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Technical Paper

CAE based ‘Multi Objective Optimization approach for Spot Weld Connections Layout’ in Automotive Structure

Spot weld connections are used extensively in the automotive industry to join panels of automotive structures. Spot weld connections play a very vital role in the overall structural rigidity and integrity of the Body in White. The spot weld connections and layout have direct impact on functionability of automotive structure and capital investment for robots, guns and operators. There is continuous pressure on automotive engineers to reduce the number of spot weld connections in a structure without compromising on the structural performance across various disciplines such as crash, NVH & durability. Hence the need is felt to develop a generic and systematic CAE simulation procedure which will guide the designer towards arriving at an optimum design, with minimum number of spot weld connections, which meet all the performance requirements of the structure.
Technical Paper

Vehicle Level Remote Range Improvement with Low Cost Approach

Basic Function: Vehicle remote is used for vehicle lock/unlock/search/Hazard lights /approach light functions for customer convenience and vehicle security system. Conventional approach: 1 Use of separate RF (Radio Frequency) receiver -Additional Cost impact. 2 High remote RF power - Reduced remote battery life and bigger remote size required 3 High sensitivity RF receiver - High cost. Low Cost approach: It involves the followings: 1 Integration of RF receiver inside the Body Control Module (BCM). 2 Low Power Remote and Optimization of Remote PCB layout to get the maximum power. 3 External wired antenna taken out from BCM and proper routine need be ensured to get the best performance. 4 BCM mounting location to get the best remote range in all vehicle directions. This paper relates to the methodology for low cost approach for the RF communication between remote transmitter and receiver with achieving the best remote performance at vehicle level condition.
Technical Paper

Hydropneumatic Suspension Design for Light Military Tracked Vehicle

In this paper hydropneumatic suspension system design methodology for light military tracked vehicle is discussed in detail. A guide to locate the major impact factor & its effect on the system level design is demonstrated. Spring & damping characteristics of hydropneumatic suspension have significant bearing on the tracked vehicle mobility characteristics. A methodology has been derived to optimize the kinematics of the suspension system by optimizing the load transferring leverage ratio resulting in enhanced system life. The paper also discusses the analytical method used for prediction of spring & damping characteristics and the factors affecting them.
Technical Paper

One-Dimensional Solar Heat Load Simulation Model for a Parked Car

Passenger comfort and safety are major drivers in a typical automotive design and optimization cycle. Addressing thermal comfort requirements and the thermal management of the passenger cabin within a car, which involves accurate prediction of the temperature of the cabin interior space and the various aggregates that are present in a cabin, has become an area of active research. Traditionally, these have been done using experiments or detailed three-dimensional Computational Fluid Dynamics (CFD) analysis, which are both expensive and time-consuming. To alleviate this, recent approaches have been to use one-dimensional system-level simulation techniques with a goal to shorten the design cycle time and reduce costs. This paper describes the use of Modelica language to develop a one-dimensional mathematical model using Modelica language for automotive cabin thermal assessment when the car is subjected to solar heat loading.
Technical Paper

Design Methodology of New Generation Noiseless Antiroll Bar Bushes for Car Suspension

In this paper, design methodology of antiroll bar bush is discussed. Typical antiroll bar bushes have slide or slip mechanism, to facilitate the relative motion between ARB and bush. Inherently, this relative motion causes wear and noise of bush. To eliminate stated failure modes, the next generation bushes have been developed, which are using torsion properties instead of slip function. These bushes are already being used in various vehicles. This paper focuses on developing the simple mathematical model, design approach and optimization of ARB bushes. Also, comparison study is presented exploring, the differences and design criteria's between conventional and new generation anti-roll bar bushes.
Technical Paper

Optimization of Sheet Metal Forming Process Parameters using Optimization Tool

In an era of exceptional digital computation and immense indulgence in the theoretical behavior of sheet metal during its manufacturing process, the simulation of sheet metal forming becomes the most feasible and viable option for every OEM to consider this prior to its manufacturing. This paper contains a methodology for using an optimizing tool like Hyper Study to get the best formed part by incorporating forming benchmarked parameters like FLD (forming limit diagram), percentage thinning and plastic strains as responses by building up expressions among various variables and thus optimizing the forming process parameters like blank holding pressure, sliding friction, and Draw bead restraining force effectively to meet the formability requirements. This would reduce the time and effort of a forming engineer to reiterate among these parameters to get the desired result effortlessly.
Technical Paper

A Mitigation Strategy for Steering Wobble Phenomenon in Passenger Vehicle

Vehicles have a wide range of resonance band due to design nature & characteristics of its aggregates. First order, vehicle speed dependent, wheel disturbance due to wheel imbalances can result in excitation of different vehicle aggregates. Steering wobble refers specifically to first order road wheel excitation effects, in frequency range of 10-16 Hz, that manifest themselves as significant steering wheel torsional vibrations at highway speeds i.e. at the range of 80 km/h to 120 km/h on smooth roads. The tire, being an elastic body analogous to an array of radial springs, may exhibit variations in stiffness about its circumference; hence, it may vibrate at different frequencies due to wheel imbalance. This paper introduces dynamic steering wobble analysis methodology either using vehicle speed at Discrete (individual speeds) or by Sweep (low to high speed) method to investigate steering wobble in the virtual environment using the full vehicle MBD model.
Technical Paper

1D Tire Model Parameter Synthesis for Vehicle Handling Targets Assessment “A Strategy of Optimization and Evaluation of Tire Math’s”

Handling performance of a vehicle is a key characteristic determining the response of vehicle under different operating scenarios. An insight into these vehicle-handling characteristics at early stage can be extremely useful in the design and development process. Tire characterization and tuning is important and mandatory to scrutinize each functional and individual parameter of tire. Tire force and moment data is having a significant effect in vehicle handling. Segregation of tire parameter, which is contributing vehicle-handling performance, helps to identify and perform optimization for improvisation. The main objective of this study is development and integration optimized 1D tire model into multibody dynamics model of the vehicle to observe various vehicle compliances towards its handling performance target.
Technical Paper

Improvement in Shift Quality in a Multi Speed Gearbox of an Electric Vehicle through Synchronizer Location Optimization

Electrical and Series Hybrid Vehicles are generally provided with single speed reduction gearbox. To improve performance and drive range, a two-speed gearbox with coordinated control of traction motor and gearshift actuator is proposed. For a two-speed gearbox, gearshift without clutch would increase the shifting effort. Active Synchronization is introduced for a smoother gearshift even without clutch. The quality of gearshift is considered as a function of applied shift force and time taken. To enhance the quality of the gearshift further, the location of the synchronizer in the transmission system is optimized. To validate the improvement in the quality of the gearshift, a mathematical model of the two-speed gearbox incorporating proposed location of synchronizer assembly along with active synchronization is developed. The qualitative and quantitative analysis of the results achieved is presented.