Browse Topic: Bumpers, fasciae and grilles

Items (239)

ENGINE AIR INTAKE WATER SEPARATION PERFORMANCE USING CFD FOR CLASS-8 TRUCK WITH CORRELATION

2022-01-107203/29/2022

Engine air intake water ingestion needs to be estimated and minimized in order to maximize filter life and to ensure optimal engine operation. In addition, air intake water separation features need to be implemented to minimize water ingestion into the filter and then into the engine. In this paper, we replicate the air intake water separation test performed on a Volvo class-8 truck based on SAE J2554 test procedure. Using CFD, two different intake grille configurations were evaluated, first one is without a grille and a second with the intake grille. In the study presented within this paper the engine air intake water separation performance of a class-8 truck with and without the air intake grille are compared using SIMULIA PowerFLOW Lattice Boltzmann based solver. The simulation results were compared to the physical test and show good correlation with the experimental data.

Dasarathan, Devaraj, Sowmianarayanan, Bhargav, Jilesen, Jonathan, Gona, Kiran, Banala, Ajaybabu

SAE TOMORROW TODAY: Chipotle's Pioneering Approach to Digital

1290609/11/2020

How does a quick service restaurant transform itself into a lifestyle brand? For Chipotle Mexican Grill, its all about being real and staying ahead of digital trends to create the ultimate customer experience. Nicole West, Vice President of Digital Strategy and Product for Chipotle, joins us this week to dig into the digital experience that Chipotle has pioneered within the industry. Nicole shares her experience building Chipotle's digital commerce business and how consumer adoption of digital ordering and experiences has led to digital making up 61% of company sales in Q2 2020. She discusses what trends the company saw when it developed the industry's first ordering app and how they continue to experiment with new ways to engage with customers and drive sales. As the conversation continues, Nicole explains the ways that Chipotle has innovated and disrupted the industry when appropriate, including its ordering app, Chipotlanes, Digital Kitchen, packaging, walk-up contactless pickups

Hineman, Marcie

A Design and Optimization Method for Pedestrian Lower Extremity Injury Analysis with the aPLI Model

2020-01-092904/14/2020

As pedestrian protection tests and evaluations have been officially incorporated into new C-NCAP, more stringent requirements have been placed on pedestrian protection performance. In this study, in order to reduce the injury of the vehicle front end structure to the pedestrian's lower extremity during the collision, the advanced pedestrian legform impactor (aPLI) model was used in conjunction with the finite element vehicle model for collision simulation based on the new C-NCAP legform test evaluation regulation. This paper selected the key components which have significant influences on the pedestrian's leg protection performance based on the CAE vehicle model, including front bumper, front-cover plate, upper impact pillar, impact beam and lower support plate, to form a simplified model and conducted parametric modeling based on it. Then, the variable correlation analysis was carried out on the sample results obtained from the design of experiment (DOE), and the contribution analysis

Fu, Yue, Xu, Huijie, Lin, Guan, Zhan, Zhenfei, Wang, Ping, Chen, Ruyi, Yu, Huili

Design of Lightweight Composites for Vehicle Front End Energy Management of Bumper Beam

2019-28-008510/11/2019

Application of advance composites in place of the various conventional materials such as steel can give significant weight and performance advantages. The application of composites is now finding it’s way in the automotive industry due to the growing requirement of the lightweight solutions and high strength to weight ratio. However, their low mechanical properties have limited their application in automotive structural components. The study presented here is focused on the explicit dynamic analysis of a bumper beam and advance composites are used for the study. Different configurations and designs of the bumper are considered to be able to make a comparative study of the stress and deformation levels. The analysis was done in coherence to the Euro NCAP tests and the offset frontal impact analysis was done. The boundary conditions were aligned with the real time impact conditions for proper prediction of the results. Based on stress, deformation, specific strength and weight, the

Kumar, Praveen, Akella, Sarma Sr, Chakraborty, Ayan, Muthiah, Balasubramanian, Ramachandran, Velmurugan, M Venugopal, Shankar

Low-Speed Impact Bumper System Test Procedure for Passenger Vehicles

J2319_201910 (Current)10/03/2019

The scope of this SAE Recommended Practice is restricted to the testing of original equipment on passenger vehicles and to provide for a uniform industry test procedure.

Motor Vehicle Council

Optimization Design of Rear-Engine Bus Cooling System Based on 1D/3D Coupling Simulation

2018-01-077104/03/2018

This study investigated the effects of underhood structure parameters (two types of air ducts, two types of inlet grilles and the opening angle of inlet grilles) on the cooling characteristics of the rear-engine bus; then, the optimum design scheme of the underhood was determined. The air-side resistance load of the cooling system, which is based on fan performance, was selected as the optimization objective. Simulations were created based on a porous media model and standard a k-ε model. The next step was to build a 1D/3D coupling simulation to utilize the advantages of 1D simulation’s fast convergence speed and 3D simulation’s extensive research range. Besides, the use of 1D/3D coupling simulation can efficiently avoid the errors of simulation results which arise from the non-uniform airflow on the cooling module. Results show that the airflow rate of the rectangular air duct increased by 7 to 11percent. Compared with the airflow rate of the underhood without an air duct, the air

