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2016-04-05
Technical Paper
2016-01-0415
Sijin Wu, Xinya Gao, Yong Lv, Yanpeng Jiang, Yao Fang, Aiguo Zhou
Abstract Temporal phase-shifting and spatial-carrier techniques are the two dominant phase extraction methods used in digital speckle pattern interferometry (DSPI). Temporal phase-shifting technique enjoys the advantages of precise phase extraction and capability of high-quality phase map formation, but suffers from the limitation in its use in dynamic measurement due to the time cost for carrying out the phase shift. To meet the rising demand of dynamic measurement of deformations in modern industry, spatial-carrier technique is developed to extract the phase information from a single speckle interferogram, yielding less time cost during a test. In this paper, both temporal phase-shifting and spatial-carrier techniques are investigated in theory as well as experiment. The experiment results from measuring a same deformation behavior using both techniques are used to compare the performances of the two phase extraction techniques.
2016-04-05
Technical Paper
2016-01-0418
Xin Xie, Danielle Zeng, Junrui Li, Jeffrey Dahl, Qiancheng Zhao, Lianxiang Yang
Abstract Polymer plastics are widely used in automotive light weight design. Tensile tests are generally used to obtain material stress-strain curves. Due to the natural of the plastic materials, it could be elongated more than several hundred percent of its original length before breaking. Digital Image Correlation (DIC) Analysis is a precise, full field, optical measurement method. It has been accepted as a practical in-field testing method by the industry. However, with the traditional single-camera or dual-camera DIC system, it is nearly impossible to measure the extreme large strain. This paper introduces a unique experimental procedure for large elongation measurement. By utilization of quad-camera DIC system and data stitch technique, the strain history for plastic material under hundreds percent of elongation can be measured. With a quad-camera DIC system, the correlation was conducted between two adjacent cameras.
2016-04-05
Technical Paper
2016-01-0405
Fupin Wei, Li Xu, Chen Cao, Youmei Zhao
Crash Test Dummies are the very important tools to evaluate the vehicle safety performance. In order to ensure the dummy performance during the crash tests, the dummy components need to be certificated. In the neck certification procedure, the head angle is the most important parameter, which is the head rotation respect to the neck base. To get the head angle, couples of rotary potentiometers should be mounted either on the calibration fixture or on the dummy head. The rotation is then calculated from those potentiometer readings. There are two potentiometers mounted in the Hybrid III family dummies, while three potentiometers mounted in ES2, ES-2re, SID-IIs, and WorldSid 50th dummies. In the certification, maximum head angle and time occurred should be within certain ranges in the Hybrid III family dummies while for the ES2 and WorldSid 50th dummies, not only the maximum head angle, but also the other angles and their timings should meet the requirements.
2016-04-05
Technical Paper
2016-01-0410
Joseph V. Gabiniewicz, Douglas M. Baker, Michael Testani
Abstract Historically, driveshaft torque data has been obtained using slip rings. Slip rings, however, are expensive, and require time-intensive driveshaft modifications for proper installation. In addition, the time and expense involved in field servicing units is prohibitive. For these reasons, AISIN Technical Center of America (ATCA) investigated a viable telemetry solution. At the onset of this development activity, existing torque telemetry solutions had their own issues. In particular, they did not offer the same data resolution as slip rings, they lacked sufficient battery life for long-term, real-world testing applications, and they suffered from data drop-outs. ATCA worked with TECAT Performance Systems to develop a torque telemetry solution that addressed all of these issues. This paper presents the development activity involved, alongside real-world measurement data showing the results of both the slip ring and telemetry solutions.
2016-04-05
Technical Paper
2016-01-0463
Juan Sierra, Camilo Cruz, Luis Munoz, Santiago Avila, Elkin Espitia, Jaime Rodriguez
Abstract Brake systems are strongly related with safety of vehicles. Therefore a reliable design of the brake system is critical as vehicles operate in a wide range of environmental conditions, fulfilling different security requirements. Particularly, countries with mountainous geography expose vehicles to aggressive variations in altitude and road grade. These variations affect the performance of the brake system. In order to study how these changes affect the brake system, two approaches were considered. The first approach was centered on the development of an analytical model for the longitudinal dynamics of the vehicle during braking maneuvers. This model was developed at system-level, considering the whole vehicle. This allowed the understanding of the relation between the braking force and the altitude and road grade, for different fixed deceleration requirement scenarios. The second approach was focused on the characterization of the vacuum servo operation.
