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“Spotlight on Design: Insight” features an in-depth look at the latest technology breakthroughs impacting mobility. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. Extreme environment sensors require extreme environment cables that can reliably perform in temperatures up to 2300° F, withstand intense vibration, and have extraordinary strength. In the episode “Sensors: Noise Avoidance and Cable Manufacturing” (8:53), an engineer at Meggitt Sensing Systems demonstrates the intricate process of developing cable for sensors used in these situations.

Quality control of NVH performance of Body and Chassis systems is a challenging task. In-line NVH monitoring is part of a practical solution in many cases. The associated technology is maturing, flexible, and economical. Benefits extend beyond a “safety net” sorting function. This paper presents a general overview of the current state of commercially available technology, and presents an example application of an in-line NVH monitoring system for a window regulator assembly line. A couple specific issues and resulting NVH monitoring techniques are discussed - the use of an enveloping function to highlight a cable interference issue, and the use of a microphone to highlight a motor noise issue in a relatively noisy environment.

In the development and manufacture of vehicle components and systems, it is often necessary to quickly identify optimal design modifications for mitigating noise and vibration problems to meet the production schedule. To address this need, experimental techniques for determining the sensitivity of forced vibration response to changes in mass, damping or stiffness properties are of great use. In order to distinguish physical changes in the system from nonlinear input-output distortion, experimental techniques for identifying nonlinear input-output models in mechanical systems are also needed. The use of experimental sensitivity measurements and analyses for studying linear and nonlinear forced vibration data is examined in this work. Embedded sensitivity functions are first used to identify design modifications for reducing a vibration resonant problem.