Hao, Zhenzhen, Ni, Jimin, Shi, Xiuyong

Analysis and Simulation of Low-Speed Collision of Car Front Bumpers

2018-01-146004/03/2018

Bumper systems are vital to improving automotive passive safety and reducing the maintenance cost in low-speed collision. Automotive companies need to develop bumpers with adequate strength, high energy absorption rate, minimum weight and least expense. To shorten the product development period and lower the development cost, four evaluation conditions were proposed to assess the behaviors of car front bumpers based on the three main low-speed collision regulations of the US Part 581, the Canadian CFVSS215 and the European ECE-R42. A finite element method was put forward to model the car front bumper and to analyze the low-speed collision performance of the bumper system. A drop hammer impact test was carried out to verify the validity of the method, and experiment results indicated the correctness of the finite element model. The dynamic response and the energy absorption parameters of the bumper system were calculated, including structural deformation, collision force and energy

Li, Min, Xia, Zhangyang, Shangguan, Wenbin

Eleven Instrumented Motorcycle Crash Tests and Development of Updated Motorcycle Impact-Speed Equations

2018-01-051704/03/2018

Eleven instrumented crash tests were performed as part of the 2016 World Reconstruction Exposition (WREX2016), using seven Harley-Davidson motorcycles and three automobiles. For all tests, the automobile was stationary while the motorcycle was delivered into the vehicle, while upright with tires rolling, at varying speeds. Seven tests were performed at speeds between 30 and 46 mph while four low-speed tests were performed to establish the onset of permanent motorcycle deformation. Data from these tests, and other published testing, was analyzed using available models to determine their accuracy when predicting the impact speed of Harley-Davidson motorcycles. The most accurate model was the Modified Eubanks set of equations introduced in 2009, producing errors with an average of 0.4 mph and a standard deviation (SD) of 4.8 mph. An updated set of Eubanks-style equations were developed adding data published since 2009, and advancing from two equations (pillars/axles and doors/fenders) to

Peck, Louis, Manning, Joseph, Bartlett, Wade, Dickerson, Charles, Deyerl, Eric

Polypropylene Copolymer Material for Automotive Thin Wall Front Bumper with Integrated Grill Application

2018-01-015304/03/2018

This paper describes modified polypropylene copolymer (PPCP) material for thin wall front bumper development (2.5 mm) with integrated grill in automotive application. This compounded PPCP material has optimized flow behavior, tensile strength, modulus, impact strength, and thermal properties to meet the functional requirements. This is a ready to mold material used in injection molding process. Front bumper and grill are functional components with slow speed impact requirement to absorb impact in real world. These parts have precise fitment requirement under sun load condition. Front bumper is also having other critical criteria with respect to vehicle variants such as aesthetic mold-in-color finish as well as painted finish. Grill has air entry performance criteria to ensure cooling efficiency in intercooler compartment. In this paper, PPCP material filled with talc filler has been explored for thin wall front bumper part with a wall thickness of 2.5 mm and with an integration of

Govindaraj, Karthik, Junankar, Ashish, Venkateshwara, Rao, Papanal, Vijay

Modelling a Rear Bumper of Goods Transport Vehicle Made of Glass Fiber Reinforced Polymer

2017-36-041311/07/2017

Due to the mass production process of the automobile industry, develop a product by reducing its cost has become an important aspect in its elaboration. This goal is to replace the higher cost material for an alternative that offers the same performance at a lower cost. The use of composite materials in the automotive industry has gradually evolved over the years. However, the use of composite materials in the structure of the automobile depends on a number of factors, such as large production scale, fast manufacturing process and economy, suiting the high demand of the automobile industry. Fiberglass composites are widely used in the market because of their good mechanical and physical properties combined with the comparatively low cost of production. Therefore, the objective of the work is to analyze the feasibility of other inputs as alternatives to the manufacture of rear bumper of transporting goods vehicle, using composite materials with satisfactory performances in this

Branco, César T. N. M., Figueiredo, Jullyane M. S., Veloso, Mauro J. G., Fujiyama, Roberto T.

Optimizing the Rear Fascia Cutline Based On Investigating Deviation Sources of the Body Panel Fit and Finish

2017-01-160003/28/2017

A vehicle’s exterior fit and finish, in general, is the first system to attract customers. Automotive exterior engineers were motivated in the past few years to increase their focus on how to optimize the vehicle’s exterior panels split lines quality and how to minimize variation in fit and finish addressing customer and market required quality standards. The design engineering’s focus is to control the deviation from nominal build objective and minimize it. The fitting process follows an optimization model with the exterior panel’s location and orientation factors as independent variables. This research focuses on addressing the source of variation “contributed factors” that will impact the quality of the fit and finish. These critical factors could be resulted from the design process, product process, or an assembly process. An empirical analysis will be used to minimize the fit and finish deviation. Experimental approach as well as Response Surface Methodology “RSM” will be used for

Mansour, James, Jawad, Badih, Liu, Liping, Fernandez, Vernon, Abro, Sabah, Tibbenham, Jeff

