Terminal defect analysis and classification methodology for automotive industry

The impact of end customer quality complaints with direct relationship with automotive components has presented negative trend at European level for the entire automotive industry. Thus, this research proposal is to concentrate efforts on the most important items of Pareto chart and understand the failure type and the mechanism involved, link and impact of the project and parameters on the process, ending it with the development of one of the company’s most desired tool, that hosted this project – European methodology of terminals defects classification, and listing real opportunities for improvement based on measurement and analysis of actual data. Through the development of terminals defects classification methodology, which is considered a valuable asset to the company, all the other companies of the YAZAKI’s group will be able to characterize terminals as brittle or ductile, in order to put in motion, more efficiently, all the other different existing internal procedures for the safeguarding of the components, improving manufacturing efficiency. Based on a brief observation, nothing can be said in absolute sense, concerning the failure causes. Base materials, project, handling during manufacture and storage, as well as the cold work performed by plastic deformation, all play an important role. However, it was expected that this failure has been due to a combination of factors, in detriment of the existence of a single cause. In order to acquire greater knowledge about this problem, unexplored by the company up to the date of commencement of this study, was conducted a thorough review of existing literature on the subject, real production sites were visited and, of course, the actual parts were tested in lab environment. To answer to many of the major issues raised throughout the investigation, were used extensively some theoretical concepts focused on the literature review, with a view to realizing the relationship existing between the different parameters concerned. Should here be stated that finding technical studies on copper and its alloys is really hard, not being given all the desirable information. This investigation has been performed as a YAZAKI Europe Limited Company project and as a Master Thesis for Instituto Superior de Engenharia do Porto, conducted during 9 months between 2012/2013.

A future dynamically reconfigurable automotive software system

Embedded software systems in vehicles are of rapidly increasing commercial importance for the automotive industry. Current systems employ a static run-time environment; due to the difficulty and cost involved in the development of dynamic systems in a high-integrity embedded control context. A dynamic system, referring to the system configuration, would greatly increase the flexibility of the offered functionality and enable customised software configuration for individual vehicles, adding customer value through plug-and-play capability, and increased quality due to its inherent ability to adjust to changes in hardware and software. We envisage an automotive system containing a variety of components, from a multitude of organizations, not necessarily known at development time. The system dynamically adapts its configuration to suit the run-time system constraints. This paper presents our vision for future automotive control systems that will be regarded in an EU research project, referred to as DySCAS (Dynamically Self-Configuring Automotive Systems). We propose a self-configuring vehicular control system architecture, with capabilities that include automatic discovery and inclusion of new devices, self-optimisation to best-use the processing, storage and communication resources available, self-diagnostics and ultimately self-healing. Such an architecture has benefits extending to reduced development and maintenance costs, improved passenger safety and comfort, and flexible owner customisation. Specifically, this paper addresses the following issues: The state of the art of embedded software systems in vehicles, emphasising the current limitations arising from fixed run-time configurations; and the benefits and challenges of dynamic configuration, giving rise to opportunities for self-healing, self-optimisation, and the automatic inclusion of users’ Consumer Electronic (CE) devices. Our proposal for a dynamically reconfigurable automotive software system platform is outlined and a typical use-case is presented as an example to exemplify the benefits of the envisioned dynamic capabilities.

Intelligent pipeline control - a simulation study in the automotive sector

Automotive producers are aiming to make their order fulfilment processes more flexible. Opening the pipeline of planned products for dynamic allocation to dealers/ customers is a significant step to be more flexible but the behaviour of such Virtual-Build-To-Order systems are complex to predict and their performance varies significantly as product variety levels change. This study investigates the potential for intelligent control of the pipeline feed, taking into account the current status of inventory (level and mix) and of the volume and mix of unsold products in the planning pipeline, as well as the demand profile. Five ‘intelligent’ methods for selecting the next product to be planned into the production pipeline are analysed using a discrete event simulation model and compared to the unintelligent random feed. The methods are tested under two conditions, firstly when customers must be fulfilled with the exact product they request, and secondly when customers trade-off a shorter waiting time for compromise in specification. The two forms of customer behaviour have a substantial impact on the performance of the methods and there are also significant differences between the methods themselves. When the producer has an accurate model of customer demand, methods that attempt to harmonise the mix in the system to the demand distribution are superior.

