Proceedings of SAE-China Congress 2016: Selected Papers (eBook)

Contents 6
1 Effect of Compression Ratio on the Combustion Characteristics of Premixed Charge Induced Ignition for Diesel Engine 12
Abstract 12
1.1 Introduction 12
1.2 Experimental Fuels, Apparatus and Procedures 13
1.3 Results and Discussion 15
1.4 Summary 18
References 18
2 Study of the Effect of Combustion Chamber Shapes on the Mixture Formation and Combustion Characteristic on CNG-DI Engine 20
Abstract 20
2.1 Research Condition and Method 21
2.1.1 Research Condition of Optical Engine 21
2.1.2 The Simulation Condition and Validation 23
2.1.3 The Technically Condition and Research Program of Prototype 24
2.2 Simulation Result and Analysis 25
2.2.1 The Effect of Combustion Chamber on Turbulence Characteristic in Cylinder 25
2.2.2 The Effect of Combustion Chamber Shape on Concentration Field and Combustion Characteristic 28
2.2.3 The Effect of Combustion Chamber Shape on NO Formation Law 30
2.3 Conclusion 33
References 33
3 Damage Risk Evaluation and Optimization for BIWS Spots-Weld 34
Abstract 34
3.1 Introduction 34
3.2 Method for Spots Damage Risk Evaluation 35
3.2.1 Linear Damage Theory 35
3.2.2 Spots Damage Risk Index 35
3.3 Application Examples 37
3.3.1 Finite Element Model 37
3.3.2 Determined the Analysis Load 38
3.3.3 Evaluation Results and Optimization 38
3.4 Conclusions 40
4 Fatigue Durability Analysis of a Frame Based on Multi Body Dynamics 42
Abstract 42
4.1 Introduction 42
4.2 Establishment and Validation of Finite Element Model of Frame 44
4.2.1 The Establishment of the Finite Element Model of Frame 44
4.2.2 Modal Analysis and Verification of Vehicle Frame 44
4.3 Vehicle Dynamics Analysis 46
4.3.1 The Frame of the Rigid Flexible Coupling Multi-Body Dynamics Model 46
4.3.2 Establishment of Road Spectrum 47
4.3.3 Vehicle Dynamic Response 48
4.4 Fatigue Life Analysis 49
4.4.1 Fatigue Analysis Method 49
4.4.2 Fatigue Life Analysis 50
4.5 Conclusion 53
References 54
5 Study on Calibration of Secondary Air Injection System in a V12 Engine 55
Abstract 55
5.1 Introduction 55
5.2 SAI System Scheme 56
5.2.1 Development Object 56
5.2.2 SAI System Structure 56
5.2.3 SAI Control Strategy 57
5.2.4 Emission Analysis of V12 Engine 58
5.3 Calibration 58
5.3.1 Emission Analysis of a Foreign Vehicle 58
5.3.2 SAI Work Period 60
5.3.3 Control of Air-Fuel Ratio 61
5.3.4 Control of Ignition Angle 62
5.3.5 Diagnosis of SAI System 63
5.4 Conclusions 63
References 64
6 Research on Soot Filtration and Pressure Drop Characteristics of DPF 65
Abstract 65
6.1 Introduction 65
6.2 Modeling of Soot Filtration 66
6.2.1 Deep Bed Filtration Model 66
6.2.2 Cake Filtration Model 69
6.2.3 Pressure Drop Model 70
6.3 Parameter Calibration and Verification of Models 70
6.4 Characteristics Analysis of Soot Filtration 72
6.4.1 Characteristics Variation of Pressure Drop 72
6.4.2 Soot Mass Distribution Characteristics 73
6.5 Conclusions 74
Acknowledgements 74
References 75
7 Research on the Present Situation and Factors of Volatile Organic Compounds in Car Cabin 76
Abstract 76
7.1 Preface 76
7.2 Data 77
7.2.1 Data Sources 77
7.3 Analysis on VOCs Emission of Vehicle in China 78
7.3.1 Attainment Rate 78
7.3.2 The Mean Value 78
7.3.3 Data Distribution in 2015 79
7.4 Study on Influencing of Sample Time, Testing Temperature and Seasonal Factors 80
7.4.1 Effect of Sample Time on VOCs Test 80
7.4.2 Effect of Temperature on VOCs Test 81
7.4.3 VOCs Test in Different Seasons 82
7.5 Conclusions 83
References 83
8 Optimization Method of Low Exhaust Temperature Emissions of City Buses Meet China V 84
Abstract 84
8.1 Introduction 84
8.2 Test Program 85
8.2.1 Test System 85
8.2.2 Test Vehicle 86
8.2.3 Test Program 86
8.3 Result and Discussion 87
8.3.1 Test Result of Fuel Economy 87
8.3.2 Emission Test Results 88
