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To ensure adequate visibility without excessive glare, vehicle headlights are designed to use a specific source of illumination. The optical designs of headlights gather the luminous flux produced by the light source to produce a useful beam pattern that meets the relevant requirements and standards for vehicle forward lighting. With the advent of solid state, light emitting diode sources for general illumination, an increasing number of LED replacement headlight bulb products has emerged over the past decade. In most cases, these LED replacement bulbs are not permitted for legal use on public roadways, but some countries have begun to permit specific LED replacement bulbs to be used legally on the road for specific makes, models and production years of certain vehicles. If they can be demonstrated to produce a beam pattern that meets the photometric requirements for a legal headlight, they are permitted to be used legally for on-road use.

This article proposes a novel methodology for the definition of an optimized immersion cooling fluid for lithium-ion battery applications aimed to minimize maximum temperature and temperature gradient during most critical battery operations. The battery electric behavior is predicted by a first order equivalent circuit model, whose parameters are experimentally determined. Thermal behavior is described by a nodal network, assigning to each node thermal characteristics. Hence, the electro-thermal model of a battery is coupled with a thermal management model of an immersion cooling circuit developed in MATLAB/Simulink. A first characterization of the physical properties of an optimal dielectric liquid is obtained by means of a design of experiment. The optimal values of density, thermal conductivity, kinematic viscosity, and specific heat are defined to minimize the maximum temperature and temperature gradient during a complete discharge of the battery at 2.5C.

A new generation of low heat capacitance Thermal Barrier Coatings (TBCs) has been developed under U.S. Dept. of Energy / Advanced Research Projects Agency - Energy (ARPA-E) sponsored research. The TBCs developed under this project have significantly lower thermal conductivity of < 0.35 W/m-K, thermal heat capacitance of < 500 kJ/m3-K, and density of <0.35 g/cm3. Two different binder types were used for thermal barrier coatings applied by High Velocity Low Pressure (HVLP) spraying to the piston, cylinder head, and valve combustion surfaces of a small natural gas engine. The effects of thermal barrier coatings on engine efficiency and knock characteristics were studied in a small, high compression ratio, spark-ignition, internal combustion engine operating on methane number fuels from 60 to 100. The new TBCs with low thermal conductivity and low thermal heat capacities have been shown to increase overall engine efficiency through reduced heat transfer to the piston and cylinder head.

The major drivers in the development of the latest generation of engines are environmental. For diesel engines, mitigating the effects of soot contamination remains a significant factor in meeting these challenges. There is general consensus of soot impacting oil performance. Considerable efforts have been made towards a greater understanding of soot-lubricant interaction and its effects on engine performance. However, with evolution of engine designs resulting in changes to soot composition/ properties, the mechanisms of soot-lubricant interaction in the internal combustion engine continue to evolve. A variety of mechanisms have been proposed to explain soot-induced wear in engine components. Furthermore, wear is not the only topic among researchers. Studies have shown that soot contributes to oil degradation by increasing its viscosity leading to pumpability and lubricant breakdown issues.

A multi-function computer program was composed with the synthetical method by graph. It contains a subprogram for judging geometrical contraditions in a planetary gearbox scheme. With this program, a large number of reasonable schemes of 2 to 4 (even 6) gearset planetary gearboxes with three degrees of freedom oan be automatically selected from all the possible schemes. It is very convenient to use it to design and analyze a multi-speed planetary gearbox. In this paper, the mathematical models, the principles and the flowcharts of this program and the subprogram for judging geometrical contradictions are narrated. Lastly, several examples of the application of the program are cited. We can obtain many reasonable schemes from which the optimum one may be selected.

Lubricant quality impacts performance and durability of heavy-duty off-highway equipment. Accordingly, equipment manufacturers work cooperatively with the petroleum and additive industries to develop performance specifications for lubricants and utilize these specifications in making recommendations for the end user. Currently, a new industry classification is being developed for multipurpose power transmission fluids. This paper discusses this proposed classification and other trends in power transmission lubrication.