External Biofidelity Evaluation of Pedestrian Leg-Form Impactors

2017-01-145003/28/2017

Current state-of-the-art vehicles implement pedestrian protection features that rely on pedestrian detection sensors and algorithms to trigger when impacting a pedestrian. During the development phase, the vehicle must “learn” to discriminate pedestrians from the rest of potential impacting objects. Part of the training data used in this process is often obtained in physical tests utilizing legform impactors whose external biofidelity is still to be evaluated. This study uses THUMS as a reference to assess the external biofidelity of the most commonly used impactors (Flex-PLI, PDI-1 and PDI-2). This biofidelity assessment was performed by finite element simulation measuring the bumper beam forces exerted by each surrogate on a sedan and a SUV. The bumper beam was divided in 50 mm sections to capture the force distribution in both vehicles. This study, unlike most of the pedestrian-related literature, examines different impact locations and velocities. The results show how the Flex-PLI

Perez-Rapela, Daniel, Forman, Jason, Crandall, Jeff, Jeon, Haeyoung

Influence of Honeycomb Cellular Meso-structure on Frontal Crash Analysis for Passenger Vehicle

2017-01-130103/28/2017

Frontal collisions account for majority of car accidents. Various measures have been taken by the automotive OEMs’ with regards to passive safety. Honeycomb meso-structural inserts in the front bumper have been suggested to enhance the energy absorption of the front structure which is favorable for passive safety. This paper presents the changes in energy absorption capacity of hexagonal honeycomb structures with varying cellular geometries; under frontal impact simulations. Honeycomb cellular metamaterial structure offers many distinct advantages over homogenous materials since their effective material properties depend on both, their constituent material properties and their cell geometric configurations. The effective static mechanical properties such as; the modulus of elasticity, modulus of rigidity and Poisson’s ratio of the honeycomb cellular meso-structures are controlled by variations in their cellular geometry. While the crushing responses in terms of energy absorption and

Patil, Deepak A., Buddhe, Hrishikesh

Development of GFRTP Crush Box with Consideration of Use Environment and Effect of Fiber Orientation

2017-01-049803/28/2017

Regulation of automotive CO2 emissions is becoming increasingly stringent throughout the world in response to global warming. For automakers, this means a focus not only on increasing the fuel economy of powertrains, but also on reducing automotive driving resistance. High expectations are held for thermoplastic fiber-reinforced plastics (FRP) for the realization of automotive weight savings while also offering high levels of productivity and recyclability. Thermoplastic FRP crush boxes display a higher level of energy absorption performance than metal (steel, aluminum, etc.) crush boxes. This will contribute to automotive weight savings and improved package design. In the case of automotive front bumper beam systems, it is necessary to realize stable load characteristics irrespective of the use environment. It is therefore necessary to consider the effects of temperature and thermoplastic resin degradation. The molding process for discontinuous fiber-reinforced FRP produces

Yabu, Tomoya, Yasuhara, Shigeto, Kashiwagi, Masakazu

A Tailgate(Trunk) Control System Based on Acoustic Patterns

2017-01-163403/28/2017

When customers use a tailgate (or trunk), some systems such as power tailgate and smart tailgate have been introduced and implemented for improving convenience. However, they still have some problems in some use cases. Some people have to search for the outside button to open the tailgate, or they should take out the key and push a button. In some cases, they should move their leg or wait a few seconds which makes some people feel that it is a long time. In addition, they have to push the small button which is located on the inner trim in order to close the tailgate. This paper proposes a new tailgate control technology and systems based on acoustic patterns in order to solve some inconvenience. An acoustic user interaction (AUI) is a technology which responds to human’s rubbing and tapping on a specific part analyzing the acoustic patterns. The AUI has been recently spotlighted in the automotive industry as well as home appliances, mobile devices, musical instruments, etc. The AUI is

Lee, Hui Sung

Experimental Investigation with R1234yf Condenser Airflow Blockages of Non-Hotspot and Hotspot Objects to Impact on A/C System Performance

2016-01-025504/05/2016

This paper addresses R1234yf A/C system performance impacted by condenser airflow passage blockages of nonhotspot and hotspot objects. With the modern vehicle design trend, more and more chances exist in blocking condenser airflow passages by objects such as TOC (transmission oil cooler) or fine grills etc. These objects create hotspots and narrowed airflow passages to the condenser and result in A/C performance degradation. It is important to understand the specific area of the condenser which is most impacted by a blockage so this area can be avoided in the design/packaging of front end components. In addition, it is important to understand the magnitude of performance loss associated with the specific areas of blockage. As a result of this understanding, optimal design locations for these blockages (including hotspots and grilles) can be proposed in order to mitigate the impact on A/C cooling performance. The study indicated that blocking condenser airflow passages by both the

Zheng, Yinhua

Implications of Manufacturers’ Bumper Ratings in Low Speed Collision Analysis

2016-01-147304/05/2016

Evaluation of the severity of low speed motor vehicle crashes has been the subject of significant research for more than 25 years. These crashes typically result in little if any damage to the vehicles involved and therefore the ability to determine the threshold of damage would be very useful in analysis of such cases. One such threshold, which has been used by accident reconstructionists, is the manufacturer’s published bumper rating in compliance with Federal Motor Vehicle Safety Standards (FMVSS) for vehicle bumpers. The rationale is that if there is any damage to the bumper system of the vehicle in question, the impact must have had a severity greater than the rated bumper speed. This paper examines the FMVSS bumper standards upon which the published bumper ratings are reportedly in compliance, historical low speed testing damage results, and engineering considerations of bumper damage in low speed impacts. The results demonstrate that using manufacturers’ bumper ratings as a

