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Technical Paper
2014-04-01
Prashant Khapane, Uday Ganeshwade
Abstract Vehicle water wading capability refers to vehicle functional part integrity (e.g. engine under-tray, bumper cover, plastic sill cover etc.) when travelling through water. Wade testing involves vehicles being driven through different depths of water at various speeds. The test is repeated and under-body functional parts are inspected afterwards for damage. Lack of CAE capability for wading equates to late detection of failure modes which inevitably leads to expensive design change, and potentially affects program timing. It is thus of paramount importance to have a CAE capability in this area to give design loads to start with. Computational fluid dynamics (CFD) software is used to model a vehicle travelling through water at various speeds. A non-classical CFD approach was deemed necessary to model this. To validate the method, experimental testing with a simplified block was done and then verified with CFD modelling. The simple rectangular block at two different speeds and three immersion depths in water was utilized for the purpose.
Technical Paper
2014-04-01
Derek R. Braden, David M. Harvey
Abstract There is a continual growth of test and validation in high reliability product applications such as automotive, military and avionics. Principally this is driven by the increased use and complexity of electronic systems deployed in vehicles, in addition to end user reliability expectations. Higher reliability expectations consequently driving increased test durations. Furthermore product development cycles continue to reduce, resulting in less available time to perform accelerated life tests. The challenge for automotive electronic suppliers is performing life tests in a shorter period of time whilst reducing the overall associated costs of validation testing. In this paper, the application of prognostic and health monitoring techniques are examined and a novel approach to the validation and testing of automotive electronics proposed which it is suggested may be more cost effective and efficient than traditional testing. The holistic method explored in this paper fuses real time test data obtained during the monitoring of products throughout an environmental exposure with key factors from manufacturing and product design.
Technical Paper
2014-04-01
Valerie Earlene Bumbaca
Abstract Virtually every major automaker has announced intentions of producing an electric vehicle (EV). Hyundai Motor Group has also announced plans to sell an electric vehicle in the next several years. There is strong and increasing support for electric vehicles in the USA due to an interest in protecting the environment, limiting dependence on oil, and reducing the associated cost of petroleum-based transportation. From a durability perspective, battery performance and longevity are significant concerns. In order to better prepare for upcoming electric vehicles, Hyundai-Kia America Technical Center, Inc (HATCI) Vehicle Evaluation group is developing an EV durability test and battery lifecycle laboratory test based on real world EV customer usage. Since there is limited availability of real world customer information for electric vehicles, a program has been started to collect EV customer usage data. This will be correlated with test inputs for both road and lab testing. An outside vendor has been contracted to collect data on customer usage from existing Nissan Leaf and Chevrolet Volt customers.
Technical Paper
2014-04-01
Ram Kiran Tholeti, Shyamsundar Kumbhar, Nainish Kumar B, R Govindarajan
Abstract Scooter segment growth is tremendously increasing in India. The increased competition challenges automotive manufacturers to deliver the high quality and high reliable product to the market. Higher reliability involves increased durability testing which involves time and cost. Stress testing a part of durability is initially conducted on prototype vehicles for structural design validation and then later on production units to ensure its structural integrity. The obtained data from the tests can be used for future structural design improvements. Scooters with small tires, suspension limitations transfers more loads to structure, challenges engineers to design robust structure without compromising on weight much. It is necessary to look at Real World Usage Pattern (RWUP) and to create a stress life cycle block for simulation of accelerated testing, thereby optimizing the testing time and the development costs. The aim of this paper is to provide a procedure for deriving an accelerated stress test cycle for evaluation of chassis based on Road Load Data Acquisition (RLDA).
