Vehicle and Automotive Engineering (eBook)

Preface 6
Acknowledgements 8
Contents 9
About the Editors 13
Design 15
1 Investigation of Rolling Element Bearings Using Time Domain Features 16
Abstract 16
1 Introduction 16
2 Bearing Test Device 17
3 Description of Investigation 18
4 Analysis of Measurements 20
5 Conclusion 24
Acknowledgements 24
References 24
2 Truck Floor Design for Minimum Mass and Cost Using Different Materials 26
Abstract 26
1 Introduction 26
2 Load Cases 27
2.1 Loads in the Horizontal Floor Position 27
2.2 Loads on the Distorted Floor 28
3 Geometric Characteristics of Cross Members 29
4 Design Constraints 30
4.1 Constraints on Fatigue Stress Range for the Horizontal Floor Position 30
4.2 Constraint on Fatigue Stress Range for the Distorted Floor Position 31
4.3 Constraints on Local Buckling of Profiles 32
4.4 Fabrication Constraints: Size Limitations 32
5 Optimization Characteristics and Results 33
6 Mass Savings 34
7 Cost Savings 35
8 Conclusions 37
Acknowledgements 37
References 38
3 Theoretical and Parametric Investigation of an Automobile Radiator 39
Abstract 39
1 Introduction 39
2 Calculation of the Automotive Radiator—Theorems 40
2.1 Theorem of Fábry 40
2.2 Theorem of Perry 42
2.3 Cengel’s Theorem 42
3 Comparisons of the Theorem’s Results 44
4 Sensitivity Analysis, Optimization 45
4.1 Preliminary Calculations 46
4.2 Effect of the Radiator Width 47
5 Summary 48
Acknowledgements 48
References 49
4 Past and Present: Teaching and Research in Vehicle Engines at the University of Miskolc 50
Abstract 50
1 Introduction 50
2 In the Beginning 51
3 Nowadays 56
Acknowledgements 58
References 58
5 Alternating Current Hydraulic Drive the Possibility of Applying in the Automotive Industry 59
Abstract 59
1 Introduction 59
2 The Synchronous Alternating-Current Hydraulic Drive (S-ACH) 61
3 Measurement 65
4 Conclusion 66
References 67
6 Comparative Destructive and Non-Destructive Residual Stress Measuring Methods for Steering Rack Bar Semi-Product 68
Abstract 68
1 Introduction 69
2 Experimental 69
3 Results and Discussion 71
3.1 Residual Stress States 71
3.2 Stress Asymmetry 73
4 Summary 77
Acknowledgements 77
References 77
7 Dynamical Modelling of Vehicle’s Maneuvering 78
Abstract 78
1 Introduction 78
2 Dynamics of Vehicle’s Movement 79
3 Equations of Dynamical Model 80
4 Simulation Results 81
4.1 Overtaking 82
4.2 Turning in Left Direction 82
5 Conclusions 85
Acknowledgements 86
References 86
8 Developing a Rotary Internal Combustion Engine Characterised by High Speed Operation 87
Abstract 87
1 Introduction 87
2 The Suggested New Internal Combustion Engine 89
2.1 The Build-up of the Motor 90
2.2 The Working of the Motor 90
3 Positive and Negative Properties of the Engine 90
3.1 Cost 91
3.2 Efficiency 91
3.3 Noise 92
3.4 Properties Resulting in High Speed Operation 92
3.5 Disadvantages 92
4 Manufacturing Considerations 93
4.1 Analyzing the Grinding Possibilities 93
5 Summary 96
Acknowledgements 96
References 96
9 Simulation Methods in the Vehicle Noise, Vibration and Harshness (NVH) 98
Abstract 98
1 Introduction 98
2 Simulation Methods 99
2.1 General Aspects of a Simulation Method 99
2.2 Multi-Body Simulation 100
2.3 Finite Element Method (FEM) 100
2.4 Statistical Energy Analysis (SEA) 102
3 Hybrid Methods 103
4 Summary 104
References 104
10 Optimal Damping of Random Excited Systems 105
Abstract 105
1 Signal Transmission of Time Series 105
2 Transformation of Variances 106
3 Dynamic Models of a Mechanical System 107
4 Seeking the Optimal Damping 109
Appendix 111
References 113
11 Application of Knowledge-Based Design in Computer Aided Product Development 114
Abstract 114
1 Introduction 114
2 Brief Overview of Knowledge-Based Design 115