A simple technique for determining the speeds of planetary gear sets is available to the design engineer. Central to this technique is the reduction of complicated planetary arrangements into rows containing basic planetary elements, or building blocks, which can be simulated using simple expressions. This reduction into rows is amenable to formulation of the simple expressions in an interactive software code.

This paper presents an extensive set of permeation data on automotive fuel system materials. It adds significantly to the information provided by the same authors in SAE paper 983160 [1]. The permeation measurements refer to three different test fuels: fuel C, CE10 and CM15 at 40, 50 and 60°C. The materials examined include poly-ethylenes, nylons, polyketons, ethylene-vinyl alcohol copolymers, acetals, fluoropolymers and fluoroelastomers. These data are important in the design of automotive fuel system components capable of meeting LEVII or PZEV requirements. In particular, data of this kind are crucial in optimizing the permeation performance of multilayer structures for fuel system applications.

The study of temperature distribution and heat transfer over non-uniform geometry is of great importance to engineers because of universal occurrence in many engineering applications such as diesel engine, boilers, heaters, radiators, dosers, etc. Performance of engine and its components (mechanical and electronic) is highly depending upon efficient thermal management. An accurate heat transfer analysis is necessary in automotive application and power plant. This study presents one dimensional model for prediction of conjugate heat transfer in Aftertreatment system and Sensors Module (Nox Sensor, PM Sensor, EGTS etc..) for diesel engine. Three-dimensional conductive, convective and radiative thermal analysis is computationally expensive as underhood models are of complex shape in nature and total turnaround time for product development project is also significantly high.

The process of assembling the bearing and crimp ring to the steering pinion shaft is intricate. The bearing is pressed into its position via the crimp ring, which is tipped inward and fully fitted into a groove on the pinion shaft. Only when the bearing is pressed to a low surface on the pinion shaft, the caulking force for the crimp ring is achieved. The final caulking distance for the crimp ring confirms the proper bearing position. Simulating this transient fitting process using CAE is a challenging topic. Key factors include controlling applied force, defining contact between bearing and pinion surface, and defining contact between crimp ring and bearing surface from full close to half open transition. The overall CAE process is validated through correlation with testing.

Whether high-precision torque control or motor condition monitoring need accurate motor parameters. For the three parameters of surface-mounted permanent magnet synchronous motor (SPMSM), the voltage equation is rank-deficient. To solve this problem, some scholars proposed methods that build full rank equations with signal injection, but this will produce motor torque ripple, which is not suitable for application to the EPS. Therefore, this paper proposes a method based on MRAS to identify motor parameters step by step. The proposed two steps identification method can make the reference model full rank in every step, but the total decoupling between parameters identification processes cannot be realized for the assumption that the prior step result is the real value. It was found in experiment that this effect varies with the motor operating conditions.

The properties of contact patch are key factors for tire modeling. Researchers have paid more attention to the contact patch shape and vertical pressure distribution. Some innovative concepts, such as Local Carcass Camber, have been presented to explain special tire modeling phenomena. For a pragmatic tire model, a concise model structure and fewer parameters are considered as the primary tasks for the modeling. Many empirical tire models, such as the well-known Magic Formula model, would become more complex to achieve satisfactory modeling accuracy, due to increasing number of input variables, so the semi-empirical or semi-physical modeling method becomes more attractive. In this paper, the concept of Tire Carcass Camber is introduced first. Different from Local Carcass Camber, Tire Carcass Camber is an imaginary camber angle caused only by lateral force on the unloaded tire.

This study investigates the fundamental stiffness and damping properties of a self-damped pneumatic suspension system, based on both the experimental and analytical analyses. The pneumatic suspension system consists of a pneumatic cylinder and an accumulator that are connected by an orifice, where damping is realized by the gas flow resistance through the orifice. The nonlinear suspension system model is derived and also linearized for facilitating the properties characterization. An experimental setup is also developed for validating both the formulated nonlinear and linearized models. The comparisons between the measured data and simulation results demonstrate the validity of the models under the operating conditions considered. Two suspension property measures, namely equivalent stiffness coefficient and loss factor, are further formulated.

