Browse Topic: Vehicle styling

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Feature-Based Stereo Vision for Ship-Deck LandingF-0081-2025-02135/20/2025
In this paper, we develop a new feature-based algorithm using stereo cameras to estimate stochastic ship-deck motion at high sea states. Unlike our previous algorithms, this algorithm is able to estimate the motion of arbitrary ship structures without prior information on the ship's visual appearance or geometry. The algorithm requires an initial pose and suffers from drift over time, which was resolved by fusing it with our previous 2D feature-based vision algorithm. The combined vision algorithm is validated using a simulated ship featuring 3D ship structures and 2D flight deck markings representative of a DDG-51 ship. The results indicate that the algorithm can accurately estimate the pose of a simulated ship undergoing Sea-State 6 motion. The vision algorithm was further validated in a simple free-flight test.
Chopra, Inderjit
An eleventh one for CUR-1174PC11-CUR-1174 (Current)4/2/2024
Italic
Flight Simulator Engineering and Maintenance Committee
N&V Component Structural Integration and Mounted Component Durability Implications2020-01-13964/14/2020
Exterior component integration presents competing performance challenges for balanced exterior styling, safety, ‘structural feel’ [1] and durability. Industry standard practices utilize noise and vibration mode maps and source-path-receiver [2] considerations for component mode frequency placement. This modal frequency placement has an influence on ‘structural feel’ and durability performance. Challenges have increased with additional styling content, geometric overhang from attachment points, component size and mass, and sensor modules. Base excitation at component attachment interfaces are increase due to relative positioning of the suspension and propulsion vehicle source inputs. These components might include headlamps, side mirrors, end gates, bumpers and fascia assemblies. Here, we establish basic expectations for the behavior of these systems, and ultimately consolidate existing rationales that are applied to these systems. We consider a simple two degree-of-freedom system subject to a base excitation consisting of masses attached via springs and dampers. Component mode decoupling, vibration amplification and basic design guidance relationships are suggested.
Stebbins, Mark, Schudt, Joseph
Advanced Mathematical Modelling for Glass Surface Optimization with PSO2019-28-010410/11/2019
In automotive door engineering, fitting the side door glass surface from styling into the cylinder or torus is the basic requirement. Optimization is required to do this, which requires a solver which could be efficacious for best surface fitting. This paper propounds a methodology which could be used for fitting a side door glass surface from styling into the cylinder or torus. The method will significantly help in developing the required surface and can successfully eliminate the cumbersome manual calibrations. The mathematical model mentioned is a novel approach based on “Particle Swarm Optimization” (“PSO” will be used to represent in the paper) towards surface optimization technique. VB script is used to make it applicable in CATIA but could be easily applied in any other programming language like python, java etc. Usually the surface fitting problems deals with the initial guess of the required surface and then its further optimization. Herewith we have discussed some geometrical methods to find the initial guess of the cylindrical and toroid surface and then Particle Swarm Optimization for refining of the obtained data. This article aims at providing the best surface fit at the initial stage itself so that the faster output convergence rates are achieved. The proposed algorithm is efficient and easy to code, and the experiment results indicate its effectiveness. Since we have avoided analytical method and used an evolutionary stochastic approach in the process in which the chances of getting stuck in local minimum are very limited.
Pandey, Pawan, Askari, Hasan, Raadhaasaminathan, Sreebalajinarayanan
New design for 2020 Mitsubishi Outlander Sport as brand awaits alliance's new platforms, products19AUTP06_166/1/2019
The 2020 Mitsubishi Outlander Sport carries over with no mechanical changes compared to the 2019 model. But its new face-part of a front/rear styling redo plus new interior trims/tech for the 5-seat, 2-row SUV-signals a new start for the brand in the U.S. Having pared its product lineup to all-SUV plus the economy minded B-segment Mirage, the triple-diamond brand is saucing up its styling while it awaits a bevy of new platforms and products from its alliance with Nissan/Renault. Mitsubishi sold over 100,000 vehicles in the U.S. for the last two years running. Compared to the nearly 350,000 vehicles it sold in 2002 (or the 800K pickups Ford delivers in a year), this might not sound spectacular. But compared to the sub-54K year it had in 2009, the steady growth over the last 10 years (including a 14% jump last year in a flat-overall market) shows that life is returning to the brand.
Seredynski, Paul
AV ‘Goiters’ Be Gone!19AVEP05_125/1/2019
Magneti Marelli's ‘Smart Corner’ technology aims to reduce cost, complexity and mass by integrating key vehicle sensors seamlessly into a vehicle's lighting modules. Warts. Bumps. Blisters. Protuberances. These and other less-flattering terms are used by vehicle designers and engineers to describe the bulging, non-integrated sensor placement that has become the unfortunate visual signature for automated vehicles (AVs). “We actually call them ‘goiters,’” said Bill Grabowski, head of innovation and technology for Automotive Lighting division at Magneti Marelli. “While they're [sensors] primarily for function, the OEM and the end customer don't want to see these protrusions littering the vehicle exterior in production. Packaging up to 25 sensors that handle all levels of ADAS and autonomous driving has become a major problem for the automakers.”
