Automotive Engineering Commons^™

Trim-Transfer: A Transfer Learning Approach For Cross-Trim Level Can Intrusion Detection, Baylor J. Whitehead

Master's Theses

Modern vehicles contain many Electronic Control Units (ECUs) that communicate through CAN. While CAN enables efficient data communication, it lacks built in authentication and encryption, allowing adversarial actors to inject malicious CAN messages. This limitation has motivated the development of CAN intrusion detection systems (IDS). However, deploying IDS across a vehicle lineup requires collecting large labeled datasets and retraining models, increasing development cost and limiting scalability.

This thesis investigates the use of transfer learning with LSTM-based deep neural networks to reduce retraining cost while maintaining model detection performance. A baseline LSTM model is trained using CAN data from a base …

A Comparative Study Of Model Predictive Control And The Stanley Method For Vehicle Path Tracking Applications, Noah S. Fitzgerald

Master's Theses

This thesis compares a model predictive controller (MPC) and a lateral Stanley controller for vehicle path-tracking applications under simulation-based and perception-driven operating conditions. Both controllers were evaluated in simulation using a nonlinear dynamic bicycle model executing single and double lane change maneuvers. Following simulation-based evaluation, both controllers were implemented on hardware within a perception-driven steering-control pipeline. This pipeline utilized recorded sensor data from the MXcarkit 1/8^th-scale autonomous vehicle platform, incorporating lane instance segmentation and homography-based roadway estimation.

Under idealized simulation conditions, the MPC demonstrated improved trajectory-tracking performance during aggressive maneuvers while requiring greater steering activity and computational effort …

Power Distribution Controller For Formula Sae Vehicles, Michael Yuen

Electrical Engineering

The Power Distribution Controller (PDC) is designed for low-voltage (12V) automotive applications, specifically Formula SAE vehicles. It aims to replace the current and outdated MOSFET-based system, which suffers from inefficiencies such as lossy current sense resistors and limited configurability. Instead, this new system uses a PROFET-based architecture controlled over the Controller Area Network (CAN) and an updated microcontroller, enabling intelligent power management and data logging.

Designed with FSAE regulations in mind, the PDC not only enhances the reliability of low-voltage systems but also provides a quickly adaptable solution to fuse boxes. It achieves this by providing firmware-adjustable overcurrent protection, incorporating …

Low-Cost Vehicle Controller Testing System, Kevin R. Jung

Electrical Engineering

This project aims to create a system to facilitate easier evaluation of PCBs designed for low-voltage vehicle applications with an emphasis on accessibility for student teams in collegiate design series' such as Formula SAE. Student teams or smaller vehicle electronics manufacturers often need to verify designs and validate functionality during both development and manufacturing. An inexpensive, small, and portable, yet capable, system for taking measurements and simulating inputs would allow designers to put their boards into vehicle-representative conditions and environments without needing to connect to actual vehicle hardware. Additionally, while systems exist off-the-shelf that could fulfill the requirements needed by …

Piston Crown Design, Kurt L. Lippmann, Liam T. Janssen, Alex Rangel, Larry J. Davis

Mechanical Engineering

This project investigates the effects of dimpling a piston crown, and its impact on engine combustion dynamics. Through computational methods, the effects of piston crown dimpling on flow characteristics were evaluated. Theoretical results were verified with experimental methods. Experimental methods included characterization of exhaust gas content, engine horsepower and torque, and exhaust opacity.

Autonomous Apple Harvester Robot, Jack Ryan Cline, Tyus Green, Devon Woolston

Electrical Engineering

As agricultural demands rise and manual labor costs increase, there has become a dire need to automate apple harvesting. However, the precision and speed necessary for cost-efficient apple harvesting pose a significant challenge for robotic automation. To maintain cost-effective production, a harvester must be able to operate fast enough and long enough to compete with human labor. It must also be able to navigate and traverse apple orchards autonomously and pick apples without damaging the fruit or tree. This project presents an apple harvesting robot that uses a Mask R-CNN vision system with an RGB-D camera to detect the location …

Exhaust Manifold Pressure As Engine Tuning Parameter, Kieran Truth Cunningham, Adam Sullivan Mathews, Connor Richard Smullen

Mechanical Engineering

In this project, the exhaust manifold absolute pressure (EMAP) of a 1986 Toyota Corolla was analyzed across a variety of load cases and was compared with the mass air flow (MAF) of the intake, simultaneously. Correlations were found in the trends of EMAP and MAF sensor readings that may prove helpful in tuning engines that have difficulty in accommodating a MAF sensor. These correlations were found in areas of the powerband where aftermarket tuned engines typically have poor airflow sensing. An equation was developed to spoof MAF input using EMAP and other engine operating parameters.

