Proceedings of SAE-China Congress 2015: Selected Papers (eBook)

Founded in 1963, SAE-China is a national and academic body corporate and a non-profit organization composed voluntarily by enterprises, institutions, incorporations and professionals in the fields of automotive and relative industries which focus on research, design, manufacture, education, sales, management and so on. And it is also the member of FISITA (International Federation of Automotive Engineering Societies) as well as one of the initiators in organizing IPC (International Pacific Conference on Automotive Engineering. Now it is renamed as Asia Pacific Automotive Engineering Conference/APAC). SAE-China has become an indispensable and important force for promoting healthy and continuous development of automotive industry through over 40 years' development and has been recognized by domestic and international automotive industries, different social circles, government and nationwide automotive professionals. SAE-China has tens of thousands of personal members and hundreds of group members, with more than 20 professional committees, and has established business guidance relationship with provincial societies of automotive engineers. SAE-China has become an important force for spreading new ideas, exchanging new technologies and propagandizing new conception of China auto industry and also an important bridge for promoting the exchange among international auto industries.

Contents 6
1 Optimization and Improvement of Off-Road Vehicle Tail Door System 12
Abstract 12
1.1 Introduction 12
1.2 Problem Description 13
1.3 Analysis 13
1.3.1 Weak Stiffness and Strength on Tail Frame 13
1.3.2 Non-conforming Hinge in Design Verification Test 15
1.3.3 Weak Stiffness and Strength of Tail Door System 17
1.3.4 Unreasonable Tail Door Accessories Layout and Design 18
1.4 Solutions 20
1.4.1 Optimization of Tail Frame Structure and Improvement of Structure Stiffness 20
1.4.2 Optimization of Tail Door Hinge Structure to Improve Hinge Stiffness 23
1.4.3 Optimization of Hinge Reinforcement Panel and Application of Mounting Pad to Improve the Stiffness and Strength of Tail Door 24
1.4.4 Optimization the Tail Door Accessories Layout and Design 24
1.5 CAE Analysis 27
1.6 Road Test Verification 28
1.7 Conclusion 28
References 28
2 Analysis on Lock Problem in Frontal Collision for Mini Vehicle 29
Abstract 29
2.1 Introduction 29
2.2 Classifications of Car Doors and Car Door Latch Systems 30
2.3 Stress Analysis on Sliding Door Latch System 32
2.3.1 Acceleration Analysis on the Vehicle's B Pillar 32
2.3.2 Stress Analysis on the Sliding Door's Lock Mechanism 32
2.4 Improvement Plans for the Sliding Door's Lock Mechanism 34
2.4.1 Plan One: Adjust the Torsion Spring Torque 35
2.4.2 Plan Two: Adjust the Inertia Moment of the Lock Switching Panel 36
2.4.3 Test Verification 39
2.5 Conclusion 40
References 40
3 Development and Application of Intelligent Diesel Idling Start/Stop Technology for Commercial Vehicle 41
Abstract 41
3.1 Introduction 41
3.2 Scheme of Diesel Start-Stop Technology 42
3.3 Development Work of Intelligent Diesel Start-Stop 43
3.4 Field Test of Start-Stop Engine in City Bus 47
3.5 Conclusion 50
References 50
4 Kinematics and K& C Experiment of a Rectilinear Rear Independent Suspension
Abstract 51
4.1 Introduction 51
4.2 Kinematic Analysis 52
4.3 K& C Experiment and Discussion
4.4 Conclusion 58
References 58
5 Flatness-Based Vehicle Coupled Control for Steering Stability and Path Tracking 59
Abstract 59
5.1 Introduction 59
5.2 Vehicle Steering and Driving/Breaking Model 60
5.3 The Target Path and Vehicle Variables 61
5.3.1 Target Path 61
5.3.2 Target Stable State 62
5.4 Flatness-Based Control 63
5.4.1 Differential Flatness Theory 63
5.4.2 Controller Design 63
5.5 Simulation Results 65
5.6 Conclusion 69
Acknowledgments 70
References 70
6 Analysis of Parameter Matching Characteristics for Centrifugal Pendulum Vibration Absorber 71