Brooke, Lindsay
Porsche reveals eighth-generation of fabled 91119AUTP01_151/1/2019
Regularly updating and evolving the Porsche 911's aesthetic signature might seem an impossible task. But more than half a century after its birth, the unveiling of the eighth-generation at the 2018 L.A. Auto Show demonstrated that it is in fact still a totally possible art-with design boss Michael Mauer the chief artist. Designated in-house as the 992 series and slightly larger than the outgoing 991, it is launched in rear-wheel-drive and all-wheel-drive forms-Carrera S and Carrera 4S-and now only in the wide-body width previously used for the Carrera 4 GT3 and GTS, instead of two body widths. Across the nose, the new 911 is 45 mm (1.8 in) wider than the outgoing version, a figure some 911 purists may look at askance, as growth in recent years has already been considerable.
Birch, Stuart
2019 Honda Pilot gets refined 9-speed, tougher styling18AUTP10_1310/1/2018
The 2019 Honda Pilot arrives with few but important changes for the 3-row, 8-seat SUV, most notably revisions to its 9-speed automatic. New, more-rugged exterior styling is designed to remind consumers the Pilot has a thoroughly capable torque-vectoring all-wheel-drive setup, and Honda's suite of radar-based safety systems is now standard on all Pilot models. Meanwhile, extensive cabin tech upgrades include a welcome return of the volume knob to the central touchscreen and other refinements to the infotainment interface, plus and an available 4G LTE Wi-Fi hotspot.
Seredynski, Paul
Truck and Sport Utility Vehicle Front End Stiffness Corridors2018-01-05184/3/2018
The purpose of this study was to characterize front stiffness response of contemporary sport utility vehicles (SUVs) and trucks. Vehicle front impact test data were obtained from data published by the National Highway Traffic Safety Administration [NHTSA]. For all tests, force data were obtained from barrier load cells and stroke data were derived from accelerometers. Data from 53 truck and SUV tests were aggregated by vehicle product segment according to body style to obtain mean ± standard deviation (SD) stiffness corridors: (1) compact unibody SUV/crossover, (2) small unibody SUV/crossover, (3) mid-size unibody SUV/crossover, (4) frame SUV, and (5) frame truck. To compare between vehicle product segments, this study also considered the average stiffness (slope) within the stroke region required to achieve 300 kN total barrier force. Across unibody SUV segments, average stiffness varied from 1.4–1.8 kN/mm. Stiffness of frame SUVs and trucks was up to 93% higher than stiffness of unibody SUVs (2.7 vs. 1.4 kN/mm). Observed differences in stiffness corridors may have been due in part to unibody SUV design differences. For example, additional stroke (structure) was observed forward of the front axle comparing an exemplar mid-size SUV and frame SUV. In some cases, this structure may include a low stiffness bumper absorber. When stiffness corridors were offset to simulate a low stiffness initial geometry, better agreement between mean stiffness corridors was observed across vehicle segments. As unibody SUVs may continue to replace frame designs, future work should confirm directly the reasons for this stiffness difference in vehicle segments.
Hallman, Jason, Buck, Jessica, Ham, Suk Jae
HONDA 2018 ACCORD: antidote for crossover fever17AUTP11_0311/1/2017
The all-new, tenth-generation Accord is Honda's best-ever-and makes the case for why crossovers shouldn't take over the planet. Honda engineers aren't saying it in so many words, but one could construe the tenth-generation 2018 Accord sedan as being purposely developed as the “anti-crossover.” At a time when most of the developed world is indicating a preference for the high-seating-position, high-center-of-gravity handling of crossovers and SUVs, the all-new Accord is lower, situates its driver lower and has a new, stiffer chassis that's oriented towards increased driver involvement. In other words, attributes that aren't strong points for most current mainstream crossovers, the body style that for several years has nibbled at the midsize sedan segment's longtime dominance. So as if to reward those who continue to choose a midsize car-still roughly two million buyers in the U.S. last year-the new Accord seems deliberately designed to be everything an SUV isn't.
Visnic, Bill
A Research on Brand Sound Positioning and Implementing with Active Sound Design2017-01-17546/5/2017
This paper aims to establish a systematic process of developing a brand driving sound. Firstly, principal factors of a brand sound identity are extracted from factor analysis of many sample cars. As a result, brand sound positioning map is drawn using jury test data. Also, the multiple regression analysis of subjective and objective test results is carried. As a result, the principal factors are expressed by objective test data and brand sound positioning map can be easily updated from the measurement data. In addition, what should be improved for designing a target sound is reviewed. Secondly, various technologies of target sound design are discussed to involve the brand identity and vehicle’s character in driving sound. Also, an efficient tool to implement the target sound with an active sound design (ASD) system in a vehicle is introduced. This tool enables to efficiently design, tune and simulate a target sound for ASD system in a laboratory. As a result, some sound examples synthesized by this tool are illustrated.
