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Training / Education
2015-08-06
Design reviews are required for ISO 9001:2000 compliance and compatible automotive and aerospace specifications. They are becoming increasingly important in product liability litigation and are accepted as a cost-effective best practice and an effective application of knowledge management, valuable for accelerating the maturity of new products. This seminar describes how formal design reviews can improve products by uncovering potential problems before they are discovered at a later stage of development or application, when the costs of correction are much higher. A broad range of effective techniques for organizing and conducting design reviews will be presented.
Training / Education
2015-07-27
Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes. Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. In this two-day seminar, you will not only learn the Boothroyd Dewhurst Method, you will actually apply it to your own product design! This seminar will include information on how DFM+A fits in with QFD, concurrent engineering, robust engineering, and other disciplines.
Event
2015-06-04
Event
2015-05-27
Event
2015-05-07
Training / Education
2015-05-06
This seminar will include a review of statistical theory and present statistical methods, which are used to better select and/or analyze Tolerance Stack-ups. The Probability (RMS) Method, the Monte Carlo Simulation Technique and tolerance optimization techniques will be discussed along with guidelines on which method(s) to use in given situations. Attendees will also view a demonstration of a microcomputer Monte Carlo Simulation program that analyzes the effects of form and assembly variation on the quality of a finished product. This seminar will provide an overview of Design of Experiments (DOE) methods, which enable effective analysis of critical product dimensions and tolerances.
Event
2015-04-27
Event
2015-04-24
Event
2015-04-09
Event
2015-03-13
Training / Education
2015-02-17
Today's transportation industries are facing multi-disciplinary challenges. The product design and development process challenges often contradict each other, for example cost, weight, quality and performance. A central challenge is the need for cost and mass reduction to compete in the global market, while continuing to meet all new and existing requirements for quality and performance. Accelerated Concept to Product (ACP) Process is a performance-driven, holistic, product design development method intended to create a balance between structure and strength, synchronizing the individual facets of the product development process.
Training / Education
2015-01-21
Today's transportation industries are facing multi-disciplinary challenges. The product design and development process challenges often contradict each other, for example cost, weight, quality and performance. A central challenge is the need for cost and mass reduction to compete in the global market, while continuing to meet all new and existing requirements for quality and performance. Accelerated Concept to Product (ACP) Process is a performance-driven, holistic, product design development method intended to create a balance between structure and strength, synchronizing the individual facets of the product development process.
Training / Education
2014-12-02
Failure Mode and Effects Analysis (FMEA) is a systematic method for preventing failure through the discovery and mitigation of potential failure modes and their cause mechanisms. Actions are developed in a team environment and address each high: severity, occurrence or detection ranking indicated by the analysis. Completed FMEA actions result in improved product performance, reduced warranty and increased product quality. This course assists FMEA team members to apply severity, occurrence and detection rankings consistently and efficiently and explores, in detail, the linkage of the Design FMEA and the Process FMEA through special characteristics development and product and process design collaboration.
Training / Education
2014-11-20
Engineers are taught to create designs that meet customer specifications. When creating these designs, the focus is usually on the nominal values rather than variation. Robustness refers to creating designs that are insensitive to variability in the inputs. Much of the literature on robustness is dedicated to experimental techniques, particularly Taguchi techniques, which advocate using experiments with replications to estimate variation. This course presents mathematical formulas based on derivatives to determine system variation based on input variation and knowledge of the engineering function.
Book
2014-11-07
Gijs Mom
This book covers one and a quarter century of the automobile, conceived as a cultural history of its technology, aimed at engineering students and all those who wish to have a concise introduction into the basics of automotive technology and its long-term development . Its approach is systemic and includes the behavior of drivers, producers, nonusers, victims, and other "stakeholders" as well as the discourse around mobility. Nowadays, students of innovation prefer the term co-evolution, emphasizing the parallel and mutually dependent development of technology and society. This acknowledges the importance of contingency and of the impact of the past upon the present, the very reason why The Evolution of Automotive Technology: A Handbook looks at car technology from a long-term perspective. Often we will conclude that the innovation was in the (re)arrangement of existing technologies. Since its beginnings, car manufacturers have brought a total of 1 billion automobiles to the market. We are currently witnessing an explosion toward the second billion.
Technical Paper
2014-10-13
Ajay Paul John, Vikas Kumar Agarwal
Abstract The Valve Train system is an integral part of any engine and the impact of its design is very crucial, particularly in high speed engines. Maintaining the required valve timing throught the engine operating speed and longer component life are the two important parameters which drive current valvetrain designs. An engine ValveTrain system designed for a valve lift of 7mm is to be modified for an increased valve lift of 8mm. A study was conducted to understand which design parameters are to be changed /modified to make this possible. For this study, the valvetrain of an air-cooled motorcycle engine is taken up. The valvetrain arrangement was an Over Head Camshaft (OHC) design with a Roller-Follower. A 1D commercially available numerical code was used to simulate the kinematics and dynamics of the system. The effect of the addition of stiffer springs to the base valvetrain layout to counter the decrease in its dynamic stability because of the larger cam (which was provided to produce the required 8mm valvelift) is studied.
