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2017-04-18 ...
  • April 18-27, 2017 (4 Sessions) - Live Online
  • October 17-26, 2017 (4 Sessions) - Live Online
Training / Education Online Web Seminars
Tough times require searching for things that we can change and making them better. But so often problems are solved with 'band-aids' and not root cause solutions. This approach is getting too expensive and at best only helps companies tread water. To combat these issues and adopt a fresh approach, teams can use the methods and tools of Root Cause Problem Solving to first view problems as opportunities for improvement, identify root causes and implement solutions to prevent recurrence. Benefits include improved quality and customer satisfaction, reduced operation costs, and greater employee knowledge of work processes.
2017-04-04
Event
This technical session deals with research and development efforts addressing the advancement and applications of Lean methodologies and Quality improvement in the mobility Industry. Papers presented in this session will portray the latest developments in the principles, practices, tools, processes, and applications of Lean and Quality improvement methodologies.
2017-04-04
Event
This session presents the theory, practices and technology used in development of trends in reliability and durability testing (ART/ADT) technology and accurate physical simulation for successful performance predicting. The purpose is covering a new ideas and unique approaches to simulation interaction of full field inputs, safety, and human factors, improvement the ART/ADT steps-components, implementation that leads to development dependability, reduce recalls, life cycle cost, time, etc.
2017-04-03 ...
  • April 3-5, 2017 (8:30 a.m. - 4:30 p.m.) - Detroit, Michigan
  • August 16-18, 2017 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • December 13-15, 2017 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
RMS (Reliability-Maintainability-Safety-Supportability) engineering is emerging as the newest discipline in product development due to new credible, accurate, quantitative methods. Weibull Analysis is foremost among these new tools. New and advanced Weibull techniques are a significant improvement over the original Weibull approach. This workshop, originally developed by Dr. Bob Abernethy, presents special methods developed for these data problems, such as Weibayes, with actual case studies in addition to the latest techniques in SuperSMITH® Weibull for risk forecasts with renewal and optimal component replacement.
2017-04-03 ...
  • April 3-4, 2017 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • August 14-15, 2017 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • December 7-8, 2017 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
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.
2017-03-28
Technical Paper
2017-01-0276
Lev Klyatis
This paper considers the situation in the laboratory testing: different stress types and accelerated testing, including accelerated reliability/durability testing, accelerated life testing, reliability testing, proving grounds, vibration, temperature, voltage, humidity, and others. In comparison with field situation, most of these testing simulate only one or part of the field input influences. One uses often not accurately the theory of physics-of-degradation process or failures for comparison of the field results with laboratory results. Thos situation will be considered with practical examples. It will be demonstrated that often used laboratory testing does not offer the possibility for successful prediction of product performance during service life As a result, there are many complaints, recalls, less profit than was predicted during design and manufacturing. It will be shown how one can improve this situation..
2017-03-28
Technical Paper
2017-01-0297
Alan Baumgartner, Bruce Barth, Timothy Hajduk
Current data monitoring techniques used by typical plant floor systems are good for collecting data, but operators have little visibility to what that data might be indicating. Processing the data into a story that leads to corrective action is usually done by specialists (e.g. Black Belts, Quality Analysts, etc.), requires mining and integration of data from multiple systems, and is typically only triggered by the occurrence of systemic poor quality (e.g. scrap production / rework cycles / waste). It was theorized that significant improvements in 1) throughput; 2) quality (consistency of throughput); and 3) reduction of waste could all be achieved if operators could be notified of the onset of variation before rather than after it cascades into a systemic failure mode. A new methodology for automating the traditional analysis practices and eliminating the need for operators to step aside to query any systems for current quality diagnostics was developed.
2017-03-28
Technical Paper
2017-01-0296
Oberti Dos Santos Almeida
One of the biggest challenges for the Product Development Engineers is to have a clear understanding of the Quality Principles and Disciplines they should follow while they are engineering. In general, the current Product Development System guides of the Automakers companies are mostly focused on provide guidance for the Engineers on the following areas: Design Efficiency; Design Rules for Product Robustness; Design Validation; Product Reliability; Testing Procedures. The introduction of a new/advanced technology system alone does not mean low incidence of customer complaints. The only way to get that is plan/execute Consumer Driven Design with excellence. Global Vehicles are more sensitive to Quality since they must satisfy diverse cultural customers without compromise reliability. When a new vehicle is being developed to be sold in many markets around the world – Global Product - this problem is even bigger. Different markets mean different customer expectations.