Chang, Kyoung-Jin, Kim, Seonghyeon, Park, Dong Chul, Moon, So Youn, Park, Sunghwan, Yun, Myung Hwan
Aerodynamic CFD Based Optimization of Police Car Using Bezier Curves2017-01-94504/11/2017
This paper investigates the optimization of the aerodynamic design of a police car, BMW 5-series which is popular police force across the UK. A Bezier curve fitting approach is proposed as a tool to improve the existing design of the warning light cluster in order to reduce drag. A formal optimization technique based on Computational Fluid Dynamics (CFD) and moving least squares (MLS) is used to determine the control points for the approximated curve to cover the light-bar and streamline the shape of the roof. The results clearly show that improving the aerodynamic design of the roofs will offer an important opportunity for reducing the fuel consumption and emissions for police vehicles. The optimized police car has 30% less drag than the non-optimized counter-part.
Gaskell PhD, Philip, Hewson PhD, Rob, Taherkhani, Ali Reza, Gilkeson PhD, Carl, Thompson, Harvey, Toropov PhD, Vassili, Rezaienia PhD, Amin
Multisensory Contributions to Perceived Quality and Authenticity of Materials for the Vehicle Interior2017-01-04943/28/2017
Material authenticity is an important factor for appearance and perceived quality of the vehicle interior. The term authenticity implies ambivalence: For the product designer, it means identification and trueness of the origin of the material. The customers, however, can only access information on the nature of the materials via their own perception of surface features. Thus, the intended authenticity of a material always needs to be conveyed by its surface. Specific cases illustrate the context: 1. The customer touches a part of known matter, but various layers prevent from directly touching the natural material: e.g. leather at the steering wheel, applications of wood. 2. Perception of a thin surface layer indicates authentic material, which is not fulfilled by the whole part: e.g. plastic parts plated with metal. 3. A part consists of authentic material, but newly composed, so that it is not easily identified, such as recycled materials, e.g. leather fiber layers for seats. Optimization of the perceivable authenticity is always a multi-sensory task. Customers see and touch materials in the show room. Sound is usually generated by touching surfaces. Smell is important for natural materials, like leather. Even if the material is only observed visually, its appearance points towards tactile features, like softness, roughness, etc. Beside general considerations, multi-sensory perception of leather and vinyl materials as well as haptic appearance of thin metal layers is described in detail. An innovative method for measurement of the contact temperature is introduced, which helps to evaluate the materials potential to provide authentic “metal feel”.
Haverkamp, Michael Christian, Moos, Anja
A Spline-Based Modeling Algorithm for Application to Aerodynamic Shape Optimization Based on CFD Analysis2017-01-15103/28/2017
In early phases of conceptual design stages for developing a new car in the modern automobile industry, the lack of systematic methodology to efficiently converge to an agreement between the aesthetics and aerodynamic performance tremendously increases budget and time. During these procedures, one of the most important tasks is to create geometric information which is versatilely morphable upon the demands of both of stylists and engineers. In this perspective, this paper proposes a Spline-based Modeling Algorithm (SMA) to implement into performing aerodynamic design optimization research based on CFD analysis. Once a 3-perspective schematic of a car is given, SMA regresses the backbone boundary lines by using optimum polynomial interpolation methods with the best goodness of fit, eventually reconstructing the 3D shape by linearly interpolating from the extracted boundaries minimizing loss of important geometric features. As a preliminary study, an aerodynamic shape optimization based on CFD analysis is conducted using ANSYS fluid dynamics solutions. To maximize the performance, we employed state-of-art design methodologies such as design-of-experiments (DOE) and surrogate modeling techniques that incorporate a series of procedures from creating geometries to conducting CFD simulations. The SMA is programmatically integrated with the CFD procedures to automatically morph and create corresponding automobile external shapes. For validation and verification, three notional vehicles are explored by investigating aerodynamic performance. Not only does the baseline geometries obtained from SMA show well-matched drag coefficients (CD) but also the optimization study results in a significant amount of CD reduction.
Song, Kisun, Choo, Kyung Hak, Mavris, Dimitri
A Low Profile Loop Antenna Design for Automotive Applications2017-01-16963/28/2017
This paper proposes a novel antenna design for automotive communication applications. The antenna design combines a resonant Alford loop with folded dipole elements to allow for efficiencies that are higher than electrically small loop antenna designs. The Alford loop provides the horizontal polarization and omnidirectional pattern coverage on the horizon which is desired for remote keyless entry and other narrowband automotive applications. With the use of folded dipole elements, the design allows for low profile mounting desired by automotive styling.
