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Design Optimization Methods for Forced Lubrication System Used in Automotive Transmissions 汽车变速器强制润滑系统的优化设计方法
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2023-07-18 DOI: 10.4271/02-16-04-0025
R. Shamini, P. Jadhav, S. Deshpande, S. Chavan
Lubrication has been a major area of interest in engineering. Especially in vehicle transmissions, lubrication plays a very crucial role because gears and bearings are constantly subjected to heavy loads. Proper lubrication is essential for maintaining system performance and ensuring endurance life. Insufficient lubrication can lead to excessive wear, increased friction, and eventually, failures in the transmission components. However, excess lubrication can result in power losses due to the resistance offered by the excessive lubricant. Therefore, achieving effective lubrication using optimized lubrication system design is vital for ensuring the longevity and efficiency of the transmission system. Majorly, two types of lubrication methods are used in transmissions: splash lubrication and forced lubrication. This article focuses on forced lubrication, where the lubrication system actively delivers the required flow of lubricant to specific locations within the transmission. Pump outflow, orifice diameters, and channel dimensions are a few of the critical design parameters of the forced lubrication system. This article presents two design optimization methods: one using ANSYS DX (3D) and the other using GT-Suite (1D) tool. In the 3D method, ANSYS Fluent is used for CFD (computational fluid dynamics) simulations and subsequently ANSYS DesignXplorer (DX) is leveraged for design optimization. Predictions from CFD simulations are validated against physical test data and show good agreement (>90% match for flow rate). GT-SUITE is used in the 1D method, which is validated with predictions from 3D CFD method. The optimized designs obtained from both methods are effective in achieving the desired flow rate distribution, demonstrating their reliability. The ANSYS DX method provides an advantage in terms of reduced overall turnaround time (50% less) for the optimization. On the other hand, co-simulation (CFD+1D) approach can prove beneficial if it is required to perform minor routing changes on the lube system layout.
润滑一直是工程领域的一个主要兴趣领域。特别是在车辆变速器中,润滑起着非常关键的作用,因为齿轮和轴承经常承受重载荷。适当的润滑对于维持系统性能和确保耐久性至关重要。润滑不足会导致过度磨损,增加摩擦,最终导致传动部件失效。然而,过量的润滑会导致功率损失,因为过量的润滑剂所提供的阻力。因此,利用优化的润滑系统设计实现有效润滑对于保证传动系统的寿命和效率至关重要。变速器主要采用两种润滑方式:飞溅润滑和强制润滑。这篇文章的重点是强制润滑,其中润滑系统主动提供所需的润滑油流量的特定位置内的变速器。泵出口、孔直径和通道尺寸是强制润滑系统的几个关键设计参数。本文介绍了两种设计优化方法:一种是利用ANSYS DX (3D),另一种是利用GT-Suite (1D)工具。在三维方法中,使用ANSYS Fluent进行CFD(计算流体动力学)模拟,随后利用ANSYS DesignXplorer (DX)进行设计优化。CFD模拟的预测与物理测试数据进行了验证,并显示出良好的一致性(约90%的流量匹配)。GT-SUITE用于一维方法,并与3D CFD方法的预测结果进行了验证。两种方法得到的优化设计都能有效地达到预期的流量分布,证明了它们的可靠性。ANSYS DX方法在减少总体周转时间(减少50%)方面为优化提供了优势。另一方面,如果需要对润滑油系统布局进行微小的路由更改,则联合模拟(CFD+1D)方法可以证明是有益的。
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引用次数: 0
Development of Load Reconstruction Technique and Application on Commercial Vehicle Suspension 负载重构技术的发展及其在商用车悬架上的应用
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2023-06-12 DOI: 10.4271/02-16-03-0019
Subhash Hanmant Bhosale, Rajat Pratap, Amol A. Apte
The ability to predict the durability of a structure depends on the knowledge of operating loads experienced by the structure. Typically, multi-body dynamics (MBD) models are used to cascade measured wheel loads to hard points. However, in this approach, there are many sources by which errors creep into cascaded forces. Any attempt to reduce sources of such errors is time consuming and costly. In typical program development timelines, it is very difficult to accommodate such model calibration efforts. Commercial load cells exist in the industry to give engineers insight into understanding the complex real-world loading of their structures. A significant limitation to the use of load cells is that the structure needs to be modified to accept the load cell, and not all desired loading degrees of freedom (DOFs) can be measured. One of the innovative solutions to calculate operating loads is to convert the structure itself into its own load transducer. The D-optimal algorithm along with the pseudo-inverse technique provides a theoretically sound and versatile method to identify optimum positions and locations to place the sensors (i.e., strain gauges) on the structure where its response is to be measured. A pre-calculated calibration matrix through pseudo-inverse is then used along with measured responses to reverse calculate loads acting on the structure. The accuracy of calculated loads with this approach is typically high compared with conventional load cascading methods as sources of errors are less in this method. This work is focused on load reconstruction, FE analysis, and lightweighting of the bell crank lever of a commercial vehicle. Practical difficulties associated with the load reconstruction method and solutions are also discussed in this research paper.