3 Application of Ball Screw Drives in Automotive Equipment 116
4 Application of Ball Screw Drives in Automotive Equipment 117
5 Conclusions 118
Acknowledgements 119
References 119
12 Elementary Calculations for Deflection of Circular Rings 120
Abstract 120
1 Introduction 120
2 The Mechanical Model 122
2.1 The Bending Moment Along the Circular Centre Line 122
2.2 The Deflection Curve 123
2.3 The Deflection by Strain Energy 123
2.4 The Equivalence of the Formulae 125
3 Conclusion 126
Acknowledgements 126
References 127
13 Position- and Speed-Dependent, Power-Absorbing Hydraulic Cylinder with Mathematically Predictable Characteristics 128
Abstract 128
1 Introduction 128
2 Theoretical Bases 129
3 Hydraulic Basic Research 129
4 Testing of Prototypes and Steps of Utilization 135
References 136
Technology 137
14 Utilization of the GD OES Depth Profiling Technique in Automotive Parts Analysis 138
Abstract 138
1 Introduction 138
2 Glow Discharge Optical Emission Spectrometry (GD-OES) 139
3 Testing Multilayered Coatings (Car Body Panels) with GD-OES Depth Profiling 142
4 Plasma Cleaning and GD OES Testing of the Cleanliness 143
5 Summary 145
Acknowledgements 145
References 145
15 Analysis of Surface Topography of Diamond Burnished Aluminium Alloy Components 146
Abstract 146
1 Introduction 146
2 Experimental Investigations 149
2.1 Workpiece Characteristics 149
2.2 Burnishing of Outer Cylindrical Surfaces 149
2.3 The Applied Burnishing Parameters 151
2.4 Measurement of Surface Roughness 152
3 Results 153
4 Summary 155
Acknowledgements 156
References 156
16 Investigation of Tyre Recycling Possibilities with Cracking Process 158
Abstract 158
1 Introduction 159
2 Energetical Significance of Recycling 160
2.1 Products of Cracking of Rubber Tyre 160
2.1.1 Challenges of the Cracking Process 161
3 Recycling Options of Rubber Tyres and Polymer Derivatives 161
3.1 Mechanical Recycling of Waste 161
3.2 Waste Incineration 162
3.3 Chemical Utilization of Polymers 162
3.3.1 Theory of Thermal and Thermo-Catalytic Thermal Cracking 162
3.3.2 Composition of Rubber Tyres 163
4 Most Relevant Parameters of Thermal Cracking Processes 164
4.1 Effect of Temperature on Thermal Cracking Processes 165
4.2 Effect of the Catalyst in the Thermal Cracking Process 165
5 Presentation of the Experimental Process 166
5.1 Decisive Processes and Components of the Experiments 166
5.2 Presentation of Raw Materials Applied 167
5.3 The Steps of Measurements 168
5.4 Presentation of Measurements 169
5.4.1 Results of Cracking of Homogeneous Polystyrene Waste 169
5.4.2 Results of Cracking of Homogeneous Rubber Waste 170
5.4.3 Results of Polystyrene and Rubber Waste Blend 171
6 Summary 171
References 172
17 Utilisation of Various Hydro-Carbon-Based Wastes by Thermo-catalytic Conversion 173
Abstract 173
1 Introduction 174
2 Significance of Cracking Technologies 175
2.1 Characters of the Products of Technology 175
2.1.1 Most Relevant Contaminants of Products 176
3 The Role of Applied Mathematical Models 177
3.1 System Models 177
3.1.1 A Priori Models 177
3.1.2 A Posteriori Models 178
3.2 Reaction Kinetics Approach of Thermal Cracking Processes 178
3.2.1 Reaction Kinetic Examination of Rubber, Plastic and Biomass Waste 179
4 Measured and Calculated Results 180
4.1 The Experimental Equipment and Steps of Measurement 181
4.1.1 Steps of Experiments 181
4.1.2 Experimental Results 182
4.2 The Mathematical Model Fitted to the Experiments 182
4.2.1 Results Obtained via the Mathematical Model 184
5 Conclusion and Determinate of Research Goals 186
References 187
18 Development of Nitrided Selective Wave Soldering Tool with Enhanced Lifetime for the Automotive Industry 188
Abstract 188
1 Introduction 188
