signal-tracing diagrams. These technologies empower after sales service teams with state-of-the-art capabilities; which not only reduce costs but also improve the quality of the brand in the eyes of its customers.
2017-03-28
Technical Paper
2017-01-1229
Ken Yamamoto, Nobuyasu Sadakata, Hidetoshi Okada, Yusuke Fujita
Electric oil pumps (EOP) for automobiles are used to lubricate and cool moving mechanisms and supply oil pressure to components. Conventional EOPs consist of two separate units including a driver and a pump system comprised of a motor and a pump, which, as a result, impedes layout flexibility for vehicles. To overcome this shortcoming, we have developed an ECU-integrated oil pump in which a driver, a motor and a pump are incorporated as a single unit. In the course of the project, we focused on improving vibration resistance and developing a compact design. The first challenge was to improve vibration resistance because of the driver located in close proximity of the powertrain. Since the driver is installed on the motor unit via bus bars that are electrically welded, the joints of the driver and the bus bar become susceptible to vibration.
2017-03-28
Technical Paper
2017-01-1690
Dirk Hall, Tim Felke
An IVHM Fault Model contains relations between Symptoms, Failure Modes, and Corrective Actions. Since it also encode the specific vehicle variants for which these items are applicable, it can be used to create vehicle variant specific fault isolation plans for a pattern of symptoms on a specific vehicle. This paper will discuss the methodology through which a diagnostic reasoner can use a fault model, vehicle reported symptoms and vehicle configuration data to produce a vehicle fault specific troubleshooting plan. This paper will also discuss how a wide variety of diagnostic troubleshooting plans can be automatically created for a platform and its variants and how these plans can be adapted by Service Engineering authors to further improve their content.
2017-03-28
Technical Paper
2017-01-1439
John C. Steiner, Christopher Armstrong, Tyler Kress
The use of the United States’ Global Positioning System (GPS) to assist with the management of large commercial fleets of vehicles is quickly becoming commonplace. The GPS system can be used to track fleet vehicles resulting in more efficient and safe operations by refining and streamlining routing and operations. GPS-based fleet telematics data is also valuable for reducing unnecessary engine idle times and minimizing fuel consumption. Driver performance and policy adherence can also be monitored, for example by transmitting data regarding seatbelt usage when there is vehicle movement. Despite its advantages for fleet management, there are performance limitations that affect the utility of the system for analysis and reconstruction of accidents. The U.S. Air Force, responsible for maintaining and operating the GPS space and control segments, publishes information about these limitations.
2017-03-28
Technical Paper
2017-01-1624
Tim Felke, Steven Holland, Sachin Raviram
Suppliers and integrators are working with SAE’s HM-1 standards team to develop mechanisms to enable “Health Ready Components” to be more effectively and efficiently integrated into larger systems to better deliver IVHM functionality (see SAE JA6268). This paper will discuss how the operational functionality provided by the supplier of a component/subsystem can be integrated into a vehicle level IVHM system. The intent is to better communicate how supplier provided functionality can be integrated into the vehicle IVHM infrastructure whether it be embedded into the platform or hosted in the off-platform infrastructure or through syndicated web services. As a specific example, the paper will describe the JA6268 run-time functionality provided by the supplier of the Turbocharger and other Engine Air System components are integrated with Vehicle Level Services in order to clarify the integration processes.
2017-03-28
Technical Paper
2017-01-1627
Stephan Rinderknecht, Rafael Fietzek, Stéphane Foulard
An online and real-time Condition Prediction system, so-called lifetime monitoring system, was developed at the Institute for Mechatronic Systems in Mechanical Engineering (IMS) of the TU Darmstadt, which is intended for implementation in standard control units of series production cars. Without additional hardware and only based on sensors and signals already available in a standard car, the lifetime monitoring system aims at recording the load/usage profiles of transmission components in aggregated form and at estimating continuously their remaining useful life. For this purpose, the dynamic transmission input and output torques are acquired realistically through sensor fusion. In a further step, the lifetime monitoring system is used as an input-module for the introduction of innovative procedures to more load appropriate dimensioning, cost-efficient lightweight design, failure-free operation and predictive maintenance of transmissions.
