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Viewing 1 to 30 of 15281
2015-04-14
Technical Paper
2015-01-0498
Matt Gynn, Jamie Steele
This study explores the process changes and challenges encountered during the transition to Virtual Automotive maintenance and service operations—for example, training existing manpower on new tools, the overall schedule adjustments, and to check the item applicability. The confirmation process was reworked significantly, while the final evaluation and reporting process was able to be maintained. Problems were encountered with the organization of the digital part data, the increase in workload of Virtual simulations over physical checks, and the limitations of current simulation technologies. Virtual tools are much slower than physical checks. Ideas for future enhancements of Product Lifecycle Management (PLM) and simulation systems are explored.
2015-04-14
Technical Paper
2015-01-0495
Shohei Mikami, Georgi Chakmakov
Designing a lightweight and high-strength engine product is universally important from the standpoints of fuel consumption, power, and cost; however, it is difficult to find an optimal solution accomplishing these characteristics in products such as the cylinder heads that are simultaneously affected by a thermal load and various mechanical loads. We focused on an optimization means called “nonparametric optimization” and created a method of cylinder head design that utilized it. Our optimization process was divided into topological optimization and shape optimization. In the topological optimization process, we searched for a structure with the highest theoretical stiffness in the given design space. This provided an efficient structure when pursuing both lightweight and high-strength characteristics in the subsequent shape optimization process. Strain energy and displacement of the combustion chamber were used as the parameters for controlling stiffness.
2015-04-14
Technical Paper
2015-01-0490
Ryosuke Saito
We discuss the achievement of accurate and rapid appearance evaluation of a commodity from a design perspective. In design development, it is important to evaluate the quality of products in accordance with the customer’s viewpoint. Appearance evaluation using an actual model, such as a Mock-Up Model, is the optimal means. However, in order to respond to flaws or design changes quickly, we use a digital model. Therefore, we developed a graphic tool, TOPS, which can be used to obtain correct rendering results equivalent to an actual model, enabling a high level of precision and efficiency in digital design development.
2015-04-14
Technical Paper
2015-01-0489
Jason Rogers
A Catia-and-Excel-based predictive tool was developed to predict trunk spring movement for preventing recurrence of a noise problem. While effective, the tool could not completely explain measured CBU results. Since design data was used for the study, it was hypothesized that the difference between study and actual results was related to tolerance variation on the actual vehicle. Using Siemens VSA software, the vehicle was built and simulated virtually with tolerances using a Monte Carlo model. The study found that the hypothesis was correct; tolerance variation was fully responsible for the differences. The study also allowed accurate prediction of failure rates.
2015-04-14
Technical Paper
2015-01-0664
Hiroko Tada
We optimized the soundproof packages. This optimization study should be done in the early stage of vehicle development. The process for improving automotive interior quietness includes setting the marketability targets, the vehicle body acoustical performances, and the parts specifications. The acoustical system performance in this process is accomplished by evaluating the acoustical energy level of each system with the unit power of the exterior speaker excitation. The system was defined as the partial surface of the interior cavity, and one interior cavity surface was divided into a number of systems. Each system includes panel, damping material and exterior and interior soundproof packages. This system performance is named as the Energy Transmission Loss (ETL). The applicability of the method with ETL was verified by evaluating the results against the predicted values using the new method with the vehicle operation on a chasse-dynamometer.
2015-04-14
Technical Paper
2015-01-0663
Ling Zheng, Zhanpeng Fang, Zhongcai Tang, Zhenfei Zhan, Jiang-hua FU
The design optimization of vehicle body structure is addressed to reduce interior noise and improve customer satisfaction in this paper. The structural-acoustic model is established and the response of sound pressure in frequency domain is obtained by using finite element method. The minimization of sound pressure near the driver’s right ear depends on the geometry of vehicle body structure and the layout of damping treatments. The panel participation analysis is performed to find out the key panels as design variables and improve the efficiency of optimization computation. Response Surface Method (RSM) is utilized to optimize the vibro-acoustic properties of vehicle body structure instead of complex structural-acoustic coupling finite element model. Structural-acoustic problem is approximated by a series of quadratic polynomial using RSM. Geometric optimization problem of panels is described and solved to minimize the interior noise in vehicle.