2016-04-05
Journal Article
2016-01-0459
Jian Zhao, Jing Su, Bing Zhu, Jingwei Shan
Abstract Proper tire pressure is very important for multiple driving performance of a car, and it is necessary to monitor and warn the abnormal tire pressure online. Indirect Tire Pressure Monitoring System (TPMS) monitors the tire pressure based on the wheel speed signals of Anti-lock Braking System (ABS). In this paper, an indirect TPMS method is proposed to estimate the tire pressure according to its resonance frequency of circumferential vibration. Firstly, the errors of ABS wheel speed sensor system caused by the machining tolerance of the tooth ring are estimated based on the measured wheel speed using Recursive Least Squares (RLS) algorithm and the measuring errors are eliminated from the wheel speed signal. Then, the data segments with drive train torsional vibration are found out and eliminated by the methods of correlation analysis.
2016-04-05
Technical Paper
2016-01-0451
Fu Wenkui, Liu Ligang, Shu Jin, Wang Dawei, Xu Long
Abstract Virtual Road Load Data Acquisition (vRLDA) is to replace traditional Road Load Data Acquisition (RLDA) thus becomes the important method to obtain the load for the fatigue analysis of the vehicle components. Pothole event, which is a typical loadcase among vehicle durability test in the development process, is simulated based on Adams/Car in this paper. Flex-body is adopted in the full vehicle model in order to improve the simulation accuracy. Flexible ring tire model, FTire, is used for the benefit of validity in higher frequency domain. The result shows that simulation result correlated well both in wheel center travel and load of tire and suspension parts. Consequently, it is available to predict the max effective jounce travel and body max load in the early phase of vehicle development thus decrease the potential risk in the later phase and the total research cost. vRLDA is also proven as a reliable and effective method to obtain the load.
2016-04-05
Technical Paper
2016-01-0449
Xian Xu, Wei Chen, Yuan Cao, Yingxiong Zhang, Hu Guo
Abstract The stiffness of the frame has a great influence on the ride comfort of the heavy truck. Reducing frame thickness was proved to be unacceptable in terms of ride comfort, which is verified by the testing results. The truck frame was reinforced in order to improve the ride comfort. The modal analysis showed that the pitch frequency of the vehicle has increased 0.5 Hz and the frequency response has decreased by 20%. In order to research the influence of frame stiffness on the heavy truck ride comfort, a detailed model including a flex frame, chassis suspension, cab suspension, driveline, etc., was built by MSC.ADAMS. The Simulation results showed that the ride comfort can be improved by reinforce the frame, and the ride comfort can be improved by 5%∼10%. The results of this study need to be further examined through field testing.
2016-04-05
Technical Paper
2016-01-0441
Aref M. A. Soliman
Abstract An active suspension system has better performance than a passive suspension. However, it requires a significant amount of energy and is constructed from high cost components. To solve the problem of the power required, a switchable damper suspension system has been studied. In this paper, control strategies for the switchable damper suspension system and passive are compared in terms of their relative ride performance capabilities. Practical limitations involving switching time delay and threshold delay values are modeled and their effect on the ride performance are evaluated. The four setting switchable damper is compared with the two and three setting switchable dampers. The control strategies are used to maintain suspension working space level within design limit and to minimize body acceleration level. The results showed that the four setting switchable damper gives better ride improvements compared with the two and three setting switchable dampers.
2016-04-05
Technical Paper
2016-01-0429
Paul Augustine, Timothy Hunter, Nathan Sievers, Xiaoru Guo
Abstract The performance of a structural design significantly depends upon the assumptions made on input load. In order to estimate the input load, during the design and development stage of the suspension assembly of a BAJA car, designers and analysts invest immense amount of time and effort to formulate the mathematical model of the design. These theoretical formulations may include idealization errors which can affect the performance of the car as a final product. Due to the errors associated with the assumption of design load, several components might have more weight or may have less strength than needed. This discrepancy between the assumed input load (lab or theoretical studies) and the actual load from the environment can be eliminated by performing a real life testing process using load recovery methodology. Commercial load cells exist in industry to give engineers insight to understanding the complex real world loading of their structures.
