Benchmark Investigation of Dynamics Models for Design Optimization of Articulated Heavy Vehicles

This paper represents validation of yaw plane and yaw-roll models of a tractor/semitrailer combination with TruckSim software package. A linear 3 degree-of-freedom (DOF) yaw-plane model and a linear 5 DOF yaw-roll model of tractor/semitrailer have been generated, compared and evaluated. This paper investigates the applicability of vehicle models with linear tire model. The models of the articulated heavy vehicle (AHV) yield excellent simulation results which are validated by comparing the simulation results obtained from TruckSim. This paper also includes eigenvalue analysis of the models to estimate their unstable motion modes. Benchmark comparison of the models has been performed to investigate the fidelity, complexity and applicability.

Development of a Methodology for the Evaluation of Motion Sickness Incidence in Railways

The present paper illustrates an evaluation method developed by the authors to quantify the index of motion sickness incidence (MSI) in railways motion conditions. This index is formerly defined in literature to quantify diseases coming from low frequency motions (kinetosis). The proposed method, suggested as alternative to the only one existing in reference norm, involves PCT index, well known in railways context, and weighting curves for accelerometric signals, which are also specified in railways regulations. The approach of the method, consistent with the theoretical model, developed by the authors themselves in previous works, allows to obtain MSI index versus time and/or track progressive distance. The model is validated through comparison with experimental data available in literature and with measures recorded and obtained on regular trains during tests performed in Slovenia (EU).

A Sensitivity-Based Approach to Improve Efficiency of Automotive Chassis Architecture

The strong competition of the automotive market brings the industries to look continuously for more challenging comfort and performance standards. These requirements often contrast with the need for weight reduction related to the restrictive emissions limits. In this scenario, the investments aimed at increasing the structure efficiency (stiffness-to-weight ratio) become fundamental. The objective of this work is to propose a methodology that allows to identify the most important chassis areas in terms of efficiency: the design and research efforts could then be focused on the real determinant parts. This is done through a sensitivity process that works on frame subsystems and then on each component, first varying the material properties and then the thickness (and so the mass). The designing loadcases considered are the torsional stiffness, bending stiffness, modal analysis and frequency response analysis. The results show which are the most important subsystems and components that affects the chassis efficiency and that will have to be re-designed in order to improve the current architecture.

Numerical Investigation of Heat Transfer, Fluid Flow and Formation of Emissions in Diesel Engines

The present study has been performed on heat transfer, fluid flow and formation of emissions in a diesel engine by different engine parameters. The analysis aims at an investigation of flow field, heat transfer, combustion pressure and formation of emission by means of numerical simulation which is using as parameter; hole number of injector and crank angle. Numerical simulations are performed using the AVL-FIRE commercial software depending on the crank angle. This software is successfully used in internal combustion engine applications, and its validity has been accepted. In this paper, k-zeta-f is preferred as turbulence model and SIMPLE/PISO used as algorithms. Thus, results are presented with pressure traces, temperature curves and NOx and soot levels for engine operating conditions. In addition, the relationship between the spray behaviors and combustion characteristics including NOx emissions, soot emissions, combustion pressure and temperature were illustrated through this analysis.

Vehicle’s New Anti-Roll System for Suspension Parasitic Stiffness Reduction and Non-Linear Roll Stiffness Characteristic

In general, vehicle uses torsional stiffness of a stabilizer bar to control the roll motion. But this stabilizer bar system has problems with degradation for ride comfort and vehicle’s NVH characteristic due to the suspension parasitic stiffness caused by deformation and wear of the stabilizer bar rubber bush. In addition, it is difficult to control the vehicle’s roll motion effectively in case of excessive vehicle roll behavior when it is designed to satisfy ride comfort simultaneously because of the stabilizer bar’s linear roll stiffness characteristic. In this paper, the new anti-roll system is suggested which consists of connecting link, push rod, laminated leaf spring, and rotational bearing. This new concept anti-roll system can minimize the suspension parasitic stiffness by using rotational bearing structure and give the vehicle non-linear roll stiffness by using the laminated leaf spring structure which are composed of main spring and auxiliary one. Reduction of suspension parasitic stiffness and realization of non-linear roll stiffness in this anti-roll system were verified with both vehicle dynamic simulation and vehicle test. Also, this study includes improvement of the system operating efficiency through material change and shape optimization of the leaf spring, and optimal configuration of the force transfer system.