Keifer, Orion P., Reckamp, Bradley, Moody, Charles, Timpanaro, Anthony

Conceptual Development of a Multi-Material Composite Structure for an Urban Utility/Activity Vehicle

2016-01-133404/05/2016

The Deep Orange framework is an integral part of the graduate automotive engineering education at Clemson University International Center for Automotive Research (CU-ICAR). The initiative was developed to immerse students into the world of an OEM. For the 6th generation of Deep Orange, the goal was to develop an urban utility/activity vehicle for the year 2020. The objective of this paper is to describe the development of a multimaterial lightweight Body-in-White (BiW) structure to support an all-electric powertrain combined with an interior package that maximizes volume to enable a variety of interior configurations and activities for Generation Z users. AutoPacific data were first examined to define personas on the basis of their demographics and psychographics. The resulting market research, benchmarking, and brand essence studies were then converted to consumer needs and wants, to establish vehicle target and subsystem requirement, which formed the foundation of the Unique Selling

Flegel, Christopher, Bhivate, Parth, Li, Liang, Mathur, Yash, Phalgaonkar, Sanket, Benton, Mark, Muralidharan, Prasanth, Brooks, Johnell, Pilla, Srikanth, Venhovens, Paul, Lewis, David, DeBry, Garrett, Payne, Craig

Forward Collision Warning: Clues to Optimal Timing of Advisory Warnings

2016-01-143904/05/2016

We examined the effectiveness of a heads-up Forward Collision Warning (FCW) system in 39 younger to middle aged drivers (25-50, mean = 35 years) and 37 older drivers (66-87, mean = 77 years). The warnings were implemented in a fixed based, immersive, 180 degree forward field of view simulator. The FCW included a visual advisory component consisting of a red horizontal bar which flashed in the center screen of the simulator that was triggered at time-to-collision (TTC) 4 seconds. The bar roughly overlapped the rear bumper of the lead vehicle, just below the driver’s line-of-sight. A sustained auditory tone (∼80 dB) was activated at TTC=2 to alert the driver to an imminent collision. Hence, the warning system differed from the industry standard in significant ways. 95% Confidence intervals for the safety gains ranged from -.03 to .19 seconds in terms of average correction time across several activations. Older and younger adults did not differ in terms of safety gains. Closer inspection

Rizzo, Matthew, Aksan, Nazan, Sager, Lauren, Hacker, Sarah, Marini, Robert, Dawson, Jeffrey, Anderson, Steven

Jeep will test pickup concepts at Moab 50th

16AUTP04_1104/01/2016

Military vehicle strength, functionality, and styling underscore two Jeep-based concept trucks that took on the challenging off-road trails of Moab, Utah, during the recent annual Jeep Safari. “It's a very, very important event this year because it's the 50th anniversary of the Easter Jeep Safari, and it's coinciding with the 75th anniversary of Jeep,” asserted Mike Manley, Head of Jeep Brand for FCA Global.

Buchholz, Kami

GT350 Mustang features novel composite structural component

16MEIP03_1703/01/2016

A lightweight composite material shaped by a unique assembly technique forms a grille opening reinforcement (GOR) designed specifically for the high-performance 2016 Ford Shelby GT350 Mustang. The two-piece GOR is an industry first, and the automaker is in the process of applying for a patent, according to Peter Thai, Performance Body Exterior Engineer at Ford Motor Co. Developing a GOR that would fit in a packaging space smaller than the 2015 Mustang was no easy task, noted Gari Schalte, Magna Exteriors' Product Line Engineering Manager-Front End Modules.

Buchholz, Kami

AS4886 Bumper Pad

AS4886-1 (Current)12/04/2015

No scope available.

Engine and Airframe Technical Standards Committee (TSC)

Impact Of Condenser Opening Area On A/C Performance of the Automotive HVAC System

2015-01-036804/14/2015

Bumper opening area projected on condenser to total condenser core area is referred to as condenser opening area. The condenser opening area plays a vital role in A/C Performance of vehicle particularly during idling and initial cooling of vehicle. This paper presents detail study on effects of condenser opening area on A/C performance. Based on theory, the effect of condenser opening area is studied and it is validated by experimental results. Depending on these results an optimum value of condenser opening area required for best A/C performance is concluded.

Kumar Reddy, Janampally Sandeep, Deopa, Shailendra, Sharma, Abhay, Aggarwal, Piyush

Optimization of Front Bumper Beam for RCAR Performance using Design of Six Sigma and Finite Element Analysis

2015-01-149304/14/2015

Research Council for Automotive Repairs (RCAR) has developed a bumper test at 10 km/h to assess the damageability and repairing cost during a low speed collusion. For minimum damage and minimum repairing cost during low speed collusion it is necessary to design a bumper beam which provides structural stiffness and reduced deflection. Often it is challenging to design a front bumper beam to meet all safety requirements including, RCAR, high speed offset barrier and pedestrian protection, since these requirements are not necessarily compatible with each other. Design changes in rails and packaging constraints add to this challenge. In this study, design of six sigma (DFSS) and finite element analysis are used to study the parameters that affect the stiffness and deflection of the front bumper beam. For the DFSS study, bumper beam geometry and reinforcements are investigated as control factors, vehicle rail widths as noise factors, and back of beam displacement and mass of front bumper

Virupaksha, Vinay L., Brown, Stuart

Snowmobile and Snowmobile Cutter Lamps, Reflective Devices, and Associated Equipment

J292_201404 (Historical)04/16/2014

This SAE Recommended Practice describes requirements for lamps, reflective devices, and associated equipment for signaling to enable safe operation in darkness and other conditions of reduced visibility.

