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Sensor Fusion Concept for Improved Rotational Speed Measurement in Small Engines

Institute of Electrical Measurement and Measurement Signal P-Markus Neumayer, Thomas Bretterklieber, Thomas Suppan
  • Technical Paper
  • 2019-32-0519
To be published on 2020-01-24 by Society of Automotive Engineers of Japan in Japan
Future developments for small engines, e.g. engines for handheld working tools, like chain saws require the integration of ECU-systems for engine control. For small engines often only a rotational speed senor is available. The application of additional engine sensors is in many cases unwanted, e.g. due to cost aspects and additional wiring. The lack of sensor data requires tailored control strategies and signal processing techniques to infer information about the engine from the sensor data. E.g. for rotational speed sensors the Δω method has been proposed, where the load is estimated from the temporal variation of the rotational speed. This approach requires a rotational speed sensor with sufficient angular resolution. In this paper we present a simulation study for a sensor fusion concept to improve the temporal resolution of engine speed measurements for low cost engines by means of an additional vibration sensor. The rotational sensor of the engine is assumed to have insufficient resolution to determine variations of the rotational speed over an engine revolution. However, variations of the rotational speed of the engine…
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A Study of the Control Logic of Electronically Controlled Suspension for Motorcycle

Kawasaki Heavy Industries, Ltd.-Takenori Terada, Kazuhiro Ichikawa, Hideyuki Kato, Taro Iwamoto
  • Technical Paper
  • 2019-32-0569
To be published on 2020-01-24 by Society of Automotive Engineers of Japan in Japan
Electronically controlled suspensions are expected to improve driving performance as the damping characteristics of the suspension can be adjusted in real time to respond to road conditions. This paper reports the results of testing the suspension control logic for improving ride quality, especially when driving on rough roads, using an internally developed riding simulator.The skyhook theory is widely known as a control logic for reducing vibration when driving a four-wheeled vehicle on a rough road, which we utilized in our riding simulator to examine the vibration reduction effects when applying control logic for motorcycle suspensions. The test results show that the skyhook theory can be applied in motorcycles.However, sensors for suspension systems that can be installed in mass-produced motorcycles are severely limited in terms of cost and space. Therefore, we examined a control logic based on skyhook theory that can reduce vibration even with a simple and inexpensive sensor system.A novel control logic was successfully designed that implements the relationship between the suspension stroke speed and the vertical acceleration of the sprung mass from the…
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Estimating a Rider’s Compensatory Control Actions by Vehicle Dynamics Simulation to Evaluate Controllability Class in ISO 26262

Japan Automobile Research Institute-Maki Kawakoshi, Takashi Kobayashi, Makoto Hasegawa
  • Technical Paper
  • 2019-32-0537
To be published on 2020-01-24 by Society of Automotive Engineers of Japan in Japan
Controllability is defined in ISO 26262 as a driver’s ability to avoid a specified harm caused by a malfunction of electrical and electronic systems installed in road vehicles. According to Annex C of Part 12 of ISO 26262, simulation is one of the techniques that the Controllability Classification Panel (CCP) can use to evaluate comprehensively the controllability class (C class) of motorcycles. With outputs of (i) an index for the success of harm avoidance and (ii) the magnitude of the rider’s compensatory control action required to avoid harm, the simulation is useful for evaluating the C class of the degrees of malfunction that cannot be implemented in practice for the sake of the test rider’s safety.To aim at supplying data that the CCP can use to judge the C class, we try to estimate the vehicle behavior and a rider’s compensatory control actions following a malfunction using vehicle dynamics simulations. The simulated scenario is the occurrence of unintended deceleration during cornering caused by a malfunction of the electronically controlled combined braking system. The parameter values…
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The effects of contamination on commercial trucks rear suspension springs durability