2017-03-28
Technical Paper
2017-01-0298
Allen Dobryden, Brian Rutter, Derek Hartl, Eric Bramson
Integration of a new, complex technology which crosses several powertrain subsystem boundaries (and thereby involves multiple organizations), without introducing inadvertent failure modes, can be a difficult task. This paper illustrates an approach to addressing this task at a system level using an example new technology. In product development activities involving primarily reuse of known technologies, perhaps with minor improvements, organizational and subsystem boundaries are generally clear. Interfaces are well established and responsibilities for failure mode avoidance are generally known. Implementation of a new technology which involves multiple parts of the organization, however, presents unique challenges to failure mode avoidance. The example technology primarily impacts the exhaust system, the powertrain cooling system, and the powertrain control system. It can affect engine operation, emissions, and performance.
2017-03-28
Technical Paper
2017-01-0397
Salah H. R. Ali
There is a strong close correlation between the metrology and industry, especially in the automotive industry, which positively affects the world economy. Based on a local and world survey in the area of automotive industry, there is a great spreading of automotive in Egypt and world. Where, the automotive industry is considered as a leading industry for the world economy. This industry includes the complete vehicles’ manufacturing and their feeding industries for spare parts and accessories. This industry needs a wide background in many fields of engineering applications based on mechanical, chemical, mechatronic and material science. The metrology (the science of measurement and its applications) is considered as one of the very important science which can enhances this industry, where, it can increases the manufacturing quality of the main parts of the automotive.
2017-03-28
Technical Paper
2017-01-0295
Silvio César Bastos
Automotive industries has been seeking quality excellence as a key factor of competitiveness. Product characteristics and functions should meet the expectations of customers in terms of warranty and reliability. The objective of this paper is to present a method to improve the synchronization of customer´s products requirements with their suppliers in terms of key performance indicators. The improvement allows suppliers to take corrective and preventive actions through knowledge of components application in engines and vehicles. Engines assembly lines maintain records and daily meeting to explore trends of productivity and supplier quality performance is measured based on engines failure instead parts supplied. This methodology results integration between Lean Manufacturing and Supplier Quality Engineering and respective targets communizing efforts toward Quality Assurance.
2017-03-28
Technical Paper
2017-01-0347
Yat Sheng Kong, Dieter Schramm PhD, Zaidi Omar PhD, Sallehuddin Mohd. Haris, Shahrum Abdullah PhD
This paper presents the development of a relationship between objective vehicle ride level and coil spring durability life using road data to shorten suspension design process. Current development processes of vehicle suspension systems which include vehicle ride and suspension spring durability are categorized into different stages of analysis and therefore, consumes lots of time. Through the developed predictive model, the ISO weighted accelerations were used to describe durability of spring components or vice versa. This model has led to immediate solution of suspension design with reduced number of testing. In order to construct the model, strain and acceleration data from various roads were measured using data acquisition which was involving car movements. Prior to the strain measurement, a finite element model of the spring was measured to identify the critical region of the spring and strain gauges were applied on the particular spot.
2017-03-28
Technical Paper
2017-01-0420
Prashant Khapane, Sumiran Lohani
Vibration Isolation is the key objective of engine mounting systems in the automotive industry. A well-designed, robust engine mount must be capable of isolating the engine assembly from road-based excitations. The durability of engine mounts is a concern due to their susceptibility to wear and failure owing to high vibrational inputs. A design validation methodology has been developed at Jaguar Land Rover using Multibody Dynamics (MBD) to enhance the prognosis of engine mount loads during full - vehicle durability test events. This paper describes the development of a virtual multi-axial simulation table rig (MAST Rig) to test engine mount designs. For the particular example considered here, a simple sinusoidal input is applied to the MAST Rig. The development of the virtual MAST Rig has been described including details of the modelling methodology.