Snowmobile Technical Committee

Further Assessment of the Uncertainty of CRASH3 ΔV and Energy Loss Calculations

2014-01-047704/01/2014

In a 2012 paper, Brach, Brach, and Louderback (BBL) investigated the uncertainty that arises in calculating the change in velocity and crush energy with the use of the CRASH3 equations (2012-01-0608). They concluded that the uncertainty in these values caused by variations in the stiffness coefficients significantly outweighed the uncertainty caused by variations in the crush measurements. This paper presents a revised analysis of the data that BBL analyzed and further assesses the level of uncertainty that arises in CRASH3 calculations. While the findings of this study do not invalidate BBL's ultimate conclusion, the methodology utilized in this paper incorporated two changes to BBL's methodology. First, in analyzing the crash test data for several vehicles, a systematic error that is sometimes present in the reported crush measurements was accounted for and corrected. This systematic error arises when a vehicle's plastic bumper fascia rebounds more than the underlying structure

Rose, Nathan A., Carter, Neal

Numerical Simulation of Unsteady Natural Convection in a Simplified Engine Bay Enclosure under Soak Conditions

2014-01-065104/01/2014

At the onset of soak, air and surface temperatures in an engine bay enclosure are elevated since temperature of heat sources are high while convective cooling is sharply reduced as a result of airflow being shut off from the inlet grilles of the vehicle leading to temperature spikes. Accurate simulation of this important thermal and flow regime that is natural convection driven, highly transient and complex is therefore very important. In this investigation, we simulate flow in the engine bay at the onset of soak with fixed thermal boundary conditions where the geometries representing the engine bay and components are simplified. Good agreement was observed with detailed experimental data available in references for both velocities and temperatures.

Wang, Zun, Han, Jaehoon, Mukutmoni, Devadatta

Development of High Efficiency and Compact Bumper Recycling Equipment

2014-01-197304/01/2014

This paper describes the development of high efficiency and compact bumper recycling equipment for facilitating bumper recycling globally. Various equipment to remove paint coat from bumper has been developed since 90s', using mechanical, physical or chemical method. However, it is difficult to promote bumper recycling without realizing cost effective overall system from paint coat removal to pelletizing. Our company jointly developed method of mechanically removing paint coat and has committed to bumper recycling in the form of outsourcing since 2000. In 2010, a dedicated plant for recycling bumpers was launched on the premises of our Oppama Assembly Plant in Japan. In the future, promoting bumper recycling at other overseas assembly plants is necessary as vehicle production will expand globally. Having more compact and cost effective recycling system compared to the one at the Oppama plant is required since the scale of the system including bumper crushing, paint coat removal, and

Mizutani, Atsushi

Characterization of Force Deflection Properties for Vehicular Bumper-to-Bumper Interactions

2014-01-199104/01/2014

This is the complete manuscript and replacement for SAE paper 2014-01-0482, which has been retracted due to incomplete content. This paper reports on 76 quasi-static tests conducted to investigate the behavior of road vehicle bumper systems. The tests are a quasi-static replication of real world low speed collisions. The tests represented front to rear impacts between various vehicles. Force and deflection were captured in order to quantify the stiffness characteristics of the bumper-to-bumper system. A specialized test apparatus was constructed to position and load bumper systems into each other. The purpose was to replicate or exceed damage that occurred in actual collisions. The fixture is capable of positioning the bumpers in various orientations and generates forces up to 50 kips. Various bumper-to-bumper alignments were tested including full overlap, lateral offset, and override/underride configurations. Force and displacement were recorded and the data was analyzed to develop

Bonugli, Enrique, Wirth, Jeffrey, Funk, James, Cormier, Joseph, Guzman, Herbert, Gwin, Lisa, Freund, Mark

Development of TPO Based Rear Bumper Back Beam

2013-01-139604/08/2013

TPO (thermoplastic olefin) composite for rear bumper back beams was developed. In this study, the composition of PP (polypropylene), rubber and mineral fillers was optimized to minimize the intrusion and the failure after crash. The optimization of the composition was achieved using the mixture design of experiments. The physical properties of TPO composites with various compositions were investigated and the effect of each material on the crash performance of back beam was studied through CAE (computer-aided engineering). The back beams made of the optimized TPO composite for a subcompact car were prepared for the ECE 42 crash test and the TPO-based back beam showed even better performance than conventional PC/PBT-based counterpart. In addition, the newly developed composite has delivered a 15 ~ 40% cost saving and 4 ~ 10% weight reduction versus conventional PC/PBT and GMT (glass mat-reinforced thermoplastic).

