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2016-06-15
Technical Paper
2016-01-1806
Sumon Sinha, Farokh Kavarana, Dan Williams, Kazuya Asao
Abstract A high performance rigid airfoil profile sunroof wind deflector has been developed for high speed freeway driving with the sunroof open. This deflector is clearly superior to the conventional bar type deflector and less expensive compared to tall flexible fabric mesh deflectors applied on high end vehicles today. It provides superior speech intelligibility under high speed driving with sunroof open. The criterion for designing this deflector was to get the highest airspeed possible to span the sunroof opening under all conditions. The customized shape also utilizes flow unsteadiness, including those at the onset of buffeting, in order to condition the shear layer. The airfoil profiled deflector yielded superior mid and high frequency acoustic performance with acceptable low frequency performance. A shorter airfoil deflector was sufficient to keep the external airflow from entering the forward tilted sunroof opening on a mid-size SUV under test.
2016-06-15
Journal Article
2016-01-1795
Charly Faure, Charles Pezerat, Frédéric Ablitzer, Jérôme Antoni
In this paper, a local method of structure-borne noise source characterization is presented. It is based on measurements of transverse displacement and local structural operator knowledge and allows to localize and quantify sources without any need of boundary condition information. To fix the instability caused by measurement noise, the regularization step inherent to inverse problem is realized with a probabilistic approach, within the Bayesian framework. When a priori distributions about noise and sources are considered as Gaussian, the Bayesian regularization is equivalent to the well-known Tikhonov regularization. The optimization of the regularization is then performed by the Gibbs Sampling (GS) algorithm, which is part of Markov Chain Monte Carlo (MCMC) techniques. The whole probability of the regularized solution is inferred, providing access to confidence intervals.
2016-06-15
Journal Article
2016-01-1825
Jung-Han Woo, Da-Young Kim, Jeong-Guon Ih
Abstract To hear the powerful and spectrally rich sound in a car is costly, because the usual car audio system adopts small loudspeakers. Also, the available positions of the loudspeakers are limited, that may cause the reactive effect from the backing cavity and the sound distortion. In this work, a part of the roof panel of a passenger car is controlled by array actuators to convert the specified large area to be a woofer. An analogous concept of the acoustic holography is employed to be projected as the basic concept of an inverse rendering for achieving a desired vibration field. The vibration of the radiating zone is controlled to be in a uniform phase, and the other parts outside it are to be made a no-change zone in vibration. The latter becomes a baffle for the woofer, and the backing cavity is virtually infinite if the sound radiation into the passenger cabin is only of concern.
2016-06-02
Magazine
A 24-hour battle of speed and efficiency At Le Mans this month, amped-up hybrid prototype racecars from Audi and Toyota face a revamped Porsche 919 hybrid, while Ford hopes to recapture glory with its new GT-R. Pushing the ICE forward, gradually Emergent technologies from BorgWarner, Eaton and Mahle aim for greater efficiency in gasoline and diesel engines. Smile, you're on Magna camera! Magna Electronics is rapidly expanding production of its made-in-U.S.A. onboard cameras to keep pace with booming OEM demand for safety and vehicle-autonomy vision-systems technology. Multi-material body solutions: Possibilities and manufacturing challenges The body-in-white is a prime target for lightweighting and many automakers are pursuing unique and effective multi-material approaches, but improved design tools and processes might yield greater gains.
