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Aftertreatment system solutions to meet PROCONVE P6 emissions in Brasil

ArvinMeritor-Peter Albers
Published 2006-11-21 by SAE International in United States
Proconve P6 emission limits for heavy duty diesel engines will require the application of aftertreatment devices that are new to the Brazilian market. In addition to the transient test component required for certification, the aftertreatment system solution and design to be chosen will be a function of the engine size, power density and application.An overview of the possible solutions to meet PROCONVE 6 emission standards, with examples and description of the relative advantages and major characteristics will be described in this paper.
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Analysis of Lining Assembly for Brake System

ArvinMeritor-Wangquan (Winston) Cheng, Scott Kuan, Shan Shih
Published 2006-10-31 by SAE International in United States
This paper describes an analytical process for the design of a brake shoe assembly that consists of the linings, shoe table, webs, and rivets. One fundamental performance requirement for the brake shoe assembly is that the linings will not lose clamp force within the desired service life. Key elements of the analytical process involved developing an FEA model with given loading conditions and developing a mathematical model to study the influence parameters of the forces acting on the lining.
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Backpressure Optimized Metal Supported Close Coupled PE Catalyst - First Application on a Maserati Powertrain

ArvinMeritor-Mathias Holzinger
EMITEC GmbH-Lorenzo Pace, Manuel Presti
Published 2005-04-11 by SAE International in United States
Future stringent emission limits both in the European Community and USA require continuously increased conversion efficiency of exhaust after-treatment systems.Besides the obvious targets of fastest light-off performance, overall conversion efficiency and durability, catalytic converters for maximum output engines require highly optimized flow properties as well, in order to create minimum exhaust backpressure for low fuel consumption.This work deals with the design, development and serial introduction of a close coupled main catalyst system using the innovative technology of Perforated Foils (PE).By means of PE-technology, channel-to-channel gas mixing within the metal substrate could be achieved leading to dramatically reduced backpressure values compared with the conventional design.Due to the highly improved flow properties of the advanced metal substrate, a compact converter could be designed taking into account the demanding packaging constraints in a modern V8 engine compartment.The present paper consists of numerical simulations, flow bench and engine test bench measurements carried out to assess emission performance, backpressure advantage and engine power output increase of a close-coupled single brick system compliant with LEV-II and EU4 emission limits.
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Simulation Methods for Door Module Design

ArvinMeritor-Devadas Kumbla, Pan Shi, Joseph Saxon
Published 2005-04-11 by SAE International in United States
With the automotive industry moving towards higher durability targets, reduced product development cycle time, and lower design costs, the need for simulation has never been higher. This paper explains the use of simulation techniques in the design and development of door module. A step-by-step approach to simulate a door slam event is proposed. Fatigue life estimation using simulation results is also discussed. Finally, simulation benefits are illustrated with a simulation-test case study completed at ArvinMeritor that resulted in a fatigue life improvement of more than 50%.The scope of this paper is limited to simulation methods for door slam. Test methods to collect data for door slam simulation are not discussed.
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Embedded Sensitivity Functions for Experimentally Diagnosing Vibration Problems and Identifying Nonlinear Models of Automotive Components

ArvinMeritor-Chulho Yang, Tom Wahl, Sam Ciray
Purdue University-Douglas E. Adams
Published 2005-04-11 by SAE International in United States
In the development and manufacture of vehicle components and systems, it is often necessary to quickly identify optimal design modifications for mitigating noise and vibration problems to meet the production schedule. To address this need, experimental techniques for determining the sensitivity of forced vibration response to changes in mass, damping or stiffness properties are of great use. In order to distinguish physical changes in the system from nonlinear input-output distortion, experimental techniques for identifying nonlinear input-output models in mechanical systems are also needed. The use of experimental sensitivity measurements and analyses for studying linear and nonlinear forced vibration data is examined in this work. Embedded sensitivity functions are first used to identify design modifications for reducing a vibration resonant problem. These sensitivity functions are then applied to characterize and identify a nonlinear mechanical system and the accuracy of estimated nonlinear parameters with respect to several factors is examined. A vehicle exhaust system is used to experimentally demonstrate the results achieved using the diagnostic and system identification methods.
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Production NVH Monitoring and Application on a Window Regulator Assembly Line

