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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 course, you will not only learn the Boothroyd Dewhurst Method, you will actually apply it to your own product design!

Heavy Vehicle Event Data Recorders (HVEDRs) have the ability to capture important data surrounding an event such as a crash or near crash. Efforts by many researchers to analyze the capabilities and performance of these complex systems can be problematic, in part, due to the challenges of obtaining a heavy truck, the necessary space to safely test systems, the inherent unpredictability in testing, and the costs associated with this research. In this paper, a method for simulating vehicle speed sensor (VSS) inputs to HVEDRs to trigger events is introduced and validated. Full-scale instrumented testing is conducted to capture raw VSS signals during steady state and braking conditions. The recorded steady state VSS signals are injected into the HVEDR along with synthesized signals to evaluate the response of the HVEDR. Brake testing VSS signals are similarly captured and injected into the HVEDR to trigger an event record.

In electric vehicle applications, the majority of the traction motors can be categorized as Permanent Magnet (PM) motors due to their outstanding performance. As indicated in the name, there are strong permanent magnets used inside the rotor of the motor, which interacts with the stator and causes strong magnetic pulling force during the assembly process. How to estimate this magnetic pulling force can be critical for manufacturing safety and efficiency. In this paper, a full 3D magnetostatic model has been proposed to calculate the baseline force using a dummy non-slotted cylinder stator and a simplified rotor for less meshing elements. Then, the full 360 deg model is simplified to a half-pole model based on motor symmetry to save the simulation time from 2 days to 2 hours. A rotor position sweep was conducted to find the maximum pulling force position. The result shows that the max pulling force happens when the rotor is 1% overlapping with the stator core.

Bicycle computers record and store global position data that can be useful for forensic investigations. The goal of this study was to estimate the absolute error of the latitude and longitude positions recorded by a common bicycle computer over a wide range of riding conditions. We installed three Garmin Edge 530 computers on the handlebars of a bicycle and acquired 9 hours of static data and 96 hours (2214 km) of dynamic data using three different navigation modes (GPS, GPS+GLONASS, and GPS+Galileo satellite systems) and two geographic locations (Vancouver, BC, Canada and Orange County, CA, USA). We used the principle of error propagation to calculate the absolute error of this device from the relative errors between the three pairs of computers. During the static tests, we found 16 m to 108 m of drift during the first 4 min and 1.4 m to 5.0 m of drift during a subsequent 8 min period. During the dynamic tests, we found a 95th percentile absolute error for this device of ±8.04 m.

Creating a 3-dimensional environment using imagery from small unmanned aerial systems (sUAS, or unmanned aerial vehicles -UAVs, or colloquially, drones) has grown in popularity recently in accident reconstruction. In this process, ground control points are placed at an accident scene and an sUAS is flown over an accident site and a series of overlapping, high resolution images are taken of the site. Those images and ground control points are then loaded onto a computer and processed using photogrammetric software to create a 3-dimensional point cloud or mesh of the site, which then can be used as a tool for recreating an accident scene. Many software packages have been created to perform these tasks, and in this paper, the authors examine RealityCapture, a newer photogrammetric software, to evaluate its accuracy for the use in accident reconstruction. It is the authors’ experience that RealityCapture may at times produce point clouds with less noise that other software packages.

SAE J115 specifies the relevant ISO standards for application to safety labels for use on off-road work machines as defined in SAE J1116.

Abstract TOC

Abstract The drone logistics distribution method, with its small size, quick delivery, and zero-touch, has progressively entered the mainstream of development due to the global epidemic and the rapidly developing global emerging logistics business. In our investigation, a drone and a delivery man worked together to complete the delivery order to a customer’s home as quickly as possible. We realize the combined delivery network between drones and delivery men and focus on the connection and scheduling between drones and delivery men using existing facilities such as ground airports, unmanned stations, delivery men, and drones. Based on the dynamic-vehicle routing problem model, the establishment of a delivery man and drone with a hybrid model, in order to solve the tarmac unmanned aerial vehicle for take-out delivery scheduling difficulties, linking to the delivery man and an adaptive large neighborhood search algorithm solves the model.

This document is intended to supplement the SAE J1939 documents by offering the SAE J1939 information in a form that can be sorted and search for easier use.

This document is intended to supplement the SAE J1939 documents by offering the SAE J1939 information in a form that can be sorted and search for easier use.

This SAE Recommended Practice pertains to blast cleaning and shot peening and provides for standard cast shot and grit size numbers. For shot, this number corresponds with the opening of the nominal test sieve, in ten thousandths of inches1, preceded by an S. For grit, this number corresponds with the sieve designation of the nominal test sieve with the prefix G added. These sieves are in accordance with ASTM E11. The accompanying shot and grit classifications and size designations were formulated by representatives of shot and grit suppliers, equipment manufacturers, and automotive users.