Modeling And Control Of A Planar Bounding Quadrupedal Robot, Patrick John Ward

Master's Theses

Legged robots have the potential to be a valuable technology that provides agile and adaptive locomotion over complex terrain. To realize legged locomotion's full abilities a control design must consider the nonlinear piecewise dynamics of the systems. This paper aims to develop a controller for the planar bounding of a quadrupedal robot.

The bounding of the quadruped robot is characterized by a simplified hybrid model that consists of two subsystems for stance and flight phases and the switching laws between the two states. An additional model, the Multibody model, with fewer simplifications, is used concurrently to best approximate real-world behavior. …

Baja Bug Suspension, James Ankers, Rebecca Hansen, Dakota Robert Hollingsworth, Thomas Alfred Spycher

Mechanical Engineering

The goal of this senior project was to design and build a long travel front suspension system for a VW Bug. This started by defining the scope of the project and performing preliminary research. In this step, similar products were investigated, and research was done on stakeholders and customers. Next, concept development, design, and evaluation were performed. With this, the first iteration of our CAD model was designed, and physical prototypes were made. Using all this information, and feedback from advisors and sponsors, multiple iterations of our CAD were performed until the design was ready to manufacture. Drawings were taken …

B.A.C.O.N. (Battery-Powered Autonomous Cart Conversion) Autonomous Vehicle Design, Robyn C. Ribet, Damond Li, Tanner Hillman, Christopher Or

Mechanical Engineering

The goal of our project is to convert an electric go cart into an autonomous testing platform. We must enable autonomous braking, steering, and acceleration with electro-mechanical systems. We began the project with ideation to create our initial design and have since received ample feedback from faculty, students, and our sponsor. With this feedback we were able to refine our preliminary ideas and produce a detailed design supported with ample analysis, research, and external advice. We have developed our project in four main subsystems: Steering, braking, acceleration, and emergency braking. Following, we procured, manufactured, and assembled all of our designed …

Baja Sae Semi-Active Suspension, Philip Pang, Stassa Cappos, Harrison Hirsch, John Deboer

Mechanical Engineering

This Final Design Review (FDR) Report outlines the senior design project of the Baja SAE Semi-Active Suspension group, which includes mechanical and electrical engineering students at California Polytechnic State University San Luis Obispo. This document compiles the Baja SAE Semi-Active Suspension senior project team’s research and development of a semi-active suspension system for the Cal Poly Racing Baja SAE racecar. The goal is to design a system that adjusts the damping constant of the racecar’s spring-damper suspension while the vehicle is being driven in order to improve vehicle dynamics and driver comfort. None of the semi-active dampers that exist on …

Conducted And Radiated Emi Measurements Of Parallel Buck Converters Under Varying Spread Spectrum Parameters, Elena Postupalskaya, Nathan Wang

Electrical Engineering

The Conducted and Radiated EMI Measurements with Parallel Buck Converters Under Varying Spread Spectrum Parameters research senior project aims to explore the effects from Spread Spectrum Frequency Modulation (SSFM) on the input electromagnetic interference (EMI) or noise of a switching power supply, specifically with LM53601MAEVM hardware. The input EMI is important as the main input bus needs to be clean to provide a reliable source for other sensitive devices connected to it. SSFM can replace a conventional EMI filter and save weight, space, and cost. This project provides a basis in terms of the impacts of variable SSFM in simulation …

Fluid Power Vehicle Challenge, Jacob Torrey, Kayla Londono, Bryson Chan, Aaron Trujillo

Mechanical Engineering

The FPVC combines mechanical engineering disciplines to design and manufacture a vehicle that utilizes hydraulic power. The FDR covers the final manufacturing process and verification processes developed during the front end of research and analysis built upon the Critical Design Review (CDR) and the PDR (Preliminary Design Review). This report showcases the design decisions and extensive research that supports the continuing efforts by the Team Pump My Ride, to build upon the accomplishments of Cal Poly’s previous team, The Incompressibles. The FDR presents how Team Pump My Ride produced the design changes from the CDR and PDR to achieve improvements …

Internal Combustion Engine, Philippe D. Habets, Sam S. Flood, Paing Htet Lin, Jason Wu, Ricardo Cuevas

Mechanical Engineering

The goal of this project is to modify a Honda GX35 engine to improve its fuel efficiency and maximize its competitiveness in the Shell Eco-marathon competitions. This competition has tight restrictions on the type of fuel used to power the engine, but otherwise has very few rules limiting the type of modifications which may be made. Our primary goals are to maximize volumetric efficiency and maintain an efficient operating temperature. Future work might pursue more advanced technologies such as pseudo-atkinson cycle operation.

