Remanufacturing of automobile parts is important for increasing the recycling resources. ECU(Electronic Control Unit) systems are becoming an increasingly important part of an automobile. But production company are reported in the ECU remanufacturing industry of domestic automobile parts due to a lack of remanufacturing technology and marketability. This paper introduces the ECU of remanufacturing, also grasps the structure and the analyzes failure cause that is external factors and fault in the characteristic design and steps in the Independent ECU remanufacturing process. The ECU manufacturing industry of the US was examined. The results in this paper could be used as the system information for further remanufacturing industry of domestic automobile parts.

The comparisons of performance characteristics between the super-mirror face grinding machine using variable air pressure developed in this laboratory to grind precisely the sliding face of a surface hardened workpiece with thermal spray and the conventional one are investigated by measuring the surface roughness and hardness for a SCM440. To process variously workpiece according to shape, size and materials, the rotating and contacting forces of the developed grinding machine can be changed by air pressure. The surface roughness of processed workpiece can be also attained to state of mirror face by grinding precisely the sliding face with changing the rotating speed of diamond wheel. It is possible to be attached to the various machine tools because the super-mirror face grinding machine using variable air pressure is a small size. The grinding efficiency is elevated because it can be worked by two or more grinding machines attached to concurrently a machine tool for the large workpiece. In this study, results show that the cusp height of the super-mirror face grinding machine for the particle size of 100 and $1500No./mm^2$ is lower than that of the conventional one because the vibration is reduced by rotating very fast the diamond wheel with a pressed air and it can be processed by rotating the diamond wheel with a constantly varied air pressure perpendicular to workpiece surface, and that the workpiece in the super-mirror face grinding machine for the particle size of $3000No./mm^2$ can be processed to state of mirror face that is rarely seen by the cusp height. It is also found that the surface hardness of both the conventional and the super-mirror face grinding machines are increased as the particle size of diamond wheel is reduced, and the surface hardness of the super-mirror face grinding machine is HRC 1.1 ~ 1.8 higher than that of the conventional one.

Performance of DI diesel engine with high fuel injection method is directly related to the emission characteristics and fuel consumption. At present, diesel injection system with piezo element is replacing conventional solenoid type due to their faster electro-mechanical properties. In this study, it was investigated the sensitivity characteristics regarding internal hydraulic modeling based on the AMESim environment of piezo-driven injector The analytic parameter for this study defined such as In/Out orifice, injection hole's diameter and driven voltage on piezo stack. As the results, it was shown that these parameter influence on a fast response characteristics of piezo-driven injector. Also we found fuel pressure recovery time is faster about 0.1 ms due to larger IN orifice diameter. And larger OUT orifice diameter occurs maximum pressure drop with faster its timing of about 0.2 ms.

Purpose of this study is to develop virtual components and environment for developing a controller of an Active Air Suspension System in laboratory that slough off existing development environment using real vehicle test. This paper presents an air spring modeling and analysis of air suspension system for a commercial vehicle. Preferentially, It was performed vehicle test for pneumatic system and an air spring for characteristic analysis of system. Each component of an air spring suspension system was developed through emulations and modeling of system for pressure and height sensors in the basis on test results in SILS environment. Non-linear characteristics of air spring are accounted for using the measured data. Also, pressure and volume relations for vehicle hight control is considered. After performance verification of virtual model was performed, we developed virtual environment based on HILS for an Active Air Suspension System. We studied estimation and verification technology for control algorithm that developed.

Generally, a reduced chemical mechanism of n-heptane is used as chemical fuel of a 3-D diesel engine simulation because diesel fuel consists of hundreds of chemical components and various chemical classes so that it is very complex and large to use for the calculation. However, the importance of fuel in a 3-D simulation increases because detailed fuel characteristics are the key factor in the recent engine research such as homogeneous charged compression ignition engine. In this study, normal paraffin, iso paraffin and aromatics were selected to represent diesel characteristics and n-dodecane was used as a representative normal paraffin to describe the heavy molecular weight of diesel oil (C10~C20). Reduced kinetics of iso-octane and toluene which are representative species of iso paraffin and aromatics respectively were developed in the previous study. Some species were selected based on the sensitivity analysis and a mechanism was developed based on the general oxidation scheme. The ignition delay times, maximum pressure and temperature of the new reduced n-dodecane chemical mechanisms were well matched to the detailed mechanism data.

In this paper, a theoretical weight-reduction method was suggested to substitute an underframe material of a box-type bodyshell having cut-outs with an alternative light-weight material. To utilize the material substitution method previously developed for a box-type hybrid bodyshell not having cut-outs, we derived a box-type baseline model without cut-outs which is similar to the stiffness condition of a box-type bodyshell having cut-outs. To do this, the thicknesses of roof and walls of the baseline model were determined such that the deflection of the baseline model under a distributed vertical load condition is equal to the sum of the theoretical section deflections of the original box model with cut-outs. Next, to derive a hybrid bodyshell by under-frame material substitution, the material substitution method for a box-type hybrid bodyshell without cut-outs was applied to the box-type baseline model. Finally, we compared the FE simulation results of the derived hybrid bodyshells having cut-outs for various materials with the theoretical results of the suggested method, and we obtained their good correlations.

