Physical and Virtual Testing Synergic Approach to ADAS Radar Performance Verification and Optimization

<div class="section abstract"><div class="htmlview paragraph">Conventional charging systems for electric and plug-in hybrid vehicles currently use cables to connect to the grid. This methodology creates several disadvantages, including tampering, risk, depreciation and non-value added user efforts. Loose or faulty cables may also create a safety issue. Wireless charging for electric vehicles delivers both a simple, reliable and safe charging process. The system enhances consumer adoption and promotes the integration of electric vehicles into the automotive market. Increased access to the grid enables a higher level of flexibility for storage management, increasing battery longevity.</div><div class="htmlview paragraph">The power class of 3.7kW or less is an optimal choice for global standardization and implementation, due to the readily available power installations for potential customers throughout the world. One of the key features for wireless battery chargers are the inexpensive system costs, reduced content and light weight, easing vehicle integration.</div><div class="htmlview paragraph">This paper demonstrates a wireless charging design with minimal component content. It includes a car pickup coil with 300 mm side length and low volume and mass 1.5 dm<sup>3</sup> power interface electronics. After an overview of its hardware requirements, power transfer and efficiency benefits are presented, providing the anticipated horizontal and lateral deviations.</div><div class="htmlview paragraph">An intense magnetic field is required to transfer the target power at low volumes between the transfer units. This field heats up any metal object over the transfer coil, similar to an induction oven. Consequently, the system should be powered down whenever a metal object is detected in this area. A Foreign Object Detection (FOD) design has been developed to continuously monitor the critical high field area. Device testing results are also provided.</div><div class="htmlview paragraph">Field characteristics are verified alongside the vehicle, ensuring system safety for living beings; compliant with all applicable standards reference limits which is more challenging than the basic limits [<span class="xref">13</span>].</div></div>

<div class="htmlview paragraph">The application of Computer-Aided Engineering is accelerating product design, process design, and prototype development for conversion of suspension steel fabrications to aluminum castings. Development cycle-time reduction is achieved by sharing a consistent CAE model among the system designers, component designers, and process development engineers.</div> <div class="htmlview paragraph">The CAE tools being utilized include Solid Modeling tools for geometry definition and manipulation, linear FEA for evaluating strength and stiffness, and non-linear heat-transfer for modeling the casting solidification. One of the major breakthroughs in cycle-time reduction for the CAE efforts is the utilization of automatic mesh-generation technology.</div> <div class="htmlview paragraph">The component geometry is simultaneously developed by product and casting engineers, so that the manufacturability issues are addressed up-front. Preliminary stress and solidification FEA are conducted in parallel to generate a more optimal geometry. This same geometric model is later used to create Laminated Object Model (LOM) Rapid prototypes. The tooling for the prototype sand-castings is produced from the LOM.</div> <div class="htmlview paragraph">Early prototypes are produced as sand-castings, allowing shortest possible lead-times, and permitting the maximum possible time for design optimization through Finite Element Analysis.</div> <div class="htmlview paragraph">Examples of successful aluminum conversions, and the tools and technologies enabling these successes, as well as lessons learned are presented.</div>

<div class="htmlview paragraph">Nissan utilizes ceramics in the turbine rotor of turbochargers to improve acceleration response by reducing the inertia weight of the turbine rotor.</div> <div class="htmlview paragraph">Since ceramic material does not yield, a high degree of localized stress will cause it to fail. Therefore, in order to be able to apply this brittle material to a high-speed rotor under high-stress conditions, silicon nitride material has been improved, and a low-stress shape employing the three-dimensional finite element method developed. Furthermore, a new technique for bonding the ceramic rotor to a metal shaft is employed in order to reduce residual stress caused by the difference in thermal expansion coefficients between the ceramic and metal materials. Since the strength of ceramics varies widely, it was necessary to confirm the reliability of the ceramic rotor and evaluate its life of fatigue.</div> <div class="htmlview paragraph">This paper, then, describes the design philosophy, bonding method, reliability and durability of the ceramic rotor.</div> <div class="htmlview paragraph">A turbocharger with ceramic rotor was first introduced into the automotive market in the domestic model of Nissan's 200Z last October.</div>