This SAE Recommended Practice is intended for hubs and spoke wheels used on Class 6, 7, and 8 truck/truck-tractor non-powered front axles, powered and non-powered rear axles and trailer axles, for which bearing setting is manually adjusted. Assemblies using spacers to control bearing preload and endplay may differ in geometry and bearing componentry.

This recommended practice contains dimensions and tolerances for outboard mounted brake drums and disc wheel hubs in the interface areas. This recommended practice is intended for outboard mounted brake drums and disc wheel hubs commonly used on class 7 and 8 commercial vehicles. Included are SAE J694 mounting systems II, III, IV, XIV, and X. Special and less common applications are not covered.

NVH (Noise, Vibration and Harshness) of the electric drive axle (EDA) is a key attribute in electric-vehicle development. The NVH attributes of the EDA directly determines the driving comfort and customer feeling of the vehicle. Especially in pure electric working condition, the EDA noise is more perceptible by people without the engine noise masking. This paper investigates the abnormal noise in the vehicle caused by EDA. First, the filtered playback method is used to identify abnormal noise frequency between 330Hz and 430Hz.Adopted modal analysis, MASTA simulation, modulation noise analysis to identify problematic critical parts. The validity of the results is verified using the DOE method by part exchange, and finally locked to the source of gear parameters Rs and Fr. By adjusting the production process of gear and the second shaft, the assembly process error was avoided, and the gear parameter targets are formulated.

This paper investigates the problem of whine in the E-axle (Electric Drive Axle) system during acceleration of a light bus. The problem is identified as motor and reducer whine by the noise spectrum feature analysis method. Under the condition of ensuring motor performance and low cost, the motor whine is solved by optimizing the air tightness and sound insulation of the vehicle. Starting from gear microscopic shaping research, gear manufacturing and assembly process optimization was used to control gear whine. After testing and analysis, the means to effectively solve the E-axle system whine problem. The whine noise is optimized by about 8 dB (A). The results provide key technical support for the smooth production of the vehicle. It has certain guiding significance for the NVH (Noise, Vibration and Harshness) performance design and development of the E-axle system project.

Electronic control units of Bendix® ABS/ESC and Collision Mitigation Systems have the capability to record event data in the ABS/ESC control unit. Bendix refers to this event data recording functionality as the Bendix Data Recorder (BDR). This paper presents an overview of the BDR functionality and examines the range and resolution of data elements, the synchronicity or timing of the recorded data, and application of the data for use in analyzing crashes. Various tests were performed using trucks equipped with Bendix® Wingman® Fusion™ and were conducted in a manner to trigger BDR records. BDR data was compared to data collected from the J1939 CAN Bus and from Racelogic VBOX data loggers.

The Daimler Detroit AssuranceⓇ 4.0 collision mitigation system is able to assist a driver in various aspects of safely operating their vehicle. One capability is the Active Brake Assist (ABA), which uses the Video Radar Decision Unit (VRDU) to communicate with the front bumper-mounted radar to provide information about potential hazards to the driver. The VRDU may warn the driver of potential hazards and apply partial or full braking, depending on the data being gathered and analyzed. The VRDU also records event data when an ABA event occurs. This data may be extracted from the VRDU using Detroit DiagnosticLink software. This paper presents an overview of the VRDU functionality and examines aspects of VRDU data such as the range and resolution of data elements, the synchronicity or timing of the recorded data, and application of the data for use in the analysis of crashes.

This SAE Standard establishes the maximum gradient rating during hopper discharge of self-propelled, driver-operated sweepers and scrubbers as defined by SAE J2130-1 and SAE J2130-2.

This course explains how a lithium-ion cell can be designed, sized, and produced for a specific capacity and energy. The key steps in the selection and production of the main components of the cell, i.e. electrodes, separator, and electrolyte, are discussed. The slurry formulation, mixing, coating, drying, calendaring, cutting, stacking, electrolyte formulation/injection, sealing/packing, and formation cycles are detailed both in terms of machineries and the processing parameters.

SAE J3078/2 provides a test method to determine filter performance for fresh and recirculation air filters used in operator enclosures with an air ventilation system. SAE J3078/2 is not applicable for testing vapor and gas filters. The category of machines covered includes off-road self-propelled work machines as defined in SAE J1116 and tractors and machinery for agriculture and forestry as defined in ASABE standard ANSI/ASAE S390.