Event
2014-10-08
This session will address processes, strategies and techniques for the aerodynamic design and development of commercial vehicles and components with a view toward improving efficiency and reducing emissions. This topic includes aerocoustics and aerothermodynamics including underhood and cooling flows. Technical papers on the challenges and limitations of current design studies, tools, methods and processes are desired.
Training / Education
2014-10-02
Design of Experiments (DOE) is a methodology that can be effective for general problem-solving, as well as for improving or optimizing product design and manufacturing processes. Specific applications of DOE include identifying proper design dimensions and tolerances, achieving robust designs, generating predictive math models that describe physical system behavior, and determining ideal manufacturing settings. This seminar utilizes hands-on activities to help you learn the criteria for running a DOE, the requirements and pre-work necessary prior to DOE execution, and how to select the appropriate designed experiment type to run.
Technical Paper
2014-09-30
Anatoliy Dubrovskiy, Sergei Aliukov, Yuriy Rozhdestvenskiy, Olesya Dubrovskaya, Sergei Dubrovskiy
Abstract We have developed a fundamentally new design of adaptive suspension systems of vehicles. Their technical characteristics and functional abilities are far better than the existing designs of suspensions. We have developed the following main suspension components of vehicles: a lockable adaptive shock absorber with an ultra-wide range of control performance, implementing “lockout” mode by means of blocking adaptive shock absorber, and an elastic element with progressive non-linear characteristic and automatic optimization of localization of work areas. Our patents confirm the novelty and efficiency of our major design decisions. Advantages of our developments in the vehicle suspensions are the following. Firstly, it should be noted that when the vehicle is in a wide range of speeds in a so-called “comfort zone”, we were able, by applying the non-linear elastic element, to reduce significantly the stiffness of the elastic suspension elements in compare with the regular structures - at least in two times.
Technical Paper
2014-09-30
Jon Dickson, Matthew Ellis, Tony Rousseau, Jeff Smith
Abstract Fuel efficiency for tractor/trailer combinations continues to be a key area of focus for manufacturers and suppliers in the commercial vehicle industry. Improved fuel economy of vehicles in transit can be achieved through reductions in aerodynamic drag, tire rolling resistance, and driveline losses. Fuel economy can also be increased by improving the efficiency of the thermal to mechanical energy conversion of the engine. One specific approach to improving the thermal efficiency of the engine is to implement a waste heat recovery (WHR) system that captures engine exhaust heat and converts this heat into useful mechanical power through use of a power fluid turbine expander. Several heat exchangers are required for this Rankine-based WHR system to collect and reject the waste heat before and after the turbine expander. The WHR condenser, which is the heat rejection component of this system, can be an additional part of the front-end cooling module. Packaging this WHR condenser as part of the front-end cooling module can be an engineering challenge given the tight underhood environment where the current powertrain cooling components are already near system-capable thermal limits.
Technical Paper
2014-09-30
Armin Förg, Moritz Wolter, Matthias Kreimeyer, Markus Lienkamp
Abstract This paper focuses on the manufacturer's conflict in the conceptual design of commercial vehicles between highly customized special vehicles and the greatest possible degree of standardization. Modularity and standardization are crucial success factors for realizing high variance at the best cost efficiency in development and production as well for achieving the highest quality standards at reduced efforts for technical validation. The presented virtual design approach for commercial vehicle concepts allows for purposeful design and integration of new concepts and technologies on the component level in an existing product portfolio - not neglecting manufacture's portfolio requirements concerning standardization and modularity. The integrated tool chain helps to bring trade-offs to a head that exist in balancing between dedicated vehicles with best customer-relevant characteristics and standardized vehicles with the highest degree of commonality. For this, one core aspect is KPI-based portfolio assessment which is presented in the focus of this paper.
Technical Paper
2014-09-30
Shaoyun Sun, Yin-ping Chang, Qiang Fu, Jing Zhao, Long Ma, Shijie Fan, Bo Li, Andrea Shestopalov, Paul Stewart, Heinz Friz
Abstract In the development of an FAW SUV, one of the goals is to achieve a state of the art drag level. In order to achieve such an aggressive target, feedback from aerodynamics has to be included in the early stage of the design decision process. The aerodynamic performance evaluation and improvement is mostly based on CFD simulation in combination with some wind tunnel testing for verification of the simulation results. As a first step in this process, a fully detailed simulation model is built. The styling surface is combined with engine room and underbody detailed geometry from a similar size existing vehicle. From a detailed analysis of the flow field potential areas for improvement are identified and five design parameters for modifying overall shape features of the upper body are derived. In a second step, a response surface method involving design of experiments and adaptive sampling techniques are applied for characterizing the effects of the design changes. The characterization is followed by an optimization step to find the best possible drag improvement from these design changes.