2016-06-01
Magazine
Digital Design Tools Simulating Thermal Expansion in Composites with Expanded Metal Foil for Lightning Protection Rugged Computing Designing VME Power Systems with Standard Modules Optical Sensors Optical Ice Sensors for UAVs Rotorcraft Technology Rotorcraft Icing Computational Tool Development RF & Microwave Technology Curled RF MEMS Switches for On-Chip Design: Design Software Supports BAE System's Mixed-Signal Chip Design
2016-05-05
Magazine
New dawn at Honda R&D President Yoshiyuki Matsumoto aims to invigorate Honda's technology and product-development organization with 'full soul.' Automated driving meets regulation: NHTSA and the next 50 years The challenges and opportunities on the road to 'zero deaths' demand a new level of federal automotive safety technical standards, and a new safety-defect reporting and recall system. NHTSA and the U.S. Congress must act boldly and quickly to make it happen. Autonomous driving meets regulation: Hands off, eyes off, brain off Euro NCAP'S president warns that without coherent policies, the growing availability of automated technologies may result in piecemeal technology development-and unintentional consequences. Designer yin meets engineer yang Efficient and effective vehicle development means even closer collaboration between the two former sparring partners.
2016-05-02
Standard
AS4130C
SCOPE IS UNAVAILABLE.
2016-05-02
Standard
AS4134C
SCOPE IS UNAVAILABLE.
2016-04-14
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.
2016-04-14
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.
2016-04-05
Standard
J1617_201604
The mechanism of automotive body corrosion is scientific, based on established laws of chemistry and physics. Yet there are many opinions related to the cause of body corrosion, not always based on scientific axioms. the purpose of this SAE Information report is to present a basic understanding of the types of body corrosion, the factors that contribute to body corrosion, the testing procedures, evaluation of corrosion performance, and glossary o related terms. The purpose of this document is to provide a basic understanding of body corrosion as influenced by materials, environment, design, pretreatment and paint systems, and evaluation thereof. If the reader requires in-depth information on these subjects, additional reading material and personal contacts should be pursued with raw material, paint, chemical, and equipment suppliers.
2016-04-05
Technical Paper
2016-01-1349
Siddharth Bhupendra Unadkat, Suhas Kangde, Mahalingesh Burkul, Mahesh Badireddy
Abstract In the current scenario, the major thrust is to simulate the customer usage pattern and lab test using virtual simulation methods. Going ahead, prime importance will be to reduce the number of soft tool prototype for all tests which can be predicted in CAE. Automotive door slam test is significantly complex in terms of prediction through simulation. Current work focuses on simulating the slam event and deriving load histories at different mounting locations through dynamic analysis using LSDyna. These extracted load histories are applied to trimmed door Nastran model and modal transient analysis is performed to find the transient stress history. This approach has a significant advantage of less computation time and stress-convergence with Nastran for performing multiple design iterations compared to LSDyna. Good failure correlation is achieved with the test using this approach.
2016-04-05
Technical Paper
2016-01-1365
Siddharth Bhupendra Unadkat, Suhas Kangde, Mahalingesh Burkul, Mahesh Badireddy
Abstract The overall automotive industry is moving toward first time right test which in turn needs first time right analysis. This is due to the enormous pressure of cost, mass, time to market and availability of prototype vehicles for testing. Use of finite element methods enables to upfront predict the system behavior in operating conditions and evaluation of structural strength. In vehicle product development process, hood slam durability evaluation is one of the important tests for body closure structure. Current work showcases an effort made for developing virtual hood slam test. The virtual model consists of BIW, hood, hinge joint, interface like CRFM (cooling-radiator-fan module) and latch mechanism with spring preload. Analysis performed with LSDyna solver. An impact loading is applied by converting potential energy to kinetic energy, mimicking the hood dropping from a specified height on the hood latch.
2016-04-05
Technical Paper
2016-01-1380
S. Khodaygan, Amir Ghasemali, Hamed Afrasiab
Abstract One of the most important characteristics of industrial products, especially mechanical set-ups, is considering the tolerances of production and assembly of these set-ups, which directly influences the products’ operations. In sheet metal structures, due to the high flexibility of the sheets, the errors appeared while assembly will be as highly influential as the errors due to the production tolerance of the sheets. As a result, having a comprehensive model which could analyze the assembly process of these structures and also clarifies the relation between the tolerance of the parts and the ultimate changes of the set-up will be of considerable importance. During the assembly process, the contact effect between the components is inevitable. If such effect is not considered, the contact surfaces will permeate. The purpose of this paper is to present a method to analyze the tolerance of flexible sheet structures, considering the contact effect between surfaces.