Magneto-rheological fluid squeeze mode investigations at CVeSS have shown that MR fluids show large force capabilities in squeeze mode. A novel MR squeeze mount was designed and built at CVeSS, and a dynamic mathematical model was developed, which considered the inertial effect and was validated by the test data. A variant engine mount that will be used for isolating vibration, based on the MR squeeze mode is proposed in the paper. The mathematical governing equations of the mount are derived to account for its operation with MR squeeze mode. The design method of a robust H✓ controller is addressed for the squeeze mount subject to parameter uncertainties in the damping and stiffness. The controller parameter can be derived from the solution of bilinear matrix inequalities (BMIs). The displacement transmissibility is constrained to be no more than 1.05 with this robust H✓ controller. The MR squeeze mount has a very large range of force used to isolate the vibration.

In this paper, the predictive control strategy is employed to improve the current tracking performance of hub motor in 4WD electric vehicle due to its fast dynamic response. But the performance of the conventional predictive deadbeat current control suffers greatly from the parameter variations and other disturbances. Toward this, this paper presents a new predictive control strategy for hub motor; this control scheme combines an improved predictive control law with a state-observer to estimate the future motor currents and system disturbances based on a decoupled model. It provides a decoupled control of hub motor and offers stability against the variations in motor inductance and robustness against system uncertainties. The feasibility and validity of the proposed predictive current control strategy is verified through the simulation results.

Four-wheel-drive electric vehicles (4WD Evs) utilize in-wheel electric motors and Electro-Hydraulic Braking system (EHB). Then, all wheels torque can be controlled independently, and the braking pressure can be controlled more accurately and more fast than conventional braking system. Because of these advantages, 4WD Evs have potential applications in control engineering. In this paper, the in-wheel electric motors and EHB are applied as actuators in the vehicle stability control system. Based on the Direct Yaw-moment Control (DYC), the optimized wheel force distribution is given, and the coordination control of the hydraulic braking and the motor braking torque is considered. Then the EHB hardware-in-the-loop test bench is established in order to verify the effectiveness of the vehicle stability control algorithm through experiments.

Pressure following control is the basic function of Electro-Hydraulic Braking system (EHB), which is also the key technology of stability control system and regenerative braking system for hybrid and electric vehicles. Experimental research is an important method for the control and application of EHB. This paper describes a method to test and control the EHB system through experiment on the Hardware-in-the-loop (HIL) test bench and wheel motor electric vehicle. First, the HIL test bench was established, in which the EHB was tested, including the characteristics of solenoid valves and motor. Then the wheel cylinder pressure was controlled to follow the specific signal input and the master cylinder pressure. Based on this, EHB and the pressure following control method were applied to the wheel motor electric vehicle. The results show that the braking pressure can follow the driver's braking intention to realize the conventional braking function of electric vehicles.

In this paper, a sliding mode observer for estimating vehicle slip angle and tire forces is developed. Firstly, the sliding mode observer design approach is presented. A system damping is included in the sliding mode observer to speed the observer convergence and to decrease the observer chattering. Secondly, the sliding mode observer for vehicle states is developed based on a 7 DOF embedded vehicle model with a nonlinear tire model ‘UniTire’. In addition, since the tire lateral stiffness is sensitive to the vertical load, the load transfers are considered in the embedded model with a set of algebraic equations. Finally, a simulation evaluation of the proposed sliding mode observer is conducted on a validated 14 DOF vehicle model. The simulation results show the model outputs closely match the estimations by the proposed sliding mode observer.

For high torque permanent magnet wheel motor, this paper describes an experimental research method to optimize and identify the motor parameters based on the results of offline calculation. In order to improve the accuracy of motor parameters identification, the motor model considering the affect of iron loss was established, and the motor parameters were identified using genetic algorithm (GA). Based on this, parameters validation experiment was performed. The results show that: parameters obtained by this method can be used to describe the steady-state and transient-state response of permanent magnet synchronous motors accurately.