8.4 Conclusion 90
References 90
9 Analysis and Test Research for Three-Phase Short-Circuit of Permanent Magnet Synchronous Motor for an Electric Vehicle 91
Abstract 91
9.1 Introduction 91
9.2 Three-Phase Transient Short-Circuit Model 93
9.3 Transient Short-Circuit Simulation Analysis Based on the Actual Operation Condition 97
9.4 Test Platform Design and Test Results Analyze 101
9.5 Conclusion 105
References 105
10 Based on an Improved Sliding Mode Observer for Position Estimation of PMSM 107
Abstract 107
10.1 Introduction 107
10.2 Sliding Mode Observer 109
10.2.1 Improved Sliding Mode Observer 109
10.2.2 Stability Analysis 110
10.2.3 Kalman Observer 111
10.2.4 Position Estimation 112
10.3 Simulation Results 113
10.4 Results Analysis 113
10.5 Conclusion 116
References 116
11 Simulation Analysis and Research of C70GB Fuel Cell Vehicle 118
Abstract 118
11.1 Current Situation of Fuel Cell Vehicle 119
11.2 The Configuration and Parameters of the Vehicle System 119
11.2.1 Dynamic System Configuration 119
11.2.2 Vehicle Parameters 120
11.3 Construction of the Simulation Model System 121
11.3.1 Analysis of the System Model 121
11.3.2 Controlling Strategy of Electricity Consumption and Maintenance 123
11.4 Analysis of Test Data 124
11.4.1 Analysis of Acceleration Performance 124
11.4.2 Climbing Performance Analysis 126
11.4.3 Energy Consumption Analysis 127
11.5 Conclusions 128
References 129
12 Electrochemical-Thermal Coupled Model of Lithium-Ion Batteries for Low Temperature Charging 130
Abstract 130
12.1 Introduction 130
12.2 Electrochemical-Thermal Coupled Model 131
12.3 Model Parameters 132
12.4 Model Validation 134
12.4.1 Room Temperature Charging Without Warm-Keeping Box 134
12.4.2 Low Temperature Charging Without Warm-Keeping Box 134
12.4.3 Low Temperature Charging with Warm-Keeping Box 137
12.4.4 Validation of Temperature During Charging 137
12.5 Voltage Loss Breakdown 138
12.6 Conclusion 139
References 139
13 Research on Low Frequency Torque Ripple of In-wheel Motor of Four Wheel Independent Drive 140
Abstract 140
13.1 Introduction 140
13.2 Basic Operation Principles of SR Motor 142
13.3 Low Frequency Torque Ripple 143
13.3.1 Magnetic Flux Path Pattern of Motor 144
13.3.2 Current Imbalance Analysis 145
13.4 Phase Current Balance Control 147
13.4.1 Motor Current Balancing Strategy with Odd Phase 150
13.4.2 Motor Current Balancing Strategy with Even Phase 151
13.5 Conclusion 155
Acknowledgements 156
References 156
14 Relaxed Static Stability for All-Wheel-Drive Electric Vehicle Based on Yaw Moment Control 157
Abstract 157
14.1 Introduction 157
14.2 Pole Location Discussion of Vehicle Lateral Dynamic System 158
14.3 Basic Hierarchical Control Strategy of RSS 160
14.4 Simulation Verification 161
14.5 Conclusion 163
References 164
15 Test Study on Characteristics of Multi-Hole Injector for Gasoline Direct Injection Engine 166
Abstract 166
15.1 Introduction 166
15.2 Testing Systems and Methodologies 167
15.2.1 Testing System 167
15.2.2 Testing Methodologies 167
15.3 Research on Macro Spray Characteristics 169
15.3.1 Effects of Different Injection Pressures 169
15.3.2 Effects of Injection Background Pressures 171
15.4 Research on Injector Spray Target 172
15.5 Research on Effects of Injector Flow Range on Penetration 173
15.6 Comprehensive Analyzation of Constant Volume Bench Testing Results 174
15.7 Conclusion 175
References 175
16 Integrated Exhaust Manifold Type Cylinder Head Structure Design for Gravity Casting Process 176
Abstract 176
16.1 Introduction 176
16.2 Mass Production Casting Process 178
16.3 Structure Design Optimization 178
16.3.1 Water Jacket Structure Design Optimization 179
16.3.2 Oil Channel Structure Design Optimization 181
16.3.3 Outer Model Structure Design Optimization 182
16.4 Process Simulation Analysis 184
