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2017-04-04
Event
Automotive glazing, while remaining a somewhat stable part of vehicle design, is contributing to passenger comfort in new ways, and is subject to an ever-expanding web of regulation around the world.
2017-04-04
Event
Visual perception continues to be a critical aspect of overall driver performance. This session offers presentations highlighting new developments designed to provide better support for driver rearward vision, better understanding of how to measure light and its effects on drivers’ eyes, and better understanding of how drivers accomplish the visually difficult task of negotiating intersections.
2017-04-04
Event
These papers highlight the interaction of driver vision - which is itself characterized by complexity, flexibility, and high levels of performance—with ever more sophisticated vision technologies to support driver vision. In particular, LED technology continued to advance in the past year, leading to broader lighting applications. Topics covered include lighting design strategy, lighting thermal management, driver fields of view, and characteristics of camera/display systems.
2017-04-04
Event
BE & D cover several important areas that are related to vehicle body, including its components such as instrument panel, steering column and wheel, seats, hood, decklid, transmission cross-member, hard mounted chassis, CRFM, etc. Topics included are: Novel concepts, Analysis, Design, Testing, Predictions of strength, stiffness, and fatigue life, welding methods, vehicle body quality, durability, reliability, safety, ride & handling, NVH, aerodynamics, mass reduction, as well as fuel economy.
2017-04-04
Event
Multibody system modeling and simulation, rigid and flexible body modeling, loads predictions for vehicle body, frame/sub-frame, exhaust system, driveline, and powertrain, modeling of vehicle dynamics simulation and durability loads simulation, process considering vehicle dynamics and durability loads, data processing and analysis, loads sensitivity analyses for model parameters, design load minimization, prediction of loads effects, robust design methods, driver modeling, and system modeling.
2017-04-04
Event
Presentations of this session will address application and research on coatings for exterior body and plastics (including polycarbonate) as well as vehicle interiors and underbody/underhood. Focus will be on the 3-10 year timeframe.
2016-10-04
Event
Topics Include: Product Design and Manufacturing Integration Integrated Production Systems Software Simulation Virtual Manufacturing Direct Digital Manufacturing Analysis and Modeling Tools RFID Structural Health Monitoring/Management Advanced Metrology
2016-09-27
Technical Paper
2016-01-8053
Adime Kofi Bonsi, Marius-Dorin Surcel
The objective of this project was to provide pertinent information on the performance of refrigerated and heated van semitrailers to help fleets make decisions that will improve efficiency and increase productivity. To achieve this objective, tests were designed to benchmark fuel consumption of reefers and heating units and measure the impact of trailer characteristics on fuel consumption of the unit for various temperature settings. The project compared older- to newer-design refrigerated van semitrailers to determine what potential fuel savings could be obtained while maintaining temperature control. The outcome of this project is a summary of the impact of trailer characteristics on fuel consumption. Additionally, a literature survey was conducted and best practices were identified.
2016-09-27
Technical Paper
2016-01-8049
Keith Friedman, Khanh Bui, John Hutchinson, Matthew Stephens, Francisco Gonzalez
Frame rail design advances for the heavy truck industry provide numerous opportunities for enhanced protection of fuel storage systems. One aspect of the advanced frame technology now available is the ability to vary the frame rail separation along the length of the truck, as well as the depth of the frame. The frame technology opens opportunities that are likely to improve crash compatibility, fuel economy, fuel storage system protection. While examples of integrated front, side and rear underride protection systems enabled with this frame design technology, in this study, the effect of incorporating the fuel storage system within the available curved frame rails was evaluated using virtual testing. Fuel system storage for diesel and compressed natural gas (CNG) were evaluated under impact conditions. The impact performance was evaluated under a range of horizontal impacts and rollover conditions.
2016-09-27
Technical Paper
2016-01-8050
Chihua Lu, Wenxin Yang, Hao Zheng, Jingqiang Liang, Guang Fu
In this paper, we proposed a method of dynamic simulation and analysis based on superelement modeling to increase the efficiency of dynamic simulation for vehicle body structure. Using this method, a certain MPV body structure was divided into several subsystems, and the modal parameters and frequency response functions of which were obtained through superelement condensation, residual structure solution, and superelement data restoration. The study shows that compared to the traditional modeling method, the computational time for vehicle body modal analysis can be reduced by 6.9% without reducing accuracy; for the purpose of structural optimization, the computational time can be reduced by 87.7% for frequency response analyses of optimizations; consistency between simulation and testing can be achieved on peak frequency points and general trends for the vibration frequency responses of interior front row floors under accelerating conditions.
2016-09-27
Technical Paper
2016-01-2133
Carl Landau
Aircraft manufacturers are seeking automated systems capable of positioning large structural components with a positional accuracy of 0.25mm. Previous attempts at using coordinated arm robots for such applications have suffered from the use of low accuracy robots and minimal systems integration. Electroimpact have designed a system that leverages our patented Accurate Robot technology to create an extensively automated and comprehensively integrated process driven by the native airplane component geometry. The predominantly auto-generated programs are executed on a single Siemens CNC that controls two Electroimpact-enhanced Kuka 6 axis robots. This paper documents the system design including the specification, applicable technologies, descriptions of system components, and the comprehensive system integration. The first use of this system will be the accurate assembly of production empennage panels for the Boeing 777X, 787 and 777 airplanes.