Technical Paper
2014-04-01
Sunil Kumar Chippa, Bhavani Srinivasaiah, Samraj Jabez Dhinagar
Abstract Automated testing of manufactured products reduces the lead time to considerable extent in the process of production to delivery. Products like automobiles demand automated testing, for which robots and vision systems are widely employed. The basic functionality of a vision system in automation is to detect an object and then recognize it. In current automotive industry such systems are being used for robotic guidance, component tracking, dimensional gauging etc. There is a need to test the proper functionality of a speedometer fitted on a motorbike in the production line itself. Focused work on detection and recognition of Analog type and Digital type speedometer console reading of a motorbike is described in this paper. A vision based system is proposed which recognizes the speedometer reading instantaneously at the desired time. Image binarization, connected component analysis combined with character recognition algorithms are used to achieve the desired recognition, which resulted in reduced lead time hence contributing to lean manufacturing
Technical Paper
2014-04-01
Qiang Yi, Stanley Chien, David Good, Yaobin Chen, Rini Sherony
Abstract According to pedestrian crash data from 2010-2011 the U.S. General Estimates System (GES) and the Fatality Analysis Report System (FARS), more than 39% of pedestrian crash cases occurred at night and poor lighting conditions. The percentage of pedestrian fatalities in night conditions is over 77%. Therefore, evaluating the performance of pedestrian pre-collision systems (PCS) at night is an essential part of the pedestrian PCS performance evaluation. The Transportation Active Safety Institute (TASI) of Indiana University-Purdue University Indianapolis (IUPUI) is conducting research for the establishment of PCS test scenarios and procedures in collaboration with Toyota's Collaborative Safety Research Center. The objective of this paper is to describe the design and implementation of a reconfigurable road lighting system to support the pedestrian PCS performance evaluation for night road lighting conditions. First, the test conditions of the road lighting (light intensity and uniformity) are generated by combining recommendations from road lighting design standards and the average measured lighting levels at various crash locations.
Technical Paper
2014-04-01
Jong Ho Lee
Abstract Since vehicle NVH reduction technology has improved dramatically, buzz, squeak and rattle (hereafter referred to as “BSR”) noise quantification from interior and exterior of the vehicle becomes an important factor to measure the quality of the vehicle. (The cost rate of BSR noise claims take around 10-15%, moreover BSR noise negatively affects customers to purchase vehicles.) Therefore, a research of BSR evaluation comes to the fore to make a premium car. In this paper, we would like to introduce the development of a vehicle excitation test mode, the full-vehicle BSR test system, and a sound acoustic camera to detect BSR noise. The test profiles were correlated with various road severities such as the domestic field test sites including 5,000km cross-country off road, 19 test tracks for BSR in R&D test center, and quality test tracks in domestic factories. These test modes were classified into 4 levels (Low-Normal-High-Crazy) by judging degrees of GRMS values. The full-vehicle test system can reproduce various field road profiles of the BSR for chassis parts, interior, and exterior for temperatures of −40∼60°C.
Technical Paper
2014-04-01
Chenaniah Langness, Michael Mangus, Christopher Depcik
Abstract In order to perform cutting-edge engine research that applies to modern Compression Ignition (CI) engines, a sophisticated test cell is needed that allows control of the engine and its auxiliary systems. The primary obstacle to the completion of such a test cell is the up-front expense. This paper covers the construction of a low cost, single-cylinder engine test cell while demonstrating the type of research that can be accomplished along the way. The components necessary for the construction, instrumentation, and operation of such a test cell, neglecting emissions analysis equipment, can be obtained for less than $150,000. The engine utilized, a naturally-aspirated single-cylinder Yanmar L100V, was purchased as an engine-generator package. Major upgrades to the engine include an Alternating Current (AC) dynamometer, a Variable-Geometry Turbocharger (VGT), a gaseous-additive fuel injection system, external cooled Exhaust Gas Recirculation (EGR), in-cylinder pressure measurement, and an electronically controlled common-rail fuel injection system.
Technical Paper
2014-04-01
Sunil KV, Sunil Sheepri, Kiran Kandula, Amit Kumar
Abstract The durability evaluation of overhanging components of a vehicle (Ex: horn, radiator) is a challenge to durability engineers as resonance plays an important role in determining their fatigue life. As resonance cannot be avoided always, it is desirable to develop methods to evaluate life of the component in the presence of resonance. Though the existing vibration test standards suggest test profiles to evaluate resonance failures, there are cases in which, these methods do not yield the proving ground results. This may lead to unnecessary overdesign or unrealistic failures. In such cases it is suggested to generate a sweep endurance test procedure customized to the proving ground or actual roads. This paper studies a methodology for generating a sweep endurance test procedure for evaluation of resonating components. Responses like stress and accelerations were measured in test components in proving ground. Contribution of each frequency band towards overall damage is determined.
