Automotive Industry Standards Research Articles

Research on the application of fiber-optical current sensor in power battery

Abstract Compared with the total current, the current in each parallel branch will help to achieve better battery management for new energy vehicles. However, today, accurate measurement of branch current is very difficult because the space between branches in the power battery pack is very limited. In this study, the fiber-optic current mini-sensor is used to meet this challenge. A saddle-sensing fiber structure has been designed to achieve surface measurement in response to the specific interconnection of circuitry in battery packs. A computer simulation was used to validate the feasibility, and experimental testing showed positive results. The specific experiments confirmed that the relative error between the saddle fiber-optic current sensor and conventional fiber-optic loop current sensor does not exceed 0.0119%. It meets the requirements of the automotive industry standards.

Design and development of a three-phase Net Meter for V2G enabled charging stations of electric vehicles

In today’s scenario, the estimated exponential growth of Electric vehicles (EVs) has raised the concern about the spike in electricity demand. Vehicle-to-Grid (V2G) technology has emerged as an effective solution to support the grid that operates EV in charging and discharging mode. V2G establishment involves three elements amongst the bidirectional metering plays a significant role. This paper aims to design and develop a cost-effective three-phase Net Meter at technology readiness level (TRL) 9 for V2G enabled charging stations at levels 1 and 2. It allows the bi-directional flow of current and generate bills at an associated subsidize rates. A scalable design to serve two different charging levels is adopted to achieve higher flexibility without any change in the hardware. The compilation is done considering the automotive-grade with the International Electrotechnical Commission (IEC) standards to assure class 1 accuracy. By implementing the electrical quantities defined in IEEE std. 1459-2010, coherent sampling is adopted to compute Fast-Fourier Transform (FFT). It shows a better spectral resolution and eliminates the overheads of windowing selection. To provide a cost-effective solution, C2000 Digital Signal Processor (DSP) based TMS320F28069 microcontroller is used in the application. The prototype assures the automotive industry standards (AIS) for electromagnetic compatibility in the practical environment. In experimentation, configured two test benches for three test sets operating under different conditions. The result has shown class 1 accuracy over a wide range and better harmonic detection in real-time. • Design of a cost-effective three-phase Net Meter for V2G enabled charging stations. • Net Meter is examined with AIS to verify compliance in the automotive application. • The proposed Net Meter is validated with a real-time charger in the V2G application.

Hybrid and intelligent textile structures for composites structural health monitoring in automotive industry

Automotive industry is a sector where the technologic development aims to fulfil high standard requirements regarding safety, energy efficiency and environmental pollution. The development and application of technical textiles as a reinforcement for polymeric matrixes to form high performance composite materials that comply with automotive industry standards has been increasing. Nowadays composite materials are an integral part of vehicles bringing advantages both in terms of mechanical performance and lightweighting. The current technical textiles applied in this sector focus on high mechanical performance through the application of fibres such as carbon fibre, aramid and glass fibre, these textiles combined with thermoplastic materials result in recyclable composites that reduce environmental pollution. This work was developed in the framework of TexBoost project co-financed by COMPETE 2020 – the Operational. Programme for Competitiveness and Internationalization, under Portugal 2020 through the European Regional Development Fund (ERDF). TexBoost PPS3 (AN1/AN2) main objective is the development of smart and hybrid textile structures that when integrated in the matrix result in not only high mechanical performance composites but also smart composites with structural health monitoring capabilities, allowing the evaluation of potential structural fails and necessity of vehicle part replacement (preventive maintenance of automotive parts). Therefore, different types of sensing fibres are being developed, characterized and weaved in a textile structure with carbon fibres to be further integrated in polymeric matrixes. All the developed composites are being characterized both in terms of mechanical and electrical performance.&nbsp

Structural Analysis of Motorcycle Alloy Wheel

Alloy wheels in the motor cycle play major role to carry the load over the spoke wheels. The shape and orientation of the spokes are responsible for withstand the loads which are acting on the alloy wheel rim and hub bearing surface. These alloy wheel spokes are subjected to different types of loads i.e., radial loads, impact load, bending load, torsion load and maximum deflection load. So it is necessary to study the response of the wheel under these types of loads before the product going into the market. In the present article 4 models of motor cycle alloy wheel are modeled based on the dimensions in the reference article. The material chosen for the analysis of the alloy wheel is aluminum alloy which is homogenous in nature having isotropic properties. The magnitude of the five different loading conditions and boundary conditions are taken from the Automotive Industry Standards (AIS). The four models of alloy wheels are analyzed under radial, impact, bending, torsion and maximum deflection loads cases by using by using ANSYS workbench. The results show that all four models are having enough fatigue life, strength and stiffness against the different loading conditions.