Abstract 71
6.1 Introduction 72
6.2 The Structure of the Vibration Absorber 72
6.3 The Model of Centrifugal Pendulum Vibration Absorber 73
6.3.1 Fixed Pendulum Length Case 74
6.3.2 Fluid Pendulum Length Case 75
6.3.3 Natural Frequency of the Absorber 76
6.4 The Mass Parameter Matching Characteristic of the Pendulum Block 77
6.5 The Parameter Matching Characteristics of Pendulum Paths 79
6.5.1 Circular Pendulum Path 79
6.5.2 Elliptical Pendulum Path 79
6.5.3 Polynomial Pendulum Path 80
6.5.4 Analysis of Pendulum Path Parameter Matching 82
6.6 Conclusion 83
References 83
7 Active Suspension Control for Wheel-Drive Electric Vehicle Based on Vibration Absorber 85
Abstract 85
7.1 Introduction 85
7.2 Analysis of the Vibration Absorber Model 86
7.3 Suspension Parameter Modeling 90
7.3.1 Parameter Selection 90
7.3.2 RMS Response Analysis and Optimization 90
7.4 Design of the FxLMS Controller for Electromagnetic Active Suspension 92
7.4.1 Algorithm Principle of FxLMS 92
7.4.2 FxLMS Algorithm Based on the Half-Car Model 92
7.5 Simulation Result 93
7.6 Conclusion 95
References 96
8 Design and Optimization of Halbach Active Suspension Actuator of Vehicle 97
Abstract 97
8.1 Introduction 97
8.2 Structural Design of Actuator for Active Suspension 98
8.3 Analytical Model of Halbach Tubular Modular Permanent-Magnet Linear Actuator 101
8.4 Sensitivity Analysis and Optimization for the Parameters of Linear Actuator 102
8.4.1 Local Sensitivity Analysis for the Parameters of Actuator 102
8.4.2 Optimization of Magnet Based on Gap Flux 104
8.4.3 Optimization of Slot Based on Induced EMF 105
8.5 Analysis for Electromagnetic Active Force of Actuator 107
8.5.1 EM Force Ripple Analysis 107
8.5.2 Matching Analysis of EM Force and Suspension Active Force 109
8.6 Conclusion 109
References 110
9 Study of A- and B- Substituted Perovskite CDPF Catalyst and Its' Catalytic Activity 111
Abstract 111
9.1 Introduction 111
9.2 Experimental 112
9.2.1 Catalyst Synthesis 112
9.2.2 SEM/EDS 112
9.2.3 XRD 112
9.2.4 TG 113
9.3 Results and Analysis 113
9.3.1 SEM/EDS 113
9.3.2 XRD 114
9.3.3 TG 115
9.3.4 Activation Energy Calculation 116
9.4 Summary 117
References 118
10 Gasoline Particulate Filter Technology for CHINA Stage-6 Emission Legislation 119
Abstract 119
10.1 Regulation Background 119
10.2 Design Guidelines of Gasoline Particulate Filter 121
10.2.1 GPF Concepts 121
10.2.2 GPF Parameters 121
10.2.3 Coated GPF 122
10.2.4 GPF Layout Styles 122
10.2.5 Validation Results 123
10.3 GPF Regeneration 123
10.4 Summary 125
References 125
11 Thermal Runaway Propagation Within Module Consists of Large Format Li-Ion Cells 126
Abstract 126
11.1 Introduction 126
11.2 Experiment Settings 127
11.3 Model Structure 128
11.4 Result and Discussion 128
11.4.1 EV-ARC Test 128
11.4.2 Thermal Runaway Initiation: Nail Penetration Test 129
11.4.3 Thermal Runaway Propagation Within a Battery Module 129
11.4.4 Heat Transfer Amount Through Different Paths During Thermal Runaway Propagation 130
11.4.5 Preventing Thermal Runaway Propagation Within a Battery Module 131
11.5 Conclusion 132
References 132
12 Depth Research on Brake Energy Regeneration Evaluation and Test Method of Electric Driven Vehicle 133
Abstract 133
12.1 Evaluation Index 134
12.1.1 Safety 134
12.1.2 Efficiency of Energy Recovery 134
12.1.2.1 Vehicle Force Analysis 134
12.1.2.2 Energy Flow Model 135
12.2 Test Method 137
12.3 Real Vehicle Test 138
12.3.1 Test Vehicle Parameter 138
12.3.2 Test Result 138
12.3.2.1 Braking Safety 138
12.3.2.2 Braking Energy Recycling Efficiency Test 139
12.4 Conclusion 142
References 142
13 Secondary Dendrite Arm Spacing Study of Partition in Aluminumalloy Cylinder Heads 143
Abstract 143
13.1 Introduction 143
13.1.1 Status 143
13.1.2 Significance of This Study 144
13.1.3 Secondary Dendrite Arm Spacing (SDAS) 144
13.2 Experiment Procedure 145
13.2.1 Aluminum Alloy Cylinder Heads Introduce of the Experimentations 145
13.2.2 Sampling Location 146