16.4.1 Tilting Process Simulation 184
16.4.2 Solidification Process Simulation 187
16.4.3 Internal Thermal Section Simulation 188
16.5 Trial Production Verification 189
16.6 Conclusion and Outlook 190
References 191
17 Experimental Research on Macroscopic and Microscopic Characteristics of Ethanol-Fatty Acid Methyl Ester Blends Sprays 192
Abstract 192
17.1 Experimental Setup and Procedure 193
17.1.1 Experimental Setup 193
17.1.2 Experimental Procedure 193
17.2 Experimental Results and Analysis 194
17.2.1 Spray Cone Angle Under Different Conditions 195
17.2.2 Projected Spray Area 196
17.2.3 Microscopic Results and Analysis 197
17.2.3.1 Sauter Mean Diameter 197
17.2.3.2 Distributions of Droplets 198
17.3 Conclusions 200
References 200
18 An Ultra-High Power Ignition System for EGR-Diluted GDI Engine 202
Abstract 202
18.1 Introduction 202
18.2 Experimental Setups 203
18.2.1 Ultra-High Power Ignition System 203
18.2.2 Engine Test Bench 204
18.3 Results and Discussions 206
18.3.1 Energy and Transient Power Calculation 206
18.3.2 Engine Test Results 209
18.4 Conclusions 210
References 211
19 Experimental and Simulated Study on the Cylinder Deactivation of Vehicle Gasoline Engine 212
Abstract 212
19.1 Introduction 212
19.2 Experimental Setup 213
19.3 Simulated Model 215
19.4 Simulated Results 216
19.4.1 Effect of Cylinder Deactivation Mode 216
19.4.2 Effect of Cylinder Deactivation Operating Condition 218
19.5 Conclusion 219
References 220
20 Study on Effects of Multiple Injection at Intake Stroke on Combustion and Emissions of GDI Engine Under Warm Up Conditions 221
Abstract 221
20.1 Introduction 222
20.2 Experimental Equipment and Method 223
20.3 Experimental Results and Discussions 224
20.3.1 In-Cylinder Combustion Analysis 224
20.3.2 Emission Characteristics 225
20.4 Conclusions 230
References 230
21 Study of Start-Stop Technology on a GDI Engine 232
Abstract 232
21.1 Introduction 232
21.2 Start-Stop Technology Research 233
21.2.1 Prototype Engine Parameters 233
21.2.2 Development of Start-Stop Control 233
21.2.2.1 Engine Stop Position Detection 233
21.2.2.2 Cylinder Volume Calculation 234
21.2.2.3 Fuel Injection Quantity Calculation 235
21.2.2.4 Test Bench Development 235
21.3 Experimental Result Analysis 235
21.3.1 Factors of the Rate of Ignition for Expansion Cylinder Analysis 235
21.3.1.1 Lambda Influence on the Rate of Ignition for Expansion Cylinder 236
21.3.1.2 Influence of Injection Times on the Rate of Ignition for Expansion Cylinder 237
21.3.2 Engine Starting Performance Research 239
21.3.2.1 The Opening Time of Exhaust Valve Influence on the Engine Starting Performance 239
21.3.2.2 The Performance of Starting Result Contrast 240
21.4 Conclusions 241
References 242
22 The Study of Friction and Wear Capability of Piston Ring Coatings 243
Abstract 243
22.1 Introduction 243
22.2 Experimental 244
22.2.1 Tribotests and Materials 244
22.2.2 Test Parameters 244
22.3 Results and Analyze 245
22.3.1 Material Inspection 245
22.3.2 Friction Coefficient 246
22.3.3 Wear Rate 246
22.3.4 SEM Analyses of Wear Tracks 246
22.3.5 Discussion 248
22.4 Conclusions 249
References 249
23 Direct Injection Start-Stop Piston Final Stop Position Modelling and Analysis 250
Abstract 250
23.1 Introduction 250
23.2 Engine Stop Process Modeling and Analysis 251
23.2.1 Engine Stopping Process Modeling 251
23.2.2 Model Solving 253
23.2.3 Model Simplification and Modification 254
23.2.4 Experimental Verification of Model 256
23.2.5 Stop Position Calculation via Simulation Experiment 257
23.2.6 Simulation Experiment Result Validation Application 258
23.3 Conclusions 259
References 259
24 Study on the Impact of Communication Imperfections on Forward Collision Warning and Avoidance Based on V2V Communications 260
Abstract 260
24.1 Introduction 261