2017-03-28
Technical Paper
2017-01-1626
Tomas Poloni, Jianbo Lu
This paper proposes a method to make diagnostic/prognostic judgement about the health of a tire, in term of its wear, using existing sensor signals. The approach focuses on using an estimate of the effective rolling radius (ERR) of individual tires as one of the main diagnostic/prognostic features and it determines if a tire has significant wear and how long it needs to be changed or rotated. The ERR is determined from the combination of wheel speed sensor (WSS), Global Positioning sensor (GPS), the other motion sensor signals, together with the radius kinematic model of a rolling tire. The ERR estimation fits the relevant signals to a linear model and utilizes the relationship revealed in the magic formula tire model. The ERR can then be related to multiple sources of uncertainty such as the tire inflation pressure, tire loading changes, and tire wear. The estimated ERR are further processed to compute the unloaded tire radius (UTR).
2017-03-28
Journal Article
2017-01-0237
Jonas Biteus, Tony Lindgren
Maintenance planning of trucks at Scania have previously been done using static cyclic plans with fixed sets of maintenance tasks, determined by mileage, calendar time, and some data driven physical models. Flexible maintenance have improved the maintenance program with the addition of general data driven expert rules and the ability to move sub-sets of maintenance tasks between maintenance occasions. Meanwhile, successful modelling with machine learning on big data, automatic planning using constraint programming, and route optimization are hinting on the ability to achieve even higher fleet utilization by further improvements of the flexible maintenance. The maintenance program have therefore been partitioned into its smallest parts and formulated as individual constraint rules. The overall goal is to maximize the utilization of a fleet, i.e. maximize the ability to perform transport assignments, with respect to maintenance.
2017-03-28
Technical Paper
2017-01-1235
Baoming Ge, Lihua Chen, Shuitao Yang
Electrified vehicles (xEV) require high torque/acceleration ability and wide speed range. To meet both of them, the traction machines have to be oversized, which results in large volume and weight, high cost, and low efficiency. In practical applications, high speed motors combining with gear box achieve tradeoff between torque and speed capacity, because the increased motor speed can reduce the motor volume at the same power rating and the gear box is employed to increase torque. In fact, electric machine can achieve “electrical gear” rather than using “mechanical gear”, so electric machines integrate “gear” and “motor” together, as a result that “mechanical gear” can be minimized. “Electrical gear” of electric machine is performed by pole-changing. In the past, pole-changing employs mechanical contactor, the windings are de-energized prior to pole changing and the stator winding needs to be reconfigurable using contactors, which will produce discontinuous torques.
2017-03-28
Journal Article
2017-01-0619
Ravi Teja Vedula, Thomas Stuecken, Harold Schock, Cody Squibb, Ken Hardman
Piston temperature plays a major role in determining details of fuel spray vaporization, fuel film deposition and the resulting combustion in direct-injection engines. Due to different heat transfer properties that occur in optical and all-metal engines, it becomes an inevitable requirement to verify the piston temperatures in both engine configurations before carrying out optical engine studies. A novel Spot Infrared Temperature Estimations (SITE) technique was developed to estimate the piston window temperature in an optical engine. Chromium spots of 200 nm thickness were vacuum-arc deposited at different locations on a sapphire window. An infrared (IR) camera was used to record the intensity of radiation emitted by deposited spots. From a set of calibration experiments, a relation was established between the IR camera measurements of these spots and the surface temperature measured by a thermocouple.
2017-03-28
Journal Article
2017-01-1662
Tom R. Markham, Alex Chernoguzov
Problem: The OBD-II port began as a means of extracting diagnostic information from vehicles and supporting the right to repair. However, we did not anticipated self-driving vehicles or insurance dongles plugged into the OBD-II port. ADAS, self-driving features and overall vehicle network complexity opens the door for cyber security breaches which can impact vehicle safety. Researchers have already demonstrated how the cellular modem on an OBD-II insurance dongle may be hacked to tamper with the vehicle brakes. Challenge: The industry must balance the interests of multiple stakeholders. • OEMs – are required to provide an OBD-II port. However, the OEM is also responsible for the cyber security and in turn safety of the vehicle. • Repair shops and vehicle owners - have a right to repair which includes access to many vehicle functions via the OBD-II. • Dongle providers - want to offer vehicle-related services via the OBD port.