<div class="section abstract"><div class="htmlview paragraph">Twist-beam suspensions are an example of design solution presenting acceptable performance when applied to passenger cars & light vehicles and it can provide an optimal between cost & performance in the automotive market. For these reasons, twist beam is quite popular in use in rear suspension of light vehicles. In contrary to other types of suspension, the twist-beam has a flexible torsion beam connecting the swing arms. The study of the deformation of this flexible element becomes important to understand its performance and durability behavior. As the name signifies, twist beam major performance attribute is control of twist or opposite wheel travel arising from vehicle roll or road input. Current approach for the study this deformation is through FEA & Multi-body dynamics software tools. Conventional FEA approach requires availability of full-scale CAD models to work on, which is quite time consuming and its availability is difficult in early stage of the suspension design/development.</div><div class="htmlview paragraph">The main objective of this work was to evaluate the performance behavior using simplified mathematical modeling. This approach will give an alternative way to estimate the deformations for the initial stages of the suspension design, comparison between various vehicles/designs in less time as compared to FEA approach.</div><div class="htmlview paragraph">It also helps to reduce the iterations of RLDA (Road Load Data Acquisition) to understand the difference loads and strains on the structure. This will reduce the time and cost of data collection.</div></div>

<div class="section abstract"><div class="htmlview paragraph">The job of a suspension system is to maximize the friction between the tires and the road surface, to provide steering stability with good handling and to act as a cushioning device to ensure the comfort of the driver and passengers. The suspension system also protects the vehicle and any cargo or luggage from damage and wear.</div><div class="htmlview paragraph">Commonly the strength of these suspension systems is evaluated by endurance trials on field or Rig testing which are time consuming and costly. On the other hand, virtual testing methods for strength and stiffness evaluation provide useful information early in the design cycle and save significant time and cost. However, the virtual method also needs validation, which can be achieved by physical co-relations (via rig tests).</div><div class="htmlview paragraph">A study has been done to predict the behavior of Leaf Spring Suspensions entirely through the FEA (Finite Element Analysis) route and correlating those results with physical test. Initially the acceleration data is abstracted via RLDA (Road Load Data Acquisition) pasting the accelerometers at axle points. Strain Gauges are used to acquire strain values with respect to accelerations. This acceleration data is then used as input in rig setup at axle points and relatively strain is measured at same strain gauge locations as done while RLDA. This is done primarily to validate the test rig.</div><div class="htmlview paragraph">After Rig validation, a virtual validation is required. Leaf Spring assemblies modeled in FEA are similar to rig test bed setup. Tests are performed on the rig and gauges are used to extract the data for virtual co-relation. At the time of simulation, various parameters have been modified to achieve realistic behavior. Correlations between Stiffness and Stress have been achieved at these strain gauge locations between the Rig test and CAE (Computer Aided Engineering) results.</div><div class="htmlview paragraph">Correlation (around 90%) has been achieved between Rig test data and FEA results at measured locations. Correlation has helped in reducing product design time and cost of running the rig until crack. This process has also reduced the cost by using soft validation for multiple Leaf Spring Suspensions like Semi-elliptical, Parabolic, Weveller, Bogie and Bell Crank. Hence, this FEA based methodology has facilitated our organization in designing an excellent suspension system which will prove beneficial to our customers.</div></div>