2016-04-05
Technical Paper
2016-01-0496
Leonardo Farfan-Cabrera, Ezequiel A. Gallardo
Abstract Debris are progressively generated just after wear occurred by the interaction of various mechanical elements inside the engines, steering gear boxes, transmissions, differentials, etc. Besides, debris could interfere with the normal operation of such components generating even more damage in other parts due to three-body abrasion. Hence, dynamic seals are susceptible to interact with very fine debris accumulated in the working lubes. Recently, owing to many test advantages, the micro-scale abrasion test has been extensively used to reproduce three-body abrasion in hard materials, coatings, polymers, etc., however, it has not been before employed for the wear assessment of elastomeric materials. This paper presents an adaptation of the micro-scale test method to study three-body abrasive behavior of an elastomeric dynamic seal (samples extracted from an automotive commercial Acrylonitrile-butadiene NBR rotary seal) under lubricated conditions.
2016-04-05
Technical Paper
2016-01-0484
Chad W. Chichester
Abstract Silicone fluids are known to have high Viscosity Indices (VI), and high Oxidation Onset Temperatures (OOT). Silicone VI and OOT characteristics make these fluids appealing for use as lubricants in high temperature applications, and where lubricant longevity is desired. Despite thermal and oxidative benefits, silicones lubricants have a reputation as being poor lubricants in metal-to-metal applications, and are typically only selected for use in plastic applications. Most industrial knowledge about silicone lubricants is based on characteristics of PolyDiMethyl Siloxanes (PDMS), in which case, lubricity limitations do exists. However, there are other silicone based lubricating fluid technologies, that have been commercially available for decades, that far exceed known lubricity performance of PDMS, and in some ways can rival traditional synthetic hydrocarbon.
2016-04-05
Technical Paper
2016-01-0486
Sakthinathan Ganapathy, K R Viswanathan, Saravanan Raju, Anand Kumar Appancheal
Abstract The intervention of Nanotechnology in the field of lubricants have found path to several new lubricants for high temperature applications. Nanolubricants are the nanoparticles suspended in base lubricants, are being developed to increase the performance of machine components at high temperatures, which reduces friction and wear in sliding contact encountered in many heat engines and industrial applications. An attempt has been made to study the effect of the Yttria stabilized Zirconia (YSZ), Calcia stabilized Zirconia(CSZ), and Aluminium Oxide nanoparticles in the lube oil base stock. The nanoparticles were synthesized using Ball mill and the nanoparticles were found to be in the range of 50 to 90 nm.
2016-04-05
Technical Paper
2016-01-0479
Kuniaki Goto, Takashi Kondo, Masakiyo Takahira, Eiji Umemura, Masashi Komada, Yasuhiko Nishimura
Abstract Generally, pass-by noise levels measured outdoors vary according to the influence of weather conditions, background noise and the driver’s skill. Manufactures, therefore, are trying to reproduce proving ground driving conditions on a chassis dynamometer. The tire noise that occurs on actual road surfaces, however, is difficult to reproduce in indoor tests. In 2016, new pass-by noise regulations (UN R51-03) will take effect in Europe, Japan and other countries. Furthermore, stricter regulations (2dB) will take effect in 2020. In addition to the acceleration runs required under current regulations, UN R51-03 will require constant speed runs. Therefore, an efficient measurement methods are necessary for vehicle development. To solve the above mentioned issues, an indoor evaluation system capable of reproducing the tire noise that occurs on road surfaces has been developed.