13.2.3 SDAS Tests of Raw Cylinder Heads 146
13.2.4 Mechanical Characters Test of Raw Cylinder Head 146
13.2.5 Cylinder Head Sample's Reliability Test of Assemble Engines 147
13.2.6 SDAS Measure for the Cylinder Heads Passed Reliability Test 147
13.3 Result of the Experiment 148
13.3.1 SDAS (The Secondary Dendrite Arm Spacing) of the Raw Cylinder Head 148
13.3.2 Mechanical Property Test Results of the Raw Cylinder Head 148
13.3.3 Reliability Test of the Cylinder Head 149
13.3.4 SDAS of the Reliability Test's Cylinder Head Sample 149
13.4 Discussion 150
13.4.1 Casting Process of Cylinder Heads 150
13.4.2 Mechanical Characteristics and the Total Stress of the Cylinder Head 151
13.5 Conclusion 151
References 152
14 Application of MQL in Engine Manufacturing 153
Abstract 153
14.1 Foreword 153
14.2 MQL Technical Principle 154
14.2.1 Fundamental 154
14.2.2 MQL Advantage 154
14.2.2.1 Environmental Effect 154
14.2.2.2 Occupational Health 154
14.2.2.3 Cost Effect 154
14.3 Application of MQL Technology 155
14.4 Application of MQL in Engine Manufacturing 156
14.4.1 Influence of Thermal Deformation in Process System 157
14.4.2 Change of Machining Process 157
14.4.3 Part of the Process Is not Suitable for MQL Technology 158
14.4.3.1 Milling Face 158
14.4.3.2 Turn-Turn Broaching, External Milling 158
14.4.3.3 Drilling Deep Blind Holes 159
14.4.3.4 Drilling Diameter lessthan Phi 3 Holes 159
14.4.3.5 Internal Boring (The Cylinder Hole, Crankshaft Hole, Camshaft Hole) 159
14.5 Application Prospect of MQL Technology 159
References 160
15 Study on Oil Injection Time Reducing of Engine 161
Abstract 161
15.1 Introduction 161
15.2 Modeling 162
15.2.1 Geometry 162
15.2.2 Computational Domain and Meshing 162
15.2.3 Case Setting 163
15.3 Result Analysis of Basic Model 164
15.4 Guiding Channel Structure Optimization 165
15.5 Other Factors that Affect Oil Injection Time 167
15.5.1 Oil Temperature 167
15.5.2 Height of Oil Channel's Inlet 168
15.6 Conclusion 169
References 170
16 Study of Control of Body Geometric Dimensions Precision 171
Abstract 171
16.1 Foreword 171
16.2 Text 172
16.2.1 Passing Rate of the Body 173
16.2.2 Process Capability Index 174
16.2.3 Judgment of Process Capability 176
16.2.4 Functional Dimension 177
16.3 Conclusion 178
17 Case Analysis of Typical Area of Body Corrosion 179
Abstract 179
17.1 The Skirt Component Corrosion, as Shown in Figs. 17.3 and 17.4 180
17.2 Corrosion of Wheel-Cover Component, as Shown in Figs. 17.9 and 17.10 183
17.3 Corrosion of Closer 185
17.4 Defects Such as the Sharp Edge, Burr, Welding Spot and Welding Slag 187
18 Development and Application of Dual UniValve System Based on a GDI Engine with SI/HCCI Dual Combustion Modes 190
Abstract 190
18.1 Introduction 190
18.2 Basic Geometry and Dynamics of Dual UniValve System 191
18.3 Test Results of Dual UniValve System 195
18.4 SI/HCCI Mode Switching Based on Dual UniValve System 199
18.5 Conclusion 199
Acknowledgments 200
References 200
19 Prediction of Effects of Intake Port and Chamber on Combustion Performance of Gasoline Engines 201
Abstract 201
19.1 Investigation Proposals 202
19.1.1 Geometry Model 203
19.1.2 Steady State Flow Test 203
19.2 Model Setup 204
19.2.1 Calculation Mesh 204
19.2.2 Boundary Condition and Initial Condition 205
19.2.3 Physical Model 205
19.2.4 Test Verification 206
19.3 Result Analysis 207
19.3.1 In-Cylinder Flow 207
19.3.2 Combustion and Emissions 209
19.4 Conclusion 212
References 213
20 Simulation Study of the Control Method of Adjustable Composite Supercharging System at Plateau 214
Abstract 214
20.1 Background 214
20.2 Engine Simulation Model 215
20.3 Study of the Control Method of the Adjustable Composite Supercharging System 216
20.4 Verification of Transient Switching Method of Composite Supercharging System 219
20.5 Conclusion 221
References 221
21 Emergency Dispatch Under Failure Condition of Urban Pickup and Delivery Task 222
Abstract 222
21.1 Introduction 222
