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30 May 2023, Volume 48 Issue 10 Previous Issue   
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New Energy Vehicle
Intelligent Connected Vehicle
Design and Research
Testing and Experiment
Process and Equipment
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New Energy Vehicle

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Modeling and Simulation of Arc Fault in the Charging System of Electric Vehicles DU Xinyu 2023, 48(10): 1-6.  DOI: 10.16638/j.cnki.1671-7988.2023.010.001 Abstract ( )   PDF (935KB) ( )   Due to the loose connection of high-voltage line, unstable suction of relay, aging damage of line insulation and other reasons, arc fault is often caused, which poses a great threat to the safety of the circuit. The current electric vehicle charging system can not effectively detects the arc fault in the charging process. This paper establishes an arc fault model of charging system. The model includes vehicle charging circuit model, arc fault model and pack model. The three phase pulse width modulation (PWM) rectifier circuit and phase shift full bridge transform circuit are used to simulate the vehicle-mounted charger, the Cassie arc model is used as the direct current series arc fault model,and the battery model in MATLAB toolbox is used to simulate the battery. Through computer simulation, the changes of terminal voltage of power battery pack, voltage at both ends of arc and circuit current under different state of charge are obtained, which provides a theoretical basis for electric vehicle charging circuit arc fault identification. References | Related Articles | Metrics

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Dynamic Temperature Rise Analysis of New Energy Vehicle Controller IGBT DANG Yanhui 2023, 48(10): 7-11.  DOI: 10.16638/j.cnki.1671-7988.2023.010.002 Abstract ( )   PDF (1330KB) ( )   For the thermal design of electric vehicle controller, it is necessary to consider the temperature rise of insulated gate bipolar transistor (IGBT) at low output frequency to prevent the IGBT from burning out at low output frequency. Because the low frequency load condition of IGBT is a short-time transient process, the experimental test cannot be realized, so the transient simulation is used to verify and improve the actual design. In this paper, the transient simulation of Fuji power module with water-cooled heat dissipation is carried out, and the temperature response of the power module IGBT is compared between the conventional mode and the output frequency of 50 Hz, 20 Hz, 10 Hz, 5 Hz and 2 Hz in 450 A working condition. The results show that with the decrease of IGBT output frequency, the maximum temperature gradually increases, among which the maximum temperature of 5 Hz and 2 Hz is 162 ℃ and 181 ℃ respectively, which is 39 ℃ and 58 ℃ higher than that of conventional mode. References | Related Articles | Metrics

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Influence and Optimization of Driving Range of Pure Electric Vehicle Based on Different Operating Conditions XIAO Shuying 2023, 48(10): 12-16.  DOI: 10.16638/j.cnki.1671-7988.2023.010.003 Abstract ( )   PDF (1022KB) ( )   The new European driving cycle (NEDC) conditions used in the past national standards are inconsistent with the actual driving conditions, long test cycle, single calculation method and other problems. The update of the test methods for condition switching (NEDC to China light vehicle test cycle (CLTC)) and testing in the Test Method for Energy Consumption and Range of Electric Vehicles Part 1:Light-duty Vehicles (GB/T 18386.1—2021) have significantly advanced the test and evaluation methods for the range of pure electric vehicles in China. Based on the shortening method and combined with the new energy vehicle subsidy policy, this paper takes pure electric vehicles as the research object, focuses on the difference of the driving range of pure electric vehicles under NEDC and CLTC conditions, analyzes its influencing factors, and proposes the optimization strategy.The results show that, in the test of 20 pure electric models, the average driving range measured under China light-duty vehicle test cycle-passenger (CLTC-P) cycle is slightly higher than that of NEDC, and the average driving range increased by 2.2% due to the change of working condition. The main factors affecting the driving range are rolling resistance, air resistance and motor consumption. References | Related Articles | Metrics

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Based on Bus Network Health Monitoring and Management Platform Applications in New Energy Bus XIAO Dawei 2023, 48(10): 17-21.  DOI: 10.16638/j.cnki.1671-7988.2023.010.004 Abstract ( )   PDF (1885KB) ( )   In order to meet the needs of vehicle-level safety management requirements for end-users in new energy buses, it is of great significance to make full use of controller area network (CAN), RS-485 and other buses to build a vehicle-level health monitoring platform. In this paper, based on the vehicle terminal CAN, RS-485 and other buses in the new energy bus, the data link is opened up, and all kinds of equipment data and dispatching data are gathered, and then the vehicle level health monitoring and management platform is constructed. Practical application indicates that the functions of real-time monitor, fault diagnosis and treatment, classified summation brings the huge convenience to the management and maintenance. References | Related Articles | Metrics

Intelligent Connected Vehicle

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Multi-stage Path Planning and Simulation Analysis Based on Narrow Vertical Parking Space CAI Yun 2023, 48(10): 22-29.  DOI: 10.16638/j.cnki.1671-7988.2023.010.005 Abstract ( )   PDF (1907KB) ( )   Automated parking system (APS) is a hot topic in current research. However, most studies ignore the effect of the initial vehicle heading angle deviation on the overall parking effect, this paper investigates a multi-stage path planning method with a non-zero initial vehicle heading angle in a narrow vertical parking space scenario. Firstly, based on the minimum turning radius of the vehicle, the trajectory equation of the vehicle rear axle center motion is established, and the path planning is optimized by the fifth polynomial to achieve more continuous path curvature, smoother and more comfortable parking. CarSim/Simulink joint simulation validation shows that the five polynomial parking path optimization method is feasible, and the actual width required for the parking space is reduced by 10.4% and the length is reduced by 15.3% on the basis of satisfying the parking safety. References | Related Articles | Metrics