Configuring an open pipeline fulfilment system - a simulation study in an automotive context

Automotive producers are adopting multi-modal fulfillment models in which customers can be fulfilled by products from stock, by allocating as yet unmade products that are in the planning pipeline, or by building a product to order. This study explores how fulfillment is sensitive to several parameters of the system and how they interact with different methods for sequencing products into the production plan.

Worldwide convergence of IFRS: Evidence from the global automotive industry

Worldwide convergence of International Financial Reporting Standards (IFRS), ongoing since 2002, is a requirement if international comparability between publicly listed companies is to be ensured. Convergence is examined from the point of view of regulators, accountants, and users of financial information. For this purpose, data on 534 companies from the global automotive industry is used. This paper concludes that worldwide convergence is mostly being effective. Its triumph, however, varies depending on the set of accounting standards being compared to IFRS. Options within IFRS, national tax regulation, cultural differences, different company strategies and country resistance are found to hinder convergence.

Novel Automotive Waste Heat Recovery Techniques

The United States transportation industry is predicted to consume approximately 13 million barrels of liquid fuel per day by 2025. If one percent of the fuel energy were salvaged through waste heat recovery, there would be a reduction of 130 thousand barrels of liquid fuel per day. This dissertation focuses on automotive waste heat recovery techniques with an emphasis on two novel techniques. The first technique investigated was a combination coolant and exhaust-based Rankine cycle system, which utilized a patented piston-in-piston engine technology. The research scope included a simulation of the maximum mass flow rate of steam (700 K and 5.5 MPa) from two heat exchangers, the potential power generation from the secondary piston steam chambers, and the resulting steam quality within the steam chamber. The secondary piston chamber provided supplemental steam power strokes during the engine's compression and exhaust strokes to reduce the pumping work of the engine. A Class-8 diesel engine, operating at 1,500 RPM at full load, had a maximum increase in the brake fuel conversion efficiency of 3.1%. The second technique investigated the implementation of thermoelectric generators on the outer cylinder walls of a liquid-cooled internal combustion engine. The research scope focused on the energy generation, fuel energy distribution, and cylinder wall temperatures. The analysis was conducted over a range of engine speeds and loads in a two cylinder, 19.4 kW, liquid-cooled, spark-ignition engine. The cylinder wall temperatures increased by 17% to 44% which correlated well to the 4.3% to 9.5% decrease in coolant heat transfer. Only 23.3% to 28.2% of the heat transfer to the coolant was transferred through the TEG and TEG surrogate material. The gross indicated work decreased by 0.4% to 1.0%. The exhaust gas energy decreased by 0.8% to 5.9%. Due to coolant contamination, the TEG output was not able to be obtained. TEG output was predicted from cylinder wall temperatures and manufacturer documentation, which was less than 0.1% of the cumulative heat release. Higher TEG conversion efficiencies, combined with greater control of heat transfer paths, would be needed to improve energy output and make this a viable waste heat recovery technique.

COMPARATIVE ANALYSIS OF EFFICIENCY AND OPERATING CHARACTERISTICS OF AUTOMOTIVE POWERTRAIN ARCHITECTURES THROUGH CHASSIS DYNAMOMETER TESTING

