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User Defined FE Based Connector Joints for Plastics

CAEfatigue Ltd-Neil Bishop, Paresh Murthy
Hella GmbH & Co. KGaA-Thomas Thesing, Odo Karger
  • Technical Paper
  • 2020-01-0186
To be published on 2020-04-14 by SAE International in United States
Spot Welds are a category of welds used extensively in automotive structures, normally for metals. The fatigue analysis of such spot welds can be evaluated using (a) the Point 2 Point (P2P) method where a beam or bar is used to connect the 2 surfaces being joined, (b) a more modern approach where the 1D element is replaced with an “equivalent” brick element, or (c) a third approach that falls somewhere between where a “spider” and circular ring of elements, is used to represent the spot weld. In all 3 cases there is an assumption that the cross section is circular. For some specialist cases such as plastic connectors, the cross section is not circular so a new user defined weld is proposed. This paper will describe the approach that is based on the concept that a user generated tensor line can be used (equivalent to the theoretical Force/Moment to stress algorithms built into the P2P approach) along with special S-N curves create for different joint shapes.
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In-vehicle diagnostic system for prognostics and OTA updates of automated / autonomous vehicles.

Softing Automotive Electronics GmbH-Peter Subke, Muzafar Moshref, Julian Erber
  • Technical Paper
  • 2020-01-1373
To be published on 2020-04-14 by SAE International in United States
The E/E architecture of a modern passenger car consist of a central connectivity gateway that comes with an interface to the legally required OBD connector (SAE J1978), to domain controllers and to a Telematic Control Unit (TCU). The TCU supports 4G or 5G and provides the wireless connection to the cloud. The domain controllers are connected to the gateway via 2-wire Ethernet with a star topology, whereby the domain controllers act as gateways to CAN FD bus systems. The interface to the wired OBD connector supports both OBD/UDS on CAN and UDS on IP. The new E/E system comes with increased self-diagnostic capabilities. They automatically perform tests, log diagnostic data and push such data for prognostics purposes to the cloud. They also support over-the-air (OTA) updates. This paper describes the components of an E/E system that is equipped with an in-vehicle diagnostic tester. The tester consists of standardized components, including MVCI D-Server (ISO 22900), ODX (ISO 22901), OTX (ISO 13209) and UDS on IP (ISO 14229-5). The paper includes a description of cybersecurity measures to…
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Test Method for the SAE J3138 Automotive Cyber Security Standard

DG Technologies-Mark Zachos
  • Technical Paper
  • 2020-01-0142
To be published on 2020-04-14 by SAE International in United States
This paper will provide an Overview of Automotive Cyber Security Standards related to the Vehicle OBD-II Data Link. The OBD-II Connector Attack Tree is described with respect to the SAE J3138 requirements for Intrusive vs. non-Intrusive Services. A proposed test method for SAE J3138 is described including hardware and software scripting. Finally, example test results are reviewed and compared with a potential threat boundary.
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A Novel Asynchronous UWB Positioning System for Autonomous Trucks in An Automated Container Terminal

Tongji University-Mingyang Wang, Aiguo Zhou, Xinbo Chen, Yong Shen, Zhenyu Li
  • Technical Paper
  • 2020-01-1026
To be published on 2020-04-14 by SAE International in United States
As a key technology to autonomous vehicles, high precise positioning is essential for automated container terminals to implement intelligent dispatching and to improve container transport efficiency. In view of the unstable performance of global positioning system (GPS) in some circumstances, an ultra wide band (UWB) positioning system is developed for autonomous trucks in an automated container terminal. In this paper, an asynchronous structure is adopted in the system and a three-dimension (3D) localization method is proposed. Other than a traditional UWB positioning system with a server, in this asynchronous system, positions are calculated in vehicle. Therefore, propagation delays from the server to vehicles are eliminated and real-time performance of the system can be significantly improved. Traditional 3D localization methods based on TDOA are mostly invalid with anchors in the same plane. However, in order to guarantee anchors and tags in line of sight (LOS), anchors have to be installed in a vertical plane under the tyre cranes. Coping with this problem, an improved method is presented, which overcomes the matrix singularity. Three hyperboloids can be…
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Evaluation of High Resistance Connection in Automotive Application