<div class="section abstract"><div class="htmlview paragraph">The microcellular foam injection molding process for thermoplastic materials provides design flexibility and cost savings opportunities not found in conventional injection molding. This process allows for plastic part design with material wall thickness optimized for functionality.</div><div class="htmlview paragraph">The combination of density reduction and design for functionality can result in material and weight savings of up to 20%. With the correct equipment configuration, mold design, and processing conditions, these microcellular voids are uniform in size and distribution. The use of microcellular foam molding provides significant reductions in cycle time, material consumption, injection pressure, and clamp tonnage.</div><div class="htmlview paragraph">In this work, a physical foam molding process, MuCell, is applied to a polypropylene (PP) composite. The MuCell injection molding process involves the highly controlled use of gas in supercritical state, as the physical blowing agent, to create millions of micron-sized voids in thin wall molded parts (less than 3mm).</div><div class="htmlview paragraph">The results show that a weight reduction can be achieved without significant degradation in mechanical properties, such as stiffness and impact resistance. MuCell also contributes to faster cooling from the melt as well as the elimination of pack and hold phase, which both result in shorter injection molding cycle times and reduced warpage.</div><div class="htmlview paragraph">Once material tests have been completed, final part tests will also be performed, to validate established design specifications. These results presented here indicate that microcellular foam molding technology has good potential to be applied to interior parts of vehicles, contributing to weight reduction and productivity increase.</div></div>

<div class="htmlview paragraph">Alternative powertrain configurations such as hybrid electric vehicles and fuel cell vehicles seem to be the best response to the need of reduced pollutant emissions, especially in urban areas, and to meet future emission limits, that appear to be very severe targets for traditional technologies.</div> <div class="htmlview paragraph">In hybrid electric vehicles (HEVs) an internal combustion engine is combined with one or more electric machines, with the aim of extending the range of the electric and making the entire vehicle more energy–efficient. The architecture of a hybrid drive train is complex, comprising at least two different energy conversion devices (i.e. internal combustion engine and electric machine) drawing energy from at least two different energy storage devices (i.e. fuel tank and battery). Moreover, complex control strategies must be defined in order to properly control the division of load between the thermal engine and the electric machines.</div> <div class="htmlview paragraph">To meet increasing global competition, which means reducing lead-time and costs for hybrid vehicles design, it is necessary to develop methods that wouldquickly evaluate various design concepts. Even if many computational models are available to simulate the performances of HEVs, there’s still a lack of generalized mathematical analyses.</div> <div class="htmlview paragraph">An analytical model has been developed in order to study power flows in hybrid vehicle drive trains. The mathematical formulation allows a quick analysis of the complete energy cascade from fuel energy to tractive power, comprising electricity generation and consumption and energy recovery from braking. As a result a general formulation of the total tractive energy and of the global efficiency of hybrid electric vehicles in function of the main characteristics of its components is provided.</div> <div class="htmlview paragraph">The goal of the analytical model is to enable a quick exploration of design possibilities of hybrid powertrains. Some results are presented in order to show how the present model allows a quick insight into the effects of the main system characteristics on the power flows and the corresponding component losses of the drive train.</div>

<div class="section abstract"><div class="htmlview paragraph">Style changes and technological advances have led to reduced service life of current products as automobiles. These are among the goods that are constantly re-designed to meet our growing needs for improved products.</div><div class="htmlview paragraph">However, these demands for new products and more modern has meant a great cost to our natural resources, such as excessive use of raw materials, water and energy during production, use and end of life cycle of these assets.</div><div class="htmlview paragraph">The increasing scarcity of land available for the proper disposal of waste in landfills, in addition to the high cost of implementing these areas and the increasing distances to urban centers imply the need to reduce solid waste generation, including here the automotive. The growth of the automotive market has created a serious problem due to the disposal of urban waste volumes generated, the great diversity of materials involved and their toxicity.</div><div class="htmlview paragraph">The objective of this study is to analyze the various constituent materials of the vehicle and its impact on the environment (<span class="xref">APPENDIX 1</span>). We will deal with some aspects of the project, construction, use and final disposal of automotive vehicles. We will understand how the decisions within the project to meet the performance requirements and vehicle safety may have an impact on the recyclability of motor vehicles.</div><div class="htmlview paragraph">We are also going to discuss implications of the taxes and how they can encourage or obstruct sustainable practices. We will look at how the legislation must be improved to develop the automotive recycling industry. In the end, we will examine the current conditions present in the country for treatment of vehicles at the end of the cycle of life and identify the challenges, barriers and opportunities for the treatment of End of Life Vehicles (ELV) in Brazil.</div><div class="htmlview paragraph">We will discuss the current disposal ELV in Brazil and how this impacts on the environment and natural resources.</div></div>