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Automatic Parking Control Strategy Based on Plug-in Hybrid Vehicle CHEN Cong 2023, 48(10): 30-33.  DOI: 10.16638/j.cnki.1671-7988.2023.010.006 Abstract ( )   PDF (836KB) ( )   From the perspective of vehicle control unit, this paper expounds in detail the logical control and implementation of the automatic parking strategy based on BYD plug-in hybrid vehicle. After the driver turns on the automatic parking function, the entry and exit conditions of automatic parking are judged by the vehicle controller, and the vehicle state switching in the process of automatic parking is realized by the state machine switching. Multiple controllers cooperate with each other to realize the automatic parking torque output, control the vehicle forward reverse, turn and other actions to realize the automatic parking function of the vehicle in the application scenarios such as reverse warehousing and horizontal parking. After parking, the driver confirms the parking state and operates the gear to exit automatic parking. This paper provides ideas for the landing mass production of automatic parking, and provides a reference for the research and development of automatic parking. References | Related Articles | Metrics

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Development of Lane Recommendation Based on High-definition Map CAI Kefang 2023, 48(10): 34-39.  DOI: 10.16638/j.cnki.1671-7988.2023.010.007 Abstract ( )   PDF (1039KB) ( )   In order to meet the requirement of high-level intelligent vehicles for lane recommendation, this paper has completed the mapping relationship between road and lane based on the correlation matching which is from standard definition map (SD-Map) and high-definition map (HD-Map), proposes the feasible domain space of road network, and the calculation rule of the comprehensive lane recommendation coefficient.Based on the remaining distance of road, lane speed limit and lane congestion information, a vehicle kinematics model is established, the speed space is defined by the dynamic window method (DWA) optimization algorithm, and a comprehensive cost function based on the remaining distance of the road, lane speed limit and lane congestion information is established, and the optimal lane recommendation list is obtained through iterative optimization. Finally, the optimization results are verified through the real vehicle test. Compared with the most recommended lanes based on the static map data, it can recommend lanes more effectively and flexibly based on the remaining distance from the destination, the lane speed limit and the lane congestion state, so as to ensure the optimal driving speed of the vehicle.effectively and flexibly based on the remaining distance from the destination, the lane speed limit and the lane congestion state, so as to ensure the optimal driving speed of the vehicle. References | Related Articles | Metrics

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Analysis & Verification Test for AEB to Two-Wheel Electric Bicycle Test of CNCAP 2021 ZHAN Houshun 2023, 48(10): 40-46.  DOI: 10.16638/j.cnki.1671-7988.2023.010.008 Abstract ( )   PDF (1136KB) ( )   January 1st 2022, the standard CNCAP 2021 edition has implemented, and there is a Chinese unique scenario test that autonomous emergency braking (AEB) to two-wheel electric bicycle. Based on the requirement of the test, and combined the character of the vehicle brake system, analyzed and calculated the requirement of full score of the test, and produced the result of the AEB trigger TTC. And then verified the TTC by real vehicle test. Accorded the TTC and AEB trigger strategy, and combined the collision scenario of the two-wheel electric bicycle and vehicle, and the character of the two-wheel electric bicycle brake system, furtherly produced the result form analysis and test that, it doesn't fit very well that use the strategy and TTC of AEB in the real road scenario. It needs more meticulous strategy based on the complex scenario of the character of the vehicle and the two-wheel electric bicycle and the operation of the two-wheel electric bicycle, to improve the customer experience of AEB system. References | Related Articles | Metrics

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Design and practice of smart vehicle based on K60 microcontroller CHEN Jianhui 2023, 48(10): 47-50.  DOI: 10.16638/j.cnki.1671-7988.2023.010.009 Abstract ( )   PDF (1334KB) ( )   In order to participate the national college students smart car competition with good score, this paper presents the design of an intelligent small car based on K60. A hardware circuit system with MK60DN512ZVLQ10 as the core controller is designed. The software system obtains the car planning path curve by processing the photos taken by the monocular camera. The better steering angle is obtained by the single-point preaiming optimal curvature model and the proportion integration differentiation (PID) algorithm controls the steering of the car to realize the tracking function. The obstacle expansion method is adopted to effectively avoid the collision. The test results show that the designed intelligent car can drive in a straight line, turn, cross the intersection and so on. It has basic driving functions and meets the design objectives and requirements. References | Related Articles | Metrics