Technical Paper
2014-09-28
Lijun Zhang, Cheng Ruan, Dejian Meng
Abstract Brake pedal feel characteristic is determined by the structural and kinetic parameters of the components of the brake system. As the servo power component of the brake system, vacuum booster has a significant influence on the brake pedal feel. In this paper, a brake system model for brake pedal feel which has a detail vacuum booster mathematical description is established in the software MATLAB/Simulink. The structure gaps, spring preload, friction force and reaction disc characteristics of vacuum booster are considered in this model. A brake pedal feel bench test under different input velocity and vacuum pressure is completed in order to validate the prediction of the model. Finally, based on the assessment index in pedal travel, pedal force and master cylinder pressure three-quadrant diagram, the influence of vacuum booster design parameters such as structure gaps, spring preloads, press plate and press ring areas, diaphragm effective area and reaction disc stiffness on the brake pedal feel characteristics is analyzed and discussed.
Technical Paper
2014-09-16
Jace Allen
Abstract In the last few years, we have seen a tremendous increase in the rise in product complexity due to advances in technology and aircraft system functionality enhancement. The Model-based Design (MBD) process has helped manage the complexity of these systems while making product development faster by bringing more effective tools and methods to the entire process. Developing software using MBD has required extensive, sophisticated tool-chains that allow for efficient rapid controls prototyping, automatic code generation, and advanced validation and verification techniques using model-in-the-loop (MIL), software-in-the-loop (SIL), and hardware-in-the-loop (HIL) for both component testing and integration testing. However, the MBD process leads to generation of large volumes of data artifacts and work-products throughout the V-Cycle. The various components of these environments, from models to parameters to tests, can be inundating, and variants and versions of these artifacts lead to even larger amounts of data.
Technical Paper
2014-09-16
Clément Hamel, Ruxandra Botez, Margaux Ruby
Abstract An airplane model is usually obtained from preliminary wind tunnel experiments and CFD analysis. These models are then tuned from flight test measurements using system identification, and are used for airplane stability assessment and control design. However, sometimes no or little preliminary data and documentation are available and flight test identification is the main mean to obtain the model needed for control system design. If so, the purpose of this paper is to identify the grey-box model of an airplane without initial data using a combination of the least square and output error estimation methods. A grey-box model identification is preferred because it gives aerodynamic parameter estimations of the airplane. Before flight test data are available, this method was applied to the Cessna Citation X business airplane's high fidelity simulations and carried out with human-in-the-loop on a professional level D flight dynamics simulator designed and manufactured by CAE Inc. More than 1,000 flight simulations were made for different airplane configurations in speeds (140 to 240 kt), altitudes (10,000 to 46,300 ft), masses (24,000 to 33,000 lb) and longitudinal center of gravity positions (17 to 34% of the mean aerodynamic chord).
Technical Paper
2014-09-16
Mike Boost
Abstract Rechargeable lithium batteries are essentially ubiquitous in our daily lives and in virtually every industry from pocket key fobs to billion dollar space programs, in benign as well as extreme environments. Cell production in 2012 was estimated at 4.4 billion cells and expected to double by 2016. However within civil aviation, lithium batteries are still in the early stages of deployment. The general consensus within the industry is that the use of lithium batteries within civil aviation will increase substantially in the coming years. This paper focuses on design considerations with respect to deployment of rechargeable, or secondary, lithium batteries within civil aviation.
Technical Paper
2014-09-16
Thomas Brinson, Javier A. Parrilla, Jose M. Molinar-Monterrubio
Abstract To obtain a system level, integrated perspective on vehicle energy management, the traditional methods for conducting preliminary design, gauging independent requirements, must be abandoned. This method does not capture critical interactions between the various aircraft subsystems. Instead, a more global appreciation for interactions across boundaries needs to be realized with a mosaic scheme, where models are integrated and co-simulated. The advantage of this approach is to enhance the preliminary design stage by predicting integration issues early in the development process. Legacy design practice involved gathering data from multiple vendors in order to produce design iterations. The ability to link models directly is extremely beneficial, as requirements no longer have to be executed independently. This approach reduces cumbersome iterations between model owners and accelerates trade studies. GE Aviation is developing a PREliminary Optimized Vehicle Integration Design Enabler Tool (or PREOVIDE) to facilitate this approach.
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