2015-04-14
Technical Paper
2015-01-0430
Andrew Halfpenny, Frédéric Kihm, Benoît Beaum
Rotating machinery are found in every industry. While some machines are designed for constant-speed operation, others, such as the engines and transmission systems used in ground vehicles, are designed for varying speeds. The vibration environment of a varying speed engine or transmission system is best represented using a ‘Swept-Sine-On-Random’ vibration profile. The vibration profile comprises a mixture of deterministic signals, due to the engine rotation orders, superimposed on a background of Gaussian stochastic noise. Components mounted on these rotating machines are designed to survive these vibration levels over their entire service life. In the past many vibration test specifications were based on either a Power Spectral Density (PSD) function of random noise or as a series of discrete sine sweeps. The advantage of a Swept-Sine-On-Random profile is it is more characteristic of the real vibration environment.
2015-04-14
Technical Paper
2015-01-0492
Gaurav Paliwal, Naveen Sukumar, Umashanker Gupta
The need to develop products faster and to have designs which are first time right have put enormous pressure on the product development timelines, thus making Computer Aided Optimization one of the most important tool in achieving this targets. In this paper, a Design of Experiments (DOE) study is used, to gain an insight as to, how changes to different parameters of Front Suspension & Steering of a Passenger Bus affect its kinematic properties & thus to obtain an optimized design in terms of Handling parameters such as bump steer, roll steer, percent Ackermann, Lock to Lock rotation angle. The Conventional Hit & Trial method is time consuming and monotonous & still is an approximate method, whereas in Design of Experiments (DOE), a model is repeatedly run through simulations in a single setup, for various combinations of parameter settings. Effects and interactions of the design variables of the model are then studied, which provides an insight to help design an optimized model.
2015-04-14
Technical Paper
2015-01-0496
Anindya Deb, Ranga Srinivas Gunti, Clifford Chou, Utpal Dutta
The present work is concerned with the objective of multi disciplinary optimization (MDO) of an automotive front end structure using truncated finite element model. A truncated finite element model of a real world vehicle is developed and its efficacy for use in design optimization is demonstrated. The main goal adopted here is minimizing the weight of the front end structure meeting NVH, durability and crash safety targets. Using the Response Surface Method (RSM) and the Design Of Experiments (DOE) technique, second order polynomial response surfaces are generated for prediction of the structural performance parameters such as lowest modal frequency, fatigue life, and peak deceleration value.
2015-04-14
Technical Paper
2015-01-0599
Akhilendra Pratap Singh, Aditya Gupta, Avinash Kumar Agarwal
Better understanding of flow phenomena inside the combustion chamber of a diesel engine and accurate measurement of flow parameters is necessary for engine optimization i.e. enhancing power output, fuel economy improvement and emissions control. Airflow structures developed inside the engine combustion chamber significantly influences the air-fuel mixing. In this study, in-cylinder air flow characteristics of a motored, four-valve diesel engine were investigated using time-resolved high-speed tomographic Particle Imaging Velocimetry (PIV). Single cylinder optical engine provides full optical access of combustion chamber through a transparent cylinder and flat transparent piston top. Experiments were performed in different vertical planes at different engine speeds during the intake, compression and exhaust stroke under motoring condition. For visualization of air flow pattern, graphite particles were used for flow seeding.
2015-04-14
Technical Paper
2015-01-1689
Xu Song, Ryan Fortier, Scott Sarnia
The underhood hot air recirculation greatly impacts A/C system performance at idle and low vehicle speed conditions. The hot air recirculation can raise condenser cooling airflow temperature over ambient by 18°C, which lowers condenser cooling capacity and increases compressor work. Underhood airflow research suggests that a properly designed air duct is able to minimize hot air recirculation and improve the Compressors Coefficient of Performance (COP) at idle by 27%. This paper discusses underhood hot air recirculation testing methods, airflow distribution, and air duct design concepts. This dedicated air duct design indicates it should improve A/C emissions, which could contribute to meeting the Environmental Protection Agency’s (EPA) Green House Gas Emissions Regulations in North America.