2016-04-05
Technical Paper
2016-01-1384
Mengshi Deng, Jian Lan
Abstract Glass lifter is a key part of automobile door system. Guide rail is the carrier of glass lifter, and it bears various load cases when glass lifer works. Mass, stiffness and natural frequencies are the factors that influence the performance of glass lifter. In order to design a lighter and reasonable glass lifter, topology optimization methods are studied in this paper. In a rope-wheel glass lifter, design domain is determined by the mechanical structure and working conditions. Firstly, the single target continuum structure topology optimization mathematic models of guide rail are built in this paper, and analysis of multi-stiffness topology optimization are carried out accordingly in which volume fraction is set as 0.4, 0.5 and 0.6. These models are based on SIMP (Solid Isotropic Material with Penalization) theory.
2016-04-05
Technical Paper
2016-01-1523
Libo Cao, Changhai Yao, Hequan Wu
Abstract The traditional deterministic optimal design is mostly based on meeting regulatory requirements specified in impact standards, without taking the randomness of the impact velocity and angle at the real world situation into consideration. This often leads to the optimization results that converge to the boundary constraints, thus cannot meet the reliability requirements of the product design. Structure members of B-pillar (e.g. inner panel, outer panel, and the reinforcing plate) play a major role in the side impact safety performance. This paper dealt with optimization of B-pillar by considering its dimensions and materials as the design variables, and the impact velocity and angle from real-world traffic accident conditions as the random variable inputs. Using a combination of design of experiment, response surface models, reliability theory and the reliability of design optimization method, a B-pillar was constructed based on the product quality engineering.
2016-04-05
Technical Paper
2016-01-1532
Kyoungtaek Kwak, Seungwoo Seo, Randi Potekin, Antoine Blanchard, Alexander Vakakis, Donald McFarland, Lawrence Bergman
Abstract The purpose of this study is to develop a dynamic model that can accurately predict the motion of the door handle and counterweight during side impact crash tests. The door locking system, mainly composed of the door outside handle and door latch, is theoretically modeled, and it is assumed that the door outer panel can rotate and translate in all three directions during a side impact crash. Additionally, the numerical results are compared with real crash video footage, and satisfactory qualitative agreement is found. Finally, the simplified test rig that efficiently reflects the real crash test is introduced, and its operation is analyzed.
2016-04-05
Technical Paper
2016-01-1541
Zuolong Wei, Hamid Reza Karimi, Kjell Gunnar Robbersmyr
Abstract The analysis of the vehicle crash performance is of great meaning in the vehicle design process. Due to the complexity of vehicle structures and uncertainty of crashes, the analysis of vehicle crashworthiness is generally depending on the researchers' experiences. In this paper, different deformation modes of energy absorption components are studied. More specifically, the bumper, crash box, the front longitudinal beam and the engine/firewall have different frequency characteristics in the deformation process. According to these characteristics, it is possible to identify the performance of each component in the crash process of assembled structures. To achieve this goal, the crash response of the passenger cabin is decomposed by the time-frequency transformation. Different frequency components exist mainly in a specified period of the crash process.
2016-04-05
Technical Paper
2016-01-0240
Ruobing Zhan, Gangfeng Tan, Bo Yang, Zhiwei Zhang, Tie Wang, Cenyi Liu, Xintong Wu, Yanjun Ren, Haobo Xu
Abstract The Organic Rankine Cycle System (ORC) is an effective means to use the solar energy. The system adopts the solar energy on the car roof as the heat source to make the ORC work and drive the thermoelectric air-conditioner. It can improve the entering comfort on the parking condition and the vehicle energy utilization efficiency. In this research, the system comprehensively applied the principle of sunshine concentration, heat collection and photo electricity. Then considering the working condition and performance features of ORC system, the car roof was designed to have a compact structure, through which the efficiency of the solar vehicle system could be improved. Firstly, the research analyzed the heat source temperature and the heat flux impact on the output power of the ORC system. After that, the performance of heat collection was identified according to the given thermoelectric air-condition’s power requirements.