Sohn, Chang Hee, Kim, Ok, Chun, Yong, Lee, Jong Wook

An Experimental Study on Flow Pattern of Door Trim Speaker Grille Shape

2013-01-136904/08/2013

Recently the automotive industry has focused on reducing product development time to correspond with the customer's demands. Especially when quickly changed. The decreased product development time shortens the quality assurance period. It makes difficult to guarantee the quality of the products. The improved quality assurance is required so that customer's expectations are actually higher quality than in the past. Most automotive interior parts are manufactured by using plastic. It is very sensitive to focus on quality, because it is exposed to a passenger's sight. So automotive interior companies make full use of injection molding CAE in an effective ways to reduce costs and reduce elements of poor quality. This paper suggests a methodology that improves reliability for injection molding analysis in grille shapes of door trim. And it involves an experimental analysis of flow pattern in speaker grille shapes. To analyze it, use an authentic mold of speaker grilles in door trim and Mold

Yang, Heeseung, Jo, Hyunkwon, Jang, Ikkeun, Park, Hyunmin, Yoon, Sungyun, KIM, Heejoong

The Automatic Aerodynamic CFD Framework Employing Vehicle Specifications at the Concept Stage of Development

2013-01-060404/08/2013

This paper describes tool development with which makes it possible for vehicle stylists and aerodynamicists to easily use Computational Fluid Dynamics, i.e., CFD, and evaluate aerodynamic performance at the concept stage of car development. This tool automatically provides CFD results to the user by preparing the vehicle exterior geometries and car specifications. The vehicle exterior, floor, and tires are the essential geometry data. This tool automatically generates the floor and tires based on the vehicle specifications. It, thereafter, executes the following process: automatic mesh generation, solver settings, calculations and standard post-processing. The user is able to obtain results within two hours. The tool enables stylists and aerodynamicists to understand flow phenomena in a timely fashion.

Takiguchi, Takashi, Ogawa, Kenta, Tateyama, Hiroyuki, Oda, Tatsuya

LED Inspection Lamp

TBMG-1523111/01/2012

Spectronics Corporation (Westbury, NY) has introduced the powerful Spectroline® TRITAN ™ 365, an ultra-high-intensity, multi-LED, broad-beam UV-A inspection lamp perfect for NDT applications. The TRITAN 365 features three ultra-hi-flux UV-A LEDs for NDT inspection, plus a white light LED to illuminate dark areas. It produces a nominal steady-state 365nm intensity of 9,000 μW/cm² at a distance of 15 inches (38 cm). This versatile lamp meets MIL and ASTM intensity specs for FPI and MPI.

A Displacement-Approach for Liftgate Chucking Investigation

2012-01-021704/16/2012

A displacement-based CAE analysis is applied to liftgate chucking noise problems. A CAE simulation model of a small-size sport utility vehicle (SUV) is simulated with a set of realistic road loads as a time transient simulation. The model contains a trimmed vehicle, a liftgate and structural body-liftgate interface components such as the latch-striker wire, contact wedges and slam bumpers. Simulation design of experiments (DOE) is carried out with the model. As performance measures, the relative displacements at the contact points of the interface components are selected, since they are considered the direct cause of liftgate chucking. As design variables, body structure stiffness, liftgate stiffness, liftgate opening stiffness, stiffness characteristics of the interface components and additional liftgate mass are selected. Results of the simulation DOE is post-processed, and response surface models (RSM) are fit for the performance measures. Then, a sensitivity study is carried out by

Hyun, Yul Woong, Warden, Greg, Blenman, James, Thorpe, Scott, Imam, Altaf, Garett, Roger, Tebbe, James, ukpong, Tye, Wienckowski, Steven, Chinta, Balakrishna

Reconstruction of Low-Speed Crashes using the Quasi-Static Force vs. Deformation Characteristics of the Bumpers Involved in the Crashes

2012-01-059804/16/2012

The purpose of this study was to determine if quasi-static (QS) bumper force-deformation (F-D) data could be used in a low-speed bumper-to-bumper simulation model (1) in order to reconstruct low-speed crashes. In the simulation model, the bumpers that make contact in a crash are treated as a system. A bumper system is defined as the two bumpers that interact in a crash positioned in their orientation at the time of the crash. A device was built that quasi-statically crushes the bumpers of a bumper system into each other and measures the compression force and the deformation of the bumper system. Three bumper systems were evaluated. Two QS F-D measurements were performed for each bumper system in order to demonstrate the repeatability of the QS F-D measurement. These measurements had a compression phase and a rebound phase. A series of crash tests were performed using each bumper system. In each crash test, a stationary target vehicle was struck on the rear bumper by the front bumper of

Scott, William, Bonugli, Enrique, Guzman, Herbert, Swartzendruber, Daniel

A Study of Rear Bumper Integrated Carrier System

2011-28-003210/06/2011

This study deals with general consideration points of developing a rear bumper integrated carrier system, especially in view of optimized layout for SUV.