预测结构耐久性的能力取决于结构所经历的操作载荷的知识。通常,多体动力学(MBD)模型用于将测量的车轮载荷级联到硬点。然而,在这种方法中,有许多来源可以使误差蠕变为级联力。任何减少此类错误来源的尝试都是耗时且代价高昂的。在典型的程序开发时间表中,很难适应这样的模型校准工作。工业中存在的商用测压元件可以让工程师深入了解其结构的复杂实际载荷。使用测压元件的一个重要限制是,结构需要修改以接受测压元件,并且并非所有期望的加载自由度(dof)都可以测量。计算运行载荷的创新解决方案之一是将结构本身转换为其自身的载荷传感器。d -最优算法以及伪逆技术提供了一种理论上合理且通用的方法来确定将传感器(即应变片)放置在要测量其响应的结构上的最佳位置和位置。然后,通过伪逆计算预先计算的校准矩阵与实测响应一起用于反计算作用在结构上的载荷。与传统的负荷级联方法相比,该方法计算负荷的精度通常较高,因为该方法的误差来源较少。对某商用车钟形曲柄杆进行了载荷重构、有限元分析和轻量化研究。本文还讨论了与荷载重建方法和解决方案有关的实际困难。
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引用次数: 0
Structural Design and Analysis of Sliding Composite Mono Leaf Spring 滑动复合材料单片弹簧的结构设计与分析
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2023-06-10 DOI: 10.4271/02-16-03-0020
Lubin Wang, Chendi Zhu, Xiaoqin Lu, Zhengpeng Zhang, Shiwen Liang
The lightweight structure of a semitrailer composite leaf spring is designed and manufactured using glass fiber composite to replace the conventional steel leaf spring. The sliding composite mono leaf spring was designed based on the conventional parabolic spring design theory. The composites product design (CPD) module of CATIA software is used to create the lamination of the composite leaf spring. Using finite element analysis of the position and proportion of ±45° biaxial layer by OptiStruct software, it is found that a certain proportion (nearly 5%) of a ±45° biaxial layer can effectively reduce the shear stress under the condition of keeping the total number of layers fixed. Then, the natural frequency, stiffness, and strength of the composite leaf spring are simulated by the finite element method. Finally, the stiffness, fatigue, and matching of the designed spring are tested by experiments. The design weight of the composite leaf spring is 18.5 kg, which is 55.4% lighter than the conventional steel leaf spring. The composite mono leaf spring has good fatigue performance; the vertical fatigue cycles are more than 300,000 times, 1.6 times of the traditional steel leaf spring. The results of the system bench test show that the movement state of the composite mono leaf spring is consistent with the steel leaf spring. It can be preliminarily speculated that the composite leaf spring structure can meet the requirement of vehicles. A proposed method combining theoretical analysis, calculation, and finite element simulation can be used to design and test composite products quickly. This method has a high significance for the structural optimization of other laminated composite products.