Design and Research

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Analysis and Control Vibration and Noise of Electric Fuel Pump GONG Shaoqi 2023, 48(10): 51-54.  DOI: 10.16638/j.cnki.1671-7988.2023.010.010 Abstract ( )   PDF (1738KB) ( )   In order to analysis and control the vibration and noise of electric fuel pump, in this paper, NVH experiment (Artemis/LMS) and simulation (Altair OptiStruct) analysis are combined to investigate the mechanism of internal noise and vibration, the operating deflection shapes (ODS) and grid participation analysis (GPA) of the trimmed body with fuel pump are analyzed by simulating the critical path, and the feasible scheme is proposed for the optimization of fuel pump vibration and noise. The results of NVH experiment and simulation analysis show that: 1) The mechanism of rumble noise at 100 Hz and of the idle condition is that the fuel pump operating frequency is coupled with the engine frequency (8 order); 2) The rotor dynamic balance control method of electric fuel pump is not complete, which leads to the loss of dynamic balance accuracy and that causes power frequency and harmonic frequency vibration of the fuel pump frequently; 3) Through the combination of test and simulation, it can locate the weak position of the body quickly, and optimize the vibration transfer sensitivity 3 dB, and improve the idle noise 5 dB(A). In this paper, this method with NVH experiment and simulation analysis is detailed, and an effective scheme to suppress vibration and noise of automobile fuel pump is proposed to improve vehicle riding comfort. The research results provide technical support for vibration and noise control of automobile electric fuel pump. References | Related Articles | Metrics

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Torsional Vibration Analysis and Optimization of a Hybrid Electric Vehicle Powertrain System GAO Kefeng 2023, 48(10): 55-60.  DOI: 10.16638/j.cnki.1671-7988.2023.010.011 Abstract ( )   PDF (1130KB) ( )   A multi-degree-of-freedom torsional vibration model is established for a hybrid electric vehicle with a three-cylinder engine and dual electric motors, based on the structural principle of the vehicle's powertrain system. Using the AMESim software, the inherent characteristics and excitation responses of the system are analyzed under different modes and typical working conditions. By inputting the model and system parameters, the inherent characteristics of the system and the torsional vibration effects of the failed parts are analyzed. Based on the analysis results, the parameters of the system's torsional vibration components are optimized. This paper not only provides a good reference for the analysis of failure caused by torsional vibration, but also provides direct guidance for torsional vibration design of hybrid electric vehicle powertrain systems. References | Related Articles | Metrics

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Design and Calibration Method of AMT Intelligent Shift Law for Commercial Vehicle HOU Shengdong 2023, 48(10): 61-65.  DOI: 10.16638/j.cnki.1671-7988.2023.010.012 Abstract ( )   PDF (2361KB) ( )   This paper takes an electronic mechanical automatic transmission (AMT) model as the research object. Based on slope, load, driving environment and other factors, the control strategy under different working conditions is developed and calibrated accurately.On the premise of meeting the power needs of customers in market segments, the shifting and lifting curves of electronically controlled mechanical automatic transmission are calibrated in combination with the engine fuel consumption ratio graph and emission thermal management graph, so as to ensure that the vehicle is operated within the optimal fuel economy and emission performance range of the engine, optimize the vehicle fuel consumption and achieve emission consistency standards,and meet the requirements of regulations and customers. References | Related Articles | Metrics

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Modal Study of a Commercial Vehicle Body in White Based on HyperMesh YU Hanlin 2023, 48(10): 66-69.  DOI: 10.16638/j.cnki.1671-7988.2023.010.013 Abstract ( )   PDF (2133KB) ( )   In this paper, HyperMesh software is used to establish a simulation model for the body in white of a commercial vehicle, study its natural frequency and vibration mode under free state, and carry out the modal test verification of the body in white. The test data are compared with the simulation analysis results. The frequency error of the finite element analysis and the frequency of the test results is within 5% except for the first order, which indicates that the finite element model is relatively accurate and the calculation results are reliable, The simulation results can well reflect the vibration characteristics of the actual structure. The overall modal frequency of the body in white is far from the second order unbalanced excitation frequency, which is less likely to cause vehicle resonance. The estimated vehicle comfort and vehicle fatigue life meet the requirements. The evaluation of structural characteristics by means of simulation can save the cost of development and test, shorten the development cycle and provide a theoretical basis for design. References | Related Articles | Metrics

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Simple Analysis on the Measures of Semi Trailer Tractor Lightweight YI Biao 2023, 48(10): 70-73.  DOI: 10.16638/j.cnki.1671-7988.2023.010.014 Abstract ( )   PDF (1645KB) ( )   With the increasingly strict and perfect domestic regulations, the regulatory limit is 6×4, the total weight of the tractor train is 49 000 kg, the maximum allowable total mass limit of the three axle semi-trailer is 40 000 kg, and the dead weight of the tractor is about 8 800 kg after subtracting the total weight of the semi-trailer and the weight of the passengers. The maximum limit of 40 000 kg for semi-trailer can only be met by reducing the dead weight of the whole vehicle. The text is aimed at a 6×4. The feasibility analysis of semi trailer tractor lightweight is carried out from three aspects: chassis structure optimization, lightweight material application and lightweight configuration application. The CAE analysis and test verification ensure that the design scheme is reasonable and effective. The research shows that the target of semi trailer tractor deadweight≤8 800 kg can be achieve through reasonable lightweight design. References | Related Articles | Metrics