An analytical procedure to determine a proper profile of the spring rail that generates intended contact pressure distribution in the flat wiper blade is introduced. The flat wiper blade is one piece blade and subjected to pressing force at a center point. In this type of blade, contact pressure distribution in the tip of rubber strip is determined by the pressing force, the initial profile of the blade before contact and bending stiffness of the blade. Experimentally obtained bending stiffness of the blade assembly is almost identical to that of the spring rail. Principle of reciprocity has been used to define the initial profile of spring rail from the deformed profile that is assumed to be identical to the windshield glass profile. The procedure has been verified experimentally by measuring the contact pressure of the blade assembled with the spring rail designed by the procedure proposed here. Measured contact pressure distributions of the blades show good agreements with intended distributions over the entire blade span. Consequently, it can be concluded that proposed procedure has relatively good accuracy in developing the spring rail for flat blade having a specific contact pressure distribution.

The estimation of occupant injury risk at crash accident is one of the most important assessments for the vehicle crashworthiness performance. The design of safety devices such as occupant restraining system also depend on the kinematics of occupant and its injury risk. The real world in-depth accident investigation provides detailed and realistic information of vehicle damage and occupant injury as well as the accident conditions. This paper introduces a statistical analysis of NASS/CDS database and domestic accident data to correlate speed change, vehicle damage extend, and occupant injury at frontal crash. The maximum crush extend shows a linear relationship with the effective impact speed. The injury risks of the occupant with and without restraining were also respectively quantified with the crush extend. This result can be effectively used for the emergent rescue of crash victims with automatic crash notification system.

This study is to develop and evaluate an AFS and an ARS controllers to enhance lateral stability of a vehicle. A sliding mode control (SMC) and a fuzzy logic control (FLC) methods are applied to calculate the desired additional steering angle of AFS equipped vehicle or desired rear steer angle of ARS equipped vehicle. To validate AFS and ARS systems, an eight degree of freedom, nonlinear vehicle model and an ABS controllers are also used. Several road conditions are used to test the performances. The results showed that the yaw rate of the AFS and the ARS vehicle followed the reference yaw rate very well within the adhesion limit. However, the AFS improves the lateral stability near the limit compared with the ARS. Because the SMC and the FLC show similar vehicle responses, performance discrimination is small. On split-${\mu}$ road, the AFS and the ARS vehicle had enhanced the lateral stability.

This paper presents the lane change system for collision avoidance. The proposed algorithm for the collision avoidance consists of path generation and path following. Using a calculated TTC (Time to Collision), partial braking is operated and collision avoidance path is generated considering relative distance, velocity and acceleration. Based on the collision avoidance path, desired yaw angle and yaw rate are calculated for the automated path following. The lateral controller is designed by a Lyapunov function approach using 3 D.O.F vehicle model and vehicle parameters. The required steering angle is determined from wheel velocity, longitudinal and lateral velocity in order to follow the desired yaw angle and yaw rate. This system is developed MATLAB/Simulink and its performance is evaluated using the commercial software CarSim.

Recently the use of gas spring in the combat and commercial vehicle's suspension is increasing. Because of its nonlinear characteristics, the gas spring can support wide range of dynamic loads and gives good ride quality. In design of gas spring, isothermal and adiabatic processes are applied generally, but those processes could not produce heat transfer effect in the simulation. So in this study, heat transfer differential equation and BWR/Ideal state equation are used to calculate the pressure of gas spring which is changing with time. The numerical analysis showed that the pressure of gas spring forms a hysteresis loop in the both of the state equations. But the peak pressure value of BWR equation over 0.1Hz frequency are higher than that of adiabatic process. And the test results showed that the differences between test results and ideal gas equation are smaller than those of BWR equation, so the ideal equation is more accurate than BWR equation in this case.

Conventional method to estimate mass of particulate matter accumulated in diesel particulate filter is to use pressure difference between upstream and downstream of the filter. Then measured pressure difference should be compared that of clean condition which is no particulate matter accumulated in DPF. During regeneration soot oxidation is also estimated by same method. This methodology, however, has demerit on accuracy because of pressure difference deviation of clean DPFs and pressure difference caused by non-carbon based PM which is different from that of caused by carbon based PM. This study suggests new methodology to estimate accumulated soot oxidation rate through exhaust gas characteristics during regeneration. Results, more high accuracy of soot oxidation was obtained by analysis of relationship between fuel mass and concentration of carbon dioxide and oxygen.