Technical Paper
2014-04-01
Li Yanhua, Jianping Lin
Abstract Similar laser welded blanks with same material and same gauge have been extensive applied in automobile body for improving the material utilization and extending maximum coil size. It is known that, for TWBs with dissimilar material and thicknesses, the difference of material properties and/or thickness of the welded blanks, change of the material properties in the weld seam and heat-affected zones (HAZ) as well as location and orientation of the weld seam are reasons for reduced formability. However, the plastic deformation capacity of TWBs is reduced even when the material and thickness are the same. The aim of this paper is to evaluate the deformation behaviors of similar laser welded joints. Uniaxial tensile of five laser welded joints, with 90°,60°,45°,30°and 0°weld orientations, were tested by using optical measurement-DIC (Digital Image Correlation). Strain /strain ratio distribution and evolution of each joint was analyzed and compared with base material. In addition, mechanical property of weld was determined using rule of mixture and hardness testing.
Technical Paper
2014-04-01
Guobiao Yang, Jingyu Wang, Qirong Zhu, Ruhua Fang, Lianxiang Yang
Abstract With the rapid development of computing technology, high-speed photography system and image processing recently, in order to meet growing dynamic mechanical engineering problems demand, a brief description of advances in recent research which solved some key problems of dynamic photo-elastic method will be given, including:(1) New digital dynamic photo-elastic instrument was developed. Multi-spark discharge light source was replaced by laser light source which was a high intensity light source continuous and real-time. Multiple cameras shooting system was replaced by high-speed photography system. The whole system device was controlled by software. The image optimization collection was realized and a strong guarantee was provided for digital image processing. (2)The static and dynamic photo-elastic materials were explored. The new formula and process of the dynamic photo-elastic model materials will be introduced. The silicon rubber mold was used without the release agent. The epoxy resin sheet or block was solidified at room temperature and could be poured accurately once.
Technical Paper
2014-04-01
Shulian Zhang, Weiping Wang
Abstract This paper reports the extraordinary properties and industry applications of Nd: YAG Microchip Laser Feedback Interferometer, Nd: YAG LFI. The Michelson interferometer has been invented for more than a century and is widely used in science and industry today. The Nd: YAG LFI, which is based on laser feedback effect instead of ordinary interferometry, has the different structure from Michelson interferometer, and then extraordinary properties. Therefore the Nd: YAG LFI can be used as a traditional laser interferometer with nano-meter resolution and a few meters measurement range. At the same time Nd: YAG LFI can also measure the displacement of light, thin, black, transparent (water, alcohol, glass surface) objects, even liquid evaporation rate. Some actual applications are described in this paper, including the displacement measurement with nano-meter resolution for black machine parts, measurement of evaporation rate of liquids, measurement of the hysteretic curves of PZT and displacement measurement of cylinder surface.
Technical Paper
2014-04-01
Songgang Li, Guobiao Yand, Weiming Zeng
Abstract The port structure consisting of spur pile, vertical pile and beam is subjected to impact loads, so its internal stress state of each point will rapidly change over time. Dynamic photoelastic method is used to study the dynamic stress and stress wave propagation. With epoxy resin and other materials, a photoelastic model of beam to column connection structure is processed and product. The dynamic response of the model under the impact load by the free fall is researched by the dynamic photoelastic method, and recorded by the new digital dynamic photoelastic system with a laser source and high-speed photography system. The internal dynamic stress propagation and distribution, the maximum shear stress and the dynamic stress concentration problems can be obtained by analyzing the dynamic response. Researching on the key part under impact load using dynamic photoelastic method can furnish the experimental evidence of transient stress phenomenon for theoretical research and engineering applications.
Technical Paper
2014-04-01
Guobiao Yang, Yingbin Chi, Qirong Zhu, Lianxiang Yang
Abstract In this paper, Digital Image Correlation Method (DICM) is employed to measure the shear mechanical property of the new style automotive structural adhesive specimens and traditional spot welded specimens under quasi static uniaxial shear tensile test. This experiment adopts a non-contact measuring method to measure the strain of specimens. A CCD and a computer image processing system are used to capture and record the real-time surface images of the specimens before and after deformation. Digital correlation software is used to process the imagines before and after deformation to obtain the specimen's strain of the moment. And then both the force-displacement curve and the stress-strain curve during the tensile process could be obtained. The test and analysis results show that the new style structural adhesive specimens have a great advantage with the spot welded specimens. It provides experimental evidence for further improvement of this structural adhesive. And the digital image correlation method is a non-contact measuring method.