Locke, John F., Schmidt, Stephen
Aerodynamic Performance Evaluation System at the Early Concept Stage of Automotive Styling Development Based on CFD2016-01-15844/5/2016
An aerodynamic styling evaluation system employed at an early automotive development stage was constructed. The system based on CFD consists of exterior model morphing, computational mesh generation, flow calculation and result analysis, and the process is automatically and successively executed by process automation software. Response surfaces and a parallel coordinates chart output by the system allow users to find a well-balanced exterior form, in terms of aerodynamics and exterior styling, in a wide design space which are often arduous to be obtained by a conventional CAE manner and scale model wind tunnel testing. The system was designed so that 5-parameter study is completed within approximately two days, and consequently, has been widely applied to actual exterior styling development. An application for a hatchback vehicle is also introduced as an actual example.
Ando, Kenichi, Kuratani, Naoshi, Fukuda, Hideo
CFD Analysis of Automotive Bodies in Static Pressure Gradients2014-01-06124/1/2014
Recently, the Two-Measurement correction method that yields a wake distortion adjustment for open jet wind tunnels has shown promise of being able to adjust for many of the effects of non-ideal static pressure gradients on bluff automotive bodies. Utilization of this adjustment has shown that a consistent drag results when the vehicle is subjected to the various gradients generated in open jet wind tunnels. What has been lacking is whether this consistent result is independent of the other tunnel interference effects. The studies presented here are intended to fill that gap and add more realistic model and wind tunnel conditions to the evaluations of the performance of the two-measurement technique. The subject CFD studies are designed to greatly reduce all wind tunnel interference effects except for the variation of the non-linear static pressure gradients. A zero gradient condition is generated by simulating a solid wall test section with a blockage ratio of 0.1%. The non-linear gradients are simulated using a semi-open jet test section with a very large 40 square meter nozzle exit and a variable length test section. Under these conditions, the variation in drag coefficient is observed with and without application of the two-measurement method adjustments. Conclusions are reached relative to the ability of this approach to achieve interference free results on a fully detailed sedan body style and the sources of the drag change caused by the pressure gradient.
Gleason, Mark E., Lounsberry, Todd, Sbeih, Khaled, Surapaneni, Sreekanth
Influencing Factors of Contact Force Distribution in Pedestrian Upper Legform Impact with Vehicle Front-End2012-01-02724/16/2012
Pedestrian upper leg impact protection is a challenging requirement in the Euro NCAP assessment. In upper legform to bonnet leading edge tests, the legform impact force, the legform intrusion and the injury parameters (impact force and bending moment measured on the upper legform) are highly related to design of vehicle front-end styling and structure, as well as clearance underneath bonnet leading edge. In the course of impact, the contact area variation has significant influence on the stress distribution and consequently the force and the bending moment on the upper legform. Using finite element simulations of upper legform impact with a typical sedan, the deformation of the legform and the vehicle structure, and the variation of the contact force distribution are characterized and analyzed. Based on the study, a method for calculating the contact force is put forward by assuming a shape of the contact zone on the upper legform and a stress distribution function within the contact zone. The calculation method is verified using a simplified model of vehicle front-end structure developed in a previous study. Then a parametric study is conducted using the simplified vehicle front-end model to study influence of key design variables. The results of the parametric study, to some extent, have revealed relationship among vehicle front-end design parameters such as styling, geometry and stiffness, contact characteristics such as the maximum stress on outer foam, and the injury parameters (mainly the impact force).
Nie, Bingbing, Huang, Jun, Xia, Yong, Zhou, Qing
Innovative Approaches to Global Demands of the Exterior Signal Lighting2012-01-02604/16/2012
In the last two decades and especially in the last few years we could see an extreme increase of exterior signal lighting importance from the styling point of view and today it is one of the key factors of differentiation. In addition to that, styling requirements of world's regions are influenced reciprocally and needs diversity of developed and emerging markets is obvious. That opens new challenges for innovative optical systems development, when “innovative” does not necessarily mean “more expensive”. For covering global needs in automotive signal lighting it is essential to use the whole range of light sources (including bulbs) and combine different types of optical systems to get an interesting enough but affordable output. This paper aims to review innovative approaches considering different market needs to deliver reasonable solutions for automotive signal lighting of near future.
Kropac, Miroslav, Kubena, Vladimir
Next-gen steel bodies for alternative-powertrain vehicles11AEID0607_056/7/2011
The objective of WorldAutoSteel's FutureSteelVehicle (FSV) program is to develop concepts of a radically different lightweight steel body structure for compact electrified vehicles and identify structure changes to accommodate larger vehicle variants WorldAutoSteel, the automotive group of the World Steel Association composed of 17 major global steel producers from around the world, is in the midst of a three-year program called FutureSteelVehicle (FSV) to deliver safe, lightweight, advanced-high-strength-steel (AHSS) body structures for future electrified vehicles and reduce greenhouse gas (GHG) emissions over the vehicles' life cycles. The group recently divulged details on the steel technology and design methodology used for the program and released some results through Phase 2 of three phases of development work. The engineering team's focus is on a holistic concept development approach using an anticipated expanded portfolio of steels and manufacturing technologies that will be readily available in the 2015 to 2020 time frame. The FSV engineering team is headed by EDAG AG at its Auburn Hills, MI, location. Optimization work is being done in close cooperation with Engineering Technology Associates, Inc. in Troy, MI. Noise, vibration, and harshness studies are the role of LMS in Leuven, Belgium.