2016-04-05
Technical Paper
2016-01-0474
Shukai Yang, Bingwu Lu, Zuokui Sun, Yingjie Liu, Hangsheng Hou
Abstract A low frequency vibration issue around 3.2 Hz occurs during a commercial heavy truck program development process, and it is linked to extremely uncomfortable driving and riding experiences. This work focuses on an analytical effort to resolve the issue by first building a full vehicle MBS (multi-body-system) model, and then carrying out vibration response analyses. The model validation is performed by using full vehicle testing in terms of structural modes and frequency response characteristics. In order to resolve the issue which is excited by tire non-uniformity, the influence of the cab suspension, frame modes, front leaf spring system and rear tandem suspension is analyzed. The root cause of the issue is found to be the poor isolation of the rear tandem suspension system. The analytical optimization effort establishes the resolution measure for the issue.
2016-04-05
Technical Paper
2016-01-0464
Lingyang Li, Wei Wu, Ji Chen, Jianpeng Shi, Xicheng Wang, Liuhua Qian
Abstract In order to expand the product design and development capabilities of Electric Power Steering (EPS) system, a passenger car’s simulation model integrated with EPS system model will be made. Some analytical investigation is conducted in this paper. Through simplifying the architecture model of EPS system, the mathematical equation expressions of steering wheel and column, worm gear reducer, rack and pinion, steer-wheels, brushed DC electrical motor, and ECU assistance and compensation laws will be described. A number of tests on the EPS full system and subsystems and components will be executed. The tests’ results will be used as the input parameters of the model, and then be used for model validations. After that, the EPS system model will be created. Since the most important part of control logic strategy is the top secret of steering assembly supplier and it could’t be provided to OEM in details or not even a black-box model directly.
2016-04-05
Technical Paper
2016-01-0766
Tongyang Gao, Marko Jeftic, Geraint Bryden, Graham Reader, Jimi Tjong, Ming Zheng
Abstract The control of nitrogen oxide and smoke emissions in diesel engines has been one of the key researches in both the academia and industry. Nitrogen oxides can be effectively suppressed by the use of exhaust gas recirculation (EGR). However, the introduction of inert exhaust gas into the engine intake is often associated with high smoke emissions. To overcome these issues there have been a number of proposed strategies, one of the more promising being the use of low temperature combustion enabled with heavy EGR. This has the potential to achieve simultaneously low emissions of nitrogen oxide and smoke. However, a quantitative way to identify the transition zone between high temperature combustion and low temperature combustion has still not been fully explored. The combustion becomes even more complicated when ethanol fuel is used as a partial substitution for diesel fuel.
2016-04-05
Technical Paper
2016-01-0833
Lei Meng, Yuqiang Li, Karthik Nithyanandan, Timothy Lee, Chunnian Zeng, Chia-Fon Lee
Abstract To face the challenges of fossil fuel shortage and air pollution problems, there is growing interest in the potential usage of alternative fuels such as bio-ethanol and bio-butanol in internal combustion engines. The literature shows that the acetone in the Acetone-Butanol-Ethanol (ABE) blends plays an important part in improving the combustion performance and emissions, owing to its higher volatility. In order to study the effects of acetone addition into commercial gasoline, this study focuses on the differences in combustion, performance and emission characteristics of a port-injection spark-ignition engine fueled with pure gasoline (G100), ethanol-containing gasoline (E30) and acetone-ethanol-gasoline blends (AE30 at A:E volumetric ratio of 3:1). The tests were conducted at 1200RPM with the default calibration (for gasoline), at 3 bar and 5 bar BMEP under various equivalence ratios.
2016-04-05
Technical Paper
2016-01-0891
Teri D. Kowalski, Satoshi Hirano, William A. Buscher, Eric Liu, Jerry C. Wang, James L. Linden
Abstract The study described in this paper covers the development of the Sequence IVB low-temperature valvetrain wear test as a replacement test platform for the existing ASTM D6891 Sequence IVA for the new engine oil category, ILSAC GF-6. The Sequence IVB Test uses a Toyota engine with dual overhead camshafts, direct-acting mechanical lifter valvetrain system. The original intent for the new test was to be a direct replacement for the Sequence IVA. Due to inherent differences in valvetrain system design between the Sequence IVA and IVB engines, it was necessary to alter existing test conditions to ensure adequate wear was produced on the valvetrain components to allow discrimination among the different lubricant formulations. A variety of test conditions and wear parameters were evaluated in the test development. Radioactive tracer technique (RATT) was used to determine the wear response of the test platform to various test conditions.