Technical Paper
2014-04-01
Hang Yin, Weiming Zeng, Guobiao Yang, Songgang Li
Abstract When an object was subjected an impact loading, stress wave was produced in the object. Studying the regularity of stress-wave propagation was significant to the study of objects subjected to impact loading. When stress wave travelled in the object, principal stress on free boundary was useful to theoretical analysis and calculation. In this article, a new kind of dynamic photoelastic apparatus was used. Isochromatic and isoclinic of the object subjected to impact loading could be obtained combining dynamic photoelastic experiment and related test equipment. By analyzing the isoclinic, there would be a conclusion that the angle between the isoclinic and the free boundary was not 0°or 90°. So the values of the two principal stress on the boundary were all not 0. The result obtained from the electrometric method came to the same conclusion. Analysis showed the result of dynamic photoelastic method was compatible with the result of electrometric method. So the method in this article was feasible and accurate.
Technical Paper
2014-04-01
Andrew Hall, John McPhee
Abstract Physical rig testing of a vehicle is often undertaken to obtain experimental data that can be used to ensure a mathematical model is an accurate representation of the vehicle under study. Kinematics and Compliance (K&C) testing is often used for this purpose. The relationship between the hard point locations and compliance parameters, and K&C characteristics of a suspension system is complex, and so automating the process to correlate the model to the test data can make the exercise easier, faster and more accurate than hand tuning the model. In this work, such a process is developed. First, the model parameters are adjusted, next a simulation is run, before the results are read and post processed. This automation processed is used in conjunction with an optimization procedure to carry out the K&C correlation. MATLAB scripts are created to modify the model parameters, run simulations and read the results so that MATLAB optimization algorithms can be used to identify the most appropriate suspension parameter values.
Technical Paper
2014-04-01
Xiaobo Yang
Abstract An outrigger is the device that is mounted on a test vehicle to protect it and/or its driver during handling test maneuvers, such as double lane change, constant radius cornering, J-turn, etc. The design of the outrigger is challenged by the constraints associated with its size, installation flexibility, strength, weight, and moment of inertia for a minimum or negligible impact on the test vehicle dynamics. To achieve an appropriate design of an outrigger for a specific vehicle, it is essential to determine the appropriate dynamic loads that the outrigger needs to support after its geometry and installation scheme have been determined. In this study, a flexible representation of an outrigger is mounted on a military vehicle that is simulated on a NATO double lane change maneuver at the given forward speeds. With the closed-loop driver/vehicle system simulation scheme, various drivers' choices of previewed paths are potentially applied by the ones with different levels of driving experiences and skills, which may further affect the vehicle dynamics and the outrigger contact forces.
Technical Paper
2014-04-01
Ehsan Samadani, Siamak Farhad, Satyam Panchal, Roydon Fraser, Michael Fowler
Abstract In this paper, initial results of Li-ion battery performance characterization through field tests are presented. A fully electrified Ford Escape that is equipped by three Li-ion battery packs (LiFeMnPO4) including an overall 20 modules in series is employed. The vehicle is in daily operation and data of driving including the powertrain and drive cycles as well as the charging data are being transferred through CAN bus to a data logger installed in the vehicle. A model of the vehicle is developed in the Powertrain System Analysis Toolkit (PSAT) software based on the available technical specification of the vehicle components. In this model, a simple resistive element in series with a voltage source represents the battery. Battery open circuit voltage (OCV) and internal resistance in charge and discharge mode are estimated as a function of the state of charge (SOC) from the collected test data. It is shown that although the OCV should be measured under no-load condition, still it can be estimated with an acceptable accuracy (∼5%) from the driving data.