2016-04-05
Journal Article
2016-01-0300
Lei Shi, Ji Yang, Zhaomin Zhang, Zhan Zhang
Abstract Multidisciplinary Design Optimization (MDO) has been widely used in the automotive industry to balance overall weight and stringent vehicle attributes, such as safety, NVH, durability, etc. To improve product quality and shorten product development cycle, a comprehensive MDO-based platform for vehicle attribute integration is developed in this paper. Some key issues in the platform development are addressed: Parameter model synchronization, Metamodel predictive capabilities, and Pre/post processing, etc. In addition, a strategy for body design is proposed to achieve weight targets while meeting other vehicle attributes. Lastly, the proposed methodology is demonstrated by a real world example for vehicle body design.
2016-04-05
Technical Paper
2016-01-0276
Mahalingesh Burkul, Hemant Bhatkar, Mahesh Badireddy, Narayanan Vijayakumar
Abstract In an automotive product development environment, identifying the premature structural failures is one of the important tasks for Body-In-White (BIW), sub-assemblies and components. The integrated car body structure i.e. monocoque structure, is widely used in passenger cars and SUVs. This structure is subjected to bending and torsional vibrations, due to dynamic loads. Normally the stresses due to bending are relatively small compared to stresses due to torsion in Body-In-White under actual road conditions [1]. This paper focuses on evaluating the life of Body-In-White structures subjected to torsional loading. An accelerated test method was evolved for identifying failure modes of monocoque BIW by applying torsion fatigue. The observation of the crack generation and propagation was made with respect to a number of torsion fatigue cycles.
2016-04-05
Journal Article
2016-01-0387
Yunkai Gao, Jingpeng Han, Jianguang Fang, Shihui Wang
Abstract A compiled method of the programmed load spectrum, which can simplify and accelerate the fatigue bench test of a car body, is proposed and its effectiveness is checked by the fatigue simulation. By using the multi-body dynamics model with a satisfactory accuracy, the virtual iteration is applied to cascade body loads from the wheel hubs. Based on the rain-flow counting method and statistics theory, the distributions of the body loads are analyzed, and then the programmed load spectrum is compiled and simplified. Through comparative study, the simulation results of random and programmed load spectrum are found to agree well with each other in terms of the damage distribution and fatigue life, which demonstrates the effectiveness of the presented method.
2016-04-05
Technical Paper
2016-01-1520
Gunti R. Srinivas, Anindya Deb, Clifford C. Chou
Abstract The present work is concerned with the objective of design optimization of an automotive front end structure meeting both occupant and pedestrian safety requirements. The main goal adopted here is minimizing the mass of the front end structure meeting the safety requirements without sacrificing the performance targets. The front end structure should be sufficiently stiff to protect the occupant by absorbing the impact energy generated during a high speed frontal collision and at the same time it should not induce unduly high impact loads during a low speed pedestrian collision. These two requirements are potentially in conflict with each other; however, there may exist an optimum design solution, in terms of mass of front end structure, that meets both the requirements.
2016-04-05
Technical Paper
2016-01-1508
Gernot Pauer, Michal Kriska, Andreas Hirzer
Abstract Active bonnet safety systems are implemented into vehicles, to fulfill pedestrian head impact requirements despite little available deformation space. For such systems it is necessary to consider a variety of aspects already from the very beginning of the vehicle design process and the functionality of the whole system needs to be continually cross-checked throughout the whole design process. Many of these aspects are already supported by finite element (FE) methods from vehicle manufacturers and in this paper it is shown, how the last missing links within the development process, the optimization of pedestrian detection sensor signals can also be efficiently supported by FE simulation. The modeling and validation of a pressure tube based sensor system and so called “misuse objects” are demonstrated.
