Applications for 3D machine vision are rapidly expanding in a variety of industries for several reasons. The first is that vision systems can lower production costs by increasing yields and/or reducing scrap product and wasted raw material. One example of this would be extruded products from various materials (rubber, plastic, metal), where it’s vital to know as soon as the process goes out of specification.

Standardized Dent Resistance Test Procedure

J2575_201504 (Current)04/28/2015

These test procedures were developed based upon the knowledge that steel panel dent resistance characteristics are strain rate dependent. The “quasi-static” section of the procedure simulates real world dent phenomena that occur at low indenter velocities such as palm-printing, elbow marks, plant handling, etc. The indenter velocity specified in this section of the procedure is set to minimize material strain rate effects. The dynamic section of the procedure simulates loading conditions that occur at higher indenter velocities, such as hail impact, shopping carts, and door-to-door parking lot impact. Three dent test schedules are addressed in this procedure. Schedule A is for use with a specified laboratory prepared (generic) panel, Schedule B is for use with a formed automotive outer body panel or assembly, and Schedule C addresses end product or full vehicle testing. These schedules are targeted at sheet steel samples obtained at different points in an auto/steel product development

Metals Technical Committee

MMLV: Door Design and Component Testing

2015-01-040904/14/2015

The Multi Material Lightweight Vehicle (MMLV) developed by Magna International and Ford Motor Company is a result of a US Department of Energy project DE-EE0005574. The project demonstrates the lightweighting potential of a five passenger sedan, while maintaining vehicle performance and occupant safety. Prototype vehicles were manufactured and limited full vehicle testing was conducted. The Mach-I vehicle design, comprised of commercially available materials and production processes, achieved a 364kg (23.5%) full vehicle mass reduction, enabling the application of a 1.0-liter three-cylinder engine resulting in a significant environmental benefit and fuel reduction. This paper reviews the mass reduction and structural performance of aluminum, magnesium, and steel components for a lightweight multi material door design for a C/D segment passenger vehicle. Stiffness, durability, and crash requirements are assessed. The structure incorporated aluminum sheet, aluminum extrusion, magnesium

Plourde, Larry, Azzouz, Michael, Wallace, Jeff, Chellman, Mari

Re-design of Power Sliding Door Pulley System

2015-01-131204/14/2015

The power sliding door system(PSD) is being equipped in the MPV(Multi-Purpose Vehicle/minivans) vehicle for convenience in the door operation. This study will focus on package space optimization for interior design and overall vehicle packaging for the vehicles equipped with PSD. To optimize the package, investigation for PSD's structure need to be done and the examples of other vehicle maker will be investigated and compared. The study that considers performance and package requirements resulted in a unique PSD design. And finally, this study will show the result vehicle in which the optimized mechanism is applied.

Je, MyoungKwon

Sandwich Panels with Corrugated Core - A Lightweighting Concept with Improved Stiffness

2014-01-080804/01/2014

Sandwich panels with high modulus/high strength skin material and low density/low modulus core material have higher stiffness-to-weight ratio than monolithic panels. In this paper, sandwich panels with corrugated core are explored as a lightweighting concept for improved stiffness. The skin and the core materials are a high strength steel, aluminum alloy or carbon fiber-epoxy composite. The core has a triangular corrugation, a trapezoidal corrugation and a rectangular corrugation. The stiffness of the sandwich panels is analytically determined and compared with monolithic panels of equal mass. It is shown that the stiffness of the sandwich panels is 5 to 7 times higher than that of the monolithic panels.

Mallick, Pankaj K., Boorle, Rajesh

Vehicle Body Panel Thermal Buckling Resistance Analysis

2014-01-092604/01/2014

This paper discusses CAE simulation methods to predict the thermal induced buckling issues when vehicle body panels are subjected to the elevated temperature in e-coat oven. Both linear buckling analysis and implicit quasi-static analysis are discussed and studied using a quarter cylinder shell as an example. The linear buckling analysis could produce quick but non-conservative buckling temperature. With considering nonlinearity, implicit quasi-static analysis could predict a relative conservative critical temperature. In addition, the permanent deformations could be obtained to judge if the panel remains visible dent due to the buckling. Finally these two approaches have been compared to thermal bucking behavior of a panel on a vehicle going through thermal cycle of e-coat oven with the excellent agreement on its initial design and issue fix design. In conclusion, the linear buckling analysis could be used for quick thermal buckling evaluation and comparison on a series of proposals

Zhang, Weidong, Guo, Mingchao, Stibich, Paul, Bhandarkar, Ram

A Technique to Predict Thermal Buckling in Automotive Body Panels by Coupling Heat Transfer and Structural Analysis