Technical Paper
2014-04-01
Ashish Vora, Haotian Wu, Chuang Wang, Yili Qian, Gregory Shaver, Vahid Motevalli, Peter Meckl, Oleg Wasynczuk, Haiyan Zhang
Abstract Hybrid powertrains with multiple sources of power have generated new control challenges in the automotive industry. Purdue University's participation in EcoCAR 2, an Advanced Vehicle Technology Competition managed by the Argonne National Laboratories and sponsored by GM and DOE, has provided an exciting opportunity to create a comprehensive test-bench for the development and validation of advanced hybrid powertrain control strategies. As one of 15 competing university teams, the Purdue EcoMakers are re-engineering a donated 2013 Chevrolet Malibu into a plug-in parallel- through-the-road hybrid-electric vehicle, to reduce its environmental impact without compromising performance, safety or consumer acceptability. This paper describes the Purdue team's control development process for the EcoCAR 2 competition. It describes the team's efforts towards developing a complete vehicle model of a Parallel-through-the road PHEV which can leverage SIL and HIL simulation platforms for control development.
Technical Paper
2014-04-01
Shawn Salisbury, Thomas Bradley, Jake Bucher, Benjamin Geller
Abstract Plug-in Hybrid Electric Vehicles (PHEV) offer the benefits of both home charging from grid electricity and extended range from fuels. Fuel cell PHEVs in a range-extending (FCEREV) configuration build upon the advantages of PHEV by producing zero emissions while driving. The Colorado State University Vehicle Innovation Team (CSU VIT) successfully designed, built, and demonstrated a FCEREV named ‘H2eV’ for Year Two of the 3-year EcoCAR 2 collegiate competition. The demonstrated FCEREV is based on the 2013 Chevrolet Malibu and features a 15 kW Polymer Electrolyte Membrane fuel cell system, an 18.9 kWh/177 kW Li-Ion battery, and a 145 kW motor for all-electric drive. Operational data was taken during driving on a closed course, following a cycle that approximates the Environmental Protection Agency's 5-cycle test procedure. This paper provides an overview of the CSU VIT's FCEREV and a detailed analysis of vehicle performance during its successful demonstration. Analysis of fuel cell system operation provides proof-of-concept for the CSU VIT's FCEREV and highlights the emissions and energy consumption advantages of the designed vehicle for future development.
Technical Paper
2014-04-01
John May, Dirk Bosteels, Cecile Favre
From 1 September 2014 new car types in the EU must meet ‘Euro 6’ emissions requirements. The ‘New European Driving Cycle’ (NEDC) is currently the main test for this, but the European Commission intends to also introduce PEMS (Portable Emissions Measurement Systems)-based procedures to ensure that emissions are well controlled in real use. ‘Random Cycles’ have also been considered and remain a possible option for ‘real world’ particle number measurement. At the same time, the UN Working Party on Pollution and Energy (GRPE) has developed the new Worldwide harmonized Light vehicles Test Procedure (WLTP) that is expected to be adopted in the EU in the near future. To identify and understand the differences in emissions that may arise between these various methodologies, AECC has conducted some initial tests on two modern light-duty vehicles. Chassis dynamometer emissions tests were conducted over the NEDC, the Common Artemis suite of test cycles (CADC), the new Worldwide Light-duty Test Cycle (WLTC - the test cycle for WLTP) and a set of cycles produced by a Random Cycle Generator based on ‘short trip’ segments from the EU database used to construct WLTC.
Technical Paper
2014-04-01
Amey Zare, Advaita Datar, Mitsuhiko Kikuchi, Satoshi Ichikawa, Miwako Hasegawa, Shigenori Tsunekado
A flag is a global boolean variable used to achieve synchronization between various tasks of an embedded system. An application implementing flags performs actions or events based on the value of the flags. If flag variables are not implemented properly, certain synchronization related issues can arise which can lead to unexpected behavior or failure of the underlying system. In this paper, we present an automated verification technique to identify and verify flag usage patterns at an early stage of code development. We propose a two-step approach which consists of: a. identification of all potential flag variables and b. verification of flag usage patterns against predefined set of rules. The results of our experiment demonstrate that the proposed approach reduces the cost and complexity of the flag review process by almost 70%.
Technical Paper
2014-04-01
Tobias Schmidt, Shan Jin, Jens Rogalli, Thorsten Rogier, Hartmut Pohlheim, Ingo Stürmer
Requirements-based functional testing of model-based embedded software is a crucial requirement of the ISO 26262 safety standard for passenger cars [1]. Test assessment of requirements-based test cases is a laborious task and checking test results manually is prone to error. The intent of this paper is as follows: We introduce a method for requirements-based testing, which allows testing and automatic evaluation of single as well as several (grouped) requirements with one test sequence. Within a large-scale industrial project we have already shown that our new approach reduces testing expenditures and susceptibility to errors. Within this paper we shall present a method which facilitates the fulfillment of requirements traceability stipulated by ISO 26262. This method supports automated test case generation from test specifications, which then can be executed and assessed by a test tool automatically. The combination of these two methods in an efficient testing framework results in a significant reduction of testing expenditures and considerable increase in test coverage.