2017-03-28
Technical Paper
2017-01-0455
Harshad Hatekar, Baskar Anthonysamy, Saishanker V, LAKSHMI PAVULURI, Gurdeep Singh Pahwa
Structural elastomer components like bushes, engine mounts are required to meet stringent and contrasting requirements of being soft for better NVH and also be durable at different loading conditions and different road conditions. Silent block bushes are such components where the loading in radial direction of bushes are high to ensure the durability of bushes at high loads, but has to be soft on torsion to ensure good NVH. These requirements present with unique challenge to optimize the leaf spring bush design, stiffness and material characteristics of the rubber. Traditionally, bushes with varying degree of stiffness are selected, manufactured and tested on vehicle and the best one is chosen depending on the requirements. However, this approach is costly, time consuming and iterative. In this study, the stiffness targets required for the bush were analysed using static and dynamic load cases using virtual simulation (MSC.ADAMS).
2017-03-28
Technical Paper
2017-01-0050
Mario Berk, Hans-Martin Kroll, Olaf Schubert, Boris Buschardt, Daniel Straub
With increasing levels of driving automation, the information provided by automotive environment sensors becomes highly safety relevant. A correct assessment of the sensor’s reliability is therefore crucial for ensuring the safety of the customer functions. There are currently no standardized procedures or guidelines for demonstrating the reliability of the sensor information. Engineers are faced with setting up test procedures and estimating efforts. Statistical hypothesis tests are commonly employed in this context. In this contribution, we present an alternative method based on Bayesian parameter inference, which is easy to implement and whose interpretation is more intuitive for engineers without a profound statistical education. It also enables a more realistic representation of dependencies among errors.
2017-03-28
Technical Paper
2017-01-0473
Satoshi Nakada, Toru Furusawa, Eiichiro Yokoi, R Carbas, M Costa, E Marques, G Viana, LFM da Silva
In recent years, adhesive bonding is increasingly being applied in the construction of vehicle frames in order to improve stiffness and crash performance. Regarding crash performance, the behavior of impacted components is affected by the fracture energy value of the adhesive. However, for many types of structural adhesives, the relationship between the ductility and fracture energy values under static mixed-mode loading has not been sufficiently evaluated. In this paper, the fracture energy of three structural adhesives in a static mixed-mode loading using Double Cantilever Beam (DCB) specimens is presented. To derive the fracture energy values, the Compliance Based Beam Method (CBBM) was used, which allowed for precise determination of fracture energy values. Static mixed-mode loading tests were performed in six configurations of mixed-mode loading, ranging from pure peel mode state to almost pure shear mode state.
2017-03-28
Technical Paper
2017-01-1244
Keisuke Kimura, Hiroshi Hosokawa, Tasbir Rahman, Tadashi Misumi, Takeshi Fukami, Masafumi Hara, Sachiko Kawaji, Satoru Machida
A new IGBT has been developed for Toyota’s 4th generation HV’s. The power loss reduction of power control units (PCUs) for hybrid vehicles (HVs) is essential to improve their fuel efficiency. It is important to reduce the loss of the power devices (IGBTs and FWDs) used in the PCUs, because of being about 20% of the whole power loss of the HVs. Also the trade-off between the power device downsizing and the heat dissipation feasibility is the important technical issues. In order to achieve the 4th generation PCU design goal, the IGBT development goal is to improve 19.8% of the losses, 30% of downsizing, 14% of the breakdown-voltage than the previous generation. For the loss reduction goal, SBL (Super-Body-Layer) structure is installed to improve the trade-off characteristic between the switching loss and the steady-state loss. The goal is achieved by optimizing the SBL impurity concentration which is an important parameter for trade-off characteristic improvement.
2017-03-28
Technical Paper
2017-01-0176
B. Vasanth, Uday Putcha Sr, Sathish Kumar S, Murali govindarajalu
The main function of mobile air conditioning system in a vehicle is to provide the thermal comfort to the occupants sitting inside the vehicle at all environmental conditions. Passenger thermal comfort is mainly influenced by the inside cabin temperature and airflow flows through the duct system. The function of ducts is to get the sufficient airflow from the HVAC system and distribute the airflow evenly throughout the cabin. The main focus for all OEMs is to optimize the design of the duct system and satisfy the target requirements such as airflow, velocity and temperature. In this paper, the focus is to optimize the rear passenger floor duct system to meet the target requirements through design for six sigma (DFSS) methodology. Normally floor duct design is evaluated by the target airflow, velocity and temperature achieved at passenger leg locations.