24.2 Forward Collision Warning and Avoidance Strategies 262
24.3 Simulation Settings 263
24.3.1 Description of Vehicle Following Scenario in Simulation 263
24.3.2 Parameters Concerning V2V Communications 264
24.4 Simulation Results 264
24.4.1 Single Factors 265
24.4.2 Combination of Different Factors 267
24.5 Conclusion 269
Acknowledgements 269
References 269
25 Wavelet-Based Demodulation Design for Vehicular Communication Network 271
Abstract 271
25.1 Introduction 272
25.2 Development of the WD-Based Demodulation 275
25.3 The Architecture Design of the WD-Receiver System 278
25.4 Simulation Experiments and Results 280
25.5 Discussion of Results 285
Appendix A: Algorithm Computational Complexity Comparison 286
Appendix B: WD-Demodulator and TD-Demodulator Performances Comparison 287
References 292
26 Research on Static Viscoelastic and Tribological Properties of PP-EPDM, PP-GF30 and ABS in Automobile 293
Abstract 293
26.1 Introduction 293
26.2 Experiments 294
26.2.1 Materials 294
26.2.2 Creep Performance Test 294
26.2.3 Tribological Performance Test 295
26.3 Results and Discussion 296
26.3.1 Static Viscoelastic Properties 296
26.3.2 Tribological Properties 297
26.3.3 Relationship Between Static Viscoelastic Properties and Friction Performance 299
26.4 Conclusions 300
References 301
27 Study of the Design and Torsion Performance for Carbon Fiber Composite Material Automobile Drive Shaft 302
Abstract 302
27.1 Structure Design 303
27.1.1 Axial Dimension Requirement 303
27.1.2 Material Selection and Process 304
27.1.3 Layer Design 304
27.1.4 Design and Check of the Static Torsion Strength of the Shaft Tube 306
27.1.5 Connection Design 307
27.1.5.1 Connecting Structure 307
27.1.5.2 Fatigue Analysis 308
27.2 CF Drive Shaft Prototype and Experimental Verification 309
27.2.1 Winding Process and Prototype 309
27.2.2 Static Torsional Strength Test 309
27.2.3 Durability Test 310
27.3 Conclusions 310
Acknowledgements 311
References 311
28 Effect of Solution Treatment on Structure and Mechanical Properties of Fe–Mn–Al–Si Light Steel After Cold Rolling 312
Abstract 312
28.1 Introduction 312
28.2 Experimental Materials and Methods 313
28.3 Experimental Results and Analysis 314
28.3.1 Mechanical Property Analysis 314
28.3.2 Microstructure Analysis After Heat Treatment 316
28.3.3 Microstructure Analysis After Tensile Test 319
28.3.4 Fracture Analysis 320
28.4 Conclusion 323
References 323
29 Damping Analysis and Test Research of a Composite Leaf Spring in a Light Bus 325
Abstract 325
29.1 Introduction 325
29.2 Brief Introduction of Composite Leaf Spring 326
29.3 Simulation Analysis and Experimental Verification of Damping Characteristics of Laminated Plates 327
29.3.1 E Glass Fiber/Polyurethane Laminate Damping Test 327
29.3.1.1 Test Method for Damping Properties of E Glass Fiber/Polyurethane Laminates 327
29.3.1.2 Test Scheme for Damping Properties of E Glass Fiber/Polyurethane Laminates 327
29.3.2 Simulation and Analysis Method of Damping Performance of E Glass Fiber/Polyurethane Laminate 330
29.3.2.1 Simulation Procedure and Parameter Setting of E Glass Fiber/Polyurethane Laminate Damping Performance 330
29.3.2.2 Setting Method of Damping Parameter in Simulation of E Glass Fiber/Polyurethane Laminate Damping Performance 331
29.4 Simulation Analysis and Experimental Verification of the Damping Characteristics of Coposite Leaf Spring 333
29.4.1 Simulation Analysis of Damping Characteristics of Composite Leaf Spring 333
29.4.1.1 The Simulation Steps and the Parameters of Damping Properties of Composite Leaf Spring 333
29.4.1.2 The Prediction Results of Damping Composite Leaf Spring 334
29.4.2 Experimental Verification of the Damping Properties of Composite Leaf Spring 334
29.4.2.1 Vehicle Test of Natural Frequency and Damping Ratio of Automotive Suspension System 334