采用玻璃纤维复合材料代替传统的钢板弹簧,设计制造了半挂车复合钢板弹簧的轻量化结构。基于传统的抛物面弹簧设计理论,设计了滑动复合材料单板簧。利用CATIA软件中的复合材料产品设计(CPD)模块来创建复合材料板簧的叠片。利用OptiStruct软件对±45°双轴层的位置和比例进行有限元分析,发现在保持总层数不变的情况下,一定比例(近5%)的±45°双向层可以有效降低剪切应力。然后,采用有限元方法对复合材料板簧的固有频率、刚度和强度进行了仿真。最后,通过实验对所设计的弹簧的刚度、疲劳和匹配性进行了测试。复合钢板弹簧的设计重量为18.5公斤,比传统钢板弹簧轻55.4%。复合材料单板簧具有良好的疲劳性能;垂直疲劳循环次数超过30万次,是传统钢板弹簧的1.6倍。系统台架试验结果表明,复合材料单板簧的运动状态与钢板簧一致。可以初步推测,复合材料板簧结构可以满足车辆的要求。所提出的理论分析、计算和有限元模拟相结合的方法可以用于快速设计和测试复合材料产品。该方法对其他层合复合材料产品的结构优化具有重要意义。
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引用次数: 0
Reaction Rod Link in Rear Cab Suspension to Control Cab Dynamics in Tractor-Semitrailer Vehicles 牵引半挂汽车驾驶室后悬架中的反作用连杆控制驾驶室动力学
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2023-05-24 DOI: 10.4271/02-16-04-0024
Sindhoor Bhat
Articulated vehicles form an important part of our society for the transport of goods. Compared to rigid trucks, tractor-trailer combinations can transport huge quantities of load without increasing the axle load. The fifth wheel (FW) acts as a bridge between the tractor and trailer, which can be moved within the range to achieve rated front and rear axle loads. When the FW is moved front, it adversely affects the cab dynamics and cab suspension forces. Compared to the cab pitch and roll, yaw motion increases drastically. The current study tries to address this issue by providing reaction rod links in the rear cab suspension. In this study, a 4×2 tractor with a three-axle semitrailer is considered by keeping the FW at its frontmost position, which is the worst-case scenario for a cab. Three different cases of reaction rod arrangement and its influence on cab dynamics are studied in comparison with a model without reaction rods. To assess this, time signal–based relative pseudo-fatigue damage, power spectral density (PSD), and level crossing plots are analyzed. The outcome shows that cab pitch, roll, and yaw motion reduce by a considerable amount with the presence of a reaction rod. Cab suspension forces will also reduce. The horizontal V-inclination of the reaction rod plays a major role in improving cab yaw motion and reducing the lateral forces. A straight link without any inclination helps in reducing the pitch and roll motion of the cab.
铰接式车辆是我们社会货物运输的重要组成部分。与刚性卡车相比,牵引拖车组合可以在不增加轴重的情况下运输大量负载。牵引座(FW)充当拖拉机和拖车之间的桥梁,拖车可以在一定范围内移动,以实现额定的前轴和后轴负载。当FW向前移动时,会对驾驶室动力学和驾驶室悬架力产生不利影响。与驾驶室俯仰和滚转相比,偏航运动大幅增加。目前的研究试图通过在驾驶室后悬架中提供反作用杆连杆来解决这个问题。在本研究中,考虑了一辆带三轴半挂车的4×2拖拉机,将FW保持在其最前面的位置,这是驾驶室的最坏情况。研究了反作用杆布置的三种不同情况及其对驾驶室动力学的影响,并与没有反作用杆的模型进行了比较。为了评估这一点,分析了基于时间信号的相对伪疲劳损伤、功率谱密度(PSD)和水平交叉图。结果表明,在存在反作用杆的情况下,驾驶室的俯仰、侧倾和偏航运动会显著减少。驾驶室悬架力也将减小。反作用杆的水平V形倾斜度在改善驾驶室偏航运动和减少侧向力方面起着重要作用。没有任何倾斜的直连杆有助于减少驾驶室的俯仰和侧倾运动。
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引用次数: 0
Evaluation of Fuel Economy Benefits of Radar-Based Driver Assistance in Randomized Traffic 随机交通条件下雷达辅助驾驶的燃油经济性评价
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2023-05-17 DOI: 10.4271/02-16-03-0021
Lindsey Kerbel, Daniel Yoon, K. Loiselle, B. Ayalew, A. Ivanco
Certain advanced driver assistance systems (ADAS) have the potential to boost energy efficiency in real-world scenarios. This article details a radar-based driver assistance scheme designed to minimize fuel consumption for a commercial vehicle by predictively optimizing braking and driving torque inputs while accommodating the driver’s demand. The workings of the proposed scheme are then assessed with a novel integration of the driver assistance functionality in randomized traffic microsimulation. Although standardized test procedures are intended to mimic urban and highway speed profiles for the purposes of evaluating fuel economy and emissions, they do not explicitly consider the interactions present in real-world driving between the ego vehicle equipped with ADAS and other vehicles in traffic. This article presents one approach to address the drawback of standardized test procedures for evaluating the fuel economy benefits of ADAS technologies. This approach is demonstrated by using a microsimulation of a traffic network into which the ego vehicle with the proposed driver assistance scheme is embedded for continuous interaction with the traffic. The analysis and results from stochastic simulations consider variations in the behavioral style of the driver of the ego vehicle and the traffic density. Strong variations, up to 10% in the fuel economy benefits, are observed between both variations presented in this study and what is obtained in typical deterministic evaluations mirroring standard test procedures.