2017-03-28
Technical Paper
2017-01-1331
Marko Basic, Thomas Resch
This paper describes a numerical study of the effect of hollow crankshafts on crankshaft local strength and durability as well as slider bearing contact behavior. Crankshaft dynamic simulation for durability is still a challenging task, although numerical methods are already worldwide established and integrated part of nearly every standard engine development process. Such standard methods are based on flexible multi-body dynamic simulation, combined with Finite Element analysis and multi-axial fatigue evaluation. They use different levels of simplification and consider the most influencing phenomena relevant for durability. Lightweight design and downsizing require more and more detailed methods due to higher deformation of the crankshaft. This is especially true for hollow shafts, as present in motorsport design or aerospace applications, but also for standard engine having high potential for significant weight savings.
2017-03-28
Technical Paper
2017-01-0341
Seyyedvahid Mortazavian, Javid Moraveji, Reda Adimi, Xingfu Chen
Engine camshaft cap components experience high number of fluctuating loads during engine operation. The problem is complicated in engines with variable cam timing, because the loading for these components are sensitive to engine valve timing (combustion phasing) which can lead to catastrophic overload or fatigue failures. Improving the design of these components using computer-aided tools can drastically reduce the cost and time to the market of the final acceptable design, by eliminating the number of physical prototypes. Hence, a decent and robust finite element analysis with representative load and boundary conditions can significantly reduce the premature failures in engine development. In this study, first a finite element analysis method is developed for simulating a cap punching bench test. Effect of punch radius and shape on the component stiffness is investigated and correlated with test data.
2017-03-28
Technical Paper
2017-01-0337
Kalyan S. Nadella, Yi Zhang
Ensuring durability is one of the key requirements while developing cooling modules for vehicles. Cooling modules typically include radiator, charge air cooler, transmission oil cooler, low-temp radiator and condenser. Typical loading on cooling modules comes from body, in the form of road loads. The road load accelerations are commonly utilized to predict the high-stress regions and predict the fatigue life of the components. In certain cases where components are attached to both body and engine, the cooling module components can experience additional loads which might require additional analysis to determine the fatigue life. In the proposed paper we look at the effect of engine roll on the fatigue life of transmission oil cooler which is mounted on the body through radiator and is simultaneously connected to the engine using a steel pipe. Bench tests were used to prove out the mode of failure observed in the simulations.
2017-03-28
Technical Paper
2017-01-0299
Chandra Jalluri, Himanshu Rajoria, Mark Goderis, Michael Habel, Trevor Hill
In automotive manufacturing, MQL (Minimum Quantity Lubricant) machining has been implemented on multi-axis CNC Machining Centers. In MQL machining, since there is no flood coolant, small quantities of coolant through spindle-tool is used at targeted cutting zones. However, a challenge that MQL machining faces is significant thermal growth of machine components (spindle, column, fixture etc) that must be appropriately addressed in order to achieve quality with tight tolerances. A strategy adopted by CNC OEMs is to measure the thermal growth and offset it during machining (machine thermal compensation). A gage bore is mounted in the machine fixture and its position measured using a probe. Required offsets are then calculated and applied for subsequent machining. Different OEMs use different methods for this gage bore-probe based referencing. It is imperative that this compensation be done correctly for it directly impacts quality.
2017-03-28
Technical Paper
2017-01-1131
Keith Gilbert, Srini Mandadapu, Christopher Cindric
The implementation of electronic shifters (e-shifter) for automatic transmissions in vehicles has created many new opportunities for the customer facing transmission interface and in-vehicle packaging. E-shifters have become popular in recent years as their smaller physical size leads to packaging advantages, they provide lower mass of the automatic transmission shift system, they are easier to install into the vehicle during assembly and act as an abler for autonomous driving. A button-style e-shifter has the ability to create a unique customer interface to the automatic transmission, as it is very different from the conventional column lever or linear console shifter. In addition to this, a button-style e-shifter can free the center console of valuable package space for other customer-facing functions such as storage bins and Human-Machine Interface controllers.