29.4.2.2 Simulation Analysis Results of Damping Characteristics of Composite Leaf Spring Are Compared with the Experimental Results 336
29.5 The Influencing Factors on the Damping Properties of Composite Leaf Spring 337
29.6 Conclusion 339
References 339
30 Analysis on China’s Fuel Consumption Standards and Its Influences on Curb Weight 340
Abstract 340
30.1 Introduction 340
30.2 The Evaluation Standard and Constraint Form of China’s CAFC Standard 343
30.2.1 Causes of the Evaluation Standard and Constraint Form 343
30.2.2 The Influence of Evaluation Standard and Constraint Form 344
30.3 Changes of the Slope of China’s CAFC Standards and Its Influence 347
30.3.1 Changes of the Slopes of Fuel Consumption at Phase IV in China 347
30.3.2 The Influence of the Change of Slope of Fuel Consumption Standard at Phase IV in China to Curb Weight 349
30.4 Conclusion 352
References 352
31 Prediction and Study on the Influence of Propeller Shaft to Vehicle Noise Based on BP Neural Network 354
Abstract 354
31.1 Introdution 354
31.2 BP Neural Network 355
31.2.1 BP Neural Network Structure 355
31.2.2 Algorithm of BP Neural Network 355
31.3 Sample Obtaining and Preprocessing 356
31.4 BP Neural Network Establishment and Prediction 357
31.4.1 BP Neural Network Model Establishment 357
31.4.2 Training and Checking of BP Neural Network 358
31.4.3 Prediction and Application 359
31.5 Conclusion 360
References 360
32 Optimization and Simulation of SUV Sunroof Buffeting Noise 362
Abstract 362
32.1 Introduction 362
32.2 Simulation Analysis 363
32.2.1 Methodology 363
32.2.2 Geometry 364
32.2.3 Computational Domain 364
32.2.4 Meshing 365
32.2.5 Boundary Conditions 365
32.2.6 Simulation Methods 365
32.2.7 Analysis 366
32.3 Optimization 366
32.3.1 Optimization Plan 367
32.3.2 Analysis 368
32.4 Road Test 369
32.5 Conclusions 370
References 370
33 Semi-active Intake Structure Design and Vehicle Validation 371
Abstract 371
33.1 Introduction 371
33.2 Principle of Semi-active Intake System 373
33.3 Determination of the Diameter of Normal Intake Pipe and Valve Pipe 375
33.3.1 Determination of the Diameter of Normal Intake Pipe 375
33.3.2 Research on the Opening Speed of Semi-active Valve and the Determination of the Diameter of Valve Pipe 376
33.4 Research on Spring Stiffness Matching of the Valve 379
33.4.1 The Simulation of Pressure Difference Between Both Ends of the Valve Based on STAR-CCM+ Software 380
33.4.2 Research on Spring Stiffness Matching of the Valve Based on ADAMS Software 382
33.4.2.1 Mechanical Analysis and Dynamic Model Building of the Valve 382
33.4.2.2 Simulation Results Analysis 383
33.5 Test Validation of Semi-active Intake Structure with Passive Flapper Valve 387
33.5.1 Test Research of Opening Rotating Speed and Spring Stiffness Matching 387
33.5.2 Test Research the Relationship Between Intake 2nd Order Noise Mutation and Valve Opening Angle 388
33.5.3 The Vehicle Validation Effect of Semi-active Intake 389
33.6 Conclusion 390
References 391
34 Calculation and Application of Sound Insulation of the Vehicle Dash Panel 392
Abstract 392
34.1 Introduction 392
34.2 The Theory of the Sound Transmission Loss in Reverberation Anechoic Chamber 393
34.3 The Sound Transmission Loss Measurement in the Reverberation—Anechoic Chamber 393
34.3.1 The STL Measurement of Steel Sheet and Plate Panel 393
34.3.2 The STL Measurement of Inner Dash System 394
34.4 The STL Calculation of the Inner Dash System 395
34.5 The Design and Optimization of the Inner Dash 397
34.5.1 The Effects of the Leakage and the Bared Steel Sheet 398
34.5.1.1 The Effect of the Leakage 398
34.5.1.2 The Effect of the Bared Steel Sheet Area 398
34.5.2 The Effect of the Steel Sheet Thickness and Inner Dash Thickness 398