ArvinMeritor-Christopher S. Keeney, Timothy White
Alta Solutions-Julian Hankinson
Published 2003-05-05 by SAE International in United States
Quality control of NVH performance of Body and Chassis systems is a challenging task. In-line NVH monitoring is part of a practical solution in many cases. The associated technology is maturing, flexible, and economical. Benefits extend beyond a “safety net” sorting function. This paper presents a general overview of the current state of commercially available technology, and presents an example application of an in-line NVH monitoring system for a window regulator assembly line. A couple specific issues and resulting NVH monitoring techniques are discussed - the use of an enveloping function to highlight a cable interference issue, and the use of a microphone to highlight a motor noise issue in a relatively noisy environment.
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Physics Based Contact Fatigue Analysis of Vehicle Powertrain Gears

ArvinMeritor-Wangquan (Winston) Cheng, Shan Shih
Published 2002-11-18 by SAE International in United States
Contact fatigue is a major concern on the durability of vehicle powertrain gear design. Having an effective method for gear life trend prediction will prevent over design of the powertrain gears and assure the quality of the products. The ANSI/AGMA Standard on gear contact fatigue life calculation is based on an empirical model developed from experiment data fitting. A similar approach widely used in the industry uses measured component SN curves for correspondence between loads and life cycles [1]. This method is simple. But important physical parameters such as material, lubricant, and manufacturing factors are not included in the model, therefore, the model cannot to be used for design optimization. Although some analytical models are available for the gear life prediction, they have not been accepted by the industry. On the one hand, most theoretical models are too complicated for applications. On the other hand, most product engineers are unfamiliar with these models regarding their value as well as the required effort to further develop them. This paper will apply an exist crack initiation theory…
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Exhaust system optimization for drive-by noise

ArvinMeritor-A. Jackson, I. Arbuckle
  • Technical Paper
  • 2002-04-0038
Published 2002-06-11 by Institution of Mechanical Engineers in United Kingdom
This paper studies the issue of optimizing exhaust tailpipe noise for drive by and customer tailpipe noise targets derived from vehicle sound quality targets using a range of experimental and analytical techniques. Transfer path analysis (TPA) and acoustic modelling are presented in a Genetic Algorithm (GA) optimization.Transfer Path Analysis was used to predict the exhaust tailpipe noise contribution to the overall level measured during the drive by. Once the exhaust noise was shown to be a dominant source during drive by, the muffler design was improved using a genetic algorithm to search for an optimum design. An integrated approach was taken to simultaneously optimize the exhaust system design to meet drive-by and tail-pipe noise targets.
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Simplifications and Speedup of Durability Test for Automotive Components or Systems

ArvinMeritor-Xitian Fang, Hanjun Kim
Published 2002-03-04 by SAE International in United States
It would be a benefit to make multiple excitations equivalent with one or two simple inputs. To dramatically reduce the running time and speed up the durability test, the excitations have to be enhanced. For a complicated system and structure with many loading events, the block load is the easiest to apply and can result in equivalent damage. The main objective of this paper is to systemize some methodologies for the lab durability test in order to simplify the test setup or reduce the running time.
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Modelling Exhaust Systems Using One-Dimensional Methods

ArvinMeritor-Roger J. Chuter
Flowmaster (UK) Ltd.-Stephen Massey, Paul S. Williamson
Published 2002-03-04 by SAE International in United States
The benefits of computer simulation of complex internal and external flow problems are well understood. Three-dimensional computational fluid dynamic (CFD) models are commonly being used to model exhaust systems to ensure that design back-pressures, levels are not exceeded, whilst meeting noise and vibration, weight and volume constraints so as to optimise the overall design. CFD models for such systems are usually large (typically hundreds of thousands of cells) and take considerable time to construct, validate and analyse. In general it is impractical to represent a complete system in a single CFD model.One-dimensional models of internal flow in piping systems provide significant advantages over three-dimensional CFD by both reducing model complexity and the computational time required to perform a simulation in some applications. Use of such models permit networks consisting of many components to be modelled in their entirety.By incorporating the effects of the complex branched and looped flow passages in the mufflers in a one dimensional form combined with the thermodynamics along the system as well as the pressure losses in Catalysts and Diesel Particulate…
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