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Once the design of a door sheetmetal and accessories is confirmed, the acoustics of the door system depends on the sound package assembly. This essentially consists of a watershield which acts as a barrier and a porous material which acts as an absorber. The acoustical performance of the watershield and the reverberant sound build-up in the door cavity control the performance. This paper discusses the findings of a design study that was developed based on design of experiments (DOE) concepts to determine which parameters of the door sound package assembly are important to the door acoustics. The study was based on conducting a minimum number of tests on a five factor - two level design that covered over 16 different design configurations. In addition, other measurements were made that aided in developing a SEA model which is also compared with the findings of the results of the design study.

Laser lap welding quality is a non-linear response based on a host of categorical and numeric material and process variables. This paper describes a Grammatical Evolution approach to the structure identification of the laser lap welding process and compares its performance with linear regression and a neuro-fuzzy inference system.

With the increasing emphasis on Systems Engineering, there is a need to ensure that Electrical/Electronic (E/E) Systems Endurance Testing of vehicles, in a real world environment, prior to Production Launch, is performed in a manner and at a technological level that is commensurate with the high level of electronics and computers in contemporary vehicles. Additionally, validating the design and performance of individual standalone electronic systems and modules “on the bench” does not guarantee that all the permutations and combinations of real-world hardware, software, and driving conditions are taken into account. Traditional Proving Ground (PG) vehicle testing focuses mainly on powertrain durability testing, with only a simple checklist being used by the PG drivers as a reminder to cycle some of the electrical components such as the power window switches, turn signals, etc.

This paper deals with the multi-parameter and boundary mannequin techniques in creating human models in automotive applications. The concepts and applications of single-parameter, multiple parameter and boundary mannequin method are discussed respectively to clarify certain confusion. Emphasis is put on how to create boundary mannequins for a specific application, which may have been puzzling many engineers in practical applications. The authors would like to share their experience in using the digital human modeling software and make discussions on some common issues. A number of case studies from typical automotive manufacturing assembly operations are also presented to demonstrate the usage of the multi-parameter and boundary mannequin techniques.

Variable Valve Actuation (VVA) technology provides high potential in achieving high performance, low fuel consumption and pollutant reduction. However, more degrees of freedom impose a big challenge for engine characterization and calibration. In this study, a simulation based approach and optimization framework is proposed to optimize the setpoints of multiple independent control variables. Since solving an optimization problem typically requires hundreds of function evaluations, a direct use of the high-fidelity simulation tool leads to the unbearably long computational time. Hence, the Artificial Neural Networks (ANN) are trained with high-fidelity simulation results and used as surrogate models, representing engine's response to different control variable combinations with greatly reduced computational time. To demonstrate the proposed methodology, the cam-phasing strategy at Wide Open Throttle (WOT) is optimized for a dual-independent Variable Valve Timing (VVT) engine.

Cam-phasing is increasingly considered as a feasible Variable Valve Timing (VVT) technology for production engines. Additional independent control variables in a dual-independent VVT engine increase the complexity of the system, and achieving its full benefit depends critically on devising an optimum control strategy. A traditional approach relying on hardware experiments to generate set-point maps for all independent control variables leads to an exponential increase in the number of required tests and prohibitive cost. Instead, this work formulates the task of defining actuator set-points as an optimization problem. In our previous study, an optimization framework was developed and demonstrated with the objective of maximizing torque at full load. This study extends the technique and uses the optimization framework to minimize fuel consumption of a VVT engine at part load.

Computer applications have been widely used to assist product design. The successes and sophistication of computer aided engineering (CAE) techniques are respectfully recognized in this field. CAE applications in the manufacturing area however are still developing, although the manufacturing community is increasingly starting to pay attentions to computer simulations in its daily workings. This paper will briefly introduce some of these applications and promote awareness of computer simulations in manufacturing area. It contains four main sections: finite element analysis (FEA) in machining fixture design, FEA applications in component assembly, machining process simulations and machining vibrations in the milling operation. Each section comes with a practical case study, potential benefits are identified and conclusions are presented by using an integrated design and analysis approach.