Ford Motor Company-Milton Monteverde Belli, Amilcar Tyrrell Tavares
Suspensys-Eugenio Noro, Graebin Matheus
  • Technical Paper
  • 2019-36-0083
Published 2020-01-13 by SAE International in United States
On current competitive scenario for road load transportation in Brazilian market, the operational costs should be reduced as much as possible. The suspension system commonly used on road commercial trucks is based on leaf spring use and Hotchkiss concept for axle locating devices. The use of leaf springs without bolt attachment eyelets are still common for rear suspension systems. When using the leaf spring with direct contact to the brackets, wear plates are placed between them to work as wear elements due to the friction between the parts. The friction will cause wear on the parts, and the wear plate is designed to suffer the damages of this friction instead of the leaf spring, being the cheapest element and can be easily replaced. When the system works on a severe contamination environment with high levels of grit and dirt, the degradation of the parts are accelerated. With a considerable amount of grit between the wear plate and the leaf spring, the damage caused on the leaf surface is increased and lead to a spring failure…
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Independent Aftermarket (IAM) and the Three Dimensions of Friction Material Evaluation

LINK South America-Pedro Oliveira, Henrique Rodrigues, Eduardo Ferro
  • Technical Paper
  • 2019-36-0006
Published 2020-01-13 by SAE International in United States
It is well known the difference between development levels and engineering investment applied to passenger car brake pads when compared to Original Equipment Manufacturer (OEM) and items sold in the Independent Aftermarket (IAM). Based on these differences, the objective of this paper is to propose a simple evaluation for the IAM that can provide at least some level of the understanding of frictional material behavior. Based on a tripod of variables, or three Dimensions Development, described in this work as Performance, Comfort (NVH) and Durability; and using internationally and established testing procedures to measure these dimensions in order to meet the IAM demands for the cost-benefit engineering investment. An important part of the proposed tool is to position friction material against competition for market known issues, and, more importantly, to ensure end product safety and reliability.
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Brake noise analysis on tractive axle of 6x2 tractor vehicle

CNHI - Iveco Latin America / UFMG – Programa de Pós-Graduaçã-Rafael Fortuna Pizzi
CNHI – Iveco Latin America-Getúlio Soares Júnior
  • Technical Paper
  • 2019-36-0008
Published 2020-01-13 by SAE International in United States
This study aims at analyzing the causes of noise in a heavy vehicle brake system (6x2 tractor) and proposing solutions to improve comfort during braking as it is known that, during the activation of the automotive brakes, noise can be generated in different frequency bands that can cause discomfort to the user and the study of how to reduce it is considerably important to bring more comfort in its use. As a working methodology, firstly, comparative analysis of dimension and material were performed between the axle assembly that presented noise and another axle assembly of a vehicle with no noise adopted as reference. This information was used as the basis for the frequency and acceleration virtual analysis that were validated with vehicle instrumentation and data acquisition. In parallel, vehicle tests with different brake friction materials were conducted. The answers of the dimension and material analysis from the axles assemblies highlighted the specificities of each of them but did not show great influence in the observed noise incidence. The vehicle instrumentation and data acquisition besides validate…
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Brake System Thermal Performance for Brazil Market Battery Electric Vehicles

General Motors, LLC-David Antanaitis
  • Technical Paper
  • 2019-36-0019
Published 2020-01-13 by SAE International in United States
The discussion in the braking industry that has been ongoing for over a decade now on how to specify brake systems for regenerative-brake intensive vehicle applications has intensified considerably in the past few years as the automotive industry ponders a future where electric vehicles become predominant. Major automotive manufactures have announced plans to create dedicated electric-only vehicle architectures, from which to offer a full range of electric vehicle configurations. The time to really figure out the translation of Voice of the Electric Vehicle Customer to technical requirements and brake system content is approaching very rapidly. One of the major design decisions in the brake system is the sizing of foundation brake components for thermal performance. There is no question that regenerative brakes can significantly reduce the demand on the friction brakes in normal usage, sometimes by a full order of magnitude or more. Brakes no longer need to be sized for everyday use, rather, the sizing is driven by “limit cases” such as failure of the regen system, a full state of charge in the…
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A Coupled Approach Using CFD and FEA Solution for Solving the Cooling of Automotive Disk Brake