某些先进的驾驶员辅助系统(ADAS)有可能在现实世界中提高能源效率。本文详细介绍了一种基于雷达的驾驶员辅助方案,该方案旨在通过预测性地优化制动和驱动扭矩输入,同时满足驾驶员的需求,最大限度地降低商用车的油耗。然后,通过在随机交通微观模拟中集成驾驶员辅助功能来评估所提出方案的工作情况。尽管标准化测试程序旨在模拟城市和高速公路的速度曲线,以评估燃油经济性和排放,但它们没有明确考虑配备ADAS的自我驾驶车辆与其他交通车辆之间在现实世界驾驶中存在的相互作用。本文提出了一种方法来解决评估ADAS技术燃油经济性效益的标准化测试程序的缺陷。该方法通过使用交通网络的微观模拟进行了演示,其中嵌入了具有所提出的驾驶员辅助方案的自我车辆,以与交通进行连续交互。随机模拟的分析和结果考虑了自我车辆驾驶员的行为风格和交通密度的变化。在本研究中提出的两种变化与反映标准试验程序的典型确定性评估中获得的变化之间,观察到了高达10%的燃油经济性效益的强烈变化。
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引用次数: 0
Research on Seat Static Comfort Evaluation Based on Objective Interface Pressure 基于目标界面压力的座椅静态舒适性评价研究
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2023-05-15 DOI: 10.4271/02-16-04-0023
T. Zhang, Jindong Ren
The interface pressure distribution is an important indicator for evaluating the static comfort of the seat. At present, the interface pressure of a real person is acquired through testing and used in assessing the seat comfort, which has poor consistency and accuracy, and it is difficult to combine the test results of different persons to make an objective evaluation. The idea is presented to evaluate the seat static comfort by the objective interface pressure. The H-point machine (HPM) is the standard loading device which can be used to acquire the objective interface pressure. The test criterion was made, and the measurement consistency of the standard loading device passed the experimental verification. As a case study, five seats were selected to obtain the subjective rating of static comfort and the objective interface pressure data. Based on these data, the evaluation model of seat static comfort was established. The above standard loading device, the objective interface pressure test criteria, and the seat static comfort evaluation model form a comprehensive system for assessing seat static comfort. By using the system in evaluating and optimizing the studied seat and by the afterward validation, the method of evaluating the seat static comfort by the objective interface pressure illustrated reliable and accurate performance, which is easy to use and showed the good value of engineering application.
界面压力分布是评价座椅静舒适性的重要指标。目前,对座椅舒适性进行评估时,都是通过测试获取真人的界面压力,一致性和准确性较差,难以结合不同人的测试结果进行客观评价。提出了用客观界面压力评价座椅静态舒适性的思路。h点机(HPM)是标准的加载装置,可以用来获取客观的界面压力。制定了测试准则,标准加载装置的测量一致性通过了实验验证。作为案例研究,选取了5个座位,获得了主观的静态舒适度评价和客观的界面压力数据。在此基础上,建立了座椅静态舒适性评价模型。上述标准加载装置、客观界面压力测试准则、座椅静舒适性评价模型构成了座椅静舒适性评价的综合体系。将该系统应用于所研究座椅的评价与优化,并经过后续的验证,表明用客观界面压力评价座椅静态舒适性的方法性能可靠、准确,易于使用,具有较好的工程应用价值。
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引用次数: 0
Torque Distribution Control Strategy of Electric Wheel Loader with Multiple Drive Motors Based on Optimal Motor Efficiency 基于电机最优效率的多驱动电机电动轮式装载机转矩分配控制策略
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2023-03-15 DOI: 10.4271/02-16-03-0017
Yangjun Wang, Yulun Hu, Qiaohong Ming
Wheel loaders are widely used in construction projects. In order to reduce pollution and energy consumption, major wheel loader manufacturers are developing electric powertrain technology. Our main research goal is to reduce the energy consumption of a pure electric loader. This study is intended to build a vehicle simulation model of a multiple drive motor electric loader. According to the common working conditions and empirical formulas of the loader, the simulation data of the electric loader are calculated. The torque distribution control strategy based on the optimal efficiency of the motor is designed for the multiple drive motor electric loader and is compared with the equal proportion distribution control and the axle load ratio distribution control through simulation analysis. The simulation results show that the proposed torque distribution control strategy based on motor optimal efficiency can reduce energy consumption by 7–12%.