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Performance Optimization of Defrosting Duct for Commercial Vehicle Based on CFD ZHU Shaowei 2023, 48(10): 74-78.  DOI: 10.16638/j.cnki.1671-7988.2023.010.015 Abstract ( )   PDF (2974KB) ( )   In order to meet the defrosting performance requirements of commercial vehicles and shorten the development time, CFD analysis method is used to optimize the defrosting duct for a commercial vehicle. Firstly, some performances should meet the design goals through steady state analysis during design stage, including the pressure loss of defrosting duct, air volume distribution of air outlet, wind speed coverage in the view of front and side windows field; and then transient analysis is used to predict the defrosting effect by loading temperature rise curve at the air outlet; finally, the optimized air duct defrost verification test is conducted through the actual sample vehicle. The results show that the defrosting performance meets the target requirements, and the CFD virtual verification can reduce the research and development cost and improve the development efficiency. References | Related Articles | Metrics

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Influence of Low Rolling Resistance Tires on Fuel Consumption of Light Commercial Vehicles LIANG Zhipeng 2023, 48(10): 79-84.  DOI: 10.16638/j.cnki.1671-7988.2023.010.016 Abstract ( )   PDF (1280KB) ( )   In order to verify the impact of low rolling resistance tires on the fuel consumption of the whole vehicle, a 6T light commercial prototype vehicle of a certain brand is selected and equipped with tires with different rolling resistance coefficients (rolling resistance coefficients: EZ525-7.0‰, AZ630-6.0‰, AZ630-5.5‰). Under different conditions of loading capacity of 75% (loading 4.5T) and full load (loading 6T), the sliding tests and sliding resistance tests are carried out respectively. The fuel consumption test of China heavy-duty commercial vehicle test cycle for truck (CHTC-LT) and China world transient vehicle cycle (C_WTVC) are carried out under the loading condition of 4.5T respectively.Through the test, it is concluded that the fuel consumption of the test vehicle with low rolling resistance tires is significantly lower than that of high rolling resistance coefficient tires. Rolling resistance tires can reduce the fuel consumption of the whole vehicle. References | Related Articles | Metrics

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The Optimization Design Method of Rear Head Room for Fastback Cars DAI Xiaoyan 2023, 48(10): 85-88.  DOI: 10.16638/j.cnki.1671-7988.2023.010.017 Abstract ( )   PDF (1008KB) ( )   Currently, more and more fastback models are being introduced into the market, which presents unprecedented challenges to the design of headspace for the rear passengers. The existing industry standards, including SAE J1100—2009 and global cars manufacturers information exchange group's engineering drawing standards in 2011, do not provide effective control indicators for the headspace behind the passengers. To address this shortcoming, this paper proposes an optimization design method that introduces a new index, H61-K, which represents the effective headspace for the rear seat backrest angle K, replacing the original index L39, based on the objective indicators of the four rear passenger headspaces defined by Society of Automotive Engineers (SAE). Through a design example of a new vehicle development, the effectiveness of this method is demonstrated, which is of great significance for the development of human-vehicle engineering. References | Related Articles | Metrics

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Research on a New Type of Noise Reduction Sleeve XU Jinhai 2023, 48(10): 89-91.  DOI: 10.16638/j.cnki.1671-7988.2023.010.018 Abstract ( )   PDF (2109KB) ( )   In the assembly process of bolts and nuts, our commonly used impact wrenches and sockets are common assembly tools. The impact wrench and socket produce a large noise due to the impact between the impact plate and the impact shaft inside the impact wrench during the process of tightening the bolt. In this paper, the noise source in the assembly process of impact air gun and sleeve is analyzed in depth, and a new structure sleeve is developed by using polymer materials such as carbon fiber and glass fiber on the basis of the original steel structure sleeve. On the basis of ensuring the original function and performance of the sleeve, the medium of sound propagation is changed, the amplitude of the sound is reduced, and the noise is reduced by 4 decibels compared with the general steel sleeve. References | Related Articles | Metrics

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Analysis and Countermeasures of Abnormal Flameout of a Vehicle YAO Xuesen 2023, 48(10): 92-95.  DOI: 10.16638/j.cnki.1671-7988.2023.010.019 Abstract ( )   PDF (1667KB) ( )   Based on the abnormal flameout problem of a certain model, the article starts from the problem investigation and cause analysis to find the possible causes of the valve control problem. The main causes of the problem are found to be abnormal wear of the pressure control value (PCV) valve and abnormal learning of the engine flow through the working principle of the engine and the vehicle test, and causes of possible problems are excluded one by one. Finally, the problem is solved and the power of the product is improved by optimizing the PCV structure, adopting the double buffer spring structure, and replacing the PCV material. References | Related Articles | Metrics

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Structural Design and Verification of a Vehicle-mounted Negative Pressure Medical Shelter ZHOU Wenqiang 2023, 48(10): 96-99.  DOI: 10.16638/j.cnki.1671-7988.2023.010.020 Abstract ( )   PDF (1042KB) ( )   In order to effectively alleviate the shortage of medical resources caused by public health emergencies, the purpose of quickly solving the problem of admission of mild patients has been achieved. This paper introduces a vehicle-mounted negative pressure medical shelter, which can meet the limitations of medical shelter in terms of mobility, rapid maintenance and emergency. Through the three-dimensional mathematical model construction, overall scheme design, working principle, shelter structure and functional design of each system, the air volume, refrigeration, heating capacity and light intensity are verified by calculation, and the results show that the performance meets the design requirements and meets the customer's use requirements. References | Related Articles | Metrics