21.2 Deal with Failed Customer in Classification 223
21.2.1 Intraday Customer Dynamic Dispatch 224
21.2.2 Tertian Customer Deletion 225
21.3 Emergency Dispatch of Failed Route 225
21.3.1 Failed Route Selection 226
21.3.2 Neighbour Search 226
21.3.3 Route Selection 227
21.3.4 Termination Condition 229
21.4 Calculation Example 230
21.5 Conclusion 231
References 232
22 Drivers' Lane Change Maneuver and Speed Behavior in Freeway Work Zones 233
Abstract 233
22.1 Introduction 234
22.2 Lane Change Definitions 234
22.3 Problem Statement 235
22.4 Research Objectives 235
22.5 Literature Review 236
22.6 Methodology 237
22.7 Data Collection 238
22.8 Lane Change Maneuvers Upstream of Work Zone 239
22.9 Logistic Regression Model 242
22.10 Conclusions 244
Acknowledgments 244
References 244
23 Feature-Based Automatic Modulation Recognition Design for Vehicular Network Communication 246
Abstract 246
23.1 Introduction 246
23.2 Development of the Automatic Modulation Recognition Process Using Common Features Templates 247
23.3 Algorithm for the Automatic Modulation Recognition Process 257
23.3.1 Procedure for Decision Block 1 257
23.3.2 Procedure for Decision Block 2 261
23.3.3 Procedure for Decision Block 3 262
23.3.4 Procedures for Other Decision Blocks 262
23.3.4.1 ASK and FSK Classifier Procedure 263
23.4 Simulation Experiment and Results 264
23.5 Results and Comparison 265
23.6 Conclusion 267
References 267
24 Recognition of Road Surface Condition Through an On-Vehicle Camera Using Multiple Classifiers 269
Abstract 269
24.1 Introduction 269
24.2 Theoretical Basis 270
24.2.1 Prior Research 270
24.2.2 Research Method 271
24.2.3 Innovation Point 271
24.3 Research Content and Concept 272
24.3.1 System Structure 272
24.3.2 Processing 273
24.3.2.1 Regions of Interest 273
24.3.2.2 Image Segmentation and Pre-processing 274
24.3.2.3 Classification 276
Tire Snippet Classification 277
Reflection Snippet Classification 278
Road Snippet Classification 278
24.3.2.4 Confidence Estimation and Result Interpretation 279
24.4 Conclusion and Outlook 280
References 281
25 Gas Separation Performance of Poly [1-(4-Trimethyl Silyl) Phenyl -2- Phenyl Acetylene] (Ptmsdpa)/Carbon Nanotubes (Cnts) Hybrid Composite Membrane 282
Abstract 282
25.1 Introduction 282
25.2 Experiment 283
25.2.1 Materials 283
25.2.2 Preparation and Characterization of Membrane 283
25.2.2.1 Preparation of PTMSDPA Membrane 283
25.2.2.2 Preparation of PTMSDPA/CNTs Composite Membrane 284
25.2.3 Gas Separation Experiment 284
25.3 Results and Discussion 284
25.3.1 Characterization of PTMSDPA/CNTs Hybrid Composite Membrane 284
25.3.2 Gas Permeability of PTMSDPA/CNTs Hybrid Composite Membrane 287
25.3.3 Effect of Structure of CNTs 288
25.4 Conclusion 288
References 288
26 Preparation and Properties of Carbon Fiber/Titanium Alloy Composite for Automobile 289
Abstract 289
26.1 Introduction 289
26.2 Experiment 290
26.2.1 Sample Preparation 290
26.2.2 Sample Characterization 290
26.3 Results and Discussion 293
26.3.1 Microstructure Characterization 293
26.3.2 Physical Characterization 293
26.3.3 Mechanical Characterization 294
26.4 Conclusion 295
References 295
27 On the Development of Automotive Composite Material Rear Bumper Beam 296
Abstract 296
27.1 Introduction 296
27.2 Composite Materials 297
27.3 Process for Composite Material Rear Bumper Beam 298
27.4 Development of Composite Material Rear Bumper Beam 300
27.4.1 Structure Design 300
27.4.2 CAE Analysis 301
27.4.2.1 Analysis on Low Speed Impact 301
27.4.2.2 Analysis on High Speed Impact 302
27.4.2.3 Analysis on Took Strength 303
27.4.3 Tests 304
27.4.3.1 Dimension Measurement 304
27.4.3.2 Performance Verification 304
27.4.4 Weight Reduction 304
27.4.5 Cost Analysis 304
27.5 Conclusion 306
References 307
28 Constitutive Analysis on Thermal-Mechanical Properties of WHT1300HF High Strength Steel 308
Abstract 308
28.1 Introduction 308
28.2 Experiment 309
28.3 Results and Discussion 310
28.3.1 Effect of Temperature and Strain Rate on Flow Properties 310