Thermal Properties of Bayfol® HX200 Photopolymer.

Bayfol® HX200 photopolymer is a holographic recording material used in a variety of applications such as a holographic combiner for a heads-up display and augmented reality, dispersive grating for spectrometers, and notch filters for Raman spectroscopy. For these systems, the thermal properties of the holographic material are extremely important to consider since temperature can affect the diffraction efficiency of the hologram as well as its spectral bandwidth and diffraction angle. These thermal variations are a consequence of the distance and geometry change of the diffraction Bragg planes recorded inside the material. Because temperatures can vary by a large margin in industrial applications (e.g., automotive industry standards require withstanding temperature up to C), it is also essential to know at which temperature the material starts to be affected by permanent damage if the temperature is raised too high. Using thermogravimetric analysis, as well as spectral measurement on samples with and without hologram, we measured that the Bayfol® HX200 material does not suffer from any permanent thermal degradation below C. From that point, a further increase in temperature induces a decrease in transmission throughout the entire visible region of the spectrum, leading to a reduced transmission for an original 82% down to 27% (including Fresnel reflection). We measured the refractive index change over the temperature range from C to C. Linear interpolation give a slope for unexposed film, with the extrapolated refractive index at C equal to . This refractive index change decreases to when the material is fully cured with UV light, with a C refractive index equal to . Spectral properties of a reflection hologram recorded at 532 nm was measured from C to C. A consistent 10 nm spectral shift increase was observed for the diffraction peak wavelength when the temperature reaches C. From these spectral measurements, we calculated a coefficient of thermal expansion (CTE) of by using the coupled wave theory in order to determine the increase of the Bragg plane spacing with temperature.

Self-weight and Durability Analysis of Bus Body Structure using Finite Element Analysis

Self-weight and durability analysis of non-airconditioned sleeper bus has been carried in present work. Automotive industry standards (052 and 119) are used to freeze bus dimensions. Generative surface design is used in preparation to compute model. The bus superstructure behaviour is simulated for load on cant and waist rails for self-weight analysis. Bump analysis is carried out considering total failure of suspension system. Behaviour of bus during bump is simulated for two situations i.e. bump focre applied to front left wheel suspension location and all other suspension locations are fixed and force applied to front two wheel suspension locations and rear two wheel suspension locations are fixed. Behaviour of bus under torsional load for two cases viz first, force is applied to left of front suspension location in upward direction and other on to right suspension location in downward direction while the rear wheel suspension points are fixed and in second case, force is applied to left of front suspension in upward direction while the second one is applied to right in rear suspension location. Braking and double lane change load conditions are simulated with a braking efficiency of 80% and a lateral load of magnitude 0.4g is evaluated. Durability of the bus based on outcomes from braking, bump, torsional and double-lane change road-load situations is evaluated. The stress and deflection magnitudes are in good agreement with the results available in literature.

Modal Analysis of Bus Body Structure using Finite Element Analysis Technique

Present work deals with evaluation of dynamic characteristics of a bus body structure. The bus under consideration is a sleeper non-air conditioned vehicle for a passenger capacity of thirty and it is designed adhering to automotive industry standards. Modal analysis of the proposed bus design is carried using Ansys Workbench. With the aid of modal analysis ten mode shapes of the bus are postulated, corresponding frequencies and deflections are estimated. Mesh generator is used to mesh the complex bus model. The deflection and frequency magnitudes of proposed bus model is found with the help of Finite Element Analysis (FEA) technique and they are in good agreement with experimental results available in literature. Engine being the prime source of excitation, it’s frequency is compared with the frequencies determined by FEA of the proposed bus body and it is observed that the frequencies of the bus body for ten different modes are far less than the minimum resonant engine frequency.

