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2016-04-05
Technical Paper
2016-01-1359
R. Pradeepak, Shyamsundar Kumbhar, Nainishkumar Barhate
At present, vehicle testing in laboratory is one of the important phase to quicken the product validation process. In the early phase of laboratory testing it is required to evaluate the strength of the vehicle structure through physical rig setup which represents the consumer’s usage. Two and multiple poster input excitation are among the laboratory rig testing to represent the actual road are used to predict the durability of vehicle components. The road inputs through the poster are known as drive files, a feedback controlled system which reproduces the track or real road recorded specimen’s accelerations, displacements and strains in lab. Derivation of drive files in poster testing requires iteration of physical specimen to exactly replicate the actual road. This paper discusses about generation of drive files as inputs for poster actuation with virtual model(as a substitute for actual model)which is applicable in areas of vehicle durability and ride comfort studies.
2016-04-05
Technical Paper
2016-01-0907
Matthew Blanks, Nathan Forster
In 2012, NHTSA and EPA extended Corporate Average Fuel Economy (CAFE) standards for light duty vehicles through the 2025 model year. The new standards require passenger cars to achieve an average of five percent annual improvement in fuel economy and light trucks to achieve three percent. This yearly increase in fuel economy standards and the increasing price of oil are driving research and development into fuel-saving technologies. A large portion of the current research is focused on incremental improvements in fuel economy through technologies such as new lubricant formulations. While these technologies typically yield less than two percent improvement, the gains are extremely significant and will play an increasing role in the overall effort to increase fuel economy. The ability to measure small, but statistically significant, changes in vehicle fuel economy is vital to the development of new technologies.
2016-04-05
Technical Paper
2016-01-1447
Qiang Yi, Stanley Chien, Jason Brink, Wensen Niu, Lingxi Li, Yaobin Chen, Chi-Chen Chen, Rini Sherony, Hiroyuki Takahashi
As part of active safety systems, Bicyclist Pre-Collision System (BPCS) is being studied currently by several vehicle manufactures to help reduce bicyclist fatalities and injuries. This paper describes the development of surrogate bicycle with a bicyclist mannequin on top to support the development and evaluation of BPCS. The surrogate bicyclist is designed to represent the visual and radar characteristics of real bicycles and cyclists in the United States. The size of bicycle surrogate mimics the 26 inch mountain bike which is the most popular adult bicycle sold in the US. The radar cross section (RCS) of the surrogate bicycle is designed based on RCS measurement of the 10 different adult sized bicycles. The surrogate bicycle is constructed with detachable components with shatter resistant material to prevent structural damage during collision, and matches the look and RCS of a real 26 inch mountain bicycle from all 360 degree angles.
2016-04-05
Technical Paper
2016-01-1446
Rini Sherony, Qiang Yi, Stanley Chien, Jason Brink, Mohammad Almutairi, Keyu Ruan, Wensen Niu, Lingxi Li, Yaobin Chen, Hiroyuki Takahashi
According to the U.S. National Highway Traffic Safety Administration, 743 pedal cyclists were killed and 48,000 were injured in motor vehicle crashes in 2013. Bicyclist PCS (Pre-Collision System) is being developed by many vehicle manufacturers. Therefore, developing equipment for evaluating bicyclist PCS is essential. This paper describes the development of a bicycle carrier for carrying the surrogate bicyclist in bicyclist PCS testing. An analysis of the United States national crash databases (FARS and GES) and videos from TASI 110 car naturalistic driving database was conducted to determine a set of highest occurring test scenarios, and the motion speed and profile of bicycle carrier. The carrier was designed as an autonomous platform with a 4 wheel differential driving system. Each wheel is an independent suspension system to protect motors, gears and reduce the vibrations. The height of carrier was minimized to 78mm to reduce the interference to PCS sensors.
2016-04-05
Technical Paper
2016-01-1600
Pruthviraj Mohanrao Palaskar, Vivek Kumar, Rohit Vaidya
Important vehicle performance parameters such as, fuel economy and high speed stability are directly influenced by its aerodynamic drag and lift. Wind tunnel testing to asses these parameters is a late stage in vehicle development. Hence to save cost and compress development time, it is essential to asses and optimize parameters of a vehicle in very early stages of development. Using numerical flow simulations optimization runs can be carried out digitally. Industry demands to predict aerodynamics drag and lift coefficients(CD,CL) within the accuracy of few counts, consuming minimal HPC resources and in short turnaround time. Different OEMs deploy different testing methods and different softwares for numerical simulations. Hence, correlation level for numerical prediction depends on factors viz; type of meshing, boundary conditions, turbulent models, CAD geometry and wind tunnel used for correlation.