The thesis "COMPARATIVE ANALYSIS OF EFFICIENCY AND OPERATING CHARACTERISTICS OF AUTOMOTIVE POWERTRAIN ARCHITECTURES THROUGH CHASSIS DYNAMOMETER TESTING" was completed through a collaborative partnership between Michigan Technological University and Argonne National Laboratory under a contractual agreement titled "Advanced Vehicle Characterization at Argonne National Laboratory". The goal of this project was to investigate, understand and document the performance and operational strategy of several modern passenger vehicles of various architectures. The vehicles were chosen to represent several popular engine and transmission architectures and were instrumented to allow for data collection to facilitate comparative analysis. In order to ensure repeatability and reliability during testing, each vehicle was tested over a series of identical drive cycles in a controlled environment utilizing a vehicle chassis dynamometer. Where possible, instrumentation was preserved between vehicles to ensure robust data collection. The efficiency and fuel economy performance of the vehicles was studied. In addition, the powertrain utilization strategies, significant energy loss sources, tailpipe emissions, combustion characteristics, and cold start behavior were also explored in detail. It was concluded that each vehicle realizes different strengths and suffers from different limitations in the course of their attempts to maximize efficiency and fuel economy. In addition, it was observed that each vehicle regardless of architecture exhibits significant energy losses and difficulties in cold start operation that can be further improved with advancing technology. It is clear that advanced engine technologies and driveline technologies are complimentary aspects of vehicle design that must be utilized together for best efficiency improvements. Finally, it was concluded that advanced technology vehicles do not come without associated cost; the complexity of the powertrains and lifecycle costs must be considered to understand the full impact of advanced vehicle technology.

Innovative Al Alloys for High Performance Automotive Pistons: Enhancement of Specific Strength at High Temperature and Resistance to Knock Damage

The increasingly strict regulations on greenhouse gas emissions make the fuel economy a pressing factor for automotive manufacturers. Lightweighting and engine downsizing are two strategies pursued to achieve the target. In this context, materials play a key role since these limit the engine efficiency and components weight, due to their acceptable thermo-mechanical loads. Piston is one of the most stressed engine components and it is traditionally made of Al alloys, whose weakness is to maintain adequate mechanical properties at high temperature due to overaging and softening. The enhancement in strength-to-weight ratio at high temperature of Al alloys had been investigated through two approaches: increase of strength at high temperature or reduction of the alloy density. Several conventional and high performance Al-Si and Al-Cu alloys have been characterized from a microstructural and mechanical point of view, investigating the effects of chemical composition, addition of transition elements and heat treatment optimization, in the specific temperature range for pistons operations. Among the Al-Cu alloys, the research outlines the potentialities of two innovative Al-Cu-Li(-Ag) alloys, typically adopted for structural aerospace components. Moreover, due to the increased probability of abnormal combustions in high performance spark-ignition engines, the second part of the dissertation deals with the study of knocking damages on Al pistons. Thanks to the cooperation with Ferrari S.p.A. and Fluid Machinery Research Group - Unibo, several bench tests have been carried out under controlled knocking conditions. Knocking damage mechanisms were investigated through failure analyses techniques, starting from visual analysis up to detailed SEM investigations. These activities allowed to relate piston knocking damage to engine parameters, with the final aim to develop an on-board knocking controller able to increase engine efficiency, without compromising engine functionality. Finally, attempts have been made to quantify the knock-induced damages, to provide a numerical relation with engine working conditions.

Employment of Real-Time/FPGA Architectures for Test and Control of Automotive Engines

Nowadays the production of increasingly complex and electrified vehicles requires the implementation of new control and monitoring systems. This reason, together with the tendency of moving rapidly from the test bench to the vehicle, leads to a landscape that requires the development of embedded hardware and software to face the application effectively and efficiently. The development of application-based software on real-time/FPGA hardware could be a good answer for these challenges: FPGA grants parallel low-level and high-speed calculation/timing, while the Real-Time processor can handle high-level calculation layers, logging and communication functions with determinism. Thanks to the software flexibility and small dimensions, these architectures can find a perfect collocation as engine RCP (Rapid Control Prototyping) units and as smart data logger/analyser, both for test bench and on vehicle application. Efforts have been done for building a base architecture with common functionalities capable of easily hosting application-specific control code. Several case studies originating in this scenario will be shown; dedicated solutions for protype applications have been developed exploiting a real-time/FPGA architecture as ECU (Engine Control Unit) and custom RCP functionalities, such as water injection and testing hydraulic brake control.

