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2017-03-28
Technical Paper
2017-01-1681
Kyaw Soe
Abstract This paper describes a test system for improving the completeness and representativeness of automotive electrical/electronic (E/E) test benches. This is with the aim to enable more testing and hence increase the usage and effectiveness of these facilities. A proportion of testing for automotive electrical and electronics systems and components is conducted using E/E testing boards (“test-boards”). These are table-like rigs consisting of most or all electrical and electronic parts connected together as per a car/truck/van. A major problem is that the testing is conducted on the equivalent of a static vehicle: test-boards lack basic dynamic elements such as a running engine, vehicle motion, environmental, component and fluid temperatures, etc. This limits the testing that can be carried out on such a test-board.
2017-03-28
Journal Article
2017-01-1527
Felix Wittmeier
Abstract After being in operation since 1989, the 25% / 20% model scale wind tunnel of University of Stuttgart received its second major upgrade in 2016. In a first upgrade in 2001, a rolling road with a 5 belt system from MTS was installed. This system includes a steel center belt to simulate the road underneath the vehicle and four FKFS designed rubber belts for wheel rotation. The recent upgrade now enables the wind tunnel to be used not only for standard, steady state aerodynamic measurements but also for measurements of unsteady aerodynamic effects. This enables the use of the FKFS swing system as a standard measurement technique. Therefore, the former balance was replaced by a balance manufactured by AND with a high Eigenfrequency and the ability to sample the measurement data at up to 1000 Hz. The second large part of the upgrade was the replacement of the control system. With the new Wind Tunnel Control System (WCTS), control system.
2017-03-28
Journal Article
2017-01-1534
Nina Tortosa, David Schroeck, Tony Nagle, Guy Flynt
Abstract The General Motors Reduced Scale Wind Tunnel Facility, which came into operation in the fall of 2015, is a new state-of-the-art scale model aerodynamic test facility that expands GM’s test capabilities. The new facility also increases GM’s aerodynamic testing through-put and provides the resources needed to achieve the growing demand for higher fuel economy requirements for next generation of vehicles. The wind tunnel was designed for a nominal model scale of 40%. The nozzle and test section were sized to keep wind tunnel interference effects to a minimum. Flow quality and other wind tunnel performance parameters are on par with or better than the latest industry standards. A 5-belt system with a long center belt and boundary layer suction and blowing system are used to model underbody flow conditions. An overhead probe traverse system is installed in the test section along with a model positioning robot used to move the model in an out of the test section.
2017-01-10
Technical Paper
2017-26-0195
Sachin Kumar Jain, Manasi Joshi, Harshal Bankar, Prashant Kamble, Prasad Yadav, Nagesh Karanth
Abstract The paper discusses the methodology for measuring the sound absorption of sound package materials in a different sizes of reverberation chambers. The large reverberation chamber is based on test methods and requirements as per ASTM C423 and ISO 354 standards. Both the test standards are similar and recommend a reverberation chamber volume of at least 125 m3 and 200 m3 respectively for sound absorption measurements from 100 Hz to 5000 Hz. The test sample size requirements are from 5.5 to 6.7 m2 as per ASTM C423 and 10 to 12 m2 as per ISO 354. In the automotive sector passenger car, heavy truck, and commercial vehicle, the parts that are used are much smaller in size than the size prescribed in both the standards. The requirement is to study the critical parameters such as the chamber volume, sample size, reverberation time and cut-off frequency etc. which are affecting the sound absorption property of acoustic material.
2017-01-10
Technical Paper
2017-26-0315
Jyoti Kale, Satish Kumar, Pravin Lavangare, Anand Subramaniam
Abstract The Steering system is one of the most safety critical systems in an automobile. With time the durability, reliability and the fine-tuning of the parameters involved in this subsystem have increased along with the competitiveness of the market. In a competitive market, accelerated testing is the key to shorter development cycles. It is observed that the majority of component manufacturers have a preference on vehicle level testing to achieve their development goals. The vehicle level trials are time consuming and lack the control and repeat-ability of a laboratory environment. This paper describes the development of a steering test rig designed to simulate the disturbances experienced on road within a controlled laboratory environment. The five axis steering rig would allow simulation of individual road wheel displacement along with steering wheel angle input and lateral steering rack displacements. The rig also is designed to be adaptable to a range of vehicle categories.