2016-04-05
Technical Paper
2016-01-0984
Venkatraman Mahadevan, Suresh Iyer, David Klinikowski
This paper investigates the effect of time alignment in the calculation of emissions from the raw exhaust stream of heavy-duty vehicles when tested on a chassis dynamometer. The effect of time alignment is significant in this case, as time-variant raw exhaust flow rate and emissions concentrations data are acquired continuously during a test (at 10 Hz), and their product is integrated during calculations. The response of the analyzer is delayed due to the time taken for transportation of the sample gases from the probe tip to the analyzer, and ‘flattened’ due to diffusion during this transport. This ‘convolution’ of the concentration data stream introduces an error in the final result, calculated in grams/mile. The convolution of the concentration data is corrected by the following method: the analyzer response (output) to a step change in the concentration of the species at the probe tip (input) is recorded to determine the ‘convolution function’.
2016-04-05
Technical Paper
2016-01-0045
Takanori Uno, Akahori Ichiro, Iwata Yasuaki
In this paper, consideration is made to create a simulation model of BCI test method, which is one of the EMC evaluation methods for in-vehicle electronic devices, and an intrinsic model of BCI probe is provided. Using this model, it is demonstrated that when the impedance of the BCI probe is sufficiently high, the BCI probe serves as a transformer with the coil turn ratio of 1:1, and the admittance of a line or a load connected to each wire becomes proportional to the magnitude of current flowing each wire. This model also can be applied when leakage inductance inside the BCI probe is taken into consideration. The validity of this model is verified by the experiment using a jig which can clamp multiple wires. In addition, by using this model, it is demonstrated that S-parameters when dozens of wires are clamped with the BCI probe can be generated from the measurement results of S-parameters when one wire is clamped.
2016-04-05
Technical Paper
2016-01-0478
Yinzhi He, Zhigang Yang, Yigang Wang
The full scale aeroacoustic wind tunnel of Shanghai Automotive Wind Tunnel Center (SAWTC) of Tongji University has been under full operation since 2009 after nearly 5 years construction and commissioning. This facility is designed with nozzle area 27m2 not only for full scale automobile testing of aerodynamics and aeroacoustics, but also for Buses, light trucks, scale train model etc. The maximal wind speed of this wind tunnel can reach 250km/h. One of the highlights is the extremely low background noise of only 61dBA at 160km/h. It is so quiet a wind tunnel first of all in China and contributes very much to the vehicle development of the vehicles marketed in the Chinese market. In this paper, after a short introduction about layout of the full scale aeroacoustic wind tunnel of Tongji University, the special acoustic measures to achieve so low background noise of this wind tunnel are presented as well.
2016-04-05
Technical Paper
2016-01-1007
Benjamin Ellies, Charles Schenk, Paul Dekraker
As part of its technology assessment for the upcoming midterm evaluation of the 2017-2025 LD vehicle GHG emissions regulation, EPA has been benchmarking engines and transmissions to generate inputs for use in its ALPHA model, a physics-based, forward-looking, full vehicle computer simulation tool. One of the most efficient engines today, a 2.0L Mazda SkyActiv engine, is of particular interest due to its high geometric compression ratio and use of an Atkinson combustion cycle. EPA benchmarked the 2.0L SkyActiv at its National Vehicle and Fuel Emissions laboratory. EPA then incorporated ALPHA into an engine dynamometer control system so that vehicle chassis testing could be simulated with a hardware-in-the-loop (HIL) approach.