2016-09-27
Technical Paper
2016-01-2105
Thomas G. Jefferson, Richard Crossley, Anthony Smith, Svetan Ratchev
This paper presents a novel reconfigurable assembly cell which can assemble multiple fuselage and wing variants. Most aerostructure assembly systems are designed to produce one variant only. For multiple variants, each assembly typically has a dedicated assembly cell, despite most assemblies requiring a process of drilling and fastening to similar tolerances. Assembly systems that produce more than one variant do exist but have long changeover or involve extensive retrofitting. Quick assembly of multiple products using one assembly system offers significant cost savings from reductions in NRC and lead time. Recent trends advocate Reconfigurable Assembly Systems (RAS) as a solution designed to have exactly the functionality necessary to produce a group of similar components. Components with similar geometries and processes are grouped into part families by iterating between design and manufacturing.
2016-09-27
Technical Paper
2016-01-2095
Agata Suwala, Lucy Agyepong, Andrew Silcox
Reduction of overall drag to improve aircraft performance has always been one of the goals for aircraft manufacturers. One of the key contributors to decreasing drag is achieving laminar flow on a large proportion of the wing. Laminar flow requires parts to be manufactured and assembled within tighter tolerance bands than current build processes allow. Drilling of aircraft wings to the tolerances demanded by laminar flow requires machines with the stiffness and accuracy of a CNC machine while having the flexibility and envelope of an articulated arm. This paper describes the development and evaluation of high accuracy automated processes to enable the assembly of a one-off innovative laminar flow wing concept. This project is a continuation of a previously published SAE paper related to the development of advanced thermally stable and lightweight assembly fixture required to maintain laminar flow tolerances.
2016-09-27
Technical Paper
2016-01-2130
Enkhsaikhan Boldsaikhan, Shintaro fukada, Mitsuo Fujimoto, Kenichi Kamimuki, Hideki Okada, Brent Duncan, Phuonghanh Bui, Michael Yeshiambel, Brian Brown, Alan Handyside
The Refill Friction Spot Joining (RFSJ) is an emerging solid-state spot welding technology that creates a molecular-level bond between the work-pieces through a thermo-mechanical processing. The RFSJ process does not consume any filler or foreign materials so that no additional weight is introduced to the assembly. As the solid-to-liquid phase transition is not involved in RFSJ in general, there is no fusion lack or material deterioration caused by liquefaction and solidification. Unlike the conventional friction stir spot welding, RFSJ produces a spot joint with a perfectly flush surface finish without a key or exit hole. Currently, the aerospace industry employs solid rivets for fastening the primary structures as they meet the baseline requirements and have well-established standards and specifications.
2016-09-27
Technical Paper
2016-01-2124
Sara Nilsson, Jonas Jensen, Mats Björkman, Erik Sundin
For the aerospace industry carbon fiber reinforced plastics (CFRP) is one of the fastest developing materials right now. The material has a strength-to-weight ratio that is several times higher than aluminium and steel, which makes it a great fit for applications where a low weight is crucial while maintaining strength and stiffness. It is specifically CFRP in pre-impregnated form, so called pre-preg, which has made its way into the aircrafts. Pre-preg is an anisotropic material that lets the designer control its properties to a high level of detail. Analogously to the material becoming used more widely in the aerospace industry the costs have decreased as the manufacturing methods have developed to follow the demands. However, how material and manufacturing method change the requirements and affect a product's design and performance can be hard to determine.
2016-09-27
Journal Article
2016-01-2112
Hilmar Apmann
As a new material FML made by aluminum foils and Glasfibre-Prepreg is a real alternative to common materials for fuselages of aircrafts. Since experiences within A380 this material has some really good advantages and becomes status as alternative to Aluminum and composite structures. Main goal for an industrial application for a higher production rates of aircrafts (like for single aisle) is the automation of production processes inside the process chain for FML-parts like skins and panels for fuselages. To reach these goals for high production rates first steps of automation inside this process chain have been developed in the last two years. Main steps is the automated lay-up of metallic foils and Glasfibre-Prepreg and also for integration of the bond film. Over this there are some more steps within positioning of i.e. stringers and doublers by automatic integration and shorter process chain to reduce process cost significantly.
2016-09-27
Journal Article
2016-01-2139
Hendrik Susemihl, Christian Moeller, Simon Kothe, Hans Christian Schmidt, Nihar Shah, Christoph Brillinger, Jörg Wollnack, Wolfgang Hintze
Highly growing production rates and the demand for efficient large-scale machining tools in aerospace industry have led to an increasing request for more flexible and productive manufacturing solutions. Robots are a promising solution, although there are some major disadvantages regarding the poor absolute accuracy, low structural stiffness, gear elasticity and limited workspace. Industry and research have shown a high ambition in optimizing industrial robots. Primary aircraft structures are commonly machined by portal, gantry or movable column machines of large dimensions. Due to high investment and time-consuming referencing processes, cost-effectiveness of these machines is often non-satisfying. With mobile robot-based solutions machining can be executed simultaneously which increases the productivity significantly. In this publication a mobile robotic machining system with enhanced absolute accuracy will be presented.
2016-09-27
Journal Article
2016-01-2120
David Judt, Kevin Forster, Helen Lockett, Craig Lawson, Philip Webb
In the civil aircraft industry there is a continuous drive to increase the aircraft production rate, particularly for single aisle aircraft where there is a large backlog of orders. One of the bottlenecks is the wing assembly process which is largely manual due to the complexity of the task and the limited accessibility. The presented work describes a general wing build approach for both structure and systems equipping operations. A modified build philosophy is then proposed, concerned with large component pre-equipping, such as skins, spars or ribs. The approach benefits from an offloading of the systems equipping phase and allowing for higher flexibility to organize the pre-equipping stations as separate entities from the overall production line. Its application is presented in the context of an industrial project focused on selecting feasible system candidates for a fixed wing design, based on assembly consideration risks for tooling, interference and access.
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