Crash Analysis of Bus Body Structure using Finite Element Analysis

Crash analysis of non-air-conditioned sleeper bus has been carried in present work. Using relevant automotive industry standards (052 and 119) bus dimensions are considered for design. Surface modeling technique is used to prepare computer aided model. Further the bus design is freeze using finite element analysis for different crash conditions as front impact, side impact and rear impact. Crash analysis of the proposed bus design is carried using Ansys Workbench. Using the outcomes from finite element analysis as stresses, deflections, internal and kinetic energies during various crash conditions are estimated. Mesh generator is used to mesh the complex bus model. The stress and deflection magnitudes of proposed bus model are in good agreement with the experimental results available in literature. Design improvements are made using the finite element analysis outcomes, observing the deformation patterns additional pillar members of suitable length are added to increase the dynamic crush and further enhance occupant safety during collisions.

Processes of innovations implementation into Industry 4.0. automotive industry standards

Industry 4.0 is a designation for the automation of production and labour market changes that this will bring. It is based on the boom of digitization, robotization and automation. The Industry 4.0 concept brings the benefits of increasing productivity, reducing costs and making mistakes they result from the involvement of more sophisticated machines in all company processes. The aim of this article is to present the ongoing fourth Industrial revolution (Industry 4.0.) and the impact of innovations in the company. Implementation of innovations are presented, innovation cycle itself and innovations effect on companies. Industry 4.0 makes full use of emerging technologies and rapid development of machines and tools to cope with global challenges in order to improve industry levels. Also, concepts of innovation and digitization are currently a central task for future competitiveness. Therefore, companies are establishing brand new departments focused on innovations in Industry 4.0. Industry 4.0 and digital transformation bring new opportunities in the areas of customer search, improving product offerings, and new opportunities for creating and delivering value, thus opening up new ways to create profit. First part theoretically describes various approaches to this problematic, description of four industrial revolutions and Industry 4.0. itself. Next implementation of innovations is presented, innovation cycle itself and innovations effect on companies. The last part of the article covers innovations in context of Industry 4.0. (both methods and technology) within the automotive industry. Main impact of the work is that this article puts in correlation both importance of the ongoing fourth industrial revolution with innovations in the company. It is very interesting, that these innovations with modern technologies help companies to operate more effectively.

Analysis of Vibration Characteristics of Transport Utility Vehicle by Finite Element Method

Present work deals with the design and analysis vibration characteristics for transport utility vehicle. The transport utility vehicle is designed using automotive industry standards. The dynamic behaviour of vehicle depends on the selection of overall dimensions, wheel base, track width, overall height and width that are decided using central motor vehicle rules. The selected dimensions for vertical and horizontal pillar members of the transport bus are modified to enhance the strength, stiffness and stability of the superstructure during travel. This increased stability enhances the ride comfort and passenger safety. Analysing the effect of utilizing manual meshing in complex areas of a transport utility vehicle for vibration analysis and passenger ride comfort has also been carried out. Modal analysis to evaluate the dynamic behaviour of transport utility vehicle model is also carried. Further with the use of finite element analysis deflection vehicle structure is evaluated. The outcomes from the analysis are compared with the behaviour of chassis mounted platform in dynamic conditions and are found in close correlation. The vehicle structure behaves as a single entity in dynamic situations, so surface model is prepared. Element selection for the finite element analysis is carried by considering plane stress condition. Two-dimensional quadrilateral shell elements are extensively used for meshing of the computer model of the vehicle structure. Complex areas in the optimised vehicle structure are meshed using relevant combination of quads and trias. The values of vector sum displacement and frequencies are found to be in good agreement with the experimental ones.

Reliable and Flexible Quality Management Systems in the Automotive Industry: Monitor the Context and Change Effectively

Suppliers have an increasing role in the automotive industry and Quality Management Standards (QMS) are key requirements to ensure a competent supplier network, with properly selected and qualified suppliers.By surveying IRCA registered auditors concerning ISO 9001:2015 certified organizations, this research highlights the need for the automotive industry OEM and Suppliers to properly monitor the organizational (internal and external) context and identify the key issues that affect the ability of their QMS to deliver quality products, and to plan, design, implement and control change in an effective and timely manner, within the whole supply chain.