Design Optimization of Front Bumper System for Low Speed Impact Insurance Industry Impact Test using DFSS and CAE Analysis2011-01-00704/12/2011
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.
Squeak & Rattle Simulation - A Success Enabler in the Development of the New Saab 9-5 Cockpit without Prototype Hardware2010-01-14236/9/2010
To achieve “right first time” design for SAAB projects, thus avoiding unnecessary development loops, a squeak & rattle simulation tool was required. This paper presents a new squeak & rattle simulation approach which covers the complete development process of interior parts. The process starts with a rough model, which is mainly based on styling data and ends with a model of a very high detail level close to serial tooling status. The detailed CAD model is then represented by a simulation model of similarly increasing quality. By using different types of analyses in the frequency and time domains (modal analysis, frequency response and transient analysis), the output of these simulations can be matched to the available FE model quality. During initial development the global behavior of the structure is of interest. Finally the relative displacement between two detailed trim parts is used to evaluate the risk for squeak & rattle. In order to identify the capability of the squeak & rattle simulation different correlation work between test and simulation has been performed. Examples of modal correlation on a global and a local level of the interior assemblies are shown. Also a procedure which enables the correlation between the tested and simulated relative displacement due to a random load is presented. This new squeak & rattle simulation has been used during the development of the new SAAB 9-5. Different examples of how the simulation results supported and guided the cockpit design clearly justify the benefits of this approach.
Weber, Jens, Benhayoun, Ismail
Underhood Thermal Simulation of a Small Passenger Vehicle with Rear Engine Compartment to Evaluate and Enhance Radiator Performance2010-01-08014/12/2010
Underhood environment of a passenger vehicle consists of critical components such as heat exchangers, engine, batteries and exhaust system with complex geometries. The exterior styling and the packaging constraints along with the aerodynamic requirements of minimal grill opening areas result in a compact and packed underhood. In such a restricted environment the volume of air flow entering the underhood reduces. The airflow management issues become even more severe in case the underhood environment is located at the rear end of the vehicle, away from the ram air zone available in front of the vehicle, as is the case in the present study. In recent times, a combination of 1D and 3D simulations have gained a high importance to conduct air flow and thermal simulations of vehicle underhood to understand the complex interactions of air flow velocities and temperatures. In the present study, engine cooling performance is studied by evaluating radiator heat dissipation and Top Hose Temperatures (THT) using 1D (KULI) and 3D (FLUENT, RADTHERM) simulation codes. Various design modifications in underhood area are analysed through simulations. These design changes resulted in improved heat dissipation performance of the radiator and better airflow and thermal management of the underhood. Simulation results at steady state operating conditions are compared with vehicle test results and a good agreement observed. This work illustrates the potential use of simulation codes (1D and 3D) to predict underhood thermal environment with acceptable accuracy and to identify areas of improvements for the engine cooling system performance.
Kumar, Vivek, Shendge, Sachin A., Baskar, S.
Anthropometry for a North American Manufacturing Population2009-01-22746/9/2009
Digital Human Models are used extensively in virtual manufacturing to evaluate hand clearance and reach. Spatial assessments of accommodation are typically conducted using digital human models representative of the manufacturing population. Unfortunately, these models are often based on anthropometry gathered from sources that are not representative of the actual target worker population. For example, the size and shape might be based on data from the U.S. military, which differs in .fitness, age, and race distributions from the typical automotive manufacturing population. Ford ergonomists traced errors in accommodation predictions to these inaccurate representations. Using a recently developed statistical methodology incorporating principal components analysis, the anthropometry of the target worker population was synthesized. Using these new data, Ford updated the anthropometry of their digital human models to reflect changes due to secular trends in the U.S. The models also consider the diversity in age and race, thus producing Ford manikins that better represent the variability in their worker base. The improved ability to accurately predict accommodation allows for significant immediate and long-term reductions in engineering costs.
Nadadur, Gopal, Chiang, Jim, Parkinson, Matthew B., Stephens, Allison
Multi-objective Optimization of a Charge Air Cooler using modeFRONTIER2008-01-08864/14/2008
In order for an automotive charge air cooler (CAC) to function efficiently, the flow of air through the cross tubes should be as uniform as possible. The position of the inlet and outlet, as well as the shape of the header tanks, are generally the most important determinants of the flow uniformity, and therefore of the cooling performance of the system. In an attempt to achieve this goal of flow uniformity, however, the effect on pressure loss in the system must also be considered. Further, the cost of the CAC tanks, which is directly related to the amount of material, should be minimized. Finally, the physical space in which the CAC can be located is limited by other underhood components and vehicle styling features. This presents an optimization problem with four conflicting objectives: to reduce the pressure loss in the system, to increase the uniformity of flow in the tubes, to minimize the tank material and to conform to the package volume. In this work, CATIA v5 was used to define the package volume to which the optimized CAC must conform, and a commercial CFD tool was used to create the geometry and mesh, and to run the analysis; modeFRONTIER was used as the multi-objective optimization tool to automatically drive the process of modifying the parameters controlling the shape of the tanks, and position of the inlet and outlet, in order to achieve the above objectives.
