There is an ongoing effort in the industry to develop an accelerated corrosion test for automotive heat exchangers. This has become even more important as automakers are focusing on corrosion durability of 15 years in the field versus current target of 10 years. To this end an acid immersion test was developed and reported in a previous paper for condensers (1). This paper extends those results to evaporators and establishes the efficacy of the test using these results and those reported in the literature. The paper also discusses variability in corrosion test results as observed in tests such as ASTM G85:A3 Acidified Synthetic Sea Water Test (SWAAT), and its relation to field durability.

Rungta, Ravi, Pandit, Noori

Development of Parallel and Direct Cooling System for EV/FCEV Inverter

2018-01-045404/03/2018

This paper presents the direct liquid-cooled power module with the circular pin fin which is the inverter parallel cooling system for high output EV/FCEV. The direct cooling system of a conventional inverter is designed to supply coolant along the direction in which the heating element such as Si-chip is disposed and discharge coolant to the opposite side. In case of the inverter, the higher the output is, the larger temperature difference between inlet and outlet becomes due to the heat exchange of the heat generation element, so that temperature difference depends on the position of Si-chip. Since lifetime is judged on the basis of maximum temperature of Si-chip, the inverter itself must be replaced or discarded due to durability of the inverter even though Si-chip can drive further. The simple way to solve this problem is to increase cooling flow rate, but this leads to excessive increase in pressure loss due to circular pin fin. Purpose of this study is the concept of parallel

Seo, Heung Seok, Shin, Dongmin

Road Loads for Durability Analysis using Virtual Iterations

2018-01-056704/03/2018

Durability assessment for suspension systems and vehicle structures requires loads on each component from different road profiles. If a new vehicle is to be assessed for durability early in the design phase, a prototype must be built and tested on proving grounds. This can be time consuming and expensive. A large number of design configurations are considered for designing new vehicles in the truck industry. However, the number of prototypes that can be built and tested will be limited. The only options would be to depend on generic load cases or to use a virtual method that can translate limited measurements to various configurations. Roush CAE has successfully implemented a method called virtual iterations to back calculate the road profiles from the CAE model of a vehicle that has been tested on the desired road tracks. This paper presents the various steps involved in the virtual iterations process, the full vehicle model setup and the most important parameters which affect the

Vemuri, Achyut, Talekar, Nitin, Avutapalli, Bhaskar

An Optimal Design of Vehicle Swing Door Using Metamodeling Techniques

2018-01-102204/03/2018

In side-closures’ design, mass reduction provides numerous benefits in addition to reduced cost. This paper presents a Meta model based non-linear durability optimization to develop a lightweight structure for vehicle swing door. A surrogate model developed is using Kriging methodology and the thickness of the door components are given as input design variables. Adaptive Multi-Objective Genetic Algorithm (AMGA), a nonlinear optimization technique, is used in this study, to formulate the mass minimization under durability constraints. The optimized swing door design shows the overall mass saving of ~10% over initial design in terms of frame and sag deflection. The present investigation shows better effectiveness and practical applicability to develop the lightweight structure for the vehicle swing door. From the comparative study, Kriging method is found to be more effective in terms of measuring the accuracy, robustness and efficiency of the results than the Radial basis function (RBF

Zaman, Thoheer, Kumar, Arun, Valiyaveettil Nazir, Fazil, Velu, Jayaprakash, Appana, Kameshwara rao

Effect of Hinge Axis Inclination and Hinge Tolerance on Door Strength under Abuse Loads

2018-01-048004/03/2018

As revealed from J. D. Power surveys, today most vehicle owners consider perceived quality as a direct indicator of the vehicle build quality and durability. [5] The problem has become more prominent and noticeable in recent times, due to the desire for reduced cost, reduced weight targets, aesthetic demands, and crash requirements. The performance of the door assembly when subjected to an abuse load of sag and over opening is one such perceived quality indicator which gives the customer the first impression about the engineering and build quality of the vehicle. Door hinge inclination and hinge contact flushness tolerance are the major design parameters affecting this performance. Although these are an important design parameter, the precise quantification of the effect of these design parameters on door performance under abuse loading has remained somewhat elusive. Traditionally, this assessment was done using physical testing, thumb rules and best practices rather than using

Bhagate, Rohit Kuber, Bhirud, Pankaj, Virmalwar, Ajay

2021-12-29.TEST Delivering Maximal Robustness to Your Automotive ECU on a Frugal Budget *CSP Meta Testing*

2018-01-0002

04/03/2018

Automotive engineering has been a game of delivering more value with minimal resources confronting conflicting design choices at every design step. As more and more electronics enters the game, it becomes imperative to critically evaluate various design choices to deliver a robust hardware backbone which guarantees a robust performance on an ever-reducing budget. Hardware interface with the outside environment in particular needs to be equipped with a significant robustness. Harsh transients, tough environmental conditions, further complicate the rules to the game.

Vaidya, Vishwas

Rugged Server and Display System

TBMG-2877504/01/2018

General Micro Systems Rancho Cucamonga, CA (800) 307-4863

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