2017-01-10
Technical Paper
2017-26-0326
Michael Wohlthan, Gerhard Pirker, Igor Sauperl, Andreas Wimmer, Wolfram Rossegger, Norbert Buch
Abstract Experimental investigations on engine test beds represent a significant cost in engine development. To reduce development time and related costs, it is necessary to check the quality of measurements automatically whenever possible directly on the test bed to allow early detection of faults. A fault diagnosis system should provide information about the presence, cause and magnitude of an inconsistency in measurement. The main challenge in developing such a system is to detect the fault quickly and reliably. However, only faults that have actually occurred should be detected because the user will only adopt a system that provides accurate results. This paper presents a methodology for automated fault diagnosis at engine test beds, starting with an explanation of the general procedure. Next, the methods applied for fault detection are introduced.
2016-10-31
WIP Standard
ARP7998
This is a recommended practice for an interface to supplier simulations that utilize traditional interprocess communication (IPC) methods of shared memory and semaphore communications. These IPC methods are fairly standard practice in the computer science world, that allow for communication by separate processes running on a computer without any common runtime requirements of each process being run. So 32bit applications can talk with 64 bit applications as well as any other compiler or runtime dependency being needed by the calling program to interface with the called system. This also allows the calling program and the called program to be run on separate CPUs to allow parallel execution of the called program as well as multiple instances of the called program to execute all on separate processors.
2016-09-27
Technical Paper
2016-01-8144
John Lacey
Abstract The trucking industry is being encouraged by environmental and cost factors to improve fuel efficiency. One factor that affects fuel efficiency is the aerodynamic design of the vehicles; that is, the vehicles with lower aerodynamic drag will get better mileage, reducing carbon emissions and reducing costs through lower fuel usage. A significant tool towards developing vehicles with lower drag is the wind tunnel. The automobile industry has made great improvements in fuel efficiency by using wind tunnels to determine the best designs to achieve lower drag. Those wind tunnels are not optimum for testing the larger, longer heavy trucks since the wind tunnels are smaller than needed. The estimated costs for a heavy truck wind tunnel based on automotive wind tunnel technology are quite high. A potential nozzle concept to reduce wind tunnel cost and several other new possible approaches to lower wind tunnel costs are presented.
CURRENT
2016-08-01
Standard
AIR6236A
This AIR provides guidance to the EMI test facility on how to check performance of the following types of EMI test equipment: Current probe Line Impedance Stabilization Network (LISN) Directional coupler Attenuator Cable loss Low noise preamplifier Rod antenna base Passive antennas All performance checks can be performed without software. A computer may be required to generate an electronic or hard copy of data. This is not to say that custom software might not be helpful; just that the procedures documented herein specifically eschew the necessity of automated operation.
2016-06-15
Technical Paper
2016-01-1807
Olga Roditcheva, Lennart Carl Lofdahl, Simone Sebben, Pär Harling cEng, Holger Bernhardsson
Abstract This paper presents an experimental study of aeroacoustical sound sources generated by the turbulent flow around the side mirror of a Volvo V70. Measurements were carried out at the Volvo Cars aerodynamical wind tunnel (PVT) and at the aeroacoustical wind tunnel of Stuttgart University (FKFS). Several different measurement techniques were applied in both tunnels and the results were compared to each other. The configurations considered here were: side mirror with a cord and without the cord. The results discussed in this paper include intensity probe measurements in the flow around the side mirror, sound source localization with beamforming technique using a three-dimensional spherical array as well as standard measurements inside the car with an artificial head. This experimental study focused on understanding the differences between testing at the PVT and FKFS.
2016-05-11
Technical Paper
2016-36-0061
Juliana Negrini de Araújo, Leonardo Hoss, Alexandre Viecelli, Maicon Molon
Abstract The use of virtual and / or experimental test rigs applying random loading is becoming more relevant in the development and validation of new products. An application example is the analysis of components subject to vibrations, especially suspended components. For this type of application, product validation applying random loads and different frequencies becomes mandatory. This study developed a virtual test rig for suspended components validation and definition of experimental test rigs. The study was based on a standard component, using LMS Virtual.Lab Siemens software for the dynamic analysis and durability. The experimental data (extensometry and accelerometry) was collected on the special tracks of Randon Companies Proving Ground. From the virtual modeling and experimental data, the proper hydraulic actuators signals were defined to characterize the component behavior according to the field application.
2016-04-14
WIP Standard
AIR5925B
The report shows how the methodology of measurement uncertainty can usefully be applied to test programs in order to optimize resources and save money. In doing so, it stresses the importance of integrating the generation of the Defined Measurement Process into more conventional project management techniques to create a Test Plan that allows accurate estimation of resources and trouble-free execution of the actual test. Finally, the report describes the need for post-test review and the importance of recycling lessons learned for the next project.