2016-04-05
Journal Article
2016-01-0050
Huafeng Yu, Chung-Wei Lin, BaekGyu Kim
Abstract Modern vehicles can have millions of lines of software, for vehicle control, infotainment, etc. The correctness and quality of the software play a key role in the safety of whole vehicles. In order to assure the safety, engineers give an effort to prove correctness of individual subsystems or their integration using testing or verification methods. One needs to eventually certify that the developed vehicle as a whole is indeed safe using the artifacts and evidences produced throughout the development cycle. Such a certification process helps to increase the safety confidence of the developed software and reduce OEM’s liability. However, software certification in automotive domain is not yet well established, compared to other safety-critical domains, such as avionics and medical devices. At the same time, safety-relevant standards and techniques, including ISO 26262 and assurance cases, have been well adopted.
2016-04-05
Journal Article
2016-01-0957
Patrick Schrangl, Roman Schmied, Stephan Stadlbauer, Harald Waschl, Luigi del Re, Bernhard Ramsebner, Christoph Reiter
Abstract Abatement and control of emissions from passenger car combustion engines have been in the focus for a long time. Nevertheless, to address upcoming real-world driving emission targets, knowledge of current engine emissions is crucial. Still, adequate sensors for transient emissions are seldom available in production engines. One way to target this issue is by applying virtual sensors which utilize available sensor information in an engine control unit (ECU) and provide estimates of the not measured emissions. For real-world application it is important that the virtual sensor has low complexity and works under varying conditions. Naturally, the choice of suitable inputs from all available candidates will have a strong impact on these factors. In this work a method to set up virtual sensors by means of design of experiments (DOE) and iterative identification of polynomial models is augmented with a novel input candidate selection strategy.
2016-04-05
Technical Paper
2016-01-1007
Benjamin Ellies, Charles Schenk, Paul Dekraker
Abstract As part of its technology assessment for the upcoming midterm evaluation (MTE) of the 2022-2025 Light-Duty Vehicle Greenhouse Gas (LD GHG) emissions standards, EPA has been benchmarking engines and transmissions to generate inputs for use in its Advanced Light-Duty Powertrain and Hybrid Analysis (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 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
Journal Article
2016-01-0984
Venkatraman Mahadevan, Suresh Iyer, David Klinikowski
Abstract This paper proposes a method to recover species concentrations at the tail pipe exit of heavy-duty vehicles during chassis dynamometer tests, and investigates its effect in the calculation of emissions from their raw exhaust streams. It was found that the method shown in this paper recovered the sharp peaks of the gas species. The effect on calculations was significant, 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 transport of the sample gases from the probe tip to the analyzer, and deformed due to mixing and diffusion during this transport. This ‘convolution’ of the concentration data stream introduces an error in the final result, calculated in g/mile.
2016-04-05
Journal Article
2016-01-0889
Chuang Fan, Sunyu Tong, Xiaohong Xu, Jing Li, Xiao Yu He, Jun Deng, Liguang Li
Downsizing gasoline direct injection engine with turbo boost technology is the main trend for gasoline engine. However, with engine downsizing and ever increasing of power output, a new abnormal phenomenon, known as pre-ignition or super knock, occurs in turbocharged engines. Pre-ignition will cause very high in-cylinder pressure and high oscillations. In some circumstances, one cycle of severe pre-ignition may damage the piston or spark plug, which has a severe influence on engine performance and service life. So pre-ignition has raised lots of attention in both industry and academic society. More and more studies reveal that the auto-ignition of lubricants is the potential source for pre-ignition. The auto-ignition characteristics of different lubricants are studied. This paper focuses on the ignition delay of different lubricants in Controllable Active Thermo-Atmosphere (CATA) combustion system.