Simulation And Design Tool For Supermileage Vehicle (Smv) Club Final Design Report, Kimberly Kodama, Sung Ho An, Justice Aragon

Mechanical Engineering

The purpose of this project is to create a sensitivities tool and start an optimization tool to assist the Cal Poly SMV Team in designing their vehicle, developing a driving strategy for competition, and becoming a contender in endurance events. The development of a user-friendly vehicle simulation and design tool was proposed by Professor Joseph Mello who is the club’s advisor. The SMV Team competes in endurance events such as the Supermileage competition or the Shell Eco-marathon with the goal of achieving the best mileage possible.

This report will present the research that has been conducted to understand and define …

Comparison Of Modern Controls And Reinforcement Learning For Robust Control Of Autonomously Backing Up Tractor-Trailers To Loading Docks, Journey Mcdowell

Master's Theses

Two controller performances are assessed for generalization in the path following task of autonomously backing up a tractor-trailer. Starting from random locations and orientations, paths are generated to loading docks with arbitrary pose using Dubins Curves. The combination vehicles can be varied in wheelbase, hitch length, weight distributions, and tire cornering stiffness. The closed form calculation of the gains for the Linear Quadratic Regulator (LQR) rely heavily on having an accurate model of the plant. However, real-world applications cannot expect to have an updated model for each new trailer. Finding alternative robust controllers when the trailer model is changed was …

Optimal Direct Yaw Moment Control Of A 4wd Electric Vehicle, Winston James Wight

Master's Theses

This thesis is concerned with electronic stability of an all-wheel drive electric vehicle with independent motors mounted in each wheel. The additional controllability and speed permitted using independent motors can be exploited to improve the handling and stability of electric vehicles. In this thesis, these improvements arise from employing a direct yaw moment control (DYC) system that seeks to adapt the understeer gradient of the vehicle and achieve neutral steer by employing a supervisory controller and simultaneously tracking an ideal yaw rate and ideal sideslip angle. DYC enhances vehicle stability by generating a corrective yaw moment realized by a torque …

Implementation Of A Scale Semi-Autonomous Platoon To Test Control Theory Attacks, Erik Miller

Master's Theses

With all the advancements in autonomous and connected cars, there is a developing body of research around the security and robustness of driving automation systems. Attacks and mitigations for said attacks have been explored, but almost always solely in software simulations.

For this thesis, I led a team to build the foundation for an open source platoon of scale semi-autonomous vehicles. This work will enable future research into implementing theoretical attacks and mitigations. Our 1/10 scale car leverages an Nvidia Jetson, embedded microcontroller, and sensors. The Jetson manages the computer vision, networking, control logic, and overall system control; the embedded …

Electronic Cvt - Controls, Alec William Hardy, Jessalyn Leora Ann Bernick, Nicholas Esteban Capdevila, Tristan Charles Perry

Mechanical Engineering

The following document outlines the design process, manufacturing, and testing of the control system for an electronically controlled continuously variable transmission (ECVT). This control system was integrated into the custom designed and manufactured mechanical transmission system created in parallel by another senior project group. The transmission was designed for use in the Cal Poly Baja SAE vehicle. Through researching customer needs, competition requirements, previous and alternate CVT designs, and vehicle characteristics, we were able to determine the requirements and specifications for our unique system. Input, output, speed, and durability requirements guided our hardware selection. The primary components which comprised our …

Autonomous Vehicles Operating Collaboratively To Avoid Debris And Obstructions, Toan T. Le, Cole W. Oppenheim, James H. Gildart, Kyle M. Bybee

Mechanical Engineering

The purpose of this project is to demonstrate the safety and increased fuel efficiency of an automated collision avoidance system in collaborative vehicle platooning. This project was cosponsored by Daimler Trucks North America headquartered in Portland, Oregon, as well as Dr. Birdsong, and Dr. DeBruhl of Cal Poly. The mechanical engineering team consists of Cole Oppenheim, James Gildart, Toan Le, and Kyle Bybee who worked in coordination with a team of computer engineers. Vehicle platooning is a driving technique to increase the fuel efficiency of a group of vehicles by following a lead vehicle closely to reduce the drag experienced …

Comparison Of Lqr And Lqr-Mrac For Linear Tractor-Trailer Model, Kevin Richard Gasik

Master's Theses

The United States trucking industry is immense. Employing over three million drivers and traveling to every city in the country. Semi-Trucks travel millions of miles each week and encompass roads that civilians travel on. These vehicles should be safe and allow efficient travel for all. Autonomous vehicles have been discussed in controls for many decades. Now fleets of autonomous vehicles are beginning their integration into society. The ability to create an autonomous system requires domain and system specific knowledge. Approaches to implement a fully autonomous vehicle have been developed using different techniques in control systems such as Kalman Filters, Neural …