2016-04-05
Technical Paper
2016-01-1355
Jeffrey R. Hodgkins, Walter Brophy, Thomas Gaydosh, Norimasa Kobayashi, Hiroo Yamaoka
Current CAE (computer aided engineering) methods used to develop vehicle interior noise performances have always had the reputation for being inaccurate in predicting acoustic behavior in the mid-frequency range (300 to 1000 Hz). It is in this frequency range where the overall acoustic performance becomes sensitive to not only the contributions of structure-borne noise components, which CAE has proven capable of predicting, but also the growing contributions of air-borne noise components, where CAE usually lacks the capability to accurately reflect the physics involved in complex vibro-acoustic systems. This paper will discuss a study that was undertaken to test the capability of a finite element modeling method that can accurately simulate air-borne noise phenomena in the mid-frequency range. This modeling method was used to create a model of an enclosed simple box-shaped vibro-acoustic system fit with various acoustic trim parts (carpet and under body covers).
2016-04-05
Technical Paper
2016-01-0479
Kuniaki Goto, Takashi kondo, Masakiyo Takahira, Eiji Umemura, Masashi Komada, Yasuhiko Nishimura
Generally, the field pass-by noise level measurement is not stable under the influence of weather conditions , background noise and driver’s skill.So, automobile manufactures try to reproduce proving ground driving on chassis dynamometer measurement.But, the tire noise on actual road surface is difficult to replace on indoor test. In 2016,new pass-by noise regulation (UN R51-03)will take effect in Europe and Japan etc. Furthermore , 2dB stricter regulation will take effect in 2020. In addition to the acceleration run of the current regulation , UN R51-03 requests constant speed run . Therefore, the efficient measurement is necessary for vehicle development. To solve the above mentioned issues , we have developed an indoor evaluation system capable of reproducing the tire noise on road surface.
2016-04-05
Technical Paper
2016-01-1534
Rudolf Reichert, Pradeep Mohan, Dhafer Marzougui, Cing-Dao Kan, Daniel Brown
A detailed finite element model of a 2012 Toyota Camry was developed by reverse engineering. The model consists of 2.3M elements representing the geometry, thicknesses, material characteristics, and connections of relevant structural, suspension, and interior components of the mid-size sedan. This paper describes the level of detail of the simulation model, the validation process, and how it performs in various crash configurations, when compared to full scale test results. Under contract with the National Highway Safety Administration and the Federal Highway Administration, the Center for Collision Safety at the George Mason University has developed a fleet of vehicle models which have been made publicly available. The updated model presented in this paper is the latest finite element vehicle model with a high level of detail using state of the art modeling techniques.
2016-04-05
Technical Paper
2016-01-0029
Chuanliangzi Liu, Bo Chen, Ming Cheng, Anthony Champagne, Keyur Patel
The Electronic Control Unit (ECU) of the Electric Power Steering (EPS) system is a core device to control the electric motor to provide assist while steering. The Hardware-in-the-loop (HiL) simulation will help identify early safety issues in the development phase of a project. The intent of this paper is to focus on vehicle dynamics simulation of the EPS using the HiL system. The EPS plant model, dSPACE Vehicle Dynamics model and dSPACE Motor Model interact with a dSPACE hardware platform and a real ECU. This paper includes the design of the EPS HiL system, the simulation of sensors & actuators, the function of Automotive Simulation Model (ASM) Vehicle Dynamics model, and the integration method of the ASM Vehicle Dynamics model with the EPS model. The offline simulation of the integrated model is performed and the simulation results of different driving maneuvers are presented.
2016-04-05
Technical Paper
2016-01-0052
Jihas Khan
HILS is a proven and essential part of embedded product development life cycle which strives to reduce effort, time and cost spent on automotive validation activities. An efficient HILS system allows to create a precise simulation environment for the ECU which believes that it is sitting inside the real vehicle and there by intended functionalities implemented in the same can be tested even before the vehicle prototypes or other ECUs or sensors and actuators are available. Inefficient and faulty HILS system provides erroneous test results which leads to wrong inferences. This paper is proposing a standardized process flow aided by specific documentation and design concepts which makes sure that the test system designed is robust and catering to the actual requirement. Main agenda of the paper is to design a test system which itself is more robust than the expected device under test.