A manufacturing-oriented model for evaluating the satisfaction of workers – Evidence from Turkey

Job satisfaction, in terms of worker's satisfaction, is one of the intensively studied areas in human resource and management. However, there is little information available on how ergonomics and the manufacturing environment affect job satisfaction. This study analyzes the extent of the relationship between job satisfaction and work and workplace related conditions. A conceptual model is proposed to evaluate job satisfaction that considers 34 elements in four categories: manufacturing systems, facility design, safety and ergonomics, and human resources and management. A survey of 169 blue-collar workers working in the automotive industry was conducted to investigate the applicability of the model. A comprehensive exploratory factor analysis was used to determine inter-related elements, their underlying factors and their effects on job satisfaction. The analysis revealed 6 factors with 18 related elements. From a multi linear regression analysis, we develop a job satisfaction model built on factors of human resource policies, safety, ergonomics, air quality, thermal comfort and disturbing equipment. The results reveal that ergonomics plays the most important role in workers' satisfaction for the respondent Turkish automotive workers. In contrast, human resource policies seem not play a critical role in job satisfaction because of higher standards in automotive industry compared to other industries in Turkey.

DESIGN AND DEVELOPMENT OF A TEST RIG TO ESTIMATE FATIGUE LIFE OF THE TIMING BELT OF I. C. ENGINE

Timing belt mechanism of an internal combustion engine synchronizes the rotation of the crankshaft and camshaft. The power developed in I.C. engine, some power of that is utilized to operate timing belt mechanism. Timing valves are operated by camshaft with lever and spring mechanism. Engine valve should open and close at proper time during each inlet and exhaust strokes of the cylinder. The failure of timing belt in I.C. engine leads to problem to valve timing and this can cause collision between valves and piston in engines. It can causing serious engine damage by bending valves and breaking piston and it leads to complete breakdown or catastrophic engine failure. A large number of factors have influence on timing belt drive’s lifetime: wear, amount of transmitted power, operating environment, coaxiality of shafts and belt pulleys, handling before and during assembly and others. Failure of belt most frequently occurs because of damage of belt’s and belt pulley’s teeth or damage of tractive element due to wear and fatigue. Considering their purpose and very important role in transmission of power, motion and valve timing, it is necessary to know fatigue life of timing belt. The study was thus needed to analyze fatigue failure of timing belt. The paper includes designing and development of a test rig for estimation fatigue life of timing belt. Test rig is developed based on ISO and Automotive industry standards. The study involves observation of change of physical properties, wear and geometric parameters of the belt. Thereafter tooth deflection and tooth root strain is obtained by calculation. Tooth deflection and tooth root strain play important role in fatigue of the belt.

Knowledge Repository for Fmea Related Knowledge

Abstract This paper presents innovative usage of knowledge system into Failure Mode and Effects Analysis (FMEA) process using the ontology to represent the knowledge. Knowledge system is built to serve multi-projects work that nowadays are in place in any manufacturing or services provider, and knowledge must be retained and reused at the company level and not only at project level. The system is following the FMEA methodology and the validation of the concept is compliant with the automotive industry standards published by Automotive Industry Action Group, and not only. Collaboration is assured trough web-based GUI that supports multiple users access at any time

Quality Evaluation for Automobile Seat Woven Fabric

Industrial textiles is designed with engineering structure textiles. Transportation textiles is one of the main types of industrial textiles. Automobile seat fabric is one of the decorative materials in automobile textile fabrics. The fabric should have soft handle, good air permeability, coordinate color, luxury and generous pattern, wear-resisting, anti-fouling, flame retardant, certain friction factor and antistatic property. In recent years, requirements for automobile textiles of safety, health, environmental protection is more and more high. In order to evaluate the automobile seat woven fabric quality, need to have a simple and effective standard. Quality indexes should be comprehensive. The test method of quality index should be operable. In the existing relevant standards, the test content is not consistent. The existing relevant standards are national standards, textile industry standards and automotive industry standards. Within textile industry standard FZ/T 24005-2010 wool textiles for chair, the technical requirements include safety specification, classification rules, physical quality rating, internal quality rating, appearance quality rating. For flame retardant performance, must meet the following requirements: damaged length ≤200mm, afterflame time ≤15s. Within national standard GB 8410-2006, flammability of automotive interior materials, for flame retardant performance, must meet the following requirements: burning rate ≤100mm/min. Within automotive industry standard QC/T 633-2009 the seats of passenger vehicles, for safety specification, seat fabric must meet the B grade in GB 18401. Based on some effective standard, established suitable standard for automobile seat woven fabric. The standard covers quality evaluation content, performance levels and the methods of test to be used to determine these performance levels.