Stephenson, Phil, Chen, Yang, Fateh, Nader, Parashar, Sumeet, Poian, Mauro
Design and Dimensional Engineering - a case about style parameters and engineering standards2007-01-294411/28/2007
This article will show the relationship between visual quality and engineering technical criteria's, based on the perceptual quality about vehicles style. The meaning of this relation is demonstrated by engineering standards and style parameters. They are referenced to the people reaction to the “new” based on comparison and sensitivity. As the Dimensional Engineering coordinates the engineering standards related to the style parameters, the scope of this article is to show a case that example style characteristics and vehicles project. This relationship is a result of components surfaces and cut lines, classified in gaps, offsets, concave surfaces, convex surfaces, alignment and proportions.
Peres, Edson Maldonado, de Souza, Gilberto Francisco Martha
Automotive Engineering International 2007-10-01AUTOOCT0710/1/2007
After CD, what's next? Storing music in cars remains fraught with many engineering considerations as infotainment systems move into the next generation. Chevrolet Malibu General Motors has enhanced its midsize architecture for a more refined and luxurious ownership experience. Chrysler minivans Chrysler's family haulers feature a new look and more interior flexibility to go with a host of technology upgrades. Jaguar XF The company's middle sedan is updated with a 21st century interpretation of traditional standards. BMW M3 The high-performance version of the 3 Series coupe gets V8 power, other significant upgrades. Honda Accord The eighth generation of Honda's popular sedan offers more space, power, and safety. Fiat 500 The new car's styling harks back to the original of over 70 years ago, but it employs modern technology and shares a platform with the forthcoming Ford Ka replacement. Subaru Impreza The new model moves closer to the mainstream C-segment market, but a hatchback is added that will spawn the ultra-high-performance STi. Cooling off global warming potential There is still no decision on a new A/C refrigerant, and as the deadline draws closer toxicity issues are raised with proposed blends.
Latest Developments in Automotive Bulb Shield Design and Manufacture2007-01-37308/5/2007
Bulb shields are important components in automotive headlamps. Like other automotive stamping industries, the design and forming of bulb are facing challenges, such as, aggressive styling and strict performance regulations versus the limitation of sheet formability, increasing cost versus intensive competition from offshore suppliers. Testing sheet formability at progressive speed, progressive forming bulb shield from Tailor-welded strip, predicting cosmetic appearance by conducting FEM simulation, roughness modeling and image database, reducing cost by building up global manufacturing structure are proposed to address the challenges in this study.
Sheng, Steven Z. Q., Strazzanti, Michael
An Integrated Model of Gait and Transition Stepping for Simulation of Industrial Workcell Tasks2007-01-24786/12/2007
Industrial tasks performed by standing workers are among those most commonly simulated using digital human models. Workers often walk, turn, and take acyclic steps as they perform these tasks. Current h uman modeling tools lack the capability to simulate these whole body motions accurately. Most models simulate walking by replaying joint angle trajectories corresponding to a general gait pattern. Turning is simulated poorly if at all, and violations of kinematic constraints between the feet and ground are common. Moreover, current models do not accurately predict foot placement with respect to loads and other hand targets, diminishing the utility of the associated ergonomic analyses. A new approach to simulating stepping and walking in task-oriented activities is proposed. Foot placements and motions are predicted from operator and task characteristics using empirical models derived from laboratory data and validated using field data from an auto assembly plant. The motions of the pelvis and torso are predicted from the foot placements, operator characteristics, and task requirements. The lower-extremity motions are then generated using behavior-based inverse kinematics that relies on laboratory observations to address kinematic redundancy while respecting boundary constraints. This modular approach is highly general and can simulate gait, transition stepping, and stepping for balance maintenance in a single integrated system that can be implemented in any digital human model.
Reed, Matthew P., Wagner, David W.