Lee, Seung Mok, Cha, Dong Eun, Kim, Sung Won, Jang, Rae Ung, Cho, Hoo Taek

Strength Prediction of Bumper by Correlating FEA with Test

2011-01-215509/13/2011

To develop new markets and to respond to voice of the customers, new specifications for special components are developed from time to time. To meet new specification, the strength and durability of components need to be reevaluated in a relatively short time. The cost associated with design lead-time, re-tooling, physical prototypes, test validation and fabrication of late changes are big challenges. The industrial leading golf and utility vehicles from E-Z-GO are equipped with impact-protecting components, such as front bumper, rear bumper, floorboard, front cowl, rear body and operator station. To respond to the voice of the customer, new requirements for corner impact protection were added to existing vehicle specification for 360 degree impact protection. Virtual prototyping was introduced to accelerate redesign process and to save valuable time and money. The crash mechanism itself is complex and difficult to analyze sometimes. The life of the component including fracture and

Wen, Jingheng, Neely, Michael

Design Optimization of Front Bumper System for Low Speed Impact Insurance Industry Impact Test using DFSS and CAE Analysis

2011-01-007004/12/2011

In 2006, the Insurance Institute for Highway Safety (IIHS) released a new Low Speed Bumper Test Protocol for passenger cars1. The new test protocol included the development of a deformable barrier that the vehicle would impact at low speeds. IIHS positioned the new barrier to improve correlation to low speed collisions in the field, and also to assess the ability of the bumper system to protect the vehicle from damage. The bumper system must stay engaged to the barrier to protect other vehicle components from damage. The challenge is to identify the bumper system design features that minimize additional cost and mass to keep engagement to the barrier. The results of the Design for Six Sigma analysis identified the design features that increase the stiffness of the bumper system enable it to stay engaged to the barrier and reduce the deflection.

Brown, Stuart J.

Dual Rate Jounce Bumper Design

2011-01-079104/12/2011

Jounce bumpers are the primary component by which vertical wheel travel is limited in our suspensions. Typically, the jounce bumper is composed of closed or open cell urethane material, which has relatively low stiffness at initial compression with highly progressive stiffness at full compression. Due to this highly progressive stiffness at high load, peak loads are extremely sensitive to changes in input energy (affected by road surface, tire size, tire pressure, etc.) A “Dual Rate Jounce Bumper” concept is described that reduces this sensitivity. Additionally, various mechanizations of the concept are described as well as the specific program benefits, where applicable.

Schudt, Joseph A., Tsai, Maolin, Patil, Ravindra, Geisler, Robert

The Connected Vehicle Proving Center: A Collaborative, Architecture-Neutral Development Environment

2008-21-000810/20/2008

This paper will present one method and architecture-neutral means for accomplishing a collaborative development environment that would virtually link the needed hard facilities such as roads and test tracks, utilize embedded and nomadic devices, provide the software development tools and support multiple communication protocols. The proposed capability would be able to be linked to any other facility globally, thereby allowing public and private entities an ability to both clearly evaluate what is created elsewhere, improve or demonstrate their developments, and provide a means of advancing vehicle communications research.

McCormick, Scott J.

Safe and Pleasurable Human Machine Interfaces for Automobile

2008-21-000510/20/2008

As a consequence of the integration of additional systems to support and entertain drivers and passengers the interactions with those systems become more and more time consuming and distracting. It is therefore a basic requirement for the design of Human Machine-Interfaces to minimize the distraction from driving when interacting with those new assistance and entertainment systems. Whereas the safety is a Must-be for the design of HMI for automobiles the joy-of-use is an important aspect for the excitement of drivers. To fulfil the sometimes conflicting demands for safety and pleasure a human centred design approach for HMI design is needed.

Bruder, Ralph, Abendroth, Bettina, Didier, Muriel, Schreiber, Michael, von Wilamowitz-Moellendorff, Margeritta

PLM Promotes a Smart Outsourcing Model that Balances Cost with Intellectual Property Protection

2008-21-004410/20/2008

Capitalism has followed cheap labor since before the Industrial Revolution. However, high-skilled work like programming and engineering has recently begun traveling to low-cost nations, and as a result, the eternal challenge of balancing cost and risk has even more serious consequences. The new outsourcing models that help companies stay cost-competitive in the short run, may hurt them in the long run by creating competitors who adapt or outright steal their intellectual property. This paper outlines how product lifecycle management (PLM) solutions can be used to outsource engineering without sacrificing cost controls, intellectual property integrity, or in-house engineering talent. It describes collaboration models built around advanced design technology that inject efficiency into engineering processes at every level, enabling companies to balance short and long term concerns.

Brincheck, Bob

Framework to Aid Process Maturity Model Definition for Product Development in Global Environment

2008-21-004010/20/2008

The speed of innovations and pressure for reducing cost has forced automotive industry to move towards standardization. This standardization enhances the ease and success of Global Product Development (GPD) from a technology viewpoint. However, for overall success, an effective process model shall, additionally, support GPD. The process needs of the present day GPD programmes and more so the future ones, heavily, challenge the prevalent process maturity models. This paper presents a process framework that can be adapted by the industry to achieve industry-wide process maturity for GPD.

Somashekhar, R. H.