2015-04-14
Technical Paper
2015-01-0597
Christian Schulz, Tamara Ottenwaelder, Thomas Raffius, Thorsten Brands, Thomas Huelser, Gerd Grunefeld, Stefan Pischinger
Maintaining low NOx emissions over the operating range of diesel engines continues to be a major issue. However, optical measurements of nitric oxide (NO) are lacking particularly in the core of diesel jets, i.e. in the region of premixed combustion close to the spray axis. This is basically caused by severe attenuation of both the laser light and fluorescent emission in laser-induced fluorescence (LIF) applications. Even in non-sooting flames, ultraviolet (UV) light is strongly absorbed by combustion intermediates and products. However, the absorption decreases generally with increasing wavelength. Laser-output extinction is therefore reduced by using a KrF* excimer laser in this work, which provides tunable radiation at about 248 nm. By contrast, laser wavelengths around 226 nm were employed in most previous applications. Extinction of both laser light and LIF emission are additionally reduced by keeping absorption path lengths relatively short in this work.
2015-04-14
Technical Paper
2015-01-1692
Walter Ferraris, Fausto Di Sciullo, Carloandrea Malvicino, Francesco Vestrelli, Fabrizio Beltramelli, Giancarlo Gotta
Automotive world is rapidly changing driven by the incoming CO2 emission regulation and the need of decreased fuel consumption for every vehicle line. The introduction of high efficiency solutions in order to get fuel consumption reduction has been already done on many vehicle systems without forgetting the cost sustainability of such solutions and with a general trend of weight reduction. For what concerns cooling systems, the increased adoption of dual level cooling loops and water cooled charge air cooling is a clear trend. The present paper proposes a compact and cost effective solution with low temperature loop cooling water cooled charge air cooler and water cooled condenser for A and B segment vehicle, with the possibility to add other exchangers to the secondary loop. All the thermal load is managed by only one radiator.
2015-04-14
Technical Paper
2015-01-0715
Terry Lynn Chapin, Van Walworth
Purpose Balancing the fill sequence of multiple cavities in a rubber injection mold is desirable for efficient cure rates, optimized cure times, and consistent quality of all molded parts. The reality is that most rubber injection molds do not provide a consistent uniform balanced fill sequence for all the cavities in the mold – even if the runner and cavity layout is geometrically balanced. A new runner design technique, named “The Vanturi Effect”, is disclosed to help address the inherent deficiencies of traditional runner and cavity layouts in order to achieve a more balanced fill sequence. Design/Methodology/Approach Specialized molds for rubber injection were designed and built with a series of hot runner layouts and specialized cavity shapes. Regressive short shot techniques were employed to establish how the runners filled and how the cavities filed. The injection series included matched pairs of identical molds with identical runner and cavity layouts.
2015-04-14
Technical Paper
2015-01-0431
KI Woo Sung, Jong Gurl KIM, Dae-Un Sung, Hye Mi Kim
HKMC has implemented the term of guarantee as 10 years and 100,000 miles for North American power train in order to expand a share in the North American market in 1999. Warranty data of 10 years and 100,000 miles for North American power train is 10-year field data of sales volume in North America which is important to confirm the durability of power train parts. In addition, it is meaningful that HKMC has collected data for ten years first in the world. However, there are some difficulties in warranty data analysis because it is hard to access to warranty repair data containing life information of parts and data is not opened to the public. Although the importance of warranty data has been recognized, the accuracy of data and analysis methods have not been systematically studied in the automobile business world. Unlike warranty data on electronics, failure time of automobile warranty data is given in the two dimensions with mileage and duration of use.