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Analysis of Dynamic Optimization Method of AMT Fuel Consumption Rate Based on Dynamic Performance Reserve SUN Xiaopeng 2023, 48(10): 100-104.  DOI: 10.16638/j.cnki.1671-7988.2023.010.021 Abstract ( )   PDF (1425KB) ( )   The key technology of automatic mechanical transmission (AMT) development for commercial vehicles is to obtain the optimal gear through reasonable gear decision. In this paper, a method to decide the optimum gear and optimize fuel consumption of AMT commercial vehicle based on dynamic performance is studied. This method gives full play to the power demand of the engine at the current speed, takes into account the torque reserve and acceleration performance required by the vehicle driving dynamic performance, analyzes the reasonable gear by using weighted comparison and dynamic recursion methods, and achieves the optimal engine universal characteristics, reduces the fuel consumption rate and improves the economic performance. References | Related Articles | Metrics

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Application of DITA in Digital Publishing Automobile Service Manual HUANG Daqian 2023, 48(10): 105-110.  DOI: 10.16638/j.cnki.1671-7988.2023.010.022 Abstract ( )   PDF (1549KB) ( )   Darwin information typing architecture (DITA) is a topic-oriented digital content structured writing and publishing scheme based on extensible markup language (XML). DITA can realize the characteristics of information retrieval, organization and reusability, support the rapid generation of publications the different audiences and terminals, support the rapid generation of publications to serve different audiences and terminal display, is used by more automobile enterprises. Combined with the requirements of automobile maintenance technical information disclosure regulations and standards, the application of DITA in automobile service manual types and information classification, topics, architecture, and content reuse is introduced, information architecture and modeling of printed and electronic manuals to achieve a diverse range of deliverables. References | Related Articles | Metrics

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Functional Design of the Kick Function of a Vehicle HUANG Ke 2023, 48(10): 111-114.  DOI: 10.16638/j.cnki.1671-7988.2023.010.023 Abstract ( )   PDF (1150KB) ( )   In recent years, with the development of electronic technology, a variety of novel electrical and electronic functions begin to be applied on the vehicle, electrification, intelligence, gesture recognition, face recognition and other functions gradually become a new choice for consumers, the kick function of power tailgate is one of the major representatives. The article mainly studies the design of the kick function of power lift gate system, the article starts from the induction principle of capacitive kick, and combines the development experience of the real car kick in the work, and discusses the network architecture and layout requirements of the kick system. At the same time, in order to meet the static power consumption requirements of the whole vehicle, combined with the working characteristics of the local interconnect network (LIN) bus, the sleep wake-up strategy and functional logic are required in detail, and the vehicle equipped with the kicking system has high testing kick sensitivity, reasonable functional logic design, and low static current consumption, which has certain reference significance for the design of the kick function of subsequent models. References | Related Articles | Metrics

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Oil Leakage Analysis and Design Optimization of Crankshaft Oil Seal of an Engine WANG Xiaodong 2023, 48(10): 115-118.  DOI: 10.16638/j.cnki.1671-7988.2023.010.024 Abstract ( )   PDF (3393KB) ( )   The problem of oil leakage of crankshaft oil seal occurred in the development test of an engine. By analyzing the key influencing factors of development and application, such as structural design, test operation conditions and part quality, the root cause of seal failure is determined. This paper puts forward an optimization scheme to optimize the structure and chamfer size of the crankshaft oil seal mounting hole and improve the dust lip structure of the crankshaft oil seal. The optimized crankshaft oil seal assembly finally passed the engine bench durability test. Relevant analysis methods and solutions can provide reference for relevant engineer. References | Related Articles | Metrics

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Stiffness Calculation of Tapered Roller Bearing Based on Modified Contact Deformation Model YANG Na 2023, 48(10): 119-124.  DOI: 10.16638/j.cnki.1671-7988.2023.010.025 Abstract ( )   PDF (1492KB) ( )   The calculation of bearing contact force and stiffness is a nonlinear mechanical problem. This paper calculates the roller contact force and contact stiffness of tapered roller bearing based on the modified palmgren model. Through the calculation and superposition of the contact forces and moments of all rollers and the contact deformation caused by them on the inner and outer rings of the bearing, the stiffness model of tapered roller bearings is derived in this paper. In order to verify the model, this paper establishes a finite element model of tapered roller bearing with a large number of grids and high accuracy, calculates the stress distribution of the roller and outer ring, identifies the bearing stiffness by extracting the contact force and contact deformation from the finite element calculation results, and compares the calculation results with the model established in this paper. The results show that the model established in this paper is accurate. References | Related Articles | Metrics

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Ackerman Steering and Structural Strength Analysis of Heavy Truck Multi-link Steering System LI Qihan 2023, 48(10): 125-128.  DOI: 10.16638/j.cnki.1671-7988.2023.010.026 Abstract ( )   PDF (1305KB) ( )   In order to reduce the angle error of the multi-link steering system of a heavy truck and determine the structural strength of the steering mechanism, the multi-body dynamics model of the multi-link steering system of a heavy truck is established. Using the steering system dynamics model, firstly, the kinematics analysis of the steering system is carried out to determine the steering angle error of the steering system, and the mechanism with the smallest steering error of the steering system is solved by adopting the experimental design method. Secondly, the dynamic analysis of the steering system is carried out, and the maximum force of the steering system bar is obtained, and the structural strength of the steering system is optimized by using the finite element method. The results show that the steering error of the steering system is obviously reduced and the reliability of the steering system is improved. The performance of steering system meets the design requirements of a truck. References | Related Articles | Metrics

