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Optimization techniques can be applied to synthesize the design of automotive systems and components to meet product requirements. In this paper, the performance of two automotive designs - a rear suspension system and a clip shape - was improved by using optimization techniques. For each design, calculation of the performance indices and the formulation of the optimization problem are discussed.

A mathematical model was developed for the analysis of a fuel filler door with a torsional spring. The model calculates performance indices such as opening and closing forces, kinetic energy during opening and closing and the maximum spring stress. The model was integrated with an optimization program. Two types of optimization problems were formulated: the traditional problem which does not include the effects of random design parameters, and the stochastic type optimization, which does. An example shows how the mathematical model, in conjunction with optimization techniques, can help determine fuel filler door designs.

EAVS is a GM in-house software package to simulate dimensional variations of manufacturing process in vehicle body assembly involving flexible parts. Methods used in EAVS for clamping and its shimming optimization are described in this paper. Two application examples, a reinforcement panel and a U-ring subassembly, are given to show the implementation and performance of the methods.

A mathematical model was first developed for the opening effort analysis of vehicle side window latch. The model was then linked to an optimization program to perform optimization studies. The optimization parameters are the coordinates of key joints and the shifts of contact surface profile. Both deterministic and random optimization problems were formulated and solved. Results of the optimization studies were compared and conclusions were drawn from the results.

Robust design approaches can be applied to create designs that are insensitive to input variation so that they work almost all the time, regardless of manufacturing and operating conditions. In this paper, the performances of two automotive designs - a steering column and a deck lid system - are significantly improved by using the robust design approach through mathematical optimization. For each design, calculation of the performance indices, the formulation, and results of the optimization problem are presented.