<div class="htmlview paragraph">Anticipating that population growth during the next decade will continue to spread into suburban areas strengthens the belief that there will be an increasing need for a significant portion of that population to rely on personal and commercial transportation to maintain a high level of mobility.</div> <div class="htmlview paragraph">The now recognized trend toward lighter fuel efficient vehicles mandates that such an automotive market be served by improving on-road mobility of such vehicles particularly during construction periods and/or in inclement weather.</div> <div class="htmlview paragraph">This paper will discuss one method of achieving that mobility.</div>

<div class="htmlview paragraph">The CMS system commissioned by EPA and built by AVL, is a “start from a clean sheet of paper” approach to a full flow sampling system for aerosol matter from engine exhaust. The challenge of measuring 2007 level post DPF type particulate matter and polyaromatic hydrocarbons led to this re-thinking of sampler design.</div> <div class="htmlview paragraph">Previously used CVS designs had evolved to include elements that were not ideally suited for scaling up to large flow rates, and had mixing tunnels that were less than ideal for the sampling of complicated aerosols. The solution presented in this paper used ultrasonic time-of-flight flowmeters in place of the usual Venturi flow tubes, reducing the size and cost of air handling components. Acoustically designed dampeners were used to reduce pulsation disturbances to the flow measurement. In addition, the aerosol mixing tunnel was designed with the aid of CFD simulations to provide a portion of the dilution through the walls of its mixing zone to reduce sample loss from thermophoretic and diffusion deposition.</div> <div class="htmlview paragraph">This paper will explain the engineering design considerations and calculations, as well as the results of flow calibrations and in-use measurements that confirm them. The ultrasonic flowmeter calibrations are verified with a subsonic orifice flowmeter traceable to a standard at the National Institute of Standards and Technology. Pulsation measurements are presented for verification of the dampener performance. Data from the usual propane stratification checks verify the static performance of mixing.</div> <div class="htmlview paragraph">The viability of the use of alternative flowmeters and modified mixing schemes to lower the cost and improve the performance of a large full flow emissions sampling system is confirmed.</div>

<div class="htmlview paragraph">Many highway accidents are caused by distracted drivers and those suffering from drowsy driver syndrome. A driver alert indicating a lane departure could thwart such accidents, saving lives and making our roads safer.</div> <div class="htmlview paragraph">Products called Lane Departure Warning Systems (LDWS) have been developed to alert drivers of a lane departure. However, due to their high cost, lane departure warning systems are available only on luxury vehicles, barring their benefits from the majority of drivers. With Field Programmable Gate Arrays (FPGA) becoming more powerful and more affordable, a LDWS implementation utilizing hardware rather than software to conduct image processing eliminates the need for a costly high-power microprocessor, and could bring LDWS to a broader user base.</div> <div class="htmlview paragraph">This paper will discuss an FPGA based approach to LDWS. The proof-of-concept system is based on a Xilinx FPGA, taking its image data from an off-the-shelf NTSC camera. This implementation leverages the massively parallel nature of the FPGA to produce a high performance system that could be developed into a low-cost commercial LDWS.</div> <div class="htmlview paragraph">The proof-of-concept system detected lane departures with a detection accuracy of 74%. With the low cost of FPGA-based designs, lane departure warning systems could become profitable on more automobile models, thus increasing their availability.</div>

<div class="htmlview paragraph">South American automotive market pushes tier 1 supplier companies, as Visteon Corporation - Guarulhos, Brazil, to work in an environment of high complexity mix of products together with low volume operations.</div> <div class="htmlview paragraph">As a ring of the above supply chain, the Injection Area is a key internal supplier for the Plant, providing skins (cockpit plastic covers), consoles and other interior and exterior plastic parts to the manufacturing assembly cells.</div> <div class="htmlview paragraph">For a long time Kanban system has been used inside the Injection Area to minimize inventory through a pull system and to gain production flexibility.</div> <div class="htmlview paragraph">This paper explores the link between the Kanban system and the Economic Batch Size (EBS) calculation. The EBS is the production administration approach of optimizing the replenishment costs (mold changeover costs) and inventory holding costs (injection buffer).</div> <div class="htmlview paragraph">This paper will discuss the benefits of the proposed methodology above, based on a case inside the mentioned Injection Area.</div>