2 Materials and Methods 190
3 Results 191
4 Discussion 195
5 Conclusions 195
Acknowledgements 196
References 196
19 The Effect of Tensile Strength on the Formability Parameters of Dual Phase Steels 197
Abstract 197
1 Introduction 198
2 Samples and Materials 199
3 Results 200
3.1 Tensile Tests 200
3.2 Limiting Dome Height Tests 202
4 Summary 203
Acknowledgements 204
References 204
20 Comparison of Two Laser Interferometric Methods for the Study of Vibrations 205
Abstract 205
1 Introduction 205
2 Interferometric Measuring Systems 206
2.1 The Laser Interferometric Motion Analyser (LIMA) 206
2.2 The LDV (Laser Doppler Vibrometer) 208
3 Measurements Results 209
4 Conclusions 215
Acknowledgements 216
References 216
21 Deburring of Polimer and Metal Matrix Composites 217
Abstract 217
1 Overview of Deburring 217
2 Deburring Economics 219
3 Burr Formation Mechanism 220
4 Examples of Composite Machining 223
References 224
22 The Past, Present and Future of the Training of Internal Combustion Engines at the Department of Energy Engineering of BME 225
Abstract 225
1 Introduction 225
2 Infrastructure 226
3 Research Activities 227
4 Modelling 230
4.1 The AVL Boost Software System 230
4.2 CFD Simulations (Based on [18]) 231
5 Conclusions 233
Acknowledgements 233
References 233
23 Concept of a New Method for Helical Surface Machining on Lathe 235
Abstract 235
1 Introduction 235
2 Thread Cutting 236
3 Test with Profiled Tool 236
4 The Concept 237
5 Testing the Concept 239
6 Conclusion 240
Acknowledgements 240
References 240
Electrotechnics, Informatics 242
24 Intelligent Transportation Systems to Support Production Logistics 243
Abstract 243
1 Introduction 243
2 Literature Review 244
2.1 Research on Supply Chain Optimization 244
2.2 Research on Intelligent Transportation Systems 245
2.3 Research on Heuristic Optimization 245
3 Problem Description 246
4 Model of Its Based Supply Chain 247
5 Heuristic Algorithm for Real-Time Optimization of Its Based Supply Chain 250
6 Conclusion and Further Research Directions 253
Acknowledgements 253
References 253
25 A New Scheduling Software for Supporting Automotive Component Manufacturing 255
Abstract 255
1 Introduction 256
2 Problem Description and Requirements 257
3 Scope of the Research 258
4 Practice-Oriented Fine Scheduling Based on Simulation 259
5 Scheduling the Configuration Preparatory Tasks 260
6 Multi-objective Fine Scheduling 261
6.1 Scheduling Engine 261
6.2 Neighbouring Operators 262
6.3 Objective Functions 263
6.4 Comparing and Qualifying the Candidate Solutions 266
6.5 Advanced Functionalities of the Scheduling Software 267
7 Conclusions 271
Acknowledgements 271
References 271
26 The Context Between the Shift of Average Demand and the Safety Stock of Purchased Parts 273
Abstract 273
1 Introduction 273
2 The Analysis of Planning Reliability by Comparing the Planned and Actual Ordering for the Past Period 274
3 Definition of the Trend Function that Gives the Most Accurate Estimate with an Alignment Analysis 276
4 Forecasting the Future Expected Demand Based on the Past Actual Utilization, the Definition of Safety Stocks 280
5 Conclusions 282
Acknowledgements 283
References 283
27 An Overview of Autonomous Intelligent Vehicle Systems 284
Abstract 284
1 Introduction 285
2 The Situation of Intelligent Vehicles in Europe 286
2.1 Autonomous Unmanned Ground Vehicle 286
3 Technological Overview of the Development of Intelligent Vehicle Systems 291
3.1 Definitions/Terminology of Intelligent Vehicle Technology 291
4 Failure Mode Effects Analysis 294
5 Possibilities to Increase Safety by Using Intelligent Systems 298
6 Conclusion 300
Acknowledgement 300
References 300