New USNCAP has been carried out by NHTSA including front and side crash from MY2011. In this paper, test results for USNCAP Side crash were reviewed by statistical analysis. This review focused on side crash test results to investigate the effect of changes from new USNCAP side crash test protocol among 30 passenger cars. These results were summarized as followings. Total number of 5 star vehicles on the front seat dummy (16 vehicles, 53.3%) was slightly smaller than the rear seat's (17 vehicles, 56.7%) in MDB test. For the ES-2re dummy, chest injury, ie maximum rib deflection contributed to 66% in the mean value of $P_{joint}$. Pelvis injury was highly dependent upon performance up to 87% in the SID-IIs dummy cited on the rear seat in average $P_{joint}$. For Pole test, pelvis injury made contribution to the average performance to 83%. For standard deviation, it showed the largest value in the same body region as the mean value for each dummy. Overall front seat performance showed 14 vehicles, 44.6% with 5 star vehicles less than each MDB or Pole test result. This result showed that performances in MDB test were different pattern to Pole test on driver position. Number of 5star vehicles for overall side NCAP performance are 18 passenger cars (60%). Curtain airbag and driver thorax airbag were equipped in all test vehicles. One vehicle is equipped with thorax airbag in the rear seat. Results from two side tests considered as reliability problem, ie the cause for large standard deviation in side crash test. Consequently, the countermeasure for new USNCAP side crash test is essential to design the effective side structures for side collision and to control well dummy kinematics with curtain and thorax airbag in order to reduce chest and pelvis injuries.

High efficiency operation is required for motors of vehicle to increase fuel efficiency due to the regulation of exhaust gas. This paper presents a control method of fuel pressure to increase fuel efficiency and a sensorless control method of BLDC motor to get higher efficiency than conventional brushed DC motor. Initial rotor position of BLDC motor is detected from current value that is occurred by test voltage pulse and rotor is accelerated by defined sequence to enter sensorless operation mode. The algorithm to control flow rate of fuel pump uses PI controller that is control motor speed to maintain the target fuel pressure commanded by ECU.

Rail geometries such as cant, grade and curvature can be easily represented by means of a track coordinate system. In this analysis, in order to derive a dynamic and constraint equation of a wheelset, the track coordinate system is used as an intermediate stage. Dynamic and constraint equations of railway vehicle bodies except the wheelset are written in the Cartesian coordinate system as a conventional method. Therefore, whole dynamic equations of a railway vehicle are derived by combining wheelset dynamic equations and dynamic equations of railway vehicle bodies. Constraint equations and constraint Jacobians are newly derived for the track coordinate system. A process for numerical analysis is suggested for the derived dynamic and constraint equations of a railway vehicle. The proposed dynamic analysis of a railway vehicle is validated by comparison against results obtained from VI-RAIL analysis.

In this study, to develop a light weight duo type aluminum LPG tank in stead of a conventional steel tank optimization technology is used. Two types of optimization method are carried out for internal compression test simulation of a LPG tank. The first is the thickness only optimization of LPG tank components. The second is the thickness and shape optimization. For the case of the thickness only optimization the weight reduction rate of an optimized tank compare to that of the initial design is 42%. Also 48% weight reduction was achieved for the case of the thickness and shape optimization.

It is very important to determine specifications of components included in the drive-train of vehicles at the initial design stage. In this study, component sizing process and performance analysis for Extended-Range Electric Vehicles (E-REV) are discussed based on the foundation of determined system configuration and performance target. This process shows sizing results of an electric driving motor, a final drive gear ratio and a battery capacity for target performance including All Electric Range (AER) limit. For E-REV driving mode, the constant output power of a Gen-set (Engine+Generator) is analyzed in order to sustain State of Charge (SOC) of the battery system.

CNG buses has contributed to improve air quality in cities. But it is difficult to meet the next emission regulations such as EURO-VI without the help of additional post-processing device. Hydorgen has higher flame speed and lower combustion temperature that make it thermal efficiency increase with leaner operation. Using hydrogen natural gas blend (HCNG) fuel is promising technology which can reduce $NO_x$ and $CO_2$ emissions for a natural gas vehicle. However, fuel flow rate of HCNG should be increased since hydrogen's energy density per volume is much smaller than natural gas. In the present study, the characteristics of fuel supply system and its applicability were evaluated in a heavy duty natural gas engine. The results showed that the potential of fuel pressure regulator and fuel metering valve had enough capacity with HCNG. Employed mixer did not affect the distribution characteristics of mixture.

Expansion joint has been utilized in many areas including automotive bellows for exhaust system. Usage of expansion joint has been increased due to its inherent flexibility and excellent anti-vibration property. Simple shape of expansion joint is modeled to understand the behavior of joint system. 27 design cases using 3 design factors with 3 levels are constructed by design of experiment. Each case is simulated to find the most influential design factors. Response for this study, maximum stress in the expansion joint, has been used to determine main design factors of joint. Among the 3 design factors, factor B has affected greatly a response in the formation of optimum shape of joint. Also, interaction factor, $A{\times}B$, has also showed its influence to the response of joint. This study showed that design of experiment combined with finite element analysis could be used in the design decision process effectively in the design of expansion joint.

ESD damage by Charged Cable Model (CCM) is introduced. Due to its own impedance characteristic unlike Human Body Model (HBM) or Machine Model (MM) electric component can be destroyed even though it is located after typical protection circuit. Possible mechanism of ESD damage to automotive electric control unit (ECU) in vehicle environment by CCM discharge was investigated. Based on investigation, field-returned vehicle whose ECU is expected to be damaged by CCM discharge was tested to reproduce it and similar electric component destruction inside ECU was observed. Suggestions to reduce the possibility of ESD damage by CCM are introduced.