2016-04-05
Technical Paper
2016-01-1510
Chinmoy Pal, Tomosaburo Okabe, Kulothungan Vimalathithan, Jeyabharath Manoharan, Pratapnaidu Vallabhaneni, Munenori Shinada, Kazuto Sato
Abstract Many active safety systems are being developed with the intent of protecting pedestrians namely; pedestrian airbags, active hood, active emergency braking (AEB), etc. Effectiveness of such protection system relies on the efficiency of the sensing systems. The pop-uphood system was developed to help reduce pedestrian head injuries. A pop-up system is expected to make full deployment of the hood before the pedestrian’s head could hit the hood. The system should have the capability to detect most road users ranging from a six year old (6YO) child to a large male. To test the sensing system, an impactor model (PDI-2) was developed. Sensor response varies for vehicles with different front end profile dimensions.
2016-04-05
Technical Paper
2016-01-1398
Ahmet Turan
Abstract Optimization of a structure which is subjected to simultaneous multiple load cases starts with the investigation of worst possible load case combination. This is called conventional optimization approach, which can be considered impractical due to the excessive CPU times in the application of multiple load cases. This computational difficulty can be overcome by deploying singular value decomposition (SVD) to find the worst possible load case against which the structure should be optimized. To this end, the SVD based optimization approach to optimization of a structure subject to simultaneous multiple load cases is presented. Conventional Multiobjective optimization and SVD based Multi-objective optimization approaches are applied to a sample Commercial Truck Chassis Frame structure for durability vs. weight objectives. This will enable designer to select the optimum design parameters out of the calculated Pareto sets.
2016-04-05
Journal Article
2016-01-1395
Syed F. Haider, Zissimos Mourelatos
Abstract To improve fuel economy, there is a trend in automotive industry to use light weight, high strength materials. Automotive body structures are composed of several panels which must be downsized to reduce weight. Because this affects NVH (Noise, Vibration and Harshness) performance, engineers are challenged to recover the lost panel stiffness from down-gaging in order to improve the structure borne noise transmitted through the lightweight panels in the frequency range of 100-300 Hz where most of the booming and low medium frequency noise occurs. The loss in performance can be recovered by optimized panel geometry using beading or damping treatment. Topography optimization is a special class of shape optimization for changing sheet metal shapes by introducing beads. A large number of design variables can be handled and the process is easy to setup in commercial codes. However, optimization methods are computationally intensive because of repeated full-order analyses.
2016-04-05
Technical Paper
2016-01-1332
Fredrik Henriksson, Kerstin Johansen
Abstract In the automotive industry, mass reduction and lightweight design is a continuing trend that does not show signs of declining. When looking at where to reduce weight in a vehicle, the body is a preferential subsystem due to its large contribution to overall mass and the stability of body composition over a specific model range. The automotive industry of today moves toward a greater differentiation in materials that compose a car, which can be seen in the several different multi material vehicle bodies that have been introduced by manufacturers in recent years. But while mixing materials may contribute to a good compromise between weight reduction and vehicle cost, it also proposes a number of challenges that need to be addressed. Among other material factors, the different coefficients of thermal expansions might introduce new stresses during painting and curing.
2016-04-05
Technical Paper
2016-01-1331
Shingo Hanano, Kanehiro Nagata, Yusuke Murase
Abstract The need to add more color variations to the traditional black gloss has increased globally in recent years. The intention is for automobile manufacturers to differentiate their products in terms of appearance design. The most noticeable trend is to add embellishment around the front grill. The same trend can be seen in the areas around vehicle doors. It is most common to use a coating material to emphasize the black gloss. However, in overseas countries it is a challenge to meet the required appearance quality, and under the current circumstances CKD is imported from Japan to meet such requirements. Recently, a new film-transfer technique has been established that can express black gloss as well as any coating material by transferring the roughness of the film surface. It is achieved by crimping the PET film onto the vinyl-chloride surface after the extrusion molding is performed. Moreover, we have successfully localized this technique and reduced the manufacturing cost.
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