2016-04-05
Technical Paper
2016-01-1622
Miroslav Mokry
Abstract Lagally’s theorem is used to evaluate the increments to aerodynamic forces on automotive models, tested in solid-wall wind tunnels. The strengths of the model-representing singularities, pre-requisite for the application of the theory, are obtained from experimental wall pressure data, using an influence matrix method. The technique is demonstrated on the drag force acting on full-size and half-size truck models, measured in the same test section.
2016-04-05
Technical Paper
2016-01-1588
Abdalla Abdel-Rahman, Martin Agelin-Chaab, Gary Elfstrom, John Komar
Abstract Wind tunnels with integrated aerodynamic and thermodynamic testing with yaw capabilities are not common. In this study however, an integrated aerodynamic and thermodynamic testing system with yaw capabilities is developed and applied in the climatic wind tunnel at the University of Ontario-Institute of Technology (UOIT). This was done by installing an incremental force measuring system (FMS) on the large turntable that features a chassis dynamometer. The testing system was utilized to implement an integrated aero-thermal test on a full-scale race car. An efficient testing protocol was developed to streamline the integrated testing process. The FMS was used to enhance the test car’s stability, cornering speed, and fuel efficiency by using aerodynamic devices. These objectives were achieved by installing a high rear wing to increase the rear downforce, a modified front splitter extension to produce a front downforce gain, and front canards to contribute to drag reduction.
2016-04-05
Technical Paper
2016-01-1607
David Soderblom, Per Elofsson, Ann Hyvärinen
Abstract The effect of blockage due to the presence of the wind tunnel walls has been known since the early days of wind tunnel testing. Today there are several blockage correction methods available for correcting the measured aerodynamic drag. Due to the shape of the test object, test conditions and wind tunnel dimensions the effect on the flow may be different for two cab variants. This will result in a difference in the drag delta between so-called open-road conditions and the wind tunnel. This makes it more difficult to evaluate the performance of two different test objects when they are both tested in a wind tunnel and simulated in CFD. A numerical study where two different cab shapes were compared in both open road condition, and in a digital wind tunnel environment was performed.
2016-04-05
Technical Paper
2016-01-0235
Serenat Karagoz, Murat Karaer, Nurettin Ali Dasdemir
Abstract In this paper a combined energy recovery system is suggested for engine test facilities. System consists of two semi loops which are being active according to the temperature of the air feeded to the test cell. Winter and summer semi loops are introduced with the system requirements and equipments. Working principle of both semi-loops and components with the selection critera are explained. Also cost and benefit analysis is given in detail. It is evident that hot exhaust gases of the combustion processes is the main source that a large amount of energy wastes through it. Researchers confirm that more than 30% - 40% of fuel energy in the internal combustion engines wastes from the exhaust and just 12% -25% of the fuel energy converts to useful work. In the other hand, statistics show that producing numbers of the internal combustion engines growth very fast and the concern of decreasing the fossil fuels will be appeared.
2016-04-05
Technical Paper
2016-01-1581
Felix Wittmeier, Armin Michelbach, Jochen Wiedemann, Victor Senft
Abstract With its recent wind tunnel upgrade, FKFS installed the first interchangeable three-belt / five-belt-system (FKFS first®) in a full scale automotive wind tunnel. With the five-belt system, which today is a state-of-the-art ground simulation technique, the system is ideally suited for production vehicle development work. The five-belt system offers high flexibility, quick access to the underfloor and vehicle fixation, and setting the vehicle’s ride height by the restraint device. The first results of the five-belt system have already been published in SAE 2015-01-1557 [1]. The three-belt system on the other hand, offers a much more sophisticated ground simulation technique which is necessary especially for sports and racing cars. For such vehicles with very low ground clearances, it is important to have a more accurate ground simulation, in order to capture the same aerodynamic modes of action and response as on the road.
2016-04-05
Journal Article
2016-01-1583
Brian R. McAuliffe, Alanna Wall, Guy Larose
Abstract During the past year, a novel turbulence generation system has been commissioned in the National Research Council (NRC) 9 m Wind Tunnel. This system, called the Road Turbulence System was developed to simulate with high fidelity the turbulence experienced by a heavy duty vehicle on the road at a geometrical scale of 30%. The turbulence characteristics that it can simulate were defined based on an extensive field measurement campaign on Canadian roads for various conditions (heavy and light traffic, topography, exposure) at heights above ground relevant not only for heavy duty vehicles but also for light duty vehicles. In an effort to improve continually the simulation of the road conditions for aerodynamic evaluations of ground vehicles, a study was carried out at NRC to define the applicability of the Road Turbulence System to aerodynamic testing of full-scale light duty vehicles.