轮式装载机在建筑工程中应用广泛。为了减少污染和能源消耗,各大轮式装载机制造商都在开发电动动力总成技术。我们的主要研究目标是降低纯电动装载机的能耗。本研究旨在建立多驱动电机电动装载机的整车仿真模型。根据装载机的常用工况和经验公式,计算了电动装载机的仿真数据。针对多驱动电机电动装载机设计了基于电机最优效率的转矩分配控制策略,并通过仿真分析与等比例分配控制和轴载比分配控制进行了比较。仿真结果表明,基于电机最优效率的转矩分配控制策略可降低电机能耗7-12%。
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引用次数: 0
Pre-emptive Braking Control for Stability Improvement of Autonomous Vehicles on a Curved Road Based on Vehicle-to-Everything Technology 基于车联网技术的自动驾驶汽车弯道稳定性提升的先发制人制动控制
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2023-03-15 DOI: 10.4271/02-16-03-0018
C. Huang, Fei Lai
Vehicle-to-everything (V2X) technology has played an important role in improving the active safety of autonomous vehicles. In order to improve the stability of the autonomous vehicle on the curved road, this article presents a pre-emptive braking control method based on V2X technology. Instead of using the active safety system to try to stabilize the vehicle in case of danger, the pre-emptive braking action is proposed to reduce the vehicle speed in advance to a level that allows safe navigation of the turn to avoid danger. It is assumed that the friction and curvature of the curved road ahead can be obtained through V2X technology. Combined with a linear two degrees of freedom (2-DOF) bicycle model, an optimal control method is adopted to calculate the front and rear wheel steering angles to track the centerline of the curve lane. A more complex vehicle dynamics model established earlier is selected for simulation analysis to verify the proposed control method. The results show that the proposed control method can improve greatly the stability of the autonomous vehicle on the curved road.
V2X技术在提高自动驾驶汽车的主动安全性方面发挥了重要作用。为了提高自动驾驶汽车在弯道上的稳定性,本文提出了一种基于V2X技术的先发制人的制动控制方法。建议采取先发制人的制动措施,提前将车速降低到允许转弯安全导航的水平,以避免危险,而不是在发生危险时使用主动安全系统来稳定车辆。假设前方弯道的摩擦力和曲率可以通过V2X技术获得。结合线性两自由度(2-DOF)自行车模型,采用最优控制方法计算前轮和后轮转向角,以跟踪弯道中心线。选择先前建立的更复杂的车辆动力学模型进行仿真分析,以验证所提出的控制方法。结果表明,该控制方法可以大大提高自动驾驶汽车在弯道上的稳定性。
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引用次数: 0
Research on the Simulation of Human-Seat Interface Pressure with Consideration of the Effect of Seat Cover 考虑座套影响的人座界面压力仿真研究
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2023-01-05 DOI: 10.4271/02-16-03-0016
Tianming Zhang, Jindong Ren, Shimin Qi, Baoguo Yuan, Hao-Tse Huang
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引用次数: 1
Dimensionless Analysis of Rearward Amplification of Trucks with Single and Double Trailers: A Frequency Analysis 单双挂车载重汽车后向放大的无量纲分析:频率分析
IF 0.5 Q4 TRANSPORTATION SCIENCE & TECHNOLOGY Pub Date : 2022-12-08 DOI: 10.4271/02-16-03-0015
Zichen Zhang, Yang Chen, M. Ahmadian
{"title":"Dimensionless Analysis of Rearward Amplification of Trucks with\u0000 Single and Double Trailers: A Frequency Analysis","authors":"Zichen Zhang, Yang Chen, M. Ahmadian","doi":"10.4271/02-16-03-0015","DOIUrl":"https://doi.org/10.4271/02-16-03-0015","url":null,"abstract":"","PeriodicalId":45281,"journal":{"name":"SAE International Journal of Commercial Vehicles","volume":" ","pages":""},"PeriodicalIF":0.5,"publicationDate":"2022-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46415845","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 1
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SAE International Journal of Commercial Vehicles
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