Testing and Experiment

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Analysis of the Influence of the Oil Seal Structure Parameters of the Mechanical Rotating Shaft Parts on the Oil Seal Performance ZHOU Zhonghua 2023, 48(10): 129-133.  DOI: 10.16638/j.cnki.1671-7988.2023.010.027 Abstract ( )   PDF (1484KB) ( )   The rationality of oil seal structure design has a great impact on the comprehensive performance of oil seal. In this paper, ABAQUS software is used to establish the finite element analysis model of the oil seal, and the finite element method is used to simulate the sealing performance of the oil seal under static and dynamic conditions, and the influence of the structural parameters of the oil seal on the performance of the crankshaft oil seal is discussed, and then a theoretical basis is put forward for the structural design. The results show that the contact pressure on both sides of the crankshaft oil seal lip is asymmetrically distributed within the range of the analyzed oil seal structural parameters, and the maximum contact pressure of the crankshaft oil seal decreases with the increase of the oil side lip angle, interference and theoretical contact width R value; the maximum contact pressure of crankshaft oil seal increases with the increase of air side lip angle, spring stiffness coefficient and waist thickness; and with the increase of interference, spring stiffness coefficient and waist thickness, the radial force per unit circumference of crankshaft oil seal increases. Ecommended installation interference δ at 0.78 mm, the waist thickness of the oil seal is around 0.09 mm, which can alleviate the wear of the oil seal lip, and the stiffness coefficient of the spring is about 0.869 N/mm, which has good sealing performance; air side lip angle β the service life of oil seal can be extended at about 30°. References | Related Articles | Metrics

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Simulation Analysis of Contact Load Bearing Loss of Automobile Helical Gear Based on AMESim CHEN Lili 2023, 48(10): 134-138.  DOI: 10.16638/j.cnki.1671-7988.2023.010.028 Abstract ( )   PDF (1434KB) ( )   In order to realize the simulation, measure the axial and radial load at the contact of automobile helical gear, project it on the bearing, and calculate the load contribution in the bearing loss, so as to reduce the cost of real physical experiment and improve the design quality. Therefore, the simulation of bearing loss under contact load of automobile helical gear based on AMESim is carried out. The simulation model of automobile helical gear pair and the mathematical model of bearing loss caused by radial load, axial load and lubricating oil are established, and their respective calculation formulas are given. A new svenska kullager fabriken (SKF) model for calculating friction torque is established to calculate the friction torque produced in rolling bearing more accurately. Using proportion integration differentiation (PID) speed control method, the simulation test is carried out in AMESim. The simulation results show that the model well realizes the simulation of contact load bearing loss of automobile helical gear, and provides a reference for the simulation measurement and analysis of radial load and axial load of bearing and the selection and design of bearing. References | Related Articles | Metrics

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Intelligent Tire Load Prediction Algorithm Based on Acceleration Information LUO Jiliang 2023, 48(10): 139-143.  DOI: 10.16638/j.cnki.1671-7988.2023.010.029 Abstract ( )   PDF (1395KB) ( )   In response to the current demand of the commercial vehicle industry for tire load forecasting, a method for estimating the vertical load of 235/45ZR18 tires has been developed. Under the premise of ensuring the reliability of finite element simulation, this method obtains the acceleration waveform information on the inner side of the tire through tire finite element simulation technology, and uses this acceleration waveform information to estimate the length of the tire's ground contact footprint. Through research, it is found that the relationship between the length of the grounding footprint and the load is roughly a quadratic function. According to this rule, the empirical formula of grounding mark length and vertical load is summarized, which realizes the estimation of the vertical load of this type of tire, and can maintain a certain accuracy in the commonly used load, speed, and tire pressure range. This prediction algorithm can be applied to tire force collection to improve the safety of automotive active safety systems. References | Related Articles | Metrics

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Finite Element Analysis on Load and Stress Characteristics of Disc Spring LI Liang 2023, 48(10): 144-148.  DOI: 10.16638/j.cnki.1671-7988.2023.010.030 Abstract ( )   PDF (1361KB) ( )   The load-displacement and stress-displacement characteristics of disc spring are analysed by using ANSYS Workbench and elastoplastic material models, and compared with the theoretical results of the A-L method. On this basis, the effects of different slot fillets and slot widths on load-displacement and stress-displacement characteristics are studied. The analysis results show that in the plastic deformation stage, the finite element analysis results are quite different from the theoretical values of the A-L method. Compared with the A-L method, the finite element method is more consistent with the measured values. Increasing the slot fillet increases the load, and increasing the slot width decreases the load. Different slot fillets and slot widths will have a certain influence on the principal stresses at the four corner points of the disc spring section. This provides a theoretical basis for the design of disc springs. References | Related Articles | Metrics