2016-04-05
Journal Article
2016-01-1598
Frank Meinert, Kristian Johannessen, Fernando Saito, Bongha Song, Jewel Barlow, David Burton, Taehwan Cho, Luis Fernando Gouveia de Moraes
Abstract Wind tunnel testing of reduced-scale models is a valuable tool for aerodynamic development during the early stages of a new vehicle program, when basic design themes are being evaluated. Both full-and reduced-scale testing have been conducted for many years at the General Motors Aerodynamics Laboratory (GMAL), but with increased emphasis on aerodynamic drag reduction, it was necessary to identify additional facilities to provide increased test capacity. With vehicle development distributed among engineering teams around the world, it was also necessary to identify facilities local to those teams, to support their work. This paper describes a cooperative effort to determine the correlation among five wind tunnels: GMAL, the Glenn L.
2016-04-05
Journal Article
2016-01-1595
Haibo Wu, Jiangbin Zhou, Qian Chen, Gongwen Liu, Chaoqun Qian
Abstract In this paper we present the work which was done at Shanghai-VW for using computational aero-acoustic (CAA) simulation in the vehicle development process to assess and improve the buffeting behavior of a vehicle when the rear side window is open. In the first step, a methodology was established and validated against wind tunnel tests using a Sedan. The methodology consists of a calibration of the CAA model to represent the properties of the cabin interior of the real car in terms of damping, wall compliance and leakage followed by CAA simulations of the full vehicle at different wind speeds to obtain the transient flow field around the exterior shape and inside the passenger compartment. The interior noise spectra are directly calculated from the transient pressure inside the cabin.
2016-04-05
Journal Article
2016-01-1614
Edward Duell, Amir Kharazi, Paul Nagle, Per Elofsson, David Söderblom, Christer Michael Ramden
Abstract Scania AB has opened the new CD7 climatic wind tunnel test facility, located at the Scania Technical Center in Södertälje, Sweden. This facility is designed for product development testing of heavy trucks and buses in a range of controllable environments. Having this unique test environment at the main development center enables Scania to test its vehicles in a controlled repeatable environment year round, improving lead times from design to production, producing higher quality and more reliable vehicles, and significantly improves the capability for large vehicle performance research. This state-of-the-art facility provides environmental conditions from -35°C to 50°C with humidity control from 5 to 95 percent. The 13 m2 nozzle wind tunnel can produce wind speeds up to 100 km/h. The dynamometer is rated at 800 kW for the rear axle and 150 kW for the front axle, which also has ±10° yaw capability.
2016-04-05
Journal Article
2016-01-0982
Philip Lawson, John Houldcroft, Andrew Neil, Andrea Balcombe, Richard Osborne, Antonio Ciriello, Wilhelm Graupner
Abstract A recent trend in powertrain development organisations has been to apply processes historically associated with manufacturing. The aim is to capitalise on the resulting productivity gains to contain the increasing test demand necessary to develop current and future product. Significant obstacles to the implementation of manufacturing derived methods include the lack of clarity of the engineering test requirements and existing working practices in the product development environment. The System Optimisation Approach has been presented in previous work as a potential solution [1]. As an extension, this paper introduces a new concept closely related to the established manufacturing principle of Process Capability (Cp). Application of the resulting method quantifies the test facility’s capability to provide a test result subject to a specified statistical confidence within a certain number of test repeats.
2016-04-05
Journal Article
2016-01-1597
Christopher Collin, Steffen Mack, Thomas Indinger, Joerg Mueller
Abstract The open jet wind tunnel is a widespread test section configuration for developing full scale passenger cars in the automotive industry. However, using a realizable nozzle cross section for cost effective aerodynamic development is always connected to the presence of wind tunnel effects. Wind tunnel wall interferences which are not present under open road conditions, can affect the measurement of aerodynamic forces. Thus, wind tunnel corrections may be required. This work contains the results of a CFD (Computational Fluid Dynamics) approach using unsteady Delayed Detached Eddy Simulations (DDES) to evaluate wind tunnel interferences for open jet test sections. The Full Scale DrivAer reference geometry of the Technical University of Munich (TUM) using different rear end shapes has been selected for these investigations.
