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Computational analysis of spray pre-treatment in automotive applications

ESS Engineering Software Steyr-Muraleekrishnan Menon, Ravi Kanth Borra, Martin Schifko, Samiullah Baig
  • Technical Paper
  • 2020-01-0479
To be published on 2020-04-14 by SAE International in United States
The automotive coating industry consists of several processes targeting the reliability and longevity of the manufactured Body-In-White (BIW) with process optimization playing a key role. Pre-treatment of BIW is one of the important aspects and this involves processes in the paint shop and body-in-white shop. The relevance of cleaning every part of the BIW is well known in the industry, and we will focus on the spray wash processes. While the industry currently relies on experiences from previous designs and experimental observations from model studies, this drastically slows down process optimization for new car models. Recent developments in Computer Aided Engineering (CAE) industry has shown capability to perform reliable studies using computer models that speeds up processes. The current study focuses on the Computational Fluid Dynamic (CFD) evaluation of spray washing of a BIW using a meshless method known as Smoothed Particle Hydrodynamics (SPH). The study specifically discusses simulation of a washing process, where a car BIW is moving through pre-treatment line where, specifically arranged set of nozzles are spraying water at a constant flow…
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CAE method Development for the Seat latch effort calculation in 2nd row Bench seats and optimization

Ford Motor Co Ltd-Ravi Purnoo Munuswamy
Ford Motor Private Limited-Arunachalam Muthupandian
  • Technical Paper
  • 2020-01-1103
To be published on 2020-04-14 by SAE International in United States
There are factors that can make installation of LATCH-equipped seats difficult or, in some cases, impossible. Customers are raising complaints on latching issues to automotive industry and in turn warranty issue cost more to the company. Therefore, automotive industries are spending lot of money on physical test and method development. At present, there is no such proven virtual test available for testing seat latch effort (passenger apply effort to do the latching). Since many industries concentrating more on developing new method using CAE approach for evaluate seat latching effort with less cost. So in this paper, authors are elaborating research on new method using CAE method LS dyna solver with Hypermesh preprocessor. Further deep dive on physical test data correlation with CAE method(virtual test) to verify the design verification efficiency. Also, from this test can able to estimate the effort easily and optimize seat latching performance.
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Optimal Traffic Management In Urban Traffic Network Using PTV VISSIM And MATLAB SIMULINK

Univ of North Carolina Charlotte-Pouria Karimi Shahri
Univ. of North Carolina Charlotte-Amir H. Ghasemi
  • Technical Paper
  • 2020-01-0887
To be published on 2020-04-14 by SAE International in United States
This paper aims to develop a platform for integrating PTV VISSIM and MATLAB Simulink to design and analyze the flow of traffic in an urban traffic network. We model a non-signalized traffic network in VISSIM. From VISSIM, we take the inflow and outflow rates data and send them to the controller in MATLAB thought a VISSIM Component Object (COM) Interface. By employing an extremum seeking approach, an optimal velocity is determined and send back to the VISSM through a COM interface. Numerical simulation demonstrates the effectiveness of the platform for testing different traffic control approaches. {\bf Keywords:} Matlab-VISSIM integrated, traffic networks, model predictive control, exteremum seeking
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Design Optimization and structural validation of Onboard Vacuum cleaner

FCA Engineereing India Pvt, Ltd.-Karthik AJ
  • Technical Paper
  • 2020-01-0481
To be published on 2020-04-14 by SAE International in United States
Vacuum cleaner in the vehicle is a necessary equipment for the customer to keep the vehicle cabin clean and maintain it periodically without trashes being trapped inside the vehicle. The trash management systems in the vehicle is one of the challenging task which the OEMs don’t have the control on how the customers handle it during various circumstances. This paper attempts in discussing the robust Vacuum cleaner design approach for passenger cars and validate the design through virtual approach. Onboard Vacuum cleaner are always complex due to sophisticated packaging in the rear cargo compartment and complicated mounting points of the Interior trim which customers access too often. Appropriate mounting is required to properly hold the Vacuum cleaner in the vehicle position and isolate the vibrations coming from the body and vacuum motor itself. Since the Onboard Vacuum cleaner assembly is held with bracket attached to the body in white, where it is subjected to the body vibration profile. This causes the entire assembly subject to lot of static and dynamic stresses, proper counter measures have…
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Random Vibration Fatigue Life Assessment of Transmission Control Module (TCM) Bracket Considering the Mean Stress Effect

General Motors-Neeraj Carpenter, Sudeep Yesudas, Michael D. Nienhuis
  • Technical Paper
  • 2020-01-0194
To be published on 2020-04-14 by SAE International in United States
Random loads are experienced by many engineering systems/components such as the housing and the brackets mounted on the chassis of an automobile, wind blowing on the wind turbine blades, Printed Circuit Board (PCB) used in battery electric vehicles, fuel cell stacks mounted on housing of a fuel cell etc. In automotive systems, random load is caused due to unevenness of the road surface. As these loads are varying in nature, it could lead to the fatigue failure of systems experiencing such loads. To ensure structural integrity, they are designed considering random loads and commercially used FE software packages have the capabilities available to evaluate random vibration fatigue. While above mentioned systems undergo random loads during operation, there are other loads/stresses also acting on them such as assembly loads (bolt preload), residual stresses due to casting, static loads i.e. load due to belt or chain drive etc. Consideration of all significant loads are extremely important for a design engineer and CAE analyst while designing such systems in order to ensure the reliability of their design. The…
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An efficient path planning methodology based on the starting region selection