34.5.2.1 The Effect of the Steel Sheet Thickness 398
34.5.2.2 The Effect of the Average Thickness of the Inner Dash 399
34.5.3 The Insulation Optimization of Inner Dash System 401
34.6 Conclusion 402
References 402
35 The Analysis for Casting Axle Cover Leakage 403
Abstract 403
35.1 Introduction 403
35.2 Set Up FEA Model 404
35.2.1 Geometry Introduce and Mesh 404
35.2.2 Material Properties 404
35.2.3 Boundary Condition 404
35.2.4 Set Up the Load Steps 405
35.3 Simulate Results 406
35.3.1 The Vertical Load Case Results 406
35.3.2 Fore and Vertical Results 406
35.3.3 After and Vertical Results 408
35.4 Conclusions 409
References 410
36 The Layout Design of Rearview Mirror Based on Vehicle Ergonomics 411
Abstract 411
36.1 Styling Factors Affecting the Field of View of the External Mirror 412
36.1.1 Beltline 412
36.1.2 A Pillar 412
36.1.3 Size of Outside Mirrors 413
36.1.4 Instrument Cluster 414
36.2 Package of Outside Mirror Based on Ergonomics 415
36.2.1 Front and Rear Position 415
36.2.2 Horizontal Position 415
36.2.3 Vertical Position 416
36.3 Minimum Visual Size of the Outside Mirror Based on Visual Field Compliance 417
36.3.1 Determine the Radius of Curvature 417
36.3.2 Outside Rear View Mirror Installation Angle 417
36.3.3 The Lens Minimum Visual Size 418
36.4 Virtual Test and Verify for Rearview Mirror View Based on RAMSIS 420
36.4.1 Regulations Vision Validation 421
36.4.2 View Occlusion and Reflection Validation 421
36.5 Conclusion 423
References 423
37 Research on Curve Safety Speed Warning for Vehicle with Risk Prediction 424
Abstract 424
37.1 The Curve Safety Speed Warning Model 425
37.1.1 Calculation of Curve Safety Speed with Lateral Instability 425
37.1.2 Vehicle Curve Safety Speed Warning Model 426
37.2 Curvature Estimation Based on Machine Vision 426
37.2.1 Lane Line Model and Segmentation 426
37.2.2 Coordinate Conversion 428
37.2.3 Calibration Installation Position 429
37.2.4 Curvature Estimation 431
37.3 Curve Safety Speed Warning Algorithm Based on Risk Prediction 433
37.4 Vehicle Curve Safety Speed Warning System is Designed with LabVIEW 435
37.4.1 Project Design of Warning System 435
37.4.2 Warning System is Designed 435
37.5 Conclusions 437
Acknowledgements 438
References 438
38 Multi Objective Optimization of Vehicle Crashworthiness Based on Combined Surrogate Models 439
Abstract 439
38.1 Introductions 439
38.2 Optimization Design 440
38.2.1 Optimization Objectives 441
38.2.2 Design Variable 441
38.2.3 Optimize Processes 442
38.3 Radial Basis Functions 442
38.3.1 Experiment Design 442
38.3.2 The Modeling of Radial Basis Functions 444
38.4 Kriging Model 447
38.5 Multi-Objectives Optimization 450
38.6 Conclusions 452
Acknowledgements 452
References 452
39 The Influences of Pre-impact Braking Scenarios on Occupant Restraint System During the Full Frontal Impact 453
Abstract 453
39.1 Introduction 453
39.2 Materials and Methods 454
39.2.1 Simulation Model with Human Model 454
39.2.2 Comparison of Human Model Posture and Injuries 455
39.3 Results 457
39.3.1 Optimization Parameters and Its Levels 457
39.3.2 Influence of Three Factors on Relative RR 458
39.4 Discussions 459
39.5 Conclusions 459
Acknowledgements 459
References 460
40 Rear Seat Belt Usage Models Using FARS and Field Data 461
Abstract 461
40.1 Introduction 462
40.2 Problem Statement and Objectives 463
40.3 Literature Review 463
40.4 Methodology 465
40.5 Data Collection 467
40.5.1 Field Data 467
40.5.2 FARS Data 468
40.5.3 Data Comparison 469
40.5.4 Analysis 471
40.5.5 Predicted Logistic Regression Model 475
40.6 Conclusions 477
Acknowledgements 477
References 478
41 Study on Dynamic Torque PID Control for Automobile Diaphragm Spring Clutch Based on Kalman Filter 479
Abstract 479
41.1 Introduction 479
41.2 PHEV Powertrain Model 480
41.3 Clutch Torque Estimation Model Based on Kalman Filter Arithmetic 482