2017-03-28
Journal Article
2017-01-1623
Tim Felke, Steven Holland, Sachin Raviram
Suppliers and integrators are working with SAE’s HM-1 standards team to develop a mechanism to allow “Health Ready Components” to be integrated into larger systems to enable broader IVHM functionality (reference SAE JA6268). This paper will discuss how the design data provided by the supplier of a component/subsystem can be integrated into a vehicle reference model with emphasis on how each aspect of the model is transmitted to minimize ambiguity. The intent is to enhance support for the analytics, diagnostics and prognostics for the embedded component. In addition, we describe functionality being delegated to other system components and that provided by the supplier via syndicated web services. As a specific example, the paper will describe the JA6268 data submittal for a typical automotive turbocharger and other engine air system components to clarify the data modelling and integration processes.
2017-03-28
Journal Article
2017-01-1687
Nick Mikulec, Tim Felke, Shaunak Bangale
For an automotive OEM, it is usual to produce a wide variety of automotive models related to a common platform. As such, it is important to analyze how these variants perform with relation to reliability and warranty claims relative to each other. This paper will illustrate techniques that have been applied to use warranty claim information to assess the relative reliability and incident rates for DTC occurrences, component removals and co-occurrence with other DTCs for a family of Vehicle applications. These results are then used to identify common root cause failure modes, DTCs on specific vehicle applications that are performing much worse than fleet averages and components with much lower reliability than components in similar applications.
2017-03-28
Journal Article
2017-01-1689
Peter Subke, Muzafar Moshref, Andreas Vach, Markus Steffelbauer
Remote diagnostic systems, support diagnostic communication by having the capability of sending diagnostic requests to a vehicle and receiving diagnostic responses from a vehicle. Diagnostic communication includes but is not limited to the services that are specified in SAE J1979, SAE J1939 or ISO 14229 (UDS). Diagnostic communication utilizes the standard in-vehicle network, which is usually CAN. Any unauthorized access to the in-vehicle network poses a security vulnerability. Such vulnerabilities can severely harm the functional safety, thus causing damage to the vehicle, machine or – even worse – to life and health of the driver, passengers or operators. This paper describes the architecture of a system for remote diagnostics, its security vulnerability and measures to prevent unauthorized access to the in-vehicle network.
2017-03-28
Journal Article
2017-01-1684
Hassene Jammoussi, Imad Makki, Michael Kluzner, Robert Jentz
Air Fuel Ratio (AFR) imbalance between engine cylinders remains one of the most challenging problems in powertrain systems diagnostics. California Air Resources Board(CARB) has started imposing specific requirements on automotive companies since 2011 that required the integration of on-board diagnostics (OBD) monitor for the detection and reporting of this type of powertrain malfunction. In this paper, some methodologies of AFR cylinder imbalance monitoring are investigated and a novel approach is proposed that shows reliable detection capability compared to the other methods. The proposed method requires certain conditions during deceleration fuel shutoff events to intrusively reactivate the cylinders and determine the imbalance condition. The method was evaluated on a V6 3.7L engine in an experimental Lincoln MKZ vehicle. Vehicle results are shown and discussed.
2017-03-28
Journal Article
2017-01-1688
Hassene Jammoussi, Imad Makki
The usage of the universal exhaust gas oxygen (UEGO) sensor to control the the air-fuel ratio (AFR) in gasoline engines allowed to significantly improve the efficiency of the combustion process and reduce tailpipe emissions. The diagnostics of this sensor is very important to ensure proper operation and indicate the need for service when the sensor fails to accurately determine the AFR upstream of the catalyst. California air resources board (CARB) has imposed several legislations around the operation of the UEGO sensor and particularly when specific faults would cause tailpipe emissions to exceed certain limits. In this paper, the possible sensor faults are reviewed, and a non-intrusive diagnostics monitor is proposed to detect, identify and estimate the magnitude of the fault present. This paper extends the approach in [1] where technical details are emphasized and algorithm improvements are discussed.
2017-03-28
Technical Paper
2017-01-0233
Weihong Guo, Shenghan Guo, Hui Wang, Xiao Yu, Annette Januszczak, Saumuy Suriano
The wide applications of automatic sensing devices and data acquisition systems in automotive manufacturing have resulted in a data-rich environment, which demands new data mining methodologies for effective data fusion and information integration to support decision-making. This paper presents a new methodology for developing a diagnostic system using manufacturing system data for high-value assets in automotive manufacturing. The key issues studied in this paper include optimal feature extraction using descriptive analysis, optimal feature subset selection using statistical hypothesis testing, machine fault prediction using multivariate process control chart, and diagnostic performance assessment using process trend detection. The performance of the developed diagnostic system can be continuously improved as the knowledge of machine faults is automatically accumulated during production.