28.3.2 Constitutive Equation of Flow Behavior 311
28.4 Conclusion 314
Acknowledgement 314
References 314
29 The Research on Servo-Flexible Stamping Applied in Sheet Metal Forming of Tailored Blanks of Advanced High Strength Steel 316
Abstract 316
29.1 Introduction 316
29.2 Optimization Structure of B Pillar Blank 317
29.3 Numerical Simulation of Stamping 317
29.4 Numerical Studies of Servo-Flexible Stamping 319
29.5 Conclusion 321
References 322
30 Influence of Tread Structure Design Parameters on Tire Vibration Noise 323
Abstract 323
30.1 Introduction 323
30.2 Tire FEA Model and Test Verification 324
30.2.1 Tire FEA Model 324
30.2.2 Tire Modal Test 324
30.3 Tire Vibration Noise Analysis 327
30.3.1 Acoustic BEM 327
30.3.2 Tire Outer Contour Acoustic Contribution Analysis Model 328
30.3.3 Tire Vibration Noise Numerical Analysis 329
30.4 Influence of Tread Design Parameters on Tire Vibration Noise 330
30.4.1 Design of Experiments and Result Discussion 330
30.4.2 Analysis of Tire Noise Reduction 333
30.5 Conclusion 336
References 336
31 Control and Analysis of Gear Whine Noise in Automotive Transmission Oil Pump 337
Abstract 337
31.1 Introduction 337
31.2 Diagnosis of the Transmission Whine Noise 338
31.3 Analysis of Oil Pump Gear Whine Noise 339
31.3.1 The Model of Oil Pump External Gear 340
31.3.2 Analysis of Gear Transmission Error and Vibration Response 340
31.3.3 Sensitivity Analysis of Gear Macro-Geometry Parameter 342
31.3.4 Assembled Errors Analysis 343
31.3.5 Gear Refinement and Verification 344
31.4 Conclusion 345
References 346
32 The Structure Modal Analysis and Engineering Application of the Passenger Car Driver's Seat System 347
Abstract 347
32.1 Introduction 347
32.2 Seat Modal Analysis 348
32.2.1 Seat Structure Model 348
32.2.2 Equivalent Stiffness 350
32.2.3 Equivalent Mass 351
32.3 Seat Structure Modal Test 352
32.4 Seat Structure Mode Control Strategy 354
32.5 Engineering Application 357
32.6 Conclusion 360
Acknowledgments 361
References 361
33 Research on the Acoustical Characteristics of High Frequency Resonant Cavity and Its Application 362
Abstract 362
33.1 Introduction 362
33.2 Mechanism Analysis 363
33.2.1 Acoustical Principle of High Frequency Resonant Cavity 363
33.3 Research on Attenuation Characteristics of Single-Chamber High Frequency Resonant Cavity 365
33.4 Study on Acoustical Characteristics of Multi-cavity Parallel High Frequency Resonant Cavity 366
33.4.1 The Definition of Multi-cavity Parallel High Frequency Resonant Cavity 366
33.4.2 Study on Acoustical Characteristics of Multi-cavity Parallel High Frequency Resonant Cavity 366
33.5 Applications of Multi-cavity Parallel High Frequency Resonant Cavity 369
33.5.1 High Frequency Resonant Cavity 369
33.6 Conclusion 370
Acknowledgments 371
References 371
34 Analysis on Optimization of Mirrors to Reduce High-Speed Wind Noise 372
Abstract 372
34.1 Introduction 373
34.2 Comparison of Original Shape and Optimized Shape of the Mirror 373
34.2.1 Creating Simulation Models 373
34.2.2 Comparison of Original Mirror and Optimized Mirror 375
34.3 Experimental Analysis of Optimization of Side Mirrors 376
34.3.1 Wind Tunnel Test Validation 376
34.3.2 Validation of Sealing for Side Mirrors 376
34.4 Conclusion 379
References 379
35 Analysis of Pressure Distribution Between Human and Seat for Evaluation of Automotive Seating Comfort 380
Abstract 380
35.1 Introduction 380
35.2 Method 381
35.2.1 Test Subjects 381
35.2.2 Test Equipment 381
35.2.3 Experimental Setup 382
35.2.4 Experimental Procedure 383
35.3 Analysis 384
35.3.1 The Correlation Between Pressure and Comfort 385
35.3.2 The Correlation Between Pressure Gradient and Comfort 386
35.3.3 The Correlation Between Contact Area and Comfort 389
35.3.4 The Correlation Between Percentage of Load and Comfort 390
35.4 Discussion 390
35.5 Conclusion 391
References 392
36 Heavy Vehicle Seat Foam Evaluation of Static and Dynamic Comfort by Body Pressure Sensors 393