Advanced Driver Assist System: Its Challenges and Solutions from the Customer's Point of View

2008-21-003110/20/2008

As demand for an accident free society intensifies, people have come to look to new technologies for solutions. This has facilitated development of a variety of advanced driver assist systems (ADAS). However, despite existing technologies, due to lack of standardizations and inability to asses the value of a system which cannot be understood without test driving, customers are left unable to make appropriate decisions when determining what kind of features to purchase. Furthermore, not all vehicles offer the same options. If we are to tackle the challenges from the customer's point of view, we must establish a standardized performance criterion that will help customers and furthermore challenge the auto industry to healthy competition by establishing clear playing fields. This paper will discuss possible solutions and suggestions for the industry to create an accident free society.

Nakajima, Toyohei (Tony)

Making FlexRay a Reality in a Premium Car

2008-21-002310/20/2008

In this paper, we present some of the main tasks that have to be addressed and solved for FlexRay to become a reality in series production at Audi. The results will be used for future generations of vehicles in the Volkswagen Group. The methods established and products developed build the base for Audi's FlexRay series development.

Kötz, Jens, Poledna, Stefan

Competitive Opportunity Management

2008-21-003910/20/2008

Competitive Opportunity Management (COM) is a set of innovation-based concepts, tools and processes that provide structure for the comprehensive identification of business opportunities. This structure evolves in a logical, step-by-step manner and is a means of developing a solid foundation for defining the totality of future business opportunities in a context that can be highly leveraged. The culmination of this effort results development of an underlying structure that clearly maps how virtually all business opportunities can and will evolve toward clearly defined long-range trends. COM provides definitive tools at the front end of the generic product development cycle where only vague methods exist today, allows for the sequencing of opportunities and provides a basis for combining discrete elements into new strategies that enable decision making at the top levels of the organization.

Clarke, Dana W., Pine, William C.

Model-Based Design for Safety-Related Applications

2008-21-003310/20/2008

Production code generation with Model-Based Design has replaced document-based development and manual coding in various automotive domains such as chassis and powertrain. Safety-related applications are increasingly developed using Model-Based Design as well. For these applications, software development and quality assurance activities within Model-Based Design must meet the requirements of the safety standard relevant to the particular domain. For in-vehicle applications, currently this standard is typically IEC 61508. This paper discusses workflows for developing safety-related application software components and specific requirements with respect to Model-Based Design. Generally, the objectives of IEC 61508-3 influence the entire software development process. However, some activities are of particular importance. This paper is concerned with the following activities exhibiting certain specifics if they are carried out as part of Model-Based Design: traceability between work products

Fey, Ines, Müller, Jürgen, Conrad, Mirko

AUTOSAR on the Road

2008-21-001910/20/2008

The AUTomotive Open System ARchitecture (AUTOSAR) Development Partnership has published early 2008 the specifications Release 3.0 [1], with a prime focus on the overall architecture, basic software, run time environment, communication stacks and methodology. Heavy developments have taken place in the OEM and supplier community to deliver AUTOSAR loaded cars on the streets starting 2008 [2]. The 2008 achievements have been: Improving the specifications in order to secure the exploitation for body, chassis and powertrain applications Adding major features: safety related functionalities, OBD II and Telematics application interfaces.

Kinkelin, Gerulf, Gilberg, Alain, Delord, Bertrand, Heinecke, Harald, Fürst, Simon, Moessinger, Juergen, Lapp, Andreas, Virnich, Ulrich, Bunzel, Stefan, Weber, Thomas, Spinner, Noë, Lundh, Lennart, Svensson, Daniel, Heitkämper, Peter, Mattsson, Fredrik, Nishikawa, Kenji, Hirano, Hiroyuki, Lange, Klaus, Kunkel, Bernd

Driver Interface/HMI Standards to Minimize Driver Distraction/Overload

2008-21-000210/20/2008

This paper describes (1) the telematics distraction/overload problem, (2) what distraction and overload are and how they differ, (3) the standards and guidelines that apply to the design and evaluation of driver interfaces/human-machine interfaces (HMI) for telematics (and their strengths and weaknesses), and (4) what standards and research are needed to support the development of driver interfaces. Most of the paper is a detailed discussion of evaluation standards, in particular SAE Recommended Practices J2364 (Task Time and Occlusion Tests) and J2365 (Task Time Estimation), ISO Standards 16673 (Occlusion Test) and 26022 (Lane-Change Test), and the AAM Driver Focus Guideline.

Green, Paul

Effect of Stress Softening in Bumper Foams on the Low Speed Impact Performance of Vehicles

2008-01-112604/14/2008

The experimental findings have revealed that there is a significant stress softening phenomenon for the polymer foams used in vehicle bumpers after they are loaded repeatedly from the raw undeformed state. With a series of loading-unloading test data under different maximum strains, dependence of the stress softening on the deformation history is analyzed. The corresponding material models in ABAQUS are chosen to characterize such special features of the polymer foams in FEA. The low speed impact models of a subsystem consisting of a bumper assembly and front-rails are established, and a process for transferring the deformation history of the bumper foams between the consecutive impact-loading cases is set up in the environment of ABAQUS. Based on the FE simulations, it can be seen that the stress softening of the polymer foams compromises the low speed impact performance of bumpers in subsequent impacts. Therefore the stress softening effect of polymer foams should be taken into

Xia, Yong, Yang, Xin, Zhou, Qing

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