WIP Standard
2014-03-31
This SAE Aerospace Standard (AS) provides a method for gas turbine engine performance computer programs to be written using FORTRAN COMMON blocks. If a "function-call application program interface" (API) is to be used, then ARP4868 and ARP5571 are recommended as alternatives to that described in this document. When it is agreed between the program user and supplier that a particular program shall be supplied in FORTRAN, this document shall be used in conjunction with AS681 for steady-state and transient programs. This document also describes how to take advantage of the FORTRAN CHARACTER storage to extend the information interface between the calling program and the engine subroutine.
Standard
2014-03-31
This document provides design guidelines, test procedure references, and performance requirements for directional, single color, flashing optical warning devices used on authorized emergency, maintenance and service vehicles. It is intended to apply to, but not limited to, surface land vehicles.
Standard
2014-03-31
This recommended practice outlines a series of performance recommendations, which concern the whole data channel. These recommendations are not subject to any variation and all of them shall be adhered to by any agency conducting tests to this practice. However, the method of demonstrating compliance with the recommendations is flexible and can be adapted to suit the needs of the particular equipment the agency is using. It is not intended that each recommendation be taken in a literal sense, as necessitating a single test to demonstrate that the recommendation is met. Rather, it is intended that any agency proposing to conduct tests to this practice shall be able to demonstrate that if such a single test could be and were carried out, then their equipment would meet the recommendations. This demonstration shall be undertaken on the basis of reasonable deductions from evidence in their possession, such as the results of partial tests. In some systems it may be necessary to divide the whole channel into subsystems, for calibration and checking purposes.
WIP Standard
2014-03-26
This SAE Aerospace Standard (AS) provides performance station designation and nomenclature systems for aircraft propulsion systems and their derivatives. The systems presented herein are for use in all communications concerning propulsion system performance such as computer programs, data reduction, design activities, and published documents. They are intended to facilitate calculations by the program user without unduly restricting the method of calculation used by the program supplier. The list of symbols presented herein will be used for identification of input and output parameters. These symbols are not required to be used as internal parameter names within the engine subprogram.
WIP Standard
2014-03-26
1.1 This SAE Aerospace Standard (AS) provides performance station designation and nomenclature systems for aircraft propulsion systems and their derivatives. 1.2 The parameter naming conventions presented herein are for use in all communications concerning propulsion system performance such as computer programs, data reduction, design activities, and published documents. They are intended to facilitate calculations by the program user without unduly restricting the method of calculation used by the program supplier. 1.3 The list of symbols presented herein will be used for identification of input and output parameters. These symbols are not required to be used as internal parameter names within the engine subprogram
Standard
2014-03-25
This SAE Aerospace Standard (AS) establishes the requirements for self-aligning, self-lubricating plain spherical bearings incorporating polytetrafluoroethylene (PTFE) in a liner between the ball and the outer race for use in a temperature range of -65 to +250 °F (-54 to +121 °C).
WIP Standard
2014-03-25
Various SAE vehicle sound level measurement procedures require use of a sound level meter which meets the Type 1 or Type 2 requirements of ANSI S1.4-1983 (see 2.1.1.1), or an alternative system which can be proved to provide equivalent test data. The purpose of this SAE Recommended Practice is to provide a procedure for determining if a sound data acquisition system (SDAS) has electro-acoustical performance equivalent to such a meter. By assuring equivalent performance of the test instrumentation, the equivalence of test data is assured. Two general configurations of sound data acquisition systems will be encompassed (see Figure 1). The first configuration consists of instrument sections which perform as a sound level meter. The second configuration is a system which records data for later processing. The intent of this document is to establish guidelines which permit the test engineer to insure equivalence of sound data acquisition systems to a sound level meter. It requires that the test engineer have a working knowledge of the characteristics of the sound data being measured.
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