The use of composite materials in the automotive industry has become increasingly widespread. With this increase in use, techniques for non-destructive testing (NDT) have become more and more important. Various optical NDT inspective methods such as holography, moiré techniques, and shearography have been used for material testing. Among these methods, shearography appears to be most practical. Shearography has a simple optical setup due to its “self-referencing” system, and it is relatively insensitive against rigid-body motions. Measurements of displacement derivatives, and thus strain directly, rather than the displacement itself is achieved through this method. Therefore shearography detects defects in objects by correlating anomalies of strain which are usually easier than correlating the anomalies of the displacement itself, as in holography. To date shearography has shown potential as a NDT tool for identifying defects in small structures.

In this report, the DCX Stress Lab and the Tool Development & Test Support groups investigated automating a resonant bending crankshaft fatigue test. Fatigue testing, in general, is a laborious process since many samples are needed for analysis. This makes development cost and speed dependant on the component test efficiency. In the case of crankshaft resonant bending testing, both cost and speed are influenced by the manual feedback operation needed to run the current procedure. In order to increase the efficiency of this process, this project sought to automate the following tasks: maintaining the load on the part, reacting to resonance changes in the part, mapping resonance changes, logging the number of cycles, and discerning resonance frequency shift failure modes objectively.

A project was undertaken to demonstrate an engine stop/start at idle system utilizing a 12 volt Belt driven Starter Generator (BSG). The system was developed on a production four cylinder vehicle to determine emissions, driveability, and fuel economy impact.

Current engine development processes typically involve extensive steady-state and simple transient testing in order to characterize the engine's fuel consumption, emissions, and performance based on several controllable inputs such as throttle, spark advance, and EGR. Steady-state and simple transient testing using idealistic load conditions alone, however, is no longer sufficient to meet powertrain development schedule requirements. Mapping and calibration of an engine under transient operation has become critically important. And, independent engine development utilizing accelerated techniques is becoming more attractive. In order to thoroughly calibrate new engines in accelerated fashion and under realistic transient conditions, more advanced testing is necessary.

Tire stiffness can have a significant effect on the spindle and component loads. While its’ effect on the component loads may show a different trend. This paper deals with data acquisition loads using Wheel Force Transducer (WFT) with 17 inch, 18 inch and 20 inch tires and shows how the spindle loads changed for different tire. These loads are applied on the analytical suspension model to generate both component and the body attachment loads. Some of the measured channels are correlated for all the wheel sizes for multiple events to ensure the confidence in the model. It is found that even if spindle loads are increased with tire stiffness, the component loads do not necessarily show a similar trend. This paper studies why higher spindle forces do not always give higher component loads and what are the possible alternatives one may look into to shortlist or select one set of loads over the other.

The damping loss factor of a structural panel plays a significant role in its vibro-acoustic performance. The objective of this paper is to present a new procedure for evaluating the damping loss factors of these panels. Traditionally, the damping loss factors are determined by using the decay rate of the decay curves which are experimentally obtained from the structure. However, this is time consuming and the accuracy is limited by fluctuations in the decay curve. In this paper, the envelope signal of each decay curve is determined through its Hilbert transform, and the remaining small fluctuations in the envelope signal are further smoothed out by the exponential average method. Finally, the damping loss factor is estimated based on the smoothed envelope signal of each decay curve. A computer program has been developed to implement this procedure. It is shown that this procedure improves both accuracy and efficiency of the decay rate method for estimating damping loss factor.

This investigation evaluated different pressure transducers in one cylinder to examine the combustion measurement differences between them simultaneously. There were a total of eleven transducers ranging in both diameter and type of transducer (piezo-electric, piezoresistive, and optical). Furthermore, the sensors differed in the methodology for minimizing signal distortion due to temperature. This methodology could take the form of various size mounting passages, heat shields, watercooling or heat transfer paths. To evaluate the sensors, different engine operating conditions were conducted, focusing at full load and low speeds. Other hardware configurations of the same engine family were used to exaggerate the combustion environment, specifically a tumble-motion plate and turbocharging.