2015-04-14
Technical Paper
2015-01-0488
Andreea Elena Balau, Dennis Kooijman, Ignacio Vazquez Rodarte, Norbert Ligterink
The goal of this work is to develop a tool that stochastically generates drive cycles based on measured data, with the purpose of testing light duty vehicles in a simulation environment or on a test-bench for type approval testing. The WLTC database was used as input data. This database was created with the help of a number of European countries that collaborated and provided real world driving measurements. Consequently cycles that contain typical accelerations per velocity and road types are generated, such that these cycles are representative to real driving behaviour. The stochastic drive cycle generator is developed in Matlab and is based on Markov processes. Two different stochastic generators are used: one for generating the road type and one for generating the vehicle acceleration.
2015-04-14
Technical Paper
2015-01-1611
Wei Liu
When the hydraulic retarder is working in the heavy-duty vehicle, almost all the braking power is transformed into the thermal energy of the transmission oil. The spare heat removal capacity of engine’s cooling system could be taken full advantage for cooling the retarder. However, the relative long distance of the engine and the retarder increases the risky leakage of the cooling circuit. Furthermore, the development trend of heavy load and high speed vehicle directs the significant increase in the thermal load of the hydraulic retarder, which even higher than the engine power. Conventional engine cooling system could not meet the demand of the hydraulic retarder heat rejection within the same installation space. In this research, independent two-phase evaporator was adopted to strengthen the coolant heat absorption capacity from the transmission fluid at the oil outlet of the retarder by means of the vacuum flow boiling heat transfer.
2015-04-14
Technical Paper
2015-01-0497
Monika Filiposka, Ana M. Djuric
Gantry robots are mainly employed for applications, where large workspace is required and with limited higher manipulability to one direction than the others. The Gantries offer very good mechanical stiffness and constant positioning accuracy, but low dexterity. Common gantries are CNC machines with three translational joints XYZ (3DOF) and usually with an attached wrist (+3DOF). The translational joints are used to move the tool in any position of the 3D workspace. The wrist is used to orient the tool by rotation about X, Y and Z axis. This standard kinematic structure (3T3R) produce the rectangular workspace. In this paper full kinematic model of 6DOF general CNC machine is presented, along with the Jacobian matrix and singularity analysis. Using Denavit-Hartenberg convention, firstly, the general kinematic structure is presented, in order to assign frames at each link. The forward kinematic problem is solved using Maple 17 software.
2015-04-14
Technical Paper
2015-01-1694
Jun Li, Predrag Hrnjak
This paper presents results of the visualization of the separation in the vertical header of the automotive condenser. A prototype of a heat exchanger was made that has inlet in the middle of the header, with 21 microchannel tubes as the first pass. In the second header liquid separates and leaves through 4 microchannel tubes beneath while mostly vapor leaves through 11 microchannel tubes on the top as another exit. That way the 2nd pass has liquid below first pass and vapor above it. R134a and R1234yf are used in the tests. Mass flow was in the range 30 - 80 g/s (mass flux 170 kg/m2·s to 450 kg/m2·s) and quality at the inlet to second header over a range of 0.1 to 0.3, to see their impact on the separation of two-phase flow inside the transparent header. Visualization data were taken to better understand and define the physical parameters that dominate the separation phenomena.
2015-04-14
Technical Paper
2015-01-0205
James Price
Rapid resolution of electrical faults reduces costs, enhances brand image and maximizes vehicle availability. Although diagnostic systems continue to improve, service technicians frequently have to consult schematics, location views and other engineering resources to fix a problem. But this data can be hard to find, hard to understand, and out of date or wrong. This session presents new technology to leverage design data directly into the service domain. The technician is presented only with relevant vehicle-specific data, is able to navigate dynamically through electrical schematics, and can seamlessly link with other resources such as 3D models and repair procedures.
2015-04-14
Technical Paper
2015-01-0429
Na Xu, Chaochen Ma, Jianbing Gao, Zhiqiang Zhang, Xunzhi Qu
The low cycle fatigue experiment is extensively used to test the turbocharger reliability and durability. In the traditional low cycle fatigue test, a large air compressor is needed to drive the turbocharger under different operating conditions, which consume large amounts of electric power. This paper presents a new experiment device which has double chambers and double turbochargers. It can use the self-circulation manner to realize high and low speed switching as well as satisfy the temperature upper limit of turbine entry without the large air compressor. First, a detailed model is established in GT-Power and self-circulation test data can be used to validate the model. By utilizing the model, the relation between the valve opening and the flow distribution was obtained. Then, the dynamic simulation model is established in MATLAB/Simulink.