41.3.1 System State Space Model 482
41.3.2 State Space Model Parameter 483
41.3.3 The Simulink Model Based on Kalman Filter 484
41.4 PID Controller for Clutch Torque 485
41.4.1 PID Controller Design 485
41.4.2 Parameters Setting and Analysis of PID Controller 486
41.5 PID Control Simulation and Analysis of Clutch Torque at Starting Process Driven by Engine 487
41.6 Conclusion 488
References 489
42 Research on Parameters Optimization of Transmission System of Military Off-Road Vehicle 490
Abstract 490
42.1 Introduction 490
42.2 Mathematical Model of Powertrain Optimization 491
42.2.1 Definition of Design Variables 491
42.2.2 Establishment of Objective Functions 492
42.2.2.1 Dynamic Property Sub-objective Function 492
42.2.2.2 Fuel Economy Sub-objective Function 493
42.2.2.3 Comprehensive Objective Function 493
42.2.3 Automative Engine Model 494
42.2.4 Constraint Conditions 495
42.3 Model Optimization and Solutions in Matlab 497
42.4 Simulation Results and Analysis 498
42.5 Conclusion 501
References 501
43 Study on the Program Load Spectrum of the Suspension Fatigue Bench Test and Correlation 502
Abstract 502
43.1 Preface 502
43.2 Random Load Spectrum for Proving Ground 503
43.2.1 Random Load Spectrum Collection 503
43.2.2 Random Load Spectrum Editing 504
43.3 Program Load Spectrum Preparation 505
43.3.1 Defined SN Curve for Pseudo Damage 505
43.3.2 The Method of Program Load Spectrum 506
43.4 Bench Test and Simulation Result Comparison 510
43.5 Conclusion 513
References 513
44 Fatigue Analysis of Car Body Structure Based on Transient Response 514
Abstract 514
44.1 Introduction 514
44.2 Road Load Data Measurement and Interface Force Generation 516
44.2.1 Real Vehicle Road Test 516
44.2.2 Virtual Iteration 516
44.3 Transient Dynamic FEA 518
44.3.1 BIW Finite Element Model 518
44.3.2 Transient Analysis Based on Mode Superposition 519
44.4 Fatigue Analysis of the BIW 520
44.4.1 S-N Curve Method for Low-Cycle Fatigue 520
44.4.2 Miner Linear Damage Accumulation 521
44.4.3 Results of Fatigue Analysis 522
44.5 Conclusions 523
References 523
45 The Study on Fatigue Test of Cab With Suspension Based on 4-Channel Road Simulation Rig 524
Abstract 524
45.1 Introduction 524
45.2 Acquisition and Processing of Road Load Spectrum 525
45.2.1 Acquisition of Road Load Spectrum 525
45.2.2 Signal Analysis and Processing 525
45.3 The Design of Test Rig 526
45.3.1 The Motion Analysis of Cab 526
45.3.2 Frame Design 527
45.3.3 Multi-Body Dynamics Simulation 527
45.3.4 Construction of Test Rig 529
45.4 Physical Iteration of Load Spectrum 530
45.4.1 System Identification 531
45.4.2 Target Signal Iteration 531
45.5 Test and Result 533
45.6 Conclusion 534
References 534
46 Research on the Fluxless Brazing of Aluminum Air Cooled Oil Cooler 535
Abstract 535
46.1 Introduction 535
46.2 The Product Structure and Experimental Materials 536
46.2.1 The Product Structure 536
46.2.2 Experimental Materials 537
46.3 Experiment Process 538
46.4 Results and Discussions 539
46.4.1 Analysis of the Appearance of the Oil Cooler 539
46.4.2 Metallographic Analysis 539
46.4.3 SEM and EDS Analysis 541
46.4.3.1 Analysis of the Appearance by SEM 541
46.4.3.2 EDS Analysis 543
46.5 The Conclusions 544
References 545
47 Analysis of Manufacturing Technology for the Spherical Head Supporting Part 546
Abstract 546
47.1 Analysis of the Spherical Head Supporting Part 547
47.2 Analysis of Manufacturing Technology for the Spherical Head Supporting Part 549
47.2.1 Analysis of the Forming of the Spherical Head Supporting Part’s Workblank 549
47.2.2 The Spherical Head Supporting Part’s Middle Axis Neck Machining Process Plans 554
47.3 The Manufacturing Process of Spherical Head Supporting Part 557
47.4 The Test Results and Conclusions of Spherical Head Supporting Part 560