Automotive Radars:towards smarter vehicles

Radars are expected to become the main sensors in various civilian applications, especially for autonomous driving. Their success is mainly due to the availability of low cost integrated devices, equipped with compact antenna arrays, and computationally efficient signal processing techniques. This thesis focuses on the study and the development of different deterministic and learning based techniques for colocated multiple-input multiple-output (MIMO) radars. In particular, after providing an overview on the architecture of these devices, the problem of detecting and estimating multiple targets in stepped frequency continuous wave (SFCW) MIMO radar systems is investigated and different deterministic techniques solving it are illustrated. Moreover, novel solutions, based on an approximate maximum likelihood approach, are developed. The accuracy achieved by all the considered algorithms is assessed on the basis of the raw data acquired from low power wideband radar devices. The results demonstrate that the developed algorithms achieve reasonable accuracies, but at the price of different computational efforts. Another important technical problem investigated in this thesis concerns the exploitation of machine learning and deep learning techniques in the field of colocated MIMO radars. In this thesis, after providing a comprehensive overview of the machine learning and deep learning techniques currently being considered for use in MIMO radar systems, their performance in two different applications is assessed on the basis of synthetically generated and experimental datasets acquired through a commercial frequency modulated continuous wave (FMCW) MIMO radar. Finally, the application of colocated MIMO radars to autonomous driving in smart agriculture is illustrated.

Automotive Antennas for V2X Communications

The main topic of this thesis is about the design and prototyping of automotive antennas that allows Vehicle to Everything (V2X) communications, that is the communication between the vehicle and all what else is relevant. In particular 5G will be an enabling technology for these communications. Vehicular connectivity is a mandatory feature in nowadays car. Typical applications are that one related to the infotainment, i.e. radio or mobile telephone, or security ones, i.e. radars. The antennas that support this type of communications can be divided in two frequency range: the sub-6GHz range and the millimeter wave (mmW) range. Also the 5G standard can be divided in this two frequency ranges. In this work different automotive antennas solutions are presented for both the frequency bands. For the sub-6GHz range two different antennas are presented: a tin sheet 5G-sub6 radiating element and a complete 5G-GNSS-V2X shark fin module. For the mmW frequency band, an automotive PCB planar solution is presented. Since these frequencies are a novelty for the automotive market, satellite communications (SatCom) field has been considered. In SatCom applications mmW solutions are a well-established technology. Thus, also mmW antennas solutions for SatCom applications are here presented.

Dry grinding technology for automotive gears manufacturing: process modeling and optimization

The following thesis focused on the dry grinding process modelling and optimization for automotive gears production. A FEM model was implemented with the aim at predicting process temperatures and preventing grinding thermal defects on the material surface. In particular, the model was conceived to facilitate the choice of the grinding parameters during the design and the execution of the dry-hard finishing process developed and patented by the company Samputensili Machine Tools (EMAG Group) on automotive gears. The proposed model allows to analyse the influence of the technological parameters, comprising the grinding wheel specifications. Automotive gears finished by dry-hard finishing process are supposed to reach the same quality target of the gears finished through the conventional wet grinding process with the advantage of reducing production costs and environmental pollution. But, the grinding process allows very high values of specific pressure and heat absorbed by the material, therefore, removing the lubricant increases the risk of thermal defects occurrence. An incorrect design of the process parameters set could cause grinding burns, which affect the mechanical performance of the ground component inevitably. Therefore, a modelling phase of the process could allow to enhance the mechanical characteristics of the components and avoid waste during production. A hierarchical FEM model was implemented to predict dry grinding temperatures and was represented by the interconnection of a microscopic and a macroscopic approach. A microscopic single grain grinding model was linked to a macroscopic thermal model to predict the dry grinding process temperatures and so to forecast the thermal cycle effect caused by the process parameters and the grinding wheel specification choice. Good agreement between the model and the experiments was achieved making the dry-hard finishing an efficient and reliable technology to implement in the gears automotive industry.