2014-01-094304/01/2014

This paper describes a comprehensive methodology for the simulation of vehicle body panel buckling in an electrophoretic coat (electro-coat or e-coat) and/or paint oven environment. The simulation couples computational heat transfer analysis and structural analysis. Heat transfer analysis is used to predict temperature distribution throughout a vehicle body in curing ovens. The vehicle body temperature profile from the heat transfer analysis is applied as an input for a structural analysis to predict buckling. This study is focused on the radiant section of the curing ovens. The radiant section of the oven has the largest temperature gradients within the body structure. This methodology couples a fully transient thermal analysis to simulate the structure through the electro-coat and paint curing environments with a structural, buckling analysis. The ability to predict the buckling phenomenon using a virtual simulation will reduce the risk of late production changes to the vehicle class

Stibich, Paul R., Wu, Yu Hsien, Zhang, Weidong, Guo, Michao, Srinivasan, Kumar, Surapaneni, Sreekanth

Simulating Human Body Touch Automotive Tests Using Industrial Robot & Intelligent Grippers Equipped With Sensors

2013-01-282311/27/2013

All Automotive companies conduct various performance and Endurance tests on automotive bodies, doors by using Pneumatic Actuators. These Actuators can only give linear or rotary motion. Therefore these can neither simulate the complex motion of Human arm nor can they simulate the Force and pressure induced by the Human palm or Human back on the body domain parts. Each test need to have different test setup. This paper discusses how a system of industrial Robot coupled with intelligent Gripper with sensors and feedback signal to robot can be used to simulate the effect of Human touch during testing.

Bhatkar, Hemant R., ramakrishnan, Dakshinamoorthy, B, Venkatasubramanian, Vijayakumar, Narayanan

2014 CORVETTE 460 HP, 30 MPG, 1 G, $52,000

13MOMD1101_0311/01/2013

NO OTHER SPORTS CAR CAN MATCH THE C7'S COMBINATION OF PERFORMANCE, VALUE, AND OVERALL EFFICIENCY. CHIEF ENGINEER TADGE JUECHTER PROVIDES INSIGHT ON EXECUTING A MASTERPIECE. AFTER 60 YEARS OF ALTERNATING REDESIGN AND EVOLUTION, the seventh-generation Chevrolet Corvette has entered production, this time all new and wearing the iconic Stingray nameplate. The 2014 C7 continues Corvette's tradition as General Motors' performance and technology flagship, and it's the pacesetter for advanced lightweight materials and structures that are emerging steadily on other GM vehicle programs. Besides the new aluminum frame, carbon-fiber and lighter-density SMC (sheet molding compound) exterior body panels, and extensively upgraded Gen 5 LT-1 V8 previously detailed by SAE Magazines, the C7 also benefits from a thoroughly revamped assembly plant and almost new workforce in Bowling Green, KY. With a base price of $52,000, the C7 boasts the following significant engineering features:

Brooke, Lindsay

2014 Corvette: 460 hp, 30 mpg, 1 g, $52,000

13AEID1001_0410/01/2013

No other sports car can match the C7's combination of performance, value, and overall efficiency. Chief Engineer Tadge Juechter provides insight on executing a masterpiece. After 60 years of alternating redesign and evolution, the seventh-generation Chevrolet Corvette has entered production, this time all new and wearing the iconic Stingray nameplate. The 2014 C7 continues Corvette's tradition as General Motors' performance and technology flagship, and it's the pacesetter for advanced lightweight materials and structures that are emerging steadily on other GM vehicle programs. Besides the new aluminum frame, carbon-fiber and lighter-density SMC (sheet molding compound) exterior body panels, and extensively upgraded Gen 5 LT-1 V8 previously detailed by AEI, the C7 also benefits from a thoroughly revamped assembly plant and almost new workforce in Bowling Green, KY. With a base price of $52,000, the C7 boasts the following significant engineering features:

Brooke, Lindsay

Damping Performance Using a Panel Structure

2013-01-193805/13/2013

The performance of damping materials is generally evaluated by experimental methods. However most damping materials used in the transportation industry cannot be excited by itself. Therefore, the measurements are generally made by exciting a damped system, where the damped system extends from a bar to a panel. The paper reviews various damped systems and excitation methodologies and discusses some of the limitations of a bar to study the damping performance for different applications. It discusses a methodology where a damped panel is mounted on a fixture and the fixture is excited with a shaker. The paper discusses data acquisition and data reduction procedures to obtain the damping performance of laminated steel acoustic patch products on a third octave band frequency basis.

Saha, Pranab, Deshpande, Satyajeet P., Fisk, Jonathan, Owen, Devon E.

Structure to Assist in the Prevention of Bimetallic Corrosion of Hybrid Doors

2013-01-038604/08/2013

The use of low-density materials in body panels is increasing as a measure to reduce the weight of the vehicle body. Honda has developed an aluminum/steel sheet hybrid door that is more effective in reducing weight than an all-aluminum door. Because aluminum was used in the door skin, bimetallic corrosion at the connection between the aluminum and the steel sheets represented an issue. It was possible that the difference in the electrical potential of the two metals might promote corrosion at the connection between the aluminum door skin and the steel sheet door panel, in particular at the lower edge of the door, where rainwater and other moisture tend to accumulate, with the result that the appeal of the exterior of the door might decline. To address this issue, a watertight structure realized through the use of a high-ductility sealer was employed in order to help prevent water from infiltrating to the connection between the metals, and steel sheets with a zinc-aluminum-magnesium