References 561
48 Optimization of Design Parameters of Circular Burring 562
Abstract 562
48.1 Introduction 562
48.2 Burring and Design Parameters 563
48.3 Process Analysis and Numerical Simulation 563
48.3.1 Process Analysis 563
48.3.2 Numerical Simulation 564
48.4 Regression Analysis 565
48.4.1 Regression Theory 565
48.4.2 Regression Analysis 566
48.5 Conclusion 567
References 568
49 Experimental Study on the Application of Hydrogen Detector in Engine Leak Detection 569
Abstract 569
49.1 Introduction and Test Arrangement 569
49.2 Experimental Arrangement 570
49.3 Experimental Study on the Hydrogen Detection Equipment with the Use of the Whole Engine Leakage Test Device 570
49.3.1 Effectiveness Analysis of the Hydrogen Detection Equipment 570
49.3.2 Feasibility Analysis of Online Hydrogen Detection 572
49.3.2.1 Online Operability Verification 572
49.3.2.2 Effect of Residual Mixture Gas on Hydrogen Detection 573
49.3.3 Effect of Residual Mixture Gas on the Whole Engine Leakage Test Device 574
49.4 Summary 575
References 575
50 Investigation on Induction Hardening Treatment of Cylindrical Drive Gear Shaft 576
Abstract 576
50.1 Introduction 576
50.2 Experimental 577
50.2.1 Structure and Designed Load Capacity of the Part 577
50.2.2 Materials of the Part 578
50.2.3 Induction Hardening Process 579
50.3 Results and Discussions 579
50.3.1 Comparison of Single-Time and Two-Time Processes 579
50.3.2 Structure of Two-Time Heating Process Inductor and the Heating Uniformity 581
50.3.2.1 Structure Design of the Inductor for the Input End 581
50.3.2.2 Structure Design of the Inductor for the Output End 582
50.3.3 Determination of Optimal Parameter Range 583
50.3.4 Analysis of Quenching Deformation 586
50.3.5 Torsion Strength Test Results 586
50.4 Conclusions 591
References 591
51 Research on Automatic Automobile Air-Conditioning Controller 592
Abstract 592
51.1 Introduction 592
51.2 Hardware Design 593
51.2.1 Signal Acquisition Circuit 593
51.2.2 Circuit for Controlling Blower 594
51.2.3 Circuit for Controlling Motor 594
51.3 Software Design 595
51.3.1 Calculation of the Target Outlet Temperature 595
51.3.2 Automatic Control of Blower 595
51.3.3 Automatic Control of Compressor 596
51.3.4 Automatic Control of Motor 597
51.4 Experiment Results 597
51.5 Conclusion 598
References 598
52 Research on the Control Algorithm of EPS for Vehicle Handling Stability 600
Abstract 600
52.1 Introduction 600
52.2 Model Formulation 602
52.2.1 Vehicle Lateral Dynamic 602
52.2.2 Steering System Dynamic 604
52.2.3 State Space Equation 605
52.3 EPS Algorithm Design 606
52.4 Design Example 609
52.4.1 EPS Controller Design 609
52.4.2 Experimental Verification 611
52.5 Conclusions 614
References 614
53 Research on Flux Weakening Speed Control Strategy for PMSM 616
Abstract 616
53.1 Introduction 616
53.2 PMSM Model and Flux Weakening Control Principle 617
53.3 Strategy of Flux Weakening Speed Control 619
53.4 Simulation Experiment and Results 620
53.5 Conclusions 623
References 623
54 A Study of Three-Way Catalyst Deterioration Monitoring 624
Abstract 624
54.1 Introduction 624
54.2 Project Target and Scheme 626
54.3 Oxygen Storage Model of TWC 627
54.3.1 Boundary Conditions 627
54.3.2 Formula of TWC Oxygen Storage Capacity 627
54.4 Verification and Improvement 629
54.4.1 The OSC Measurement Result 629
54.4.2 Diagnosis Algorithm Improvement 630
54.4.3 Diagnosis Algorithm Verification 631
54.5 Conclusion 633
References 633
55 Functional Safety System Design on EPS 634
Abstract 634
55.1 Introduction for EPS System & Functional Safety
55.2 Hazard Analysis and Risk Assessment 638
55.3 Safety Goal and Safety Requirement 639
55.4 Safety Concept 640
55.5 Safety Analysis 641
55.6 Markov Analysis for Safety Path 645
55.7 Conclusion 650
References 651