An Interactive Approach to the Design of an Acoustically Balanced Vehicle Sound Package2007-01-23145/15/2007
Each time a new vehicle is developed, engineers face the challenge to develop the ideal sound insulation package. The goal is to attenuate powertrain, wind and road/tire noise from entering the vehicle while complying with cost, weight and packaging constraints. The design process is greatly facilitated if the engineer has effective tools to rapidly quantify how various sound insulation components contribute to the overall NVH performance of the vehicle. This paper discusses how an interactive vehicle acoustical design tool can be developed that assists the designer in making rapid decisions as to how to balance the performance of the various sound package components. The acoustical design tool is unique for each vehicle, and must take into account design decisions such as type of powertrain, body style, and numerous other factors in order to correctly predict the performance of the total package. Any good modeling tool must also take into account inputs from a reasonable range of operating conditions. A very good model for the acoustical behavior of the vehicle can be developed using data from measurements made while operating a sample vehicle at the target operating conditions. The authors will present a method for utilizing measurements together with some simple equations to predict the result when components of different designs are exchanged. The process of generating the needed data for this method from experiments on a vehicle is admittedly time consuming, if all of the possible design variations are to be considered. An alternative that the authors present in this paper is for the case in which a correlated Statistical Energy Analysis (SEA) model exists for the vehicle being considered [1]1. A great time savings is realized when the same acoustical behavior information about the vehicle can be extracted by running analytical experiments in the SEA model. The authors assert that even if an SEA model must be developed from scratch and correlated, this approach is preferable over the experimental approach. Once developed, an interactive design tool of the type being discussed has ongoing benefit to product development engineers by giving them a handy way to asses future design changes. If sound insulation components are later sacrificed in the interest of reducing vehicle costs or weight, the model can accurately portray the implication of the changes on sound levels in the vehicle. A case study is presented that demonstrates the use of this tool and its accuracy.
Wentzel, Richard E., Aubert, Allan C.
Conditions for Significant Efficiency Improvement in the Product Development Chain by the Application of Integrated Virtual Engineering2007-01-09514/16/2007
The traditional Vehicle Development Process is a sequence starting with geometric Packaging integration and Vehicle Configuration balanced with interior and exterior Styling. Production Design and development then follow supported by analysis & simulation and finalized with input from Manufacturing Engineering and other downstream functions. A huge challenge for the automotive industry is the reduction in development time in response to the change in consumer's evolving flexible lifestyle. With the increase of CAx tools, engineering development tasks become more simultaneous. To further respond to development time reduction is the elimination of physical prototype stages and learning cycles based on capable Virtual Engineering processes. The natural drivers of product development evolution which have traditionally been physical prototype stages are now history. A new process is emerging leveraging efficient virtual tools must be defined and integrated to support Virtual Engineering. Virtual program decision gates (Virtual Vehicle Assessments) have been introduced to support key engineering development milestones. Measurable virtual development tasks across all engineering disciplines are defined as well as the required digital design data quality and maturity. Development direction, innovation and data are synchronized at regular intervals over the Vehicle Development Process. In addition to the current Virtual Engineering process, more capability must be continuously developed. For instance a ‘Road to Lab to Math’ strategy has been introduced to decouple physical prototype tests from simulations as key component of overall Virtual Engineering. This new methodology to develop vehicles changes development organizations from their very core. Both processes and people need to change. The latter is the main challenge in order to have success. Introduction of Virtual Engineering in GM was supported by a set of progressive initiatives in order to gain understanding and buy in from the organization to facilitate the transformation to Virtual Engineering methodologies. For example, General Motors Europe achieved an overall efficiency in their product development effort by more than 50% over the past 5 years and Virtual Engineering methodologies played a key role.
Goettlicher, Christoph, Trecapelli, Anthony A.
A Study on the Analysis Method for Optimizing Mounting Brackets2006-01-14804/3/2006
Various optimization schemes have successfully been utilized to design mounting brackets of chassis components, especially suspension systems, in the large commercial vehicle development process. Depending on the design status, different optimization schemes, i.e. size, topology, and shape, are applied. There are two key elements that determine types of optimization schemes used, which are design freedom and available analysis time. First, in a case that the design is already frozen near the mass production, so that only minimal design change and time is allowed, the size optimization is attempted. Second, in the middle of the design process where relatively more room for the change is available, the topology optimization is adequate to carry out, based on the basic CAD model. Finally, early in the design process, when total freedom is given for the design and sufficient analysis time is allowed, both the topology and the shape optimization can be adopted, starting from a box model without any reference CAD model. In this paper, it is discussed how these optimization methods were exploited to achieve an optimized design of the brackets - more stiffness, strength, and less weight.
Chang, Hong Suk
A Decision Network Framework for Vehicle Systems Engineering2005-01-362311/1/2005
A Decision Network is an explicit model of the Thinking Breakdown Structure of any complex scientific, engineering, or societal challenge. Each node in the Decision Network represents a fundamental question that must be answered, i.e. a choice that demands a solution. A Decision Network provides an integrated Decision Management framework for any Systems Engineering effort that links business, technology and design choices. Effective Decision Management is the key to Systems Engineering success. This paper will provide an overview of a decision-centric approach to Systems Engineering built around Decision Networks. Lessons learned through the use of Decision Networks in other industries will be extrapolated for use in vehicle Systems Engineering.
Fitch, John A.