Xin chen, Zhaobo Qin, Jingjing Fan, Liang Chen
Tsinghua Univ-Huajian Zhou
  • Technical Paper
  • 2020-01-0118
To be published on 2020-04-14 by SAE International in United States
Automated parking is an efficient way to solve parking difficulties. Path planning is of great concern for parking maneuvers. Meanwhile, the starting points of path planning greatly affect the process and efficiency of parking. The present research of the region of the starting points are mostly determined based on a single algorithm, which limits the flexibility and efficiency of planning feasible paths. This paper, taking parallel parking and vertical parking for example, proposes a method to calculate the region of the starting points and select the most suitable path planning algorithm for parking, which can improve the parking efficiency and reduce the complexity. The collision situations of each path planning algorithm are analyzed under collision-free conditions based on parallel and vertical parking. The region of the starting points for each algorithm can then be calculated under collision-free conditions. After that, applicable starting regions for parking can be obtained, and each of those regions corresponds to a parking path planning algorithm. However, there always exists overlapping starting regions, which can be applied to multiple parking path…
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A Co-Simulation Platform for Powertrain Controls Development

Hyundai-Kia America Technical Center Inc-Shihong Fan, Yong Sun, Jason Lee, Jinho Ha
  • Technical Paper
  • 2020-01-0265
To be published on 2020-04-14 by SAE International in United States
With the advancement of simulation software development, the efficiency of vehicle and powertrain controls research and development can be significantly improved. Traditionally, during the development of a new control algorithm, dyno or on-road testing is necessary to validate the algorithm. Physical testing is not only costly, but also time consuming. In this study, a virtual platform is developed to reduce the effort of testing. To improve the simulation accuracy, co-simulation of multiple software is suggested as each software specializes in certain area. The Platform includes Matlab Simulink, PTV Vissim, Tass Prescan and AVL Cruise. PTV Vissim is used to provide traffic environment to PreScan. PreScan is used for ego vehicle simulation and visualization. Traffic, signal and road network are synchronized in Vissim and PreScan. Powertrain system is simulated in Cruise. MATALB/Simulink serves as master of this co-simulation, and integrates the different software together. It also includes human driver model and a powertrain control function. An ADAS-ISG (Idle Stop and Go) powertrain control algorithm is implemented in Simulink and tested by using the platform under different…
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A Research on Kinematic Optimization of Auto Flush Door Handle System

Hyundai Motor Group-JUNGHO HAN, KYOUNGTAEK Kwak, JINWOO NAM, OKTAE Jung, JINSANG CHUNG
  • Technical Paper
  • 2020-01-0623
To be published on 2020-04-14 by SAE International in United States
A fascinating exterior appearance is one of the most important values for customers so the realization of the innovative styling has been a major topic for car makers for several years. Also, since the base of autonomous driving and electric vehicle is being expanded recently, it is essential to not only create high-tech image on a vehicle but also realize the engineering design in reality. From that point of view, the auto flush handle can be unique sales point to enhance the degree of the completion of the exterior styling. The purpose of this study is to establish the kinematic system of auto flush door handle to overcome the exterior handicaps such as not only the excessive exposure of the internal area on the deployed position but also to determine the proper operating speed. In order to resolve these issues, the Scott-Russell mechanism is applied to the auto flush handle system. The mechanism is applied to realize the straight motion so exterior quality can be improved to minimize inner gap and prevent link exposure. In…
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Design of the powder metal shift fork and sleeve

Czech Technical University-Gabriela Achtenova, Jiri Pakosta
  • Technical Paper
  • 2020-01-1322
To be published on 2020-04-14 by SAE International in United States
The paper will present the design of shift fork for automotive manual gearbox dedicated for the manufacturing with help of powder metal technology. Based on limitations and requirements of new production technology of shifting sleeve, a new prototype of shifting sleeve is created, for which are new shifting forks then designed. The form of the prototype of the shift sleeve respected the requirements of the new technology, but from cost reason, it was manufactured from steel. The shift fork was changed accordingly to the new form of the shift sleeve. The functionality of several forks with different tolerances was tested. Prototypes were put through functional and durability tests on testing bench in real automotive gearbox. The test were accomplished on the inertia test stand. Drawings and CAD models of tested prototypes, custom tools and designed shift forks will be described.
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A Comparison of Decomposition Constructs for Supporting Modularity in Simulink

FCA Canada Inc., McMaster University-Monika Jaskolka
McMaster University-Vera Pantelic, Alan Wassyng, Mark Lawford
  • Technical Paper
  • 2020-01-1290
To be published on 2020-04-14 by SAE International in United States
The Model-Based Development (MBD) paradigm is widely used for embedded controls development, with MathWorks’ Simulink modelling environment being extensively used in the automotive industry. As production-scale Simulink models are typically large and complex, there exists a need to decompose them properly in order to facilitate their maintainability, understandability, and evolution. MathWorks recommends the use of three constructs for model “componentization” or decomposition: the Subsystem, Library, and Model Reference. However, a recently added construct, the Simulink Function, can also be used for this purpose, while also supporting information hiding due to the construct’s ability to be scoped and encapsulate data. This paper provides an in-depth comparison of these Simulink constructs to fully understand the differences in their reusability, sharing of program state, encapsulation, and code generation, with the goal of facilitating model evolution. An automotive powertrain example is provided to highlight the differences between approaches. Conventions for structuring models are also presented.