Abstract 393
36.1 Introduction 394
36.2 Static Seating Comfort Evaluation 395
36.2.1 Method 395
36.2.2 Result 398
36.2.2.1 Subjective Evaluation 398
36.2.2.2 Physical Characteristics 400
36.2.2.3 Body Pressure Distribution 400
36.3 Dynamic Riding Comfort Evaluation 403
36.3.1 Method 403
36.3.2 Result 403
36.4 Discussion 405
36.5 Conclusion 406
Acknowledgments 407
References 407
37 Research on Methods of MDB Test 408
Abstract 408
37.1 Introduction 408
37.2 Side Impact Test Protocols 409
37.3 Influence of Test Parameters 410
37.3.1 Design of Experiment 410
37.3.2 Analysis of Test Result 411
37.4 Analysis of Typical Test Protocols 414
37.5 Conclusion 418
References 419
38 Optimal Analysis of Occupant Restraint System for Frontal Female Passenger Base on Multiple Factor Variance Analysis 420
Abstract 420
38.1 Introduction 420
38.2 Materials and Methods 421
38.2.1 Simulation Model with Male Dummy 421
38.2.2 Correlation of Simulation Model with Test Results 422
38.2.3 Simulation Model with Female Dummy 423
38.3 Results 426
38.3.1 Optimization Parameters and Its Levels 426
38.3.2 Influence of Three Factors on Relative RR 427
38.4 Discussion 429
38.5 Conclusion 429
References 429
39 A Dynamic Modeling Scheme of Vehicle Leaf Spring and Its Application 431
Abstract 431
39.1 Introduction 431
39.2 Modelling of Leaf Spring 432
39.3 Simulation of the Vehicle 435
39.4 Conclusion 437
References 437
40 Research on Factors Leading to Variant Aerodynamic Drag Coefficient of Different Cabriolets 438
Abstract 438
40.1 Introduction 438
40.2 Research Object 439
40.3 Simulation Set Up 439
40.4 Validation 441
40.5 Cd Comparison 441
40.6 Analysis of Reason for Cd Variation 442
40.6.1 Eddy Dissipation 442
40.6.1.1 Eddy Formation and Development 442
40.6.1.2 Effect of Eddy Dissipation on Cd 443
40.6.2 Flow Separation 447
40.6.3 Pressure Variation 447
40.7 Conclusion 447
References 448
41 Finite Element Analysis and Fatigue Analysis of Control Arm 449
Abstract 449
41.1 Introduction 449
41.2 Modal Analysis of Control Arm 450
41.3 Experimental Modal Analysis of Control Arm 451
41.3.1 Test System Composition 451
41.3.2 Comparison of Modal Experiment and Simulation Results 452
41.4 Control Arm Force and Multi-body Dynamics Analysis 452
41.4.1 Through Rough Road 452
41.4.2 Emergency Braking Conditions 453
41.4.3 Steering Conditions 453
41.5 Strength Analysis of Control Arm 454
41.5.1 Strength Analysis Under Rough Road Conditions 454
41.5.2 Strength Analysis Under Braking Conditions 455
41.5.3 Strength Analysis Under Turning Conditions 456
41.6 Fatigue Analysis of Control Arm 458
41.6.1 Acquisition of Load Time History 458
41.6.2 Fatigue Analysis 458
41.7 Conclusion 459
References 459
42 Compared Vehicle Body Fatigue Analysis Based on VPG and Experimental Road Load Data 461
Abstract 461
42.1 Introduction 461
42.2 Building Virtual Proving Ground 462
42.2.1 Building Typical Pavement 462
42.2.2 Building Rough Road 463
42.3 Load Analysis in Virtual Proving Ground 464
42.4 Body Fatigue Analysis Comparison 465
42.5 Conclusion 468
References 468
43 Lightweight Design of BIW Based on Stiffness and Mode 469
Abstract 469
43.1 Introduction 469
43.2 Establishment of Optimization Model 470
43.2.1 Optimization Model of BIW Structure 470
43.2.2 Finite Element Model of BIW 471
43.3 Project Design of Car Body Lightweight 471
43.4 Analysis of Lightweight Car Body Design Instance 472
43.4.1 Basic Model Data and Determination of the Target Value 473
43.4.2 Optimization of the White Body 473
43.4.3 Test Comparison Verification 475
43.5 Conclusion 476
References 476
44 A Method for Truck Frame Strength Analysis with Simplified Suspension Model 477
Abstract 477
44.1 Introduction 477
44.2 Equivalent Beam Method for Leaf Spring 478
44.3 Simplified Method of Main-Auxiliary Leaf Spring 479
44.4 Analysis Case 479
44.4.1 Frame and Simplified Suspension Model 479
44.4.2 Load Case 480
44.4.3 Analysis Results 481