2017-03-28
Technical Paper
2017-01-0179
Saravanan Sambandan, Manuel Valencia
Abstract In current automotive industry, the necessity of providing quick warm up of the cabin during extreme cold conditions becomes more challenging to the engineers. A Trade-off between development time, cost and desired performance has to be achieved for deciding the right combination of HVAC (Heating ventilating air-conditioning) components to meet the customer satisfaction. In the HVAC, heater system plays a major role during winter condition to provide passenger comforts as well as to clear windshield defogging/deicing. The heater system consists of heater core, engine coolant as inner medium and air as outer medium. The coolant is circulated by engine coolant/water pump carrying heat from engine and flows across the heater core. The HVAC blower provides air to the cabin by taking heat from the heater core through floor duct systems thus warm up the cabin.
2017-03-28
Technical Paper
2017-01-0052
Andre Kohn, Rolf Schneider, Antonio Vilela, Udo Dannebaum, Andreas Herkersdorf
The reliability of safety-related systems is a primary goal of automotive ECU development and hence an essential part in developing ECU architectures. Nowadays this becomes even more challenging due to the increasing complexity of algorithms and assistance systems that are already able to manage numerous driving tasks on their own. This trend will be additionally intensified by the growing degree of automated driving, continually reducing the need for manual driver intervention. But the absence of a human driver as a fallback leads to the replacement of fail-safe architectures with new fail-operational approaches to maintain control of vehicles in case of errors. In our contribution we will point out an exemplary approach to analyze the reliability of such a fail-operational concept on ECU level. For this, we consider a typical safety-related ECU from the chassis domain, used as a basis for enhancing it to facilitate fail-operational capabilities on a single ECU.
2017-03-28
Technical Paper
2017-01-0275
Obuli Karthikeyan N, Prajitha N, SethuMadhavan P
As the technology gets upgraded every day, automotive manufacturers are also paying more attention towards delivering a highly reliable product which performs its intended function throughout its useful life without any failure. To develop a reliable product, functional and durability testing is not only sufficient rather it should undergo various types of stresses at different levels, to identify its potential modes of failure. By reliability testing, most of the failure modes of a component can be analyzed and eliminated in the design stage itself, prior to production. In this paper, electrical relay of a commercial vehicle was taken up for study to analyze the causes for field failure and to estimate its reliable life in the customer operating conditions. Few of the field failure samples were tested for its performance characteristics with typical testing protocol and strip out experiment was carried out to analyze the various failure modes.
2017-03-28
Technical Paper
2017-01-1676
Hartmut Lackner
Software systems, and automotive software in particular, are becoming increasingly configurable to fulfill customer needs. New methods such as product line engineering facilitate the development and enhance the efficiency of such systems. In modern, versatile systems, the number of theoretically possible variants easily exceeds the number of actually built products. This produces two challenges for quality assurance and especially testing. First, the costs of conventional test methods increase substantially with every tested variant. And secondly, it is no longer feasible to build every possible variant for the purpose of testing. Hence, efficient criteria for selecting variants for testing are necessary. In this contribution, we investigate the cost drivers of testing multivariable systems and define novel criteria to systematically sample variants for the purpose of testing. The presented criteria reduce the test effort by means of tested variants as well as executed test steps.
2017-03-28
Technical Paper
2017-01-0016
Don Zaremba, Emily linehan, Carlos Ramirez Ramos
For over thirty years, the silicon power MOSFET’s role has expanded from a few key components in electronic engine control to a key component in nearly every automotive electronics system. New and emerging automotive applications such as 48 V micro hybrids and autonomous vehicle operation require improved power MOSFET performance. This paper reviews mature and state of the art power MOSFET technologies, from planar to shield gate trench, with emphasis on applicability to automotive electronic systems. The automotive application environment presents unique challenges for electronic systems and associated components such as potential for direct short to high capacity battery, high voltage battery transients, high ambient temperature, EMI limitations, and large delta temperature power cycling. Moreover, high reliability performance of semiconductor components is mandatory; sub 1 ppm overall failure rate is now a fundamental requirement.
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