Kimura, Shoji

Analysis of Damage Caused to Vehicle Body Panels by Impacting Hail and Various Tools and Objects

2013-01-143804/08/2013

On the 25th December 2011 there was a hail storm in the state of Victoria, Australia, which caused approximately AU$712 million worth of damage. Some of this damage was caused to passenger vehicles. The authors conducted a number of inspections of hail-damaged vehicles as a result of insurance claims being disputed or rejected on the basis that some, or all, of the alleged hail damage was not created by hail but instead created intentionally by the vehicles' owners with the use of different tools and/or objects. As a result of the inspections and investigations of potentially fraudulent claims, the authors conducted a total of 119 tests designed to replicate damage caused to vehicle body panels by impacting hail and to recreate claimed hail damage by using tools and other objects. To do so, the authors created two sizes of hail: Ø20 mm and Ø40 mm hail. A total of 15 impact tests were conducted with Ø20 mm hail. The impact speed for the Ø20 mm hail varied between 75 km/h and 144 km/h

Josevski, Nikola, Sandvik, Andreas, Jones, Chris, Pok, Tandy, Orton, Tia, Richardson, Shane

Next-BIG-Thing

13MOMD0201_0102/01/2013

Clemson students, with the help of Mazda and others, show their concept for practical Gen Y-targeted car that could be marketed at a price of about $28,000. WHAT DOES THE YOUTH MARKET WANT IN AN AUTOMOBILE? Many companies at the recent SEMA (Specialty Equipment Market Association) Show in Las Vegas attempted to answer that question with their product lines. A team of students in the master's program in automotive engineering at Clemson University's International Center for Automotive Research (CU-ICAR) submitted its own proposal. Named the “Next-BI G-Thing” (NBT), it was viewed as a practical approach that could be marketed at a price of about $28,000. The team, led by Dr. Paul J. Venhovens, who holds the BMW-endowed chair in systems integration at CU-ICAR, said it liked “cool” cars, but that's a term heard often at the SEMA Show. The students studied Gen Y buyer satisfaction data from AutoPacific to develop insights. They enlisted many sponsors, led by Mazda North American Operation

Weissler, Paul

Carbon fiber, new aluminum structure lighten 2014 Corvette Stingray

13MOMD0201_0302/01/2013

the C7, which enters production in 3Q13, boasts an all-new aluminum chassis/passenger cell structure that is 57% stiffer in torsion and 99 lb (45 kg) lighter than the previous C6 steel-and-aluminum structure. “WE HAD VERY AGGRESSIVE WEIGHT-REDUCTION TARGETS on this program,” said Leonard Brohl, Lead Engineer for Closure Panels on the 2014 C7 Chevrolet Corvette, unveiled Jan. 13 at a media event preceding the Detroit Auto Show. General Motors has resurrected the Stingray name for the latest generation of its iconic sports car, which continues to be a lightweight-materials wellspring for the automaker. The C7, which enters production in 3Q13, boasts an all-new aluminum chassis/passenger cell structure that is 57% stiffer in torsion and 99 lb (45 kg) lighter than the previous C6 steel-and-aluminum structure, said GM engineers. At the car's world debut, GM had not yet published a production curb weight for the car. It is expected to be slightly lighter overall than the base C6 coupe's 3208

Brooke, Lindsay

Development of Liftgate Hinge-to-Roof Sealing Gasket Material for Uncoated Steel Roof Panels

2011-01-007204/12/2011

The sealing of a lift gate hinge to the body structure is necessary to avoid both the onset of corrosion and to avoid water intrusion into the interior compartment. The hinge-to-body interface typically involves horizontal metal-to-metal surface contact, creating the perfect environment for moisture entrapment and corrosion initiation. The choice of body panel material (uncoated (bare) steel vs. coated (galvanized) steel) drives different sealing approaches especially when considering corrosion avoidance.

Corman, Carl, Yergin, Mark, Kussmaul, Andy, Conrad, Lou, Martin, Gregory

Boundary Condition Effect on the Correlation of an Acoustic Finite Element Passenger Compartment Model

2011-01-0506

04/12/2011

Three different acoustic finite element models of an automobile passenger compartment are developed and experimentally assessed. The three different models are a traditional model, an improved model, and an optimized model. The traditional model represents the passenger and trunk compartment cavities and the coupling between them through the rear seat cavity. The improved model includes traditional acoustic models of the passenger and trunk compartments, as well as equivalent-acoustic finite element models of the front and rear seats, parcel shelf, door volumes, instrument panel, and trunk wheel well volume. An optimized version of the improved acoustic model is developed by modifying the equivalent-acoustic properties. Modal analysis tests of a vehicle were conducted using loudspeaker excitation to identify the compartment cavity modes and sound pressure response to 500 Hz to assess the accuracy of the acoustic models. The optimized acoustic model is also coupled with a structural

Lee, Sangyun, Park, Kwangseo, Sung, Shung H., Nefske, Donald J.