2017-03-28
Journal Article
2017-01-0015
Wolfgang Granig, Dirk Hammerschmidt, Hubert Zangl
Abstract Functional safe products conforming to the ISO 26262 standard are getting more important for automotive applications wherein electronic takes more and more response for safety relevant operations. Consequently safety mechanisms are needed and implemented in order to reach defined functional safety targets. To prove their effectiveness diagnostic coverage provides a measurable quantity. A straight forward safety mechanism for sensor systems can be established by redundant signal paths measuring the same physical quantity and subsequently performing an independent output difference-check that decides if the data can be transmitted or an error message shall be sent. This paper focuses on the diagnostic coverage figure calculation of such data correlation-checks for linear sensors which are also shown in ISO 26262 part5:2011 ANNEX D2.10.2.
2017-03-28
Journal Article
2017-01-0614
Hao Chen, Volker Sick
Abstract Plenoptic particle tracking velocimetry (PTV) shows great potential for three-dimensional, three-component (3D3C) flow measurement with a simple single-camera setup. It is therefore especially promising for applications in systems with limited optical access, such as internal combustion engines. The 3D visualization of a plenoptic imaging system is achieved by inserting a micro-lens array directly anterior to the camera sensor. The depth is calculated from reconstruction of the resulting multi-angle view sub-images. With the present study, we demonstrate the application of a plenoptic system for 3D3C PTV measurement of engine-like air flow in a steady-state engine flow bench. This system consists of a plenoptic camera and a dual-cavity pulsed laser. The accuracy of the plenoptic PTV system was assessed using a dot target moved by a known displacement between two PTV frames.
2017-03-28
Technical Paper
2017-01-1192
Amardeep Sidhu, Afshin Izadian, Sohel Anwar
In this paper, multiple-model adaptive estimation techniques have been successfully applied to fault detection and identification in lithium-ion batteries. The diagnostic performance of a battery depends greatly on the modeling technique used in representing the system and the associated faults under investigation. Here, both linear and non-linear battery modeling techniques are evaluated and the effects of battery model and noise estimation on the over-charge and over-discharge fault diagnosis performance are studied. Based on the experimental data obtained under the same fault scenarios for a single cell, the non-linear model based detection method is found to perform much better in accurately detecting the faults in real time when compared to those using linear model based method.
2017-03-28
Journal Article
2017-01-0386
Michael Wohlthan, Gerhard Pirker, Andreas Wimmer
To achieve high power output and good efficiency and to comply with increasingly stricter emission standards, modern combustion engines require a more complex engine design, which results in a greater number of control parameters. As the measurement effort and the number of sensors for engine development at the test bed continue to increase, it is becoming nearly impossible for the test bed engineer to manually check measurement data quality. As a result, automated methods for analysis and plausibility checks of measurement data are necessary in order to find faults as soon as they occur and to obtain test results of the highest possible quality. This paper presents a fully integrated methodology for automated fault diagnosis on engine test beds. The methodology allows reliable detection of measurement faults as well as the identification of the root cause of faults.
2016-11-08
Technical Paper
2016-32-0049
Kuniyoshi Eto, Masaru Nozawa, Masato Nara, Buhei Kobayashi, Daiki Shibasaki, Ken Shirai
Abstract A new air-cooled SI two-stroke gasoline engine has been developed for an arborist-chainsaw. This engine has a displacement of 25 cm3 and generates about 1.1 kW and complies with the latest CARB and EPA exhaust regulations by optimizing scavenging flows and the use of a catalytic converter. Characteristics of lightweight, compact and high power-to-weight ratio are required for handheld chainsaws, especially for arborist chainsaws. As a matter of course, these characteristics are needed for engine itself in order to satisfy such market requirements for hand-held power equipment. To realize lightweight and compact design, the placement of catalytic converter is optimized for the engine and a two-piece crankshaft is adopted.
