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Analytical study of vehicle idle shake performance is standard NVH work within the vehicle development process. Robust design for idle shake performance takes variations into account besides nominal design based performance evaluation. In other words, in addition to the nominal design, Robust Design includes additional evaluations that may incorporate variation due to manufacturing, usage or the environment. This paper presents an example of how to obtain a robust design through performing Robust Optimization on idle shake performance with respect to powertrain mount rates and their tolerance variation. The paper describes a two-phase process that has been systematically implemented to analytically obtain a robust design. In the first phase, performance variation assessment is conducted. Then a Robust Optimization is performed to obtain a robust design.

This paper presents a project that was done to solve an integration problem between a brake system and a cruise control system on a GM vehicle program, each of which was supplied by a different supplier. This paper presents how the problem was resolved using a CAE tool which was a combination of formulated MS/Excel spreadsheet, Overdrive (GM internal code), and iSIGHT of Engineous Software Inc, which is a process integrator and process automator. A sensitivity study of system reliability was conducted using iSIGHT. The most sensitive factor was found through the sensitivity study. Thereafter, a Robust design was obtained. The recommended Robust Design was implemented in the vehicle program, which led to a substantial cost saving. The CAE software tool (the combination) developed through the problem solving process will be used to ensure quality of brake and cruise system performance for future vehicle programs.