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Analysis of Vehicle Crash Compatibility Evaluation Methods Based on the MPDB Test WANG Limin 2023, 48(10): 149-155.  DOI: 10.16638/j.cnki.1671-7988.2023.010.031 Abstract ( )   PDF (1626KB) ( )   As a new development concept in the field of passive safety, crash compatibility has been paid more and more attention by automobile companies and consumers. The results of standard deviation (SD), occupant load criterion (OLC), bottom out and structure height obtained from mobile progressive deformable barrier (MPDB) test can effectively reflect the crash compatibility of vehicles. This paper analyzes the evaluation method and significance of the above four indexes in detail, and summarizes the improvement scheme to reduce the aggression of test vehicles. The European new car assessment program (Euro NCAP) and China-new car assessment program (CNCAP) have their differences and similarities in crash compatibility evaluation methods and penalty rules. This paper makes a detailed comparison and interpretation of the two regulations. Finally, a large number of MPDB test collision compatibility results in the past two years are sorted out. Through data analysis, the collision compatibility level of current mainstream models and some internal laws with practical significance are demonstrated. References | Related Articles | Metrics

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Continuous Integration and Continuous Testing Analysis Based on Automotive Embedded Software WANG Shuai 2023, 48(10): 156-162.  DOI: 10.16638/j.cnki.1671-7988.2023.010.032 Abstract ( )   PDF (1626KB) ( )   As the iteration of automotive embedded software becomes more and more frequent, it poses a higher challenge to software quality, and so software integration and testing cycles become shorter and more frequent. Continuous integration/continus testing (CI/CT) has been acknowledged as the best practice for early detection of defects. This paper analyzes the development process of automotive embedded software, though introducing the method of continuous integration testing, and a software continuous integration testing platform is built based on Jenkins. The platform supports multiple development languages, and can integrate and call the tool chain of compiler, model in loop (MIL) testing, hardware in loop (HIL) testing, etc., so as to realize the complete automation of software integration, testing and defect notification. Finally, engineers can be free themselves from tremendous software development tasks. After the application of continuous integration and continuous testing methods in a hybrid electric vehicle (HEV) vehicle control unit (VCU) software projects, nearly 90% of the software iteration time can be saved. References | Related Articles | Metrics

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Research on Decomposition Method of Vehicle Sliding Resistance YAN Su 2023, 48(10): 163-167.  DOI: 10.16638/j.cnki.1671-7988.2023.010.033 Abstract ( )   PDF (1650KB) ( )   This paper decomposes the vehicle sliding resistance through the combination of road sliding test, drum test and bench test, separates the internal resistance of the transmission system from the sliding resistance, and further decomposes the internal resistance of subsystems such as caliper drag force, gearbox+transmission shaft resistance torque, drive axle+bearing resistance torque, which provides verification method and data support for internal resistance optimization. The results show that, the internal resistance accounts for about 20%～30% of the sliding resistance. The more complex the transmission system structure or the longer the transmission chain, the greater the proportion of internal resistance; The internal resistance of transmission system increases with the increase of vehicle speed; The internal resistance dispersion of individual parts is large. How to control the consistency of parts is also the key to improve the internal resistance. References | Related Articles | Metrics

Process and Equipment

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The Application Analysis of Metal 3D Printing in Pre-production Body SUN Xianglong 2023, 48(10): 168-171.  DOI: 10.16638/j.cnki.1671-7988.2023.010.034 Abstract ( )   PDF (3548KB) ( )   The metal 3D printing technology has the advantages of no mold, forming complex parts, high precision, short cycle, lightweight and customization. The metal 3D printing technology provides a new manufacturing process for automobile body parts and greatly promotes the technological change of automobile industry body manufacturing. From the perspective of actual manufacturing application, we uses metal 3D printing technology to produce pre-production body parts, and study the strength, hardness, density, roughness, welding performance and cost for the 3D printing parts, and further discusses the application feasibility of metal 3D printing technology in pre-production body parts. References | Related Articles | Metrics

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Analysis of Ultra-thin-walled Low-smoke Halogen-free Flame Retardant Automotive Wire and Conductor Preheating Process ZHANG Xin 2023, 48(10): 172-175.  DOI: 10.16638/j.cnki.1671-7988.2023.010.035 Abstract ( )   PDF (1129KB) ( )   Lightweight of automobile has become an important topic in the original equipment manufactures and its supporting industries. Ultra-thin-walled low-smoke halogen-free flame retardant automobile wire is one of the important ways to solve the lightweight of automobile. In this paper, the effects of different materials on the scratch resistance, low temperature resistance, flame retardant and oil resistance of ultra-thin-walled low-smoke halogen-free flame retardant automobile wire are investigated. The experimental results show that when the insulation material is XLPE+PP combination and the single co-extrusion process is used, the comprehensive performance of the wire is the best. Through the preheating of conductor at different temperatures, when the preheating temperature of the conductor is 60 °C, the adhesion, strength and elongation of the wire is the best. The performance of the wire meets the requirements of ultra-thin-walled low-smoke halogen-free flame retardant automobile wire. The successful development of this kind of wire would provide technical reference for other types of thin-walled automobile wire in the future. References | Related Articles | Metrics