Torsional Stiffness Of A Race Car, Reiley A. Schraeger, Cameron Kao, Raymond Deng, Omar Roman

Mechanical Engineering

Torsional stiffness plays a major role in any road vehicle. To understand torsional stiffness of a vehicle and make future iterations and improvements, a proper torsional stiffness jig is required to prove accurate and useful data. This report encompasses the new and improved testing jig and potential improvement ideas for more accurate results. With real data result relating to FEA calculations, designers can be confident in the FEA changes to torsional stiffness is accurate and will yield the probably results they desired. This report shows the methodology, manufacturing process and testing procedure to use on any Baja or SAE vehicle …

Reinventing The Wheel, Esther K. Unti, Ahmed Z. Shorab, Patrick B. Kragen, Adam M. Menashe

Mechanical Engineering

Reinventing the Wheel selected tires and designed wheels for the 2018 Cal Poly, San Luis Obispo Formula SAE combustion vehicle. Available tire options were evaluated for steady-state and transient performance as well as vehicle integration. A single-piece composite wheel with hollow spokes was designed to meet stiffness, strength, and tolerance requirements. A detailed study of wheel loading and geometric structural efficiency was performed. Finite element analysis was used to iterate the geometry and laminate. A two-piece male mold was designed and machined to manufacture the wheel. Removable silicone inserts were used to create the hollow spokes.

Daimscale — 1:14th Tractor-Trailer For Testing Driver Assistance Technology, Christopher Marrale, Jase Sasaki, Devin Bodmer

Mechanical Engineering

Active driver assistance systems are becoming increasingly wide-spread throughout the automotive industry due to their potential for safer roads and decreased costs of transportation, but testing these systems on real trucks can be time consuming, dangerous, and costly. Testing these systems on a small-scale tractor-trailer combination will lead to faster and more efficient development of driver assistance systems and can be used by both engineers and students, leading to a larger field of experienced developers to improve these systems.

Our goal will be to design, manufacture, and build a scale 6x2 model of the tractor portion of a Daimler semi-truck …

A Novel All Wheel Drive Torque Vectoring Control System Applied To Four Wheel Independent Drive Electric Motor Vehicles Utilizing Super Twisting And Linear Quadratic Regulator Methods, Kenneth Daniel Schmutz

Master's Theses

This thesis contains the design and simulation test results for the implementation of a new all-wheel drive (AWD) torque vectoring (TV) control system. A separate algorithm using standard control methods is included in this study for a comparison. The proposed controller was designed to be applied to an AWD independent drive electric vehicle, however the main concepts can be re-purposed for other vehicle drive train configurations. The purpose of the control system is to assist the driver in achieving a desired vehicle trajectory whilst also maintaining stability and control of the vehicle. This is accomplished by measuring various real time …

A Survey Of Security Attacks And Defenses In Vehicular Ad-Hoc Networks, Pierson Yieh

Computer Science and Software Engineering

No abstract provided.

Composite Suspension For A Mass Market Vehicle, Sarah M. Chapiama, Brian Auyeung, Jose Guerrero, Ethan Lau

Mechanical Engineering

Statement of Confidentiality: The complete senior project report was submitted to the project advisor and sponsor. The results of this project are of a confidential nature and will not be published at this time.

Driver Cooling System, Joseph Fatin Bolous, Jake Donald Deboer, Alvin Theodore Lau

Mechanical Engineering

This document provides our Final Design Review (FDR) for the Driver Cooling System Project. It contains our background research, which includes current product research, technical research, and information on our sponsor’s needs as a customer as well our manufacturing process, test results, and final design. We created a problem statement to define the scope of the project, discuss sponsor and consumer needs and wants, and technical specifications. After brainstorming, we ultimately selected a thermoelectric cooling system (TEC) after presenting our Preliminary Design Report and Critical Design Report. We built the final prototype, as can be seen in the manufacturing plan, …

Small Scale Intelligent Vehicle Final Design Report, Paul Rothhammer-Ruiz, Dominic Riccoboni, Sarah De Rosier

Mechanical Engineering

No abstract provided.

Arm Mke1xf Mcu Replatform, Nathan Hong, Derek Lung, Japsimran Singh, Bevin Tang

Computer Engineering

After Cal Poly Racing’s electrical team began to hit the technical limits of the ADC and other I/O features of the current 8-bit Atmel AT90 microcontroller unit, it became clear that an upgrade was due. This replatforming project takes the functionalities of the old, 8-bit architecture, and aims to provide a 32-bit version using the ARM MKE1xF MCU. With the idea of having a working PCB as a stretch goal, the scope of the library development was limited to enable base functionality. Thus, the only libraries developed were for the Timer, ADC, SPI, UART, and CAN. Additionally, this document discusses …