2016-04-05
Technical Paper
2016-01-0055
Mark Steffka, Cyrous Rostamzadeh
Automotive systems can generate un-intentional radio frequency energy. The levels of these emissions must be below maximum values set by the Original Equipment Manufacturer (OEM) for customer satisfaction and/or in order to meet governmental requirements. Due to the complexity of electromagnetic coupling mechanisms that can occur on a vehicle, many times it is difficult to measure and identify the noise source(s) without the use of an electromagnetic interference (EMI) receiver or spectrum analyzer (SA). An efficient and effective diagnostic solution can be to use a low-cost portable, battery powered RF detector with wide dynamic range as an alternative for automotive electromagnetic compatibility (EMC) and design engineers to identify, locate, and resolve radio frequency (RF) noise problems. A practical circuit described here can be implemented easily with little RF design knowledge, or experience.
2016-04-05
Technical Paper
2016-01-1577
Tateru Fukagawa, Shinnosuke Shimokawa, Eiji Itakura, Hiroyuki Nakatani, Kenichi Kitahama
The aerodynamic stability of a vehicle with lighter weight and lower drag for saving energy is reduced in cross wind disturbance. In particular, body shapes with low drag have unsteady motion caused by their aerodynamic yaw moment in this situataion. In order to verify fluctuation of unsteady aerodynamic forces of an actual vehicle, a direct measurement method of the transient aerodynamic force on crosswind test using the data of the force of Inertia and the loads of tires is established . The former data is measured with a inertia sensor comprised of a gyro, an acceleration sensor, GPS sensor, and the latter is measured with a wheel force sensor. The noise of the measurement data caused by the inherent frequency of tires is reduced by using the spectral subtraction method. As a result , aerodynamic data measured on cross wind test corresponded to the wind tunnel test data. Numerical expression is defined in order to model the transient aerodynamic forces in cross wind.
2015-09-06
Technical Paper
2015-24-2419
Riccardo Amirante, Caterina Casavola, Elia Distaso, Paolo Tamburrano
A simple, cheap and effective way of measuring the pressure inside the cylinders of internal combustion engines is proposed in this paper. It is well known that the in-cylinder pressure is one of the most significant variables describing the combustion status in internal combustion engines; therefore, if the measured value of the actual pressure in the combustion chamber is used as a feedback variable for closed loop monitoring and control techniques, it will be possible both to improve engine performances and to reduce fuel consumptions and emissions. However, to date such a pressure-based control strategy has been limited by costs, reliability and lifetime of commercially available cylinder pressure sensors. To overcome these limitations, the present paper proposes a very simple and low cost experimental device for measuring the pressure inside the combustion chamber, developed for engine control and monitoring applications.
2015-09-06
Technical Paper
2015-24-2542
Carmelina Abagnale, Salvatore Strano, Massimo Cardone, Paolo Iodice, Mario Terzo, Giovanni Vorraro
Abstract The paper describes the development of an innovative test rig for the evaluation of e-bikes in terms of energetic performances and control system. The test rig has been realized starting from a commercial cyclist training system and suitably modified. The test rig is able to reproduce an aforethought route or paths acquired during road tests. It is possible to measure the performance of the e-bike in terms of instantaneous power and speed, by the installed sensors and data acquisition system. The experimental test rig can simulate the resistant torque of a predetermined track and it aims to test and to optimize the control strategy available on the electronic control unit (ECU). An important feature of the system is represented by the possibility to adopt a hardware in the loop approach for the testing of the e-bike and of its control. Indeed, the whole control algorithm can be implemented on a suitable controller board able to execute real time processes.
2015-06-15
Technical Paper
2015-01-2187
Mark A. Gehringer, Keith Thompson
Abstract This paper describes the development of a semi-automated end-of-line driveline system balance tester for an automotive assembly plant. The overall objective was to provide final quality assurance for acceptable driveline noise and vibration refinement in a rear wheel drive vehicle. The problem to be solved was how to measure the driveline system unbalance within assembly plant constraints including cycle time, operator capability, and integration with a pre-existing vehicle roll test machine. Several challenging aspects of the tester design and development are presented and solutions to these challenges are addressed. Major design aspects addressed included non-contacting vibration sensing, data acquisition/processing system and vehicle position feedback.
2015-06-15
Technical Paper
2015-01-2142
Colin Hatch, Roger Gent, Richard Moser
Abstract Low power ice protection systems are an important research area that is highlighted in the EU Clean Sky programme. In this paper an icing wind tunnel test of a full-scale wing incorporating both an electro-thermal and a hybrid electro-thermal electro-mechanical system is described. A description of a software tool to analyse both systems as full 3D models is also given. Preliminary comparisons of test data and prediction are shown both for the electro-thermal system and the hybrid system. Initial comparisons show a reasonable correlation in the main with recommendations for a structure tear-down to identify exact internal transducer locations. Recommendations are also made with regard to undertaking tests to determine a more consistent set of mechanical failure properties of ice. Future work in the development of the tool is also discussed.