2015-04-14
Technical Paper
2015-01-0503
Hefeng Zhan
Plenty of dust particles which are generated when a swapping vehicle is dumping harm to workers’ health. In the study, the designed vacuum dust control system could effectively capture easily raised dust particles in the air in the premise of not impacting the dumping process so as to improve the unloading work environment. Firstly, longitudinal motion trajectory model of dust particles in the dumping process is established. Based on the side collision probability model of dust particles, lateral velocity distribution of dust particles is obtained. What’s more, the scope of lateral dust particles is determined. Taking into account coupling of the dust control system and the working state of the vehicle, the suction mouth is arranged at the edge on the outside of hatch cover. Centrifugal horizontal dust removal system designed in the research is fixed in the middle of the filter cover part and discharging hatch cover area.
2015-04-14
Technical Paper
2015-01-0494
Sulki Seong, Wangoo Kim, Daesung Bae, Seungpyo Lee, Younggeol Cho, Kyeongdeok Yang
Bearing is an important part for supporting the weight and transmits power. Rotating bearing is required excellent durability. Various studies have been conducted long time, for predict performance and durability of the bearing. However, prediction of the bearing durability has been used expression computation method using a theoretical formula between the raceway and ball. Flange analysis is commonly used structural analysis. Such an approach, have assumed to be static load. So it is difficult to consider the dynamic characteristics (Centrifugal force, Gyroscope effect) of the bearing. In order to predict the accurate bearing endurance life, it should be considering the dynamic characteristics. This paper proposes the method for bearing endurance life prediction considering dynamic characteristic. Between the raceway and ball contact is one of the important factors to take into account the dynamic characteristics of the bearing.
2015-04-14
Technical Paper
2015-01-0596
Oliver Scholz, Nikolas Doerfler, Lars Seifert, Uwe Zöller
Rubber seals are used throughout the automobile for a variety of purposes, and the consequences of a failure of such a seal can range from annoying in case of an A/C component to catastrophic in the case of brake components. With the constantly increasing requirements for these components regarding e.g. pressure or new refrigerants comes the requirement for ensuring surface properties according to the specification of the application. While automatic inspection systems are available for a variety of problems, the area of seal inspection is still dominated by manual labor, partly because handling of these small, inexpensive parts is difficult and partly because visual coverage of the entire sealing surface poses a problem. It is also difficult for a human inspector to objectively assess whether or not a surface defect is critical or not, especially given that inspection of each seal must be completed within a few seconds.
2015-04-14
Technical Paper
2015-01-0501
Dengfeng Wang, Rongchao Jiang
The cost of fuel for commercial trucks takes up a great proposition in the total vehicle operating costs. In order to improve the power performance and fuel economy of a domestic self-dumping truck, an optimization matching method of the powertrain system was presented in this paper. A vehicle performance simulation model of this self-dumping truck was established using AVL-Cruise software. Then the power performance and fuel economy simulations were executed according to China National Standard GB/T 12543-2009 “Acceleration performance test method for motor vehicles” and GB/T27840-2011 “Fuel consumption test methods for heavy-duty commercial vehicles”. Moreover, the simulation results were compared with the road test results, which were measured on proving ground, to verify the validity of the vehicle performance simulation model.