2016-02-05
Magazine
Off-highway hybrids: Opportunities and challenges With oil prices declining and emissions regulations in North America 'stabilized,' is there a place for hybrid powertrains in this new world of cheap oil? Looking for a better image Display advances are helping to reduce operator fatigue. Charging up electrified powertrains Control technologies race forward while batteries improve and adopt standard sizes. Measuring and accounting for suspension TARDEC teamed with SEA Ltd. to develop a system to measure the suspension parameters, center of gravity, and moments of inertia of wheeled vehicles in the never ending quest to model and predict vehicle dynamic behavior. Looking at mobility in 2050 Cuneyt L. Oge begins his term as 2016 SAE International President with a vision about the future of auto- and aero-mobility.
2016-02-03
Magazine
Baking in protection With vehicles joining the Internet of Things, connectivity is making cybersecurity a must-have obligation for automotive engineers, from initial designs through end-of-life. New Engines 2016 Highlighting the design, engineering, and technologies inside some of the most competitive new gasoline and light-duty diesel ICEs. Citizen of the world Cuneyt L. Oge begins his term as 2016 SAE International President with a vision about auto-mobility and aero-mobility 2050. CES rollouts extend connectivity, app integration Ford looks to spread Corning's new lightweight Gorilla Glass beyond the 2017 GT New 40%-scale wind tunnel increases GM's aero-development capacity Surface Generation speeds composites throughput with one-shot stamp-forming process 2017 Cadillac XT5 debuts GM's new lightweight crossover architecture Porsche and Bentley plan electric future
HISTORICAL
2015-12-13
Standard
AIR6236
This AIR provides guidance to the EMI test facility on how to check performance of the following types of EMI test equipment: Current probe Line Impedance Stabilization Network (LISN) Directional coupler Attenuator Cable loss Low noise preamplifier Rod antenna base Passive antennas All performance checks can be performed without software. A computer may be required to generate an electronic or hard copy of data. This is not to say that custom software might not be helpful; just that the procedures documented herein specifically eschew the necessity of automated operation.
2015-12-01
Magazine
Uncertainty quantification The technique is a must for next-generation simulation tools. Oil-pump sizing Researchers from Hinduja Tech investigate options for low friction and power consumption. The future of Indian commercial aviation The growth in traffic that airport modernization has supported has also made a significant contribution to the local and national economies, while the improved infrastructure has been positive for the perception of India in the global market. Driving EVs toward lower cost The race ison to reduce battery and electric-drive systems cost while improving efficiency. Powering on Rolls-Royce's Chief Engineer discusses new technologies that inspire current R&D design and evaluation work as part of its strategic roadmap for future big commercial programs. HMIs extend beyond the cab Telematic functions are being integrated into multi-function user interfaces.
2015-10-13
WIP Standard
AIR5509A
This document defines the process steps involved in collecting and processing engine test data for use in understanding engine behavior. It describes the use of an aero-thermal cycle model for reduction and analysis of those data. The analysis process may include the calculation of modifiers to match the model to measured data, and prediction of engine performance based on that analysis
CURRENT
2015-09-25
Standard
AIR5320A
This SAE Aerospace Information Report (AIR) contains information on most of the major icing simulation ground facilities. An effort was made to obtain data from as many facilities as possible over a two year time period. The data in this document represents the state of the facilities in calendar year 1996. Facilities are constantly changing and upgrading and, therefore, some facility specifications may change during the life of this report. Of the 27 facilities described in this report, the primary use is split with approximately half for engine testing and half for wind tunnel testing. The facilities are limited to ground facilities and, therefore, icing tankers have not been included.
2015-09-15
Technical Paper
2015-01-2552
Helmut Plankl
Abstract The paper will start with a short introduction to the structure of the Airbus Group, before addressing the Airbus Defence and Space business line Military Aircraft. The Rig Operation department for airborne solutions within this organisation is responsible for the development, design, operation and support of ground test facilities and test support systems, which are used for design validation and verification of civil and military air systems. The main part of this document will start with a typical sequence of tests in our Test Centre. The presentation will then focus on some advanced methods used during the qualification of test equipment and to improve the efficiency of ground test facilities in terms of cost, time and risk reduction. The next topic is tool-based rig management and control, beginning with test preparation and test shift planning and also covering aspects of configuration control, automatisation of test facilities and support of the test report.
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