Driveline Configuration and Terrain Effect on Slippage and Efficiency of a 6×6/6×4 Truck

The power distribution between driving wheels has been shown to have a significant impact on vehicle energy efficiency, but there has only been limited research in this area. As shown in this paper, the wheel power distribution is largely dependent on the power dividing units (PDUs) which split/vector power between the driving wheels. The performance of a particular driveline system will also depend largely on the terrain conditions the vehicle encounters. This paper presents an analysis of PDU configurations in 6×6/6×4 terrain trucks. The vehicle efficiency is evaluated in a wide variety of typical operating conditions including varying surface types, speeds and accelerations, and slope conditions. An analytical method is presented which can be used to determine the tire circumferential forces and slippages. Finally, an analysis of the effects of the driveline configuration, terrain, and surface type on truck transportation efficiency is presented for three PDU combinations.

Composite Materials in Automotive: Improving Safety by Refining FEA Correlation

In the last few years, the restrictive safety standards and the need for weight reduction have brought the crashworthiness research to focus on composite materials because of their high energy absortion-to-mass ratio. On the other hand, the possibility of obtaining predictive dynamic FEA models for these new materials is still an open issue: the present work aims at developing a methodology for the characterization of composite materials with particular interest for the head impact simulation. Composite materials behavior, defined through the mathematical models implemented in FEA codes, is very complex and requires a large amount of physical and numerical setting parameters. The majority of these parameters can be obtained by an experimental campaign that involves several kind of different tests. The presented methodology allows to obtain a good numerical-experimental correlation simply performing few tests which emulate the behavior of the component during the head impact event. A software tool based on a genetic optimization technique has been developed in order to determinate automatically the material properties values that guarantee the best numerical-experimental correlation.

Prototyping a New Lightweight Passenger Seat

Profitability is the key concern for transport companies. Costs are increased due to the rising fuel prices and technological investments. As well as new legal restrictions on the emission rates have forced the sector different fuel efficient technologies. Reducing weight is one of the most important methods of improving fuel efficiency and cutting CO2 emissions. Accordingly lighter, more fuel efficient, environmentally sustainable and safety vehicles are in the priority list of European authorities. And also the future of hybrid and electric vehicles depends on the lightweighting. The seat structure was chosen as the area for study which presented the best opportunity for weight reduction by the use of new materials. A seat provides comfort and safety of an occupant’s while travelling. In the event of crash, the passenger seat is exposed many different forces. For this reason it should be designed sufficient strength and stiffness. Therefore an optimized seat design should be aesthetically pleasing, ergonomic, light and meet the safety requirements. Seats play an important role in mass of buses and coaches due to number of seats per vehicle. In this project, finite element analysis, together with topology and free-size optimization is used to design a lightweight passenger seat for new generation commercial vehicles. The seat CAD models were created with CATIA V5 and then imported into HyperMesh for finite element model creation and analysis. Results from the nonlinear analysis provide an accurate prediction of the material yielding and load path distribution on the seat structural frame components. In the end, the verification tests which were determined by ECE are applied the new seat and results were compared with the FEA results. In this study, the lightweight passenger seat prototypes have developed. High strength steel and fiber-reinforced plastic parts are used. An overall 20% weight reduction is achieved including the structural frame, cushion, armrest, and pillar. And also the new passenger seat provides ECE safety norms.

Load Dynamic Analysis of Upper and Lower Arm Automotive Suspension

To reduce weight, in last decade the transport industry had recourse to the use of more lightweight material. Currently, several static elements of the vehicles are made of aluminum. However, the dynamic elements such as suspension parts cause difficulties due to high solicitations from vibration and road roughness. To better assess this damage in depth, the modeling of a full suspension system is more than necessary. In this work, a full quarter vehicle model while considering the motion of suspension along three axes is developed. This system is composed of an upper arm, lower arm, the spring, the damper, the wheel and the fastening elements. By using this full analytical model, all parameters such as, velocities, accelerations and forces can be determined.