General Motors LLC-Manoj Modi, Brad Galgoci
  • Technical Paper
  • 2020-01-0926
To be published on 2020-04-14 by SAE International in United States
Electrical connections have a normal operational temperature range. A high resistance, such as a poor connection, in an electrical circuit has been reported to cause a temperature increase exceeding normal operational range at the connection.This study measures the temperature increase in a typical automotive bolted battery cable connection with low to zero torque values and simulated high resistance under different load conditions. The torque is changed from maximum design value to 0 Nm and the temperature increase at the connection is measured. The high resistance connections, manually created by adjusting the contacts, are tested for several power loss values at the connection. The temperature rise under these conditions at the connection is measured and subsequently recorded.The maximum temperature increase at the bolted cable connection recorded at low torque values including 0 Nm torque compared to the maximum typical design value of 17 Nm is 10.5 °C. The maximum temperature increase for the high resistance bolted connection is a function of the power loss and the voltage drop at the connection.
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Thermal Analysis of Electrical Contactor in Electric Vehicle Li-Ion Battery Packs

Romeo Power Technology-Gautam Pulugundla, Karlo Galvan, Prahit Dubey
  • Technical Paper
  • 2020-01-1345
To be published on 2020-04-14 by SAE International in United States
Modern high-power density automotive Li-Ion battery packs need robust and dedicated components to ensure efficient and safe operation of various constituent battery modules, and sub-systems. One such component is an Electrical Contactor (EC), which is an electronically controlled relay used for switching the high voltage power circuit of the DC battery pack. Specifically, the EC is operated by a control voltage that causes its internal current path to close during normal vehicle operations and open during certain pre-determined overload conditions. Therefore, ECs play an important role in providing a safe and reliable operation of an electric vehicle battery pack. An EC is typically connected to the power circuit of a battery pack through its load terminals via current carrying conductors like busbars and cables. To ensure a continuous operation of an EC under normal load conditions, the Joule heat generated by both the busbars and the internal EC circuity needs to be dissipated. Based on the power demand and voltage of the system, internal heat generation could result in overheating of the EC leading to…
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Connectors, Electrical, Reverse Bayonet, General Specification for

AE-8C1 Connectors Committee
  • Aerospace Standard
  • AS95234A
  • Current
Published 2020-03-25 by SAE International in United States

AS95234 includes reverse bayonet coupling, high current electrical connectors that are water tight and principally used in shipboard, ground vehicles and ground support equipment applications at serve voltages from 200 to 3000 V-rms and temperatures between -55 °C and +125 °C (-67 °F and +257 °F). See 6.1.5 for applications details. For aerospace application connectors, refer to AS50881.

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CONTACTS, ELECTRICAL, CONNECTOR, SOCKET, CRIMP REMOVABLE (FOR AS81714 TERMINAL JUNCTION SYSTEM SERIES II)

AE-8C1 Connectors Committee
  • Aerospace Standard
  • AS39029/22D
  • Current
Published 2020-03-24 by SAE International in United States

SCOPE IS UNAVAILABLE.

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TERMINALS, LUG AND SPLICES, CONDUCTOR, CRIMP STYLE, COPPER TERMINAL, LUG, INSULATED, TIN WHISKER RESISTANT, RING TONGUE, BELL-MOUTHED, TYPE II, CLASS 1 (FOR 150 °C TOTAL CONDUCTOR TEMPERATURE)

AE-8C2 Terminating Devices and Tooling Committee
  • Aerospace Standard
  • AS7928/13C
  • Current
Published 2020-03-24 by SAE International in United States

SCOPE IS UNAVAILABLE.

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CONNECTOR, PLUG, ELECTRIC, STRAIGHT, SOLDER CONTACTS, AN TYPE

AE-8C1 Connectors Committee
  • Aerospace Standard
  • AS31061C
  • Current
Published 2020-03-24 by SAE International in United States

SCOPE IS UNAVAILABLE.