2016-04-05
Journal Article
2016-01-0894
Kenji Matsumoto, Hironori Harada, Yuki Ono, Yuji Mihara
Abstract A simple method is frequently used to calculate a reciprocating engine’s bearing load from the measured cylinder pressure. However, it has become apparent that engine downsizing and weight reduction cannot be achieved easily if an engine is designed based on the simple method. Because of this, an actual load on a bearing was measured, and the measured load values were compared with a bearing load distribution calculated from cylinder pressure. As a result, it was found that some of actual loads were about half of the calculated ones at certain crank angles. The connecting rod’s elastic deformation was focused on as a factor behind such differences, and the rod’s deformation due to the engine’s explosion load was studied. As a result, it was found that the rod part of the engine’s connecting rod was bent by 0.2 mm and became doglegged. Additional investigation regarding these findings would allow further engine downsizing.
2016-04-05
Journal Article
2016-01-0896
Masami Ishikawa, Kazuo Yamamori, Satoshi Hirano, Teri Kowalski, James Linden
Abstract Fuel economy improvement has been one of the most important challenges for the automotive industry, and the oil and additive industries. The automotive, oil, and additive industries including related organizations such as SAE, ASTM, and testing laboratories have made significant efforts to develop not only engine oil technologies but also engine oil standards over decades. The API S category and ILSAC engine oil standard are well known and widely used engine oil specifications [1] [2]. The development of an engine oil standard has important roles to ensure the quality of engine oils in the market and encourage industries to improve the engine oil performance periodically. However, the progress of technology advancement can go faster than the revision of engine oil standard. An introduction of new viscosity grades, SAE 0W-16 and 5W-16 is one good example. The 16 grade was added into the SAE J300 standard that defines viscosity grades for engine oils in April 2013 [3].
2016-04-05
Journal Article
2016-01-0908
Norifumi Mizushima, Kyohei Yamaguchi, Daisuke Kawano, Hisakazu Suzuki, Hajime Ishii
Abstract In the conventional approval test method of fuel consumption for heavy-duty diesel vehicles currently in use in Japan, the fuel consumption under the transient test cycle is calculated by integrating the instantaneous fuel consumption rate referred from a look-up table of fuel consumptions measured under the steady state conditions of the engine. Therefore, the transient engine performance is not considered in this conventional method. In this study, a highly accurate test method for fuel consumption in which the map-based fuel consumption rate is corrected using the transient characteristics of individual engines was developed. The method and its applicability for a heavy-duty diesel engine that complied with the Japanese 2009 emission regulation were validated.
2016-04-05
Standard
J1563_201604
These guidelines are intended for those engineers and scientists who evaluate the corrosion performance of painted automotive parts in laboratory cyclic tests. The guidelines are intended to help ensure that the results of the tests can be used to reach conclusions concerning the variables under study without being confounded by the test procedure itself. The guidelines also serve as a means to assist users of this type of test in obtaining good inter-laboratory agreement of results.
2016-04-05
Technical Paper
2016-01-0146
Yonghwan Jeong, Seonwook Kim, Kyongsu Yi, Sangyong Lee, ByeongRim Jo
Abstract This paper represents a parking lot occupancy detection and parking control algorithm for the autonomous valet parking system. The parking lot occupancy detection algorithm determine the occupancy of the parking space, using LiDAR sensors mounted at each side of front bumper. Euclidean minimum spanning tree (EMST) method is used to cluster that information. After that, a global parking map, which includes all parking lots and access road, is constructed offline to figure out which cluster is located in a parking space. By doing this, searching for available parking lots has been finished. The proposed parking control algorithm consists of a reference path generation, a path tracking controller, and a parking process controller. At first, route points of the reference path are determined under the consideration of the minimum turning radius and minimum safety margin with near parking.
2016-04-05
Technical Paper
2016-01-0979
Jonathan David Stewart, Rose Mary Stalker, Richard O'Shaughnessy, Roy Douglas, Andrew Woods
Abstract Catalyst aging is presently one of the most important aspects in aftertreatment development, with legislation stating that these systems must be able to meet the relevant emissions legislation up to a specified mileage on the vehicle, typically 150,000 miles. The current industry approach for controlling aging cycles is based solely on the detailed specification of lambda (air-fuel mixture concentration ratio), flow rate and temperature without any limitations on gas mixture. This is purely based upon the experience of engine-based aging and does not take into account any variation due to different engine operation. Although accurate for comparative testing on the same engine/engine type, inconsistencies can be observed across different aging methods, engine types and engine operators largely driven by the capability of the technology used.
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