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Vehicle Manufacturing Capacity Planning Study for Two Tone Body Production TENG Xiaoqian 2023, 48(10): 176-180.  DOI: 10.16638/j.cnki.1671-7988.2023.010.036 Abstract ( )   PDF (1401KB) ( )   Currently most Chinese vehicle original equipment manufactures (OEM) apply on-line two tone production process which means using existing top coat spray and oven line to do the second topcoat step in two tone production. This paper introduces the capacity planning methods and limiting conditions for this on-line two tone process and discusses several ways to increase the two tone production capacity such as new adding mask stations, optimizing the mask and demask process, shipping production and looking for new technology application opportunities, etc. Hope to provide some basis and methods for vehicle OEM two tone capacity planning work. References | Related Articles | Metrics

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10.16638/j.cnki.1671-7988.2023.010.037 GAO Yong 2023, 48(10): 181-186.  DOI: 10.16638/j.cnki.1671-7988.2023.010.037 Abstract ( )   PDF (3321KB) ( )   For the current automobile manufacturing industry, the automobile production technology is changing with each passing day. The use of automation, intelligence and digital technology can effectively reduce production costs and improve product competitiveness. In the face of industrial transformation, the upgrading and transformation of some old production lines will become the subject of most mainstream main engine plants. This paper will take the upgrading and transformation of the welding production line as a case, and propose that under the premise of zero loss, through the new production line, flexible, automated and intelligent transformation, upgrade and transform the old welding production line, strengthen the production physique, and provide new ideas for the upgrading and transformation of other production lines in the same industry. References | Related Articles | Metrics

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Optimization Scheme of Heat Treatment Nitride Operation Process Based on Industrial Engineering Technology LIU Qi 2023, 48(10): 187-192.  DOI: 10.16638/j.cnki.1671-7988.2023.010.038 Abstract ( )   PDF (1258KB) ( )   In recent years, with the continuous development of the national manufacturing industry, in order to make the lean thinking and industrial engineering technology gradually spread to various enterprises, this paper describes HD company's application of the improvement tool of industrial engineering—value stream map, to make the operation process concrete, distinguish value-added time and non-value-added time from the value stream map, and optimize and improve its heat treatment nitriding operation process combined with lean thinking. At the same time, a special improvement team is set up to follow up the whole process of heat treatment nitriding operation, fully understand the complete process of nitriding operation, draw the current value stream map, and then organize the members of the improvement team to review the current value stream map and look for improvement points, and finally achieve the cost reduction and efficiency of the enterprise, reflecting the great value of industrial engineering technology in the automobile manufacturing industry. References | Related Articles | Metrics

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Fracture Analysis and Optimization of the Air Horn Bracket of a Vehicle XIA Pengpeng 2023, 48(10): 193-196.  DOI: 10.16638/j.cnki.1671-7988.2023.010.039 Abstract ( )   PDF (2799KB) ( )   In this paper, the fracture failure of the air horn bracket is studied based on a vehicle model market. In view of the rupture problem of the horn bracket, this paper makes a deep analysis from the factors of the rupture of the sheet metal bracket. By using computer aided engineering (CAE) for strength analysis, modal analysis and bench test, the root cause of the problem is determined and optimized, and the improved structure is verified by bench vibration test, and finally the use requirements are met and the risk of fracture is completely eliminated. In this paper, the fracture factors and verification methods are summarized to accumulate experience for optimization and verification of similar problems. References | Related Articles | Metrics

Overview

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Research on Environmentally Aware Sensors for Autonomous Vehicles 刘 炜 2023, 48(10): 197-203.  DOI: 10.16638/j.cnki.1671-7988.2023.010.040 Abstract ( )   PDF (1790KB) ( )   In recent years, autonomous driving technology, as an important part of intelligent networked vehicles, has become a hot topic, and the environmental perception system is the sensory nerve of autonomous vehicles and plays the role of "eye". This paper makes a brief introduction to the composition of the autonomous vehicle system by consulting the relevant literature and combining the current research hotspots, and at the same time introduces the types, working principles, and application scenarios of the sensors used in the environment perception system, and compares and analyzes different sensors and makes suggestions. Through the introduction of this article, it can help readers have a preliminary understanding of the environmental perception system of autonomous vehicles, and at the same time give some guidance to relevant technical personnel. References | Related Articles | Metrics

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The Key Elements Analysis and Suggestions for All-new Electric Vehicle Platform Development 韩汪利 2023, 48(10): 204-213.  DOI: 10.16638/j.cnki.1671-7988.2023.010.041 Abstract ( )   PDF (3103KB) ( )   Based on the development practice of a pure level station, this paper summarizes the necessary input, platform expansion strategy and key factors to be considered in the development of a new pure level station. The selection suggestions are obtained by comparing the layout scheme. The results show that the A-arm McPherson can obtain larger battery pack layout space than A-arm rear McPherson suspension. For the layout scheme L113 in front of the motor and steering gear layout shaft and the motor layout in front of the steering gear layout shaft, it is relatively smaller, which can improve the utilization rate of the crew cabin space. The rear motor of the rear motor arrangement can effectively improve the footstep space of three rows of human bodies; Compared with the traditional horizontal air conditioning box, split air conditioning box and longitudinal air conditioning box are conducive to the arrangement of the queen's first officer, but they have different degrees of influence on the arrangement of high voltage devices in the front cabin. References | Related Articles | Metrics