Study and experimental characterization of the laser welding process for the manufacturing of electric powertrain components in the automotive industry

The PhD project that will be presented in this thesis is focused on the study and optimization of the production process for the manufacturing of electrical powertrain components in the automotive field using the laser beam welding process (LBW). The objective is to define, through experimental activities, an optimized process condition for applications in the electrical field that can be generalized, that is, which guarantees its reproducibility as the types of connections vary and which represents the basis for extending the method to future applications in e-mobility sector. The work developed along two lines of research, the convergence of which made it possible to create prototypes of battery modules based on different types of lithium-ion cells and stator windings for electric motors. On the one hand, the different welding configurations involving the production of batteries based on pouch cells and therefore the welding of aluminum and copper in dissimilar configuration were studied, while for the prismatic cells only one configuration was analyzed. On the other hand, the welding of pure copper hairpins with rectangular shape in edge joint configuration was studied for the production of stator windings. The experimental tests carried out have demonstrated the feasibility of using the LBW process for the production of electric powertrain components entirely designed and developed internally as the types of materials and welding configurations vary; the methodologies required for the characterization methods, necessary for the end-of-line tests, for the evaluation of the properties of the different joint configurations and components (battery and electric motor) were also defined with the aim of obtaining the best performance. The entire doctorate program was conducted in collaboration with Ferrari Auto S.p.A. and the direct industrial application of the issues addressed has been faced.

Joints and innovative components for automotive applications

The research activities described in this thesis were focused on two main topics: the study of shaft-hub joint performance, with particular regard to interference-fitted and adhesively bonded connection, and the fatigue characterization of additively processed metal alloys. The research on interference-fitted shaft-hub joints dealt with some studies in the field of fretting fatigue. Rotating bending fatigue tests were performed on different materials by not conventional specimens to determine the fatigue properties of interference-fitted joints and to investigate the fretting fatigue phenomenon, which led to novel and original results. In adhesively bonded and interference-fitted shaft-hub connections (called hybrid joints) the synergic effect of anaerobic adhesive and interference has the capability of improving the joint strength. However, the adhesive contribution depends on several factors. Therefore, its behavior was investigated for different coupling pressure, coupling procedure, operating temperature and joint design. The study on additively manufactured metal alloy deals with rotating banding fatigue tests. AlSi10Mg and Maraging Stainless Steel CX were involved in the campaign for their wide applicability in Automotive. Build direction, heat and surface treatments were considered as input parameters. Fatigue results were interpreted by statistical method and microscopy analyses in order to determine the effectiveness and the beneficial or detrimental effects of the considered factors. Fracture mode and microstructure were investigated by fractographic and micrographic analyses

A framework for risk analysis in automotive cybersecurity

We address the problem of automotive cybersecurity from the point of view of Threat Analysis and Risk Assessment (TARA). The central question that motivates the thesis is the one about the acceptability of risk, which is vital in taking a decision about the implementation of cybersecurity solutions. For this purpose, we develop a quantitative framework in which we take in input the results of risk assessment and define measures of various facets of a possible risk response; we then exploit the natural presence of trade-offs (cost versus effectiveness) to formulate the problem as a multi-objective optimization. Finally, we develop a stochastic model of the future evolution of the risk factors, by means of Markov chains; we adapt the formulations of the optimization problems to this non-deterministic context. The thesis is the result of a collaboration with the Vehicle Electrification division of Marelli, in particular with the Cybersecurity team based in Bologna; this allowed us to consider a particular instance of the problem, deriving from a real TARA, in order to test both the deterministic and the stochastic framework in a real world application. The collaboration also explains why in the work we often assume the point of view of a tier-1 supplier; however, the analyses performed can be adapted to any other level of the supply chain.