2016-11-08
Journal Article
2016-32-0034
Stephan Jandl, Hans-Juergen Schacht, Stephan Schmidt, Ute Dawin, Armin Kölmel, Stefan Leiber
Abstract Worldwide increasing energy consumption, decreasing energy resources and continuous restriction of emission legislation cause a rethinking in the development of internal combustion engines and fuels. Alternative renewable fuels, so called bio-fuels, have the potential to contribute to environmentally friendly propulsion systems. This study concentrates on the usage of alcohol fuels like ethanol, methanol and butanol in non-automotive high power engines, handheld power tools and garden equipment with the focus on mixture formation and cold start capability. Although bio-fuels have been investigated intensely for the use in automotive applications yet, the different propulsion systems and operation scenarios of nonautomotive applications raise the need for specific research. A zero dimensional vaporization model has been set up to calculate the connections between physical properties and mixture formation.
2016-10-28
Technical Paper
Maintenance and Aftermarket
2016-10-25
Technical Paper
2016-36-0169
Emilio C. Baraldi, Paulo Carlos Kaminski
Abstract The competition among automotive industries increases each year worldwide. Among their diverse needs, what can be highlighted are: market expansion, model diversification, competitive prices, customer-recognized quality, new products release in shorter time periods, among others. The occurrence of flaws that might compromise the health or safety of the product’s user is admittedly one of the largest issues for any manufacturer, especially if these flaws are identified after its commercialization (recall). In this work, a study on recall in the automotive industry in the Brazilian market will be presented, comprising the years of 2013 and 2014. Reasons and causes of recall are addressed, based on the sample of the aforementioned research, with special emphasis on flaws derived from the production process. The conclusion at the end of the work is that the final assembly in the automotive manufacturing process is what requires more attention from engineering area.
2016-10-25
Technical Paper
2016-36-0325
Filipe Diniz, Caue Morais, André Luiz, Adriano Simplício, Lincoln Lima, Rogério Silvério
Abstract Based on automotive concerns related to global warming, CO2 emissions, safety and fuel efficiency, a trend to use High Strength Steels was stablished in order to meet these concerns and enhance the Body In White (BIW) performance. The usage of Press Hardened Steel (PHS) on the BIW is greatly broadcasted by the automotive industry, however OEMs should consider other important aspects for the vehicle lifecycle, such as repair and serviceability in the occasion of vehicle collision. This paper addresses a repair procedure that meets regular performance characteristics. The study was based on the conditions available on emergent markets dealers to perform an optimized repair. This procedure ensures the proper serviceability of PHS parts on BIW systems and supports the usage of High Strength Steels technology in today’s emergent market vehicles.
2016-10-25
Technical Paper
2016-36-0393
Thales Sardinha Garcia Souza, Márcio Henrique Pereira, Roberto Martins de Souza
Abstract The cost of any forged product for the automotive industry is highly influenced by the cost involved during the design and manufacturing of the forging tools. Ideally, these tools shall withstand a significant number of cycles, in order to divide their manufacturing cost in many parts as possible. There are several parameters that affect the wear behavior, and forging companies have different approaches to address the tribological issues. Moreover, a misunderstanding of these parameters may lead to an undesirable premature tool wear. This work analyses the effect of roughness on the wear of cold forming tools. The adopted tribosystem is the second stage of a horizontal press and consists of a punch of M2 hardened steel in relative movement against a working piece of SAE 10B22 normalized steel. Fifteen punches were manufactured with three roughness levels and their wear was measured after 50.000 and 100.000 forging cycles.
2016-10-17
Technical Paper
2016-01-2159
Zheming Li, Yann Gallo, Ted Lind, Oivind Andersson, Marcus Alden, Mattias Richter
Abstract Soot emissions from diesel internal combustion engines are strictly regulated nowadays. Laser extinction measurement (LEM) and natural luminosity (NL) of sooty flames are commonly applied to study soot. LEM measures soot along the laser beam path and it can probe soot regardless of temperature. NL integrates the whole field of view and relies on soot temperature. In this work, a comparison of simultaneously recorded LEM and NL data has been performed in a heavy-duty optical engine. A 685 nm laser beam is used for LEM. The laser was modulated at 63 kHz, which facilitated subtraction of the background NL signal from the raw LEM data. By Beer-Lambert’s law, KL factor can be calculated and used as a metric to describe soot measurements. A compensation of transmitted laser intensity fluctuation and soot deposits on optical windows has been performed in this work.
Viewing 1 to 30 of 4781