2015-06-15
Technical Paper
2015-01-2278
Rohit Ravindran, Debajit Das, Keval Kamani, P Sivaraman, Gyan Arora
Abstract Torsional vibration is a characteristic phenomenon of automotive powertrains. It can have an adverse impact on powertrain related noise as well as the durability of transmission and drivetrain components. Hence minimizing torsional vibration levels associated with powertrains has become important. In this context, accurate measurement and representation of angular acceleration is of paramount importance. A methodology was developed for in-house vehicle level torsional vibration measurement, analysis and representation of results. The evaluation of torsional vibration has two major aspects. First, the acquisition of raw rotational data and secondly, the processing of acquired data to arrive at usable information from which inferences and interpretations can be made about the behavior of the rotating element. This paper describes the development process followed for establishing a torsional vibration evaluation methodology.
2015-06-15
Journal Article
2015-01-2284
Chris Hocking, Simon Antonov, Arsham Shahlari
Abstract The higher cylinder peak pressure and pressure rise rate of modern diesel and gasoline fueled engines tend to increase combustion noise while customers demand lower noise. The multiple degrees of freedom in engine control and calibration mean there is more scope to influence combustion noise but this must first be measured before it can be balanced with other attributes. An efficient means to realize this is to calculate combustion noise from the in-cylinder pressure measurements that are routinely acquired as part of the engine development process. This publication reviews the techniques required to ensure accurate and precise combustion noise measurements. First, the dynamic range must be maximized by using an analogue to digital converter with sufficient number of bits and selecting an appropriate range in the test equipment.
2015-06-15
Technical Paper
2015-01-2246
Kurt Veggeberg, Mike Denton
Abstract This is an overview of the development of a portable, real-time acoustic beamformer based on FPGA (Field Programmable Gate Arrays) and digital microphones for noise source identification. Microphone arrays can be a useful tool in identifying noise sources and give designers an image of noise distribution. The beamforming algorithm is a classic and efficient algorithm for signal processing of microphone arrays and is the core of many microphone array systems. High-speed real-time beamforming has not been implemented much in a portable instrument because it requires large computational resources. Utilizing a beamforming algorithm running on a Field Programmable Gate Array (FPGA), this camera is able to detect and locate both stationary and moving noise sources. A high-resolution optical camera located in the middle of the device records images at a rate of 25 frames per second.
2015-06-15
Journal Article
2015-01-2154
Franck Hervy, Severine Maguis, François Virion, Biagio Esposito, Hugo Pervier
Abstract The A06 test facility designed for combustor testing in altitude has been modified to be converted in an icing facility for probe testing. The objective was to be able to simulate ice crystals conditions at high altitude, high Mach number and low temperature. This facility has been upgraded in several steps extending the median size of the ice crystals produced and the ice water content range. The aero-thermal and icing capabilities have been assessed during commissioning tests. Finally, in order to prepare the calibration of the facility, some measurement techniques for cloud characterization have been selected or developed, especially for cloud uniformity measurement.
2015-04-14
Technical Paper
2015-01-1092
Gabriela Achtenova, Ondrej Milacek
Abstract The purpose of the article is to describe different possibilities of the innovative concept of the closed-loop test rig. The performed tests will be demonstrated with the example of measured data. Firstly the article will describe in detail the design of the test stand and both torque units. The power flow in the closed-loop circuit will be described and measured to find out the power losses of all parts. The measurement will be done for manual and planetary pretensioning mechanism. The comparison of the overall efficiency and demanded power for both torque units will be given. For evaluation of gearbox efficiency, the magnitude of power losses will be evaluated for different revolutions, torque levels and shifted speeds. For a long term tests, the unmanned operation is prepared. For this purpose is the stand equipped with electromechanical shift robots. The description of its concept and functioning will be part of the paper.