2015-04-14
Technical Paper
2015-01-0487
Lev Klyatis
Abstract title: INTRODUCTION TO SUCCESSFUL PREDICTING OF PRODUCT PERFORMANCE (RELIABILITY, DURABILITY, SAFETY, QUALITY, RECALLS, AND OTHERS) This paper will discuss the problem with successful predicting of product performance components. The best component for analyzing performance during service life, including predicting, is recalls, because, first, recall accumulates reliability, durability, safety, profit, and total economic situation. Second, there is open official and objective information about the number of recalls from the government (National Highway Traffic Safety Administration and others), as well as companies-producers. Therefore, for analyzing the situation with the product performance , including predicting, this paper considers the situation with recalls. It will demonstrate how dangerous is the current situation with recalls, reliability, durability, safety, especially in automotive, including in the USA for last thirty years.
2015-04-14
Technical Paper
2015-01-0500
Emilio Larrodé, Alberto Torne, Alberto Fraile
This paper is collaboration between the Research Group on Sustainable Means of Transport and Systems (SMITS) of the University of Zaragoza (Spain) and the Spanish company, Zytel Automotive S.L. (ZYTEL). The analysis and decision making on design, behaviour and use of a prototype electric vehicle is the main focus has been pursued in this paper. It was modelled a prototype electric vehicle, called Gorila EV, as from the software tool Adams/Car (MSC Software Corporation). The way it decided to tackle this paper was by Computer Aided Engineering (CAE). Conduct an analysis of the vehicle by CAE allows increasing the quickness and convenience when getting results and reduce costs incurred testing with real prototypes. In this study it considers urban driving, where the vehicle trajectory is constrained by the infrastructure (road signs) and other vehicles (traffic).
2015-04-14
Technical Paper
2015-01-0598
Xiaona Li, Changqing Du, Yongjun Zhou, Xin Xie, Xu Chen, Yaqian Zheng, Thomas Ankofski, Rodrigue NARAINEN, Cedric Xia, Thomas Stoughton, Lianxiang Yang
Accurate forming limit strain determination of aluminum sheet metal is an important topic which has not been fully solved by the industry. Also, if the draw bead effects (enhanced forming limit behaviors) reported on steel sheet metals also happens on aluminum sheets metals is not fully understand. This paper introduce an experimental study on draw bead effect of aluminum sheet metals by measuring the forming limit strain zero (FLD0)of the sheet metal. Two kind of aluminum, AL 6016-T4 and AL 5754-0, are used. Virgin material, 40% draw bead material and 60% draw bead material situations are tested for each kind of aluminum. Marciniak punch tests are proceeded to create plane strain condition. A dual camera Digital Image Correlation (DIC) system is used to record and measures the deformation distribution history during the punch test. The on-set necking timing is determined directly from surface shape change. The FLD0 of each test situation is reported in this article.
2015-04-14
Technical Paper
2015-01-0493
Ying Wang, Ye Wang, You Qu, Sumin Zhang, Weiwen Deng
Research on advanced driver assistance systems (ADAS) has gained great momentum recently in addressing increasing concerns on vehicle safety, such as forward and rearward collision warning and avoidance, lane departure warning and lane keeping, autonomous driving, etc. Vision-based ADAS, mainly using cameras as sensing devices, has received tremendous attention and become more and more attractive to the market nowadays. This is not only because of its low-cost advantage compared to radar or lidar, but also due to technological advancement and maturity in image processing, pattern recognition and digital signal processing. Unlike radar-based systems, vision-based ADAS may combine with object and lane detection via pattern recognition techniques to further enhance system performance.
2015-04-14
Technical Paper
2015-01-1612
Wei Liu
The hydraulic retarder is a significant auxiliary braking device for the heavy duty vehicle. Traditionally, cooling circulation of the hydraulic retarder was coupled with the engine cooling system, and the thermal energy of the transmission oil would be cooled by the engine radiator ultimately. For this scheme, radiator’s spare heat removal capacity could be fully utilized whereas the cooling system is very complicated and is hard to maintain. Furthermore, the corresponding of thermal management system lags behind the power change of the retarder. In this research, integrated cooling evaporation system is developed for the hydraulic retarder, which makes the cooling water contact with the transmission oil through the wall of the fixed wheel so that it can rapidly response to the thermal variation of the retarder, keep the stability of the oil temperature and meanwhile reduce the risk of cooling medium leakage.
Viewing 1 to 30 of 15281