44.4.4 Optimization Measures 482
44.4.5 Optimization Results 482
44.5 Conclusion 483
References 483
45 Research on Nonlinear Dynamics Simulation of Heavy Truck in Time Domain 485
Abstract 485
45.1 Introduction 485
45.2 Basic Theory 486
45.2.1 Explicit Dynamics 486
45.2.2 Implicit Dynamics 487
45.2.3 Implicit Static Solution 488
45.2.4 Selection and Application of Solver 488
45.3 Simulation of Components 488
45.3.1 Leaf Spring Model 488
45.3.2 Tire Model 489
45.3.3 Frame Model 491
45.3.4 Simulation of Bushing and Shock Absorber 491
45.3.5 Assemble Model of a Truck 491
45.4 Simulation of Full Truck 493
45.4.1 Frequency Simulation of Front Axle Suspension System 493
45.4.2 Validating Simulation with Step Input Experiment 493
45.4.3 Time Domain Stress Simulation in the Washboard Road Condition 495
45.5 Conclusion 496
References 497
46 Static Shift Performance Evaluation Index and Optimization Measures for Manual Transmission in Passenger Car 498
Abstract 498
46.1 Introduction 498
46.2 Manual Transmission Static Shift Performance Evaluation Item Analysis 499
46.2.1 Shift Force and Consistency 499
46.2.2 Shift Smoothness 500
46.2.3 Shifting Suction Feeling 501
46.2.4 Cross Shifting Performance 501
46.3 Static Select and Shift Performance of Manual Transmission Improvement Strategy Analysis 502
46.3.1 Shift Suction Feeling Improvement Strategy Analysis 502
46.3.1.1 Shift Mechanism Body Shift Curve Profile 503
46.3.1.2 Simulation Shift Curve 504
46.3.1.3 The Test Results 505
46.3.2 Analysis of Shift Smoothness Performance Improvement Measures 506
46.3.2.1 Synchronizer Steel Ball Groove Profile 506
46.3.2.2 Simulation Shift Curve 506
46.3.3 Cross Shift Performance 507
46.4 Conclusion 510
References 511
47 Ride Comfort Simulation and Abnormal Vibration Improvement of a Commercial Vehicle 512
Abstract 512
47.1 Introduction 512
47.2 Problem Descriptions and Test 512
47.2.1 Establish a Virtual Prototype Model of the Vehicle 513
47.2.2 Simulation and Verification for Whole Vehicle 514
47.3 Optimization of Vehicle Ride Comfort 515
47.3.1 Optimization Goal 515
47.3.2 Optimization Variables 515
47.3.3 Constraint Conditions 516
47.3.4 Optimization and Test Results 516
47.4 Conclusion 517
References 518
48 The Study of Vehicle Dynamics Modeling Method Based on the Characteristics of Suspension and Steering Systems 519
Abstract 519
48.1 Modeling Method 520
48.1.1 Relationship Between Suspension and Wheels 520
48.1.2 Relationship Between Steering and Wheels 521
48.2 Model Description 522
48.2.1 Vehicle Parameters 522
48.2.2 Tires 522
48.2.3 Model DOFs 522
48.3 Model Verification 523
48.4 Conclusion 525
References 526
49 Study on Coaxial Parallel HEV Automatic Clutch Torque Estimation 527
Abstract 527
49.1 Introduction 527
49.2 HEV Powertrain Model 528
49.3 The Clutch Torque Estimation Model Based on Kalman Filtering Arithmetic 529
49.4 Clutch Torque Estimation and Simulation Analysis in HEV Mode-Switch 531
49.5 Conclusion 533
References 534
50 Study on High-Strength Steel Spot Welding Process Design and Optimization Based on SORPAS 535
Abstract 535
50.1 Introduction 535
50.2 Basic Principles of Spot Welding 536
50.2.1 Principles 536
50.2.2 Key Factors Affecting the Process and Quality of Spot Welding 537
50.2.3 Analysis of Spot Welding Cycle 539
50.2.4 Design and Optimization of Process Parameters for Spot Welding 539
50.3 The Introduction of SORPAS 540
50.4 Finite Element Modelling and Optimization Calculation of Spot Welding 541
50.4.1 B170P1, B210P1 Analysis of Spot Welding 541
50.4.2 Solder Joint Working Condition 542
50.4.3 Spot Welding Model 543
50.4.4 Loading 544
50.4.5 Simulation and Optimization Results 544
50.5 Verification by Actual Welding Test 546
50.6 Conclusion 548
References 548
51 Off-Cycle Technology Evaluation for Engine Stop-Start 549
Abstract 549
51.1 Introduction 550
51.2 Simulation 551
51.2.1 Vehicle Test Cycle 551
51.2.2 Vehicle Specifications 551
51.2.3 Unified Model 551
51.2.4 Method 552