28 Software Reliability of Complex Systems Focus for Intelligent Vehicles 305
Abstract 305
1 Introduction 306
1.1 Cases 306
1.2 Definitions 306
1.3 Circumstances that Have an Effect on the Reliability of the Software 306
1.4 Indices of Software Reliability 307
1.5 Faults and Failures 308
2 Increasing Reliability 309
3 Reliability Calculation 310
3.1 Example 311
4 Consequences and Conclusion 316
References 316
29 Usage of an Optical Flow Sensor in Robotics to Define Orientation 318
Abstract 318
1 Introduction 318
2 Introducing the Robot 319
2.1 Why Optical Flow Sensors? 319
3 Optical Flow in Theory and Presenting an Actual Sensor 320
3.1 Optical Flow Phenomenon 320
3.2 Operation of an Optical Flow Sensor 321
3.3 Benefits of Using These Sensors 321
3.4 ADNS-3080 321
3.5 Sensor Sensitivity 322
4 Using the Sensor 323
4.1 Sensor and Lens 323
4.2 Guarantee Appropriate Light Conditions for the Sensor 323
4.3 Sensor Placement 324
5 Mathematics 326
6 Conclusion 327
Acknowledgements 327
References 327
30 Pose Determination for Autonomous Vehicle Control 328
Abstract 328
1 Introduction 328
2 Proposed Method for Pose Determination 329
3 Mathematical Background of the Dead Reckoning System 331
4 Simulations 331
4.1 First Scenario 331
4.2 Second Scenario 332
4.3 Third Scenario 333
5 Conclusions 334
Acknowledgements 334
References 334
31 Description of a Method for the Handling of Customer Needs in Logistics 335
Abstract 335
1 Introduction 335
2 QFD—A Method for the Realization of Customer Expectations 336
3 General Procedure of the QFD 338
4 Example for an Automotive Industry Application 339
4.1 Registration of the Customer Expectations 340
4.2 Evaluation of the Customer Expectations According to Kano 340
4.3 Weighting of the Customer Expectations 341
4.4 Derivation from the Technical Expectations (HOW) 341
4.5 Quantitative Expression of the Technical Requirements 343
4.6 Calculation of the Technical Meanings of the “HOW”-s 343
4.7 Comparison with the Concurrent Products (Comparison of the “WHAT”) 343
4.8 Investigation of the Interdependencies Among the Characteristics (Correlation of the HOW to the HOW) and the Determination of the Direction of Optimization 344
4.9 Difficulty at the Realization and Technical Comparison with the Competition 344
5 Important Matrices 345
5.1 Component Matrix 345
5.2 Process Matrix 346
6 Other Areas of Utilization of the QFD Method in Logistics 346
7 Conclusions 347
Acknowledgements 348
References 348
32 Sensorless Determination of Load Current of an Automotive Generator Applying Neuro-Fuzzy Methods 349
Abstract 349
1 Introduction 349
2 Simulation Model of an Alternator 351
3 Performance Curve 354
4 Simulation Model of a Voltage Regulator 355
5 Simulation Model of Entire System 358
6 Laboratory Measurements 359
7 Adaptive Neuro-Fuzzy Implementation 362
8 Sensorless Determination of RPM 365
9 Conclusions 366
Acknowledgements 367
References 367
33 Distributed CAN-Bus Based Driving Assistance System on Autonomous Vehicle 368
Abstract 368
1 Introduction 368
2 The RIO Architecture 369
2.1 Real Time Controller 369
2.2 FPGA Module 370
3 The Control System 371
3.1 I/O and Communication Modules 372
4 Distributed CAN-Bus System 372
4.1 Developing of the CAN-Bus System 373
4.2 Communication with the Park Pilot ECU 373
4.3 Communication with the Radar and the Camera 374
5 Summary 374
Acknowledgements 375
References 375
34 Wall and Object Detection with FRI and Bayes-Classifier for Autonomous Robot 376
Abstract 376
1 Introduction 376
1.1 Fuzzy Rule Interpolation 377
1.2 Behaviour Description Language 377
2 Naive Bayes-Classifier 378
3 The Mobile Robot and Its Environment 378
3.1 Data Collection from the Environment 378
4 Behaviour Description for Wall Detection 380