2015-04-14
Technical Paper
2015-01-0679
Michele Maria Schirru, Mike Sutton, Rob Dwyer-Joyce, Oliver Smith, Robin Mills
Abstract A novel ultrasonic viscometer for in-situ applications in engine components is presented. The viscosity measurement is performed by shearing the solid-oil contact interface by means of shear ultrasonic waves. Previous approaches to ultrasonically measure the viscosity suffer from poor accuracy owing to the acoustic miss-match between metal component and lubricant [1]. The method described overcomes this limitation by placing an intermediate matching layer between the metal and lubricant. Results are in excellent agreement with the ones obtained with the conventional viscometers when testing Newtonian fluids. This study also highlights that when complex mixtures are tested the viscosity measurement is frequency dependent. At high ultrasonic frequencies, e.g. 10 MHz, it is possible to isolate the viscosity of the base, while to obtain the viscosity of the mixture it is necessary to choose a lower operative frequency, e.g. 100 kHz, to match the fluid particle relaxation time.
2015-04-14
Technical Paper
2015-01-0681
Yuki Ono, Kenji Matsumoto
Abstract The reciprocating frictional test is a common approach for screening the materials of the piston and sleeve of an automobile engine. The frictional speed of this test is, however, limited mainly by the vibration of test apparatus due to the absence of damping factors in engines. Considering that the frictional velocity between the piston and sleeve reaches around 20 m/s, common test conditions at less than 2 m/s are not sufficient to understand the real phenomena at a frictional interface. We therefore developed a high-speed reciprocating test apparatus that can operate at a much higher speed range and examined two materials used for piston rings and sleeves. For the piston ring material, nitrided SUS440C was used. Plates were made of centrifugal cast iron FC250 or cast aluminum AC2B, which were coated with Nikasil. The experimental results showed that the lubrication regimes of the two plate materials were different even at the same reciprocating speeds.
2015-04-14
Technical Paper
2015-01-0802
Claudio Marcio Santana, Jose Eduardo Mautone Barros, Matheus Guilherme França Carvalho, Helder Alves de Almeida, Jr.
Abstract A burning process in a combustion chamber of an internal combustion engine is very important to know the maximum temperature of the gases, the speed of combustion, the ignition delay time of fuel and air mixture exact moment at which ignition will occur. The automobilist industry has invested considerable amounts of resources in numerical modeling and simulations in order to obtain relevant information about the processes in the combustion chamber and then extract the maximum engine performance control the emission of pollutants and formulate new fuels. This study aimed to general construction and instrumentation of a shock tube for measuring shock wave. As specific objective was determined reaction rate and ignition delay time of diesel, biodiesel and ethanol doped with different levels of additive enhancer cetane number. The results are compared with the ignition delay times measured for other authors.
2015-04-14
Technical Paper
2015-01-1018
Ryoko Sanui, Katsunori Hanamura
Surface pores that are open to the inlet channel below the surface play a particularly important role in the filtration of particulate matter (i.e., soot) inside the walls of a diesel particulate filter (DPF); they are closely related to the pressure drop and filtration efficiency through the DPF as well as the performance of the regeneration process. In this study, a scanning electron microscope (SEM) was used to dynamically visualize the soot deposition process at the particle scale as “time-lapse” images corresponding to the different increases in the pressure drop at each time step. The soot was first trapped at the deepest areas of the surface pores because the porous channels in this area were constricted by silicon carbide grains; soot dendrite structures were observed to grow and finally cause obstructions here.
2015-04-14
Technical Paper
2015-01-1303
Wenli Li, Xiao-Hui Shi, Dong Guo, Peng Yi
Abstract This paper discusses the development of engine and vehicle model for performing dynamic emulation experiments on vehicle transmissions. In order to reduce costs and shorten new vehicle development cycle time, vehicle simulation on the driveline test bench is an attractive alternative at the development phase to reduce the quantity of proto vehicles. This test method moves the test site from the road to the bench without the need for real chassis parts. Dynamic emulation of mechanical loads is a Hardware-in-the-loop (HIL) procedure, which can be used as a supplement of the conventional simulations in testing of the operation of algorithms without the need for the prototypes. The combustion engine is replaced by an electric drive dynamometer, which replicates the torque and speed signature of an actual engine. The road load resistance of the vehicle on a real test road is accurately simulated on Load dynamometer.
Viewing 1 to 30 of 1304

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