<div class="section abstract"><div class="htmlview paragraph"> For nearly a century, ice build-up on aircraft surfaces has presented a safety concern for the aviation industry. Pilot observations of visible moisture and temperature has been used a primary means to detect conditions conducive to ice accretion on aircraft critical surfaces. To help relieve flight crew workload and improve aircraft safety, various ice detection systems have been developed. Some ice detection systems have been successfully certified as the primary means of detecting ice, negating the need for the flight crew to actively monitor for icing conditions. To achieve certification as a Primary ice detection system requires detailed substantiation of ice detector performance over the full range of icing conditions and aircraft flight conditions. Some notable events in the aviation industry have highlighted certain areas of the icing envelope that require special attention. </div><div class="htmlview paragraph"> Following the CRJ accident in Fredericton, New Brunswick, Canada, in December 1997, industry interest and scrutiny in the performance of ice detection systems at warmer temperatures has increased. [ <span class="xref"> 1 </span> ] In particular, the concern lies in potential differences between ice accretion on the ice detector sensing surfaces and the critical aircraft surfaces (e.g. wing, nacelle). This has led both the FAA and EASA to update advisory material to ensure that ice detector performance at low freezing fractions is addressed. </div><div class="htmlview paragraph"> To minimize this concern and alleviate the risk, Collins Aerospace (Rosemount Aerospace, Inc.) has developed an enhanced ice detection algorithm for its magnetostrictive ice detector (MID). Traditionally the MID has only been used to detect ice accretion resulting from supercooled liquid water. This new algorithm enables the MID to sense the presence of non-freezing liquid water on its sensing surface and couple that with ambient temperature information to provide a signal when conditions may be conducive for ice accretion on critical aircraft surfaces. </div><div class="htmlview paragraph"> The discussion in this paper describes the development of this new algorithm for the MID and performance verification of the algorithm through icing wind tunnel testing and icing flight tests. </div></div>

<div class="htmlview paragraph">The management of engineering and engineers provides a challenge to engineering managers to maximize cost effectiveness. Industry and the educational community have successfully developed the precision of various disciplines to achieve technical excellence of engineered items. In doing this, certain aspects of education, training, and experience may have been overlooked.</div> <div class="htmlview paragraph">Engineers have made significant contributions in many areas in developing the theories, the technologies, materials, and equipment, with their application to subsequent conversion into various levels of sophisticated and useful hardware.</div> <div class="htmlview paragraph">There is need to recognize how we reached this level of achievement, at what cost, and with what exercise of control; and in doing that, establish the improved management techniques and disciplines to provide recognition within all engineering organizations, of cost and schedule performance responsibility for design, development, and qualification, as well as the cost and schedule performance to manufacture the hardware.</div>

<div class="htmlview paragraph">In today's automotive market, rollover protection systems are drawing an increasing attention. Unlike in conventional frontal and side impact events where linear accelerometers are used to detect the crash severity and make decision on deployment/non-deployment of the air bag restraint systems, rollover events require a new detection method using angular rate sensors. In the past, various angular rate sensors have been used in navigation systems to calculate pitch angle, or in camcorders for image stabilization. These sensors work at a low dynamic operating range, i.e. less than 100 degrees/sec. Angular rate sensors in automotive applications demand a higher dynamic capacity greater than 250 degrees/sec. (or °/s).</div> <div class="htmlview paragraph">This paper reviews automotive grade angular rate sensors currently being introduced for rollover protection system applications. In addition, various detection devices ranging from basic bubble sensing to newly developed sensors using micro-machined technology are also reviewed. The principle of Coriolis force used in the angular rate sensors is described. Pros and cons of each sensor type are discussed. Test methods to evaluate angular rate sensor performance and some typical sample data are also presented.</div>