5 Bayes-Classifier for Wall Detection 381
6 Conclusions 382
Acknowledgements 382
References 382
35 Optimal Formation of Logistics Networks 383
Abstract 383
1 Supply Chain, Virtual Organization, Virtual Enterprise 383
2 Network Optimization in Case of a Virtual Enterprise 385
2.1 Objective Function—Total Cost 385
2.1.1 Raw Material and Component Cost 386
2.1.2 Production Cost 386
2.1.3 Transportation Cost 386
2.1.4 Inventory Cost 387
2.1.5 Cost of Activities at Service Providers 387
2.1.6 Operational Cost of the Virtual Enterprise 387
2.2 Constrains 388
2.2.1 Production and Service Capacity Constraints 388
2.2.2 Inventory Constraint 388
2.2.3 Flexibility Constraint 388
3 Software Conception for Optimal Network Design 389
3.1 Numerical Example for Formation of Optimal Supply Chains 389
3.2 Operation and Main Screens of the Software Application 392
4 Conclusion 394
Acknowledgements 395
References 395
Welding 396
36 Development of Complex Spot Welding Technologies for Automotive DP Steels with FEM Support 397
Abstract 397
1 Introduction 398
2 Dual-Phase Steels in Automotive Industry 399
3 Resistance Spot Welding of Automotive Dual-Phase (DP) Steel Sheets 401
4 Finite Element Modelling 406
4.1 Material Properties 407
5 Comparisons Between the Numerical Calculation and Experiment Results 409
6 Conclusions 412
Acknowledgements 412
References 412
37 A Lightweight Design Approach for Welded Railway Vehicle Structures of Modern Passenger Coach 414
Abstract 414
1 Introduction 414
2 Presentation of IC+Type Railway Passenger Coach Family 415
3 The Carbody Structures of Railway Vehicles 417
4 Design of the Carbody Structures of IC+Type Railway Passenger Coach 419
5 Developing of Innovative Methods and Joining Technologies 422
6 Optimization of Spot Welded Sidewalls 422
7 Conclusions 424
Acknowledgements 425
References 425
38 Challenges and Solutions in Resistance Welding of Aluminium Alloys—Dealing with Non Predictable Conditions 427
Abstract 427
1 Introduction 427
1.1 Pre-conditioning 428
1.2 Force-Profile 428
2 Aluminium Mode Classic AMC 429
2.1 User Interface XPegasus 429
2.2 Weld System Set-Up 430
2.3 Development of Process Factors 431
3 Pre-conditioning 432
3.1 Example with High Resistance Sn Coating 432
4 Typical Welding Quality Until Tip Dressing 433
4.1 Methods to Decrease the Number of Imperfections 434
5 Price of High Currents and Welding Times 435
6 Extension with Quality Monitoring (AMF) 437
7 Summary 438
References 439
39 High Cycle Fatigue Investigations on High Strength Steels and Their GMA Welded Joints 440
Abstract 440
1 Introduction 440
2 High Cycle Fatigue Limit Curves 441
3 Welding Experiments on High Strength Steels 442
3.1 Material Properties and Weldability 442
3.2 Welding Experiments 445
4 High Cycle Fatigue Experiments and Their Results 446
4.1 Test Specimens 446
4.2 Testing Circumstances 447
4.3 The Results of the High Cycle Fatigue Experiments 448
5 Evaluation of the High Cycle Fatigue Experiments, the Fatigue Design or Limit Curves 451
6 Summary and Conclusions 453
References 453
40 Toughness Examination of Physically Simulated S960QL HAZ by a Special Drilled Specimen 455
Abstract 455
1 Introduction 455
2 Experimental Plan 458
3 Development of a Special Drilled Specimen 459
3.1 Preliminary Tests 459
3.2 Geometry 460
3.3 Test Results 461
4 Material Tests 462
4.1 Microscopic Tests 462
4.2 Hardness Tests 464
4.3 Charpy V-Notch Impact Tests 465
5 Conclusions 466
Acknowledgements 466
References 466
41 Innovation Methods for Residual Stress Determination for the Automotive Industry 468
Abstract 468
1 Introduction 469
2 Experimental 471
3 Results and Discussion 472
4 Summary 481
Acknowledgements 481
References 481
Author Index 483