The problem of predicting the quality of weld is critical to manufacturing. A great deal of data is collected under multiple conditions to predict the quality. The data generated at Daimler Chrysler has been used to develop a model based on grammatical evolution. Grammatical Evolution Technique is based on Genetic Algorithms and generates rules from the data which fit the data. This paper describes the development of a software tool that enables the user to choose input variables such as the metal types of top and bottom layers and their thickness, intensity and speed of laser beam, to generate a three dimensional map showing weld quality. A 3D weld quality surface can be generated in response to any of the two input variables picked from the set of defining input parameters. This tool will enable the user to pick the right set of input conditions to get an optimal weld quality. The tool is developed in Matlab with Graphical User Interface for the ease of operation.

A new multi-layer co-extruded in-color Ionomer film is developed to provide an alternative decoration process to replace paint on Dodge Neon Fascias. The Ionomer film provides a high-gloss “class-A” surface in both non-metallic and metallic colors that match the car body paint finish. Using the Ionomer film to decorate fascias reduces cost; eliminates VOCs; increases manufacturing flexibility and improves performance (weatherability and durability). The molding process consists of thermoforming a film blank and injection molding Polypropylene or TPO behind the film. The paper will include the background, the benefits, the technology development objectives, the film materials development, tooling optimization, film fascia processing (co-extrusion; thermoforming and injection molding) and validation testing of the film.

In 1998, Rouhana et al. described development of a new device, called the IR-TRACC (InfraRed - Telescoping Rod for Assessment of Chest Compression). In its original concept, the IR-TRACC uses two infrared LEDs inside of a telescoping rod to measure deflection. One LED serves as a light transmitter and the other as a light receiver. The output from the receiver LED is converted to a linear function of chest compression using an analog circuit. Tests have been performed with IR-TRACC units at various labs around the world since 1998. A first-generation IR-TRACC system was retrofit into a Q3 dummy by TNO. Similarly, a mid sized male Hybrid III dummy thorax and a small female Hybrid III dummy thorax have been designed by First Technology Safety Systems (FTSS) such that each contains 4 second-generation IR-TRACC units. The second-generation IR-TRACC is the result of continued development by FTSS, especially in the areas of the analysis circuit, manufacturing and calibration methods.

In the development of several outside mirror designs for vehicles, a high frequency noise (whistling) phenomenon was experienced. First impression was that this might be due to another source on the vehicle (such as water management channels) or a cavity noise; however, upon further investigation the source was found to be the mirror housing. This “laminar whistle” is related to the separation of a laminar boundary layer near the trailing edges of the mirror housing. When there is a free stream impingement on the mirror housing, the boundary layer starts out as laminar, but as the boundary layer travels from the impingement point, distance, speed, and roughness combine to trigger the transition turbulent. However, when the transition is not complete, pressure fluctuations can cause rapidly changing flow patterns that sound like a whistle to the observer. Because the laminar boundary layer has very little energy, it does not allow the flow to stay attached on curved surfaces.

Laminated steel sheets sandwiched with a polymer core are increasingly used for automotive applications due to their vibration and sound damping properties. However, it has become a major challenge in finite element modeling of laminated steel structures and forming processes due to the extremely large differences in mechanical properties and in the gauges of the polymer core and the steel skins. In this study, circular cup deep drawing and V-bending experiments using laminated steels were conducted in order to develop a modeling technique for laminate forming processes. The effectiveness of several finite element modeling techniques was investigated using the commercial FEM code LS-Dyna. Furthermore, two production parts were selected to verify the modeling techniques in real world applications.

Different methodologies to test transfer case imbalance were investigated in this study. One method utilized traditional standard single plane and two plane methods to measure the imbalance of the transfer case when running it on a dynamic balance machine at steady RPM, while a second method utilized accelerometers and a laser vibrometer to measure vertical vibration on the transfer case when running it on a dynamic balance machine in 4 Hi open mode during a run up from 1000 to 4000 RPM with a 40 RPM difference between the input and output shaft speeds. A comparison of all of the measurements for repeatability and accuracy was done with the goal of determining an appropriate and efficient method that generates the most consistent results. By using the traditional method, the test results were not repeatable. This may be due to the internal complexity of transfer cases. With the second method, good correlation between the measurements was obtained.