REVIEW OF SPECIAL STANDARDS IN QUALITY MANAGEMENT SYSTEMS AUDITS IN AUTOMOTIVE PRODUCTION

Abstract Quality management systems (QMS) in automotive industry generally have several differences in comparison with other industrial branches. Different customers have their own specific requirements, including requirements for quality audits. Audits are one of the coretools of quality management to make the PDCA (Plan - Do - Check - Act) cycle work. As a matter of fact, compliance with ISO/TS 16949:2009 requirements is a condition for supplying the automotive industry. However, there are some standards which co-exist together with the ISO 9001 based management systems and technical specification for QMS in automotive ISO/TS16949. Which are those specific standards in automotive industry and what standard to use and why - those are the questions to be answered in this paper. The aim of the paper is to review what standards are used for audits implementation in automotive industry in the Slovak Republic, and why the organizations keep following those “extra” standards even if certification for ISO/TS 16949 is required by all the car makers. The paper is structured as follows: after short introduction to the topic and related terms, presented is our methodology. . In the third section, the achieved results are discussed. And finally, the principal findings of the paper, limitations and conclusions are presented.

Crash Analysis of Front under Run Protection Device using Finite Element Analysis

Under-running of passenger vehicles is one of the important parameters to be considered during design and development of truck chassis. Front Under-run Protection Device (FUPD) plays an important role in avoiding under-running of vehicles from front side of a truck. An explicit finite element software Altair Radio's is used in FUPD analysis for impact loading. The deformation of FUPD bar and plastic strains in FUPD components are determined in the impact analysis for predicting failure of the system to meet the compliance requirements as per IS 14812-2005. Additionally, failure analysis of the FUPD attachment points with chassis is determined. Physical testing can be reduced significantly with this approach which ultimately reduces the total cycle time as well as the cost involved in product development. I. INTRODUCTION In head-on collisions of bonnet-type cars (sedans, wagons, hatchbacks, etc., here after referred to simply as cars) and heavy trucks, the car often under runs the front of the truck, and the car crew received the serious or fatal injuries. The crash safety performance of the car depends on the way its structural parts interact with the structural parts of the truck. FUPD equipment that prevents the car from under running the truck is obligatory in India. The required strength and ground clearance of FUPDs are specified in the relevant regulations used in India. Accidents between cars and trucks are among the most fatal accidents because of the car under running. This phenomenon leads to serious and fatal injuries for car occupants because of intrusion of the car structure into the passenger compartment. This has led to the development of test procedure for energy-absorbing front under run protection systems for trucks. There is a summary of accident analysis of several European countries, where we can read that of the 48000 fatally injured people in road traffic accidents in 1992, 13000 people were killed in accident with trucks involved, about 7000 were car occupants and 4200 of them were killed in car-to-truck frontal collisions. It is very common incident that during the accident a passenger vehicle going under the heavy commercial vehicle either from rear, front or side. During collision, there is a risk that the passenger vehicle will penetrate under (run under) the front or rear part of the truck and thus there are great chances of fatal injuries to the occupants of the passenger car. The design and the strength of the Front Under-run Protection Device (FUPD) should be such that it should take the impact load and avoid the under running of the passenger vehicle from the front of the heavy commercial vehicle. Physical testing is done with 5 impactors with specific load and sequence; hit the FUPD to evaluate its strength. This scenario is replicated using Finite Element (FE) solvers like Altair Radio's. The load taken by the FUPD is evaluated using reaction forces. This virtual validation is important for cost saving in the tooling, repetitive testing of the vehicle and cost involved in the same. The Government of India felt the need for a permanent agency to expedite the publication of standards and development of test facilities in parallel when the work on the preparation of the standards is going on, as the development of improved safety critical parts can be undertaken only after the publication of the standard and commissioning of test facilities. To this end, the Ministry of Surface Transport (MOST) has constituted a permanent Automotive Industry Standards Committee (AISC) vide order No.RT-11028/11/97-MVL dated September 15, 1997. The standards prepared by AISC will be approved by the permanent CMVR Technical Standing Committee (CTSC). After approval, the Automotive Research Association of India, (ARAI), Pune, being the Secretariat of the AIS Committee, has published this standard. For better dissemination of this information ARAI may publish this document on their web site. In Indian vehicles FUPD, still it is not implemented. By this analysis will know that how it can reduce passenger life while impacting to car, pole..Etc. FUPD is designed with the help of European standard dimensions and then will apply the initial velocity from front side and check the strength of the FUPD, if it safe then this thesis is successfully projected. It's a trial and error process. The strategy in selecting a test procedure is to identify tests that have the potential to improve the crash protection provided across a broad range of real-world impact conditions. The crash test conditions, e.g., impact