51.2.4.1 Method 1 552
51.2.4.2 Method 2 553
51.2.4.3 Method 3 553
51.2.4.4 Method 4 553
51.3 Results and Discussions 554
51.3.1 Fuel Consumption Result 554
51.3.2 Off-cycle Credit Result 554
51.4 Summary and Conclusion 556
References 557
52 Power-Loss Estimation for Low-Voltage Automotive PMSM Inverter 558
Abstract 558
52.1 Introduction 558
52.2 Power Loss Model of MOSFET 559
52.2.1 Switching Characteristic of MOSFET 560
52.2.2 Switching Power Loss of MOSFET 561
52.2.3 Conduction Power Loss of MOSFET 563
52.3 Power-Loss for SVPWM Inverter 564
52.3.1 Control Model of SVPWM 564
52.3.2 Conduction Power Loss Calculation Model of MOSFET 566
52.3.3 Conduction Power Loss Calculation Model of Body Diode 569
52.3.4 Switching Power Loss Calculation Model of MOSFET 570
52.3.5 Inverter Power Loss Calculation Model 571
52.4 Simulation 571
52.5 Conclusion 574
References 574
53 A Distribution-Based Model for Electric/Electronic Architectures of Automotive 576
Abstract 576
53.1 Introduction 576
53.2 Distribution in-Vehicle Network Architecture 577
53.2.1 Centralized Electric/Electronic Architectures of Automotive 578
53.2.2 Distributed Electric/Electronic Architectures of Automotive 579
53.2.3 Characteristics of Electric/Electronic Architectures of Automotive 580
53.3 The Design Method of the Electric/Electronic Architectures of Automotive 581
53.3.1 The Design Principles of the Distributed Network Architecture 582
53.3.2 Vehicle Coordination Control 583
53.4 Verification and Analysis of the Prototype of Electric/Electronic Architectures of Automotive 583
53.4.1 Each ECU Functional Analysis 583
53.4.2 ECU Network Optimization 585
53.4.3 Design of Network Architecture 586
53.5 Conclusion 587
Acknowledgments 587
References 587
54 An Advanced Structural Analysis Method for Connector Terminal Based on Multi-step Forming 588
Abstract 588
54.1 Introduction 588
54.2 Stamping-Structural Alliance Analysis Method 590
54.3 Multi-step Stamping Forming Analysis 590
54.3.1 Hardening Constitutive Model of Material 590
54.3.2 FEM for Multi-step Bending Forming and Its Spring-Back 591
54.3.3 Multi-step Forming Analysis Results 591
54.4 Structural Analysis for Formed Terminal 594
54.4.1 Importing the Formed Terminal, Mapping Hardening Material, and Residual Stress 594
54.4.2 Structural Analysis Results 594
54.5 Discussion and Conclusion 595
54.5.1 Discussion 595
54.5.2 Conclusion 597
Acknowledgments 597
References 597
55 Fuel Consumption Optimization for an Automatic Transmission Passenger Vehicle 598
Abstract 598
55.1 Introduction 598
55.2 Analysis of the Original Calibration Data 599
55.3 Fuel Consumption Reduction Solution 600
55.3.1 Automatic Transmission Gear-Shift Curve 600
55.3.2 Deceleration Fuel Cut-off Optimization 601
55.3.3 Idle Speed Calibration Optimization 603
55.4 Effect Verification 603
55.4.1 Drivability and Emission Verification 603
55.4.2 Fuel Consumption Reduction Result 604
55.4.2.1 Actual Driving Fuel Consumption in the City Driving Condition 604
55.4.2.2 Fuel Consumption in NEDC Cycle 605
55.5 Summary 607
References 608
56 Research of Diagnosis of High-Pressure Common Rail System Based on Real-Time Model 609
Abstract 609
56.1 Model Development 610
56.1.1 Model Structure 610
56.1.2 Analyses and Implementation of Model Development 610
56.1.2.1 Implementation of Model Development 610
56.1.2.2 Implementation of Diagnosis Process 612
56.1.2.3 Fault Handling 612
56.2 Rapid Prototype and Test Bed Calibration and Validation 613
56.2.1 Data Calibration 613
56.2.2 Algorithm Validation Based on Engine Test Bed 613
56.3 Vehicle Validation Test 617
56.4 Conclusion 618
References 618
57 Road Friction Coefficient Estimation by Using Lateral Dynamics Based on In-Wheel Motor Driven Electric Vehicle 619
Abstract 619
57.1 Introduction 619
57.2 Estimation of Longitudinal Forces 620
57.3 Vehicle and Tire Models 622
57.4 Estimation Method 624
57.5 Simulation Results 625
57.6 Conclusion 626
References 626