Siemens Industry Software-Joel Sanvezzo Junior, Douglas Dutra
  • Technical Paper
  • 2019-36-0012
Published 2020-01-13 by SAE International in United States
The cooling efficiency of automotive disk brakes comprises an important area of development, since the system performance is directly related to the overheating level that is being achieved during the braking period. The heat generation occurs during the conversion of kinetic energy into heat. After this process, it is crucial an effective thermal dissipation in order to assure the decay of temperature levels. Such thermal dissipation results mainly from the interaction of the brake components with the external airflow in the wheel arch, where there are the occurrence of heat transfer mechanisms including conduction, convection and radiation. In this sense, through the application of simulation models, it is possible to predict the thermal- structural behavior by combining solutions in the fluid dynamics and structural areas. In this work, a one-way fluid-structure approach is proposed by combining conventional CFD (Computational Fluid Dynamics) and FEA (Finite Element Analysis) models. The CFD modeling aim to solve the disk brake cooling during the airflow passage in the wheel arch and its interaction with the brake components. The FEA modeling…
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Three-dimensional dynamics of a three-axle vehicle considering the suspension geometry according to the kinematic transformers method

Instituto Militar de Engenharia-Gustavo Simão Rodrigues, Marcelo Andrés Acuña, Rafael Vitor Guerra Queiroz, Ricardo Teixeira da Costa Neto
  • Technical Paper
  • 2019-36-0237
Published 2020-01-13 by SAE International in United States
The purpose of this work is to model the dynamics of a three-dimensional three-axle vehicle subjected to certain excitations from the ground and considering the geometry and inertia of the suspension elements according to the “kinematic transformers” method.The chassis is considered a rigid body with six degrees of freedom (three positions and rotations).The tire is a compliant element, which receives vibration from the ground and transmits to the wheel.Unlike simpler computational models, which make a direct connection between the wheel and the chassis by means of a spring and damper, the influence of the suspension geometry and inertia of its elements are considered. In this case of study, the suspension studied is the independent MacPherson in each wheel, although the methodology would be applied to other kind of suspensions, once its geometry is known.The kinematic transformers method is applied to study the cinematics of the suspension. It uses the minimum number of kinematic equations, allowing an efficient solution to describe the movement of the mechanism when implemented computationally.Combining the kinematic transformers method with the d'Alembert…
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ALL-WHEEL DRIVE ELECTRIC VEHICLE MODELING AND PERFORMANCE OPTIMIZATION

Department of Mechanical and Aerospace Engineering, Politecn-H. de Carvalho Pinheiro, E. Galanzino, A. Messana, L. Sisca, A. Ferraris, A. G. Airale, M. Carello
  • Technical Paper
  • 2019-36-0197
Published 2020-01-13 by SAE International in United States
Electrification of the powertrain is one of the most promising trends in the automotive industry. Among the novel architectures, this paper aims to study the latent advantages provided by in-wheel motors, particularly an All-Wheel-Drive powertrain composed by four electric machines directly connected to each wheel-hub of a high performance vehicle. Beyond the well-known packaging advantage allowed by the in-wheel motor, the presence of four independent torque sources allows more flexible and complex control strategies of torque allocation. The study explores three different control modules working simultaneously: torque vectoring, regenerative braking and energy efficiency optimization protocol. The main objectives of the project are: improving handling, measured through the lap time of the virtual driver in a simulated track, and enhance energy efficiency, assessed by the battery state of charge variation during standard events. The torque vectoring strategy is based on a feedback PID controller working in parallel to a feedforward logic that predict the desired behavior based on the driver demands (such as steering angle) and vehicle states (chassis accelerations and velocities). The regenerative braking manages…
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