Santos™: A New Generation of Virtual Humans2005-01-14074/11/2005
Presented in this paper is an on-going project to develop a new generation of virtual human models that are highly realistic in terms of appearance, movement, and feedback (evaluation of the human body during task execution). Santos™ is an avatar that exhibits extensive modeling and simulation capabilities. It is an anatomically correct human model with more than 100 degrees of freedom. Santos™ resides in a virtual environment and can conduct human-factors analysis. This analysis entails, among other things, posture prediction, motion prediction, gait analysis, reach envelope analysis, and ergonomics studies. There are essentially three stages to developing virtual humans: (1) basic human modeling (representing how a human functions independently), (2) input functionality (awareness and analysis of the human’s environment), and (3) intelligent reaction to input (memory, reasoning, etc.). This paper addresses the first stage. Specifically, we discuss a new human model in terms of mechanics and appearance. We present an optimization-based approach to kinematic and dynamic motion analysis. This approach allows the avatar to operate with complete autonomy rather than with dependence on stored animations and data, or restrictions associated with inverse kinematics. With dynamic analysis, it is not necessary to solve equations of motion. A novel approach for determining reach envelopes is also presented, and this approach provides a unique tool for ergonomic studies. Methods for evaluating the physiological status of the virtual human as tasks are completed are discussed. Finally, additional on-going research is summarized. The result is an exciting step towards a virtual human that is more extensive and more complete than any other.
Yang, Jingzhou, Marler, Tim, Kim, HyungJoo, Farrell, Kimberly, Mathai, Anith, Beck, Steven, Abdel-Malek, Karim, Arora, Jasbir, Nebel, Kyle
Development of a Subjective Human Factors Scoring and Assessment Technique for the Total Vehicle2005-01-04344/11/2005
The present paper describes two studies performed with the aim of developing a human factors evaluation technique for the total vehicle based upon users' subjective experience while interacting with automotive controls and displays. In the first study, a total vehicle task analysis was conducted using a card-sort technique to partition users- activities in and around the vehicle into conceptually cohesive groups, or task scenarios. In the second study, each task scenario was evaluated in each of two vehicles using twenty five bipolar attribute rating scales chosen to describe users' experience while interacting with controls and displays. Results of a factor analysis on these data revealed that users' experience could be described along four different dimensions. These data were used to compare and contrast the two different vehicles.
Kleiss, James A., Paine, Corinna S., Swanson, Art, Jackson, Jamie
The art of designing becomes a scienceAUTOFEB05_092/1/2005
SAE 100 Future look: During the past 10 to 15 years, automotive interiors have changed dramatically. The world's top automakers and suppliers have achieved an impressive makeover of the occupant space, as they've delivered major enhancements in every area, including performance, functionality, safety, quality, craftsmanship, materials, aesthetics, ergonomics, comfort, acoustics, versatility-and more. These changes have been market-driven. Vehicle interiors have become far more important than previously was the case to the people who buy new cars and trucks, and to those who build them. A succession of industry studies has demonstrated that consumers increasingly are influenced by vehicle interiors when they're considering which car or truck to buy. The growing market impact of automotive interiors is not surprising, given the fact that people spend more time than ever before in their vehicles. Commuting times and distances have increased with the ongoing expansion of suburbia, and cars and trucks are overwhelmingly the favored mode of transportation for vacation and leisure-time activities. For many consumers, the vehicle interior is becoming an extension of the home or the office.
Kesseler, Brian
CAD CAM and Rapid Prototyping2003-28-00038/22/2003
Rapid Prototyping is the process by which a number of related technologies are used to fabricate physical objects or models from CAD CAM data sources. These methods are unique. They add and bond materials in layers to form objects. These systems are also referred to as “solid free form fabrication” and “layered manufacturing”. This paper explores the benefits of rapid prototyping in the CAD CAM process and discusses key advancements in CAD CAM software.
Pravaz, André
3D Head Models for Protective Helmet Development2003-01-21766/17/2003
In order to improve the fit and comfort of helmets, we developed digital head models that represent the anthropometric and morphometric variability found in the U.S. Navy. We analyzed the size and shape variation using two related approaches. First, we used Procrustes superimposition, which minimizes the distances between all landmarks of all subjects. This allowed us to visualize the variation in landmark distribution of the face and to test for statistical differences. Second, we extracted curvatures along the surface of the head. This allowed us to characterize the variation in the shape of the head. To create a series of sized digital models, we used principal component analysis (PCA) to organize the variation in both the traditional measurements as well as the locations of the 3D landmarks. Using an adaptation of multivariate accommodation modeling we identified representative individuals who characterize 95% of the variation in size and shape. Simultaneously, we used traditional dimensions to divide the population into a specified number of sizes, and then used the shape contours to create a summarized head form representing the individuals in each size.
Friess, Martin, Bradtmiller, Bruce
Validation of Non-linear Load-Controlled CAE Analyses of Oil-Canning Tests of Hood and Door Assemblies2003-01-06033/3/2003
Two finite element methodologies for simulating oil-canning tests on closure assemblies are presented. Reflecting the experimental conditions, the simulation methodologies assume load-controlled situations. One methodology uses an implicit finite-element code, namely ABAQUS®, and the other uses an explicit code, LS-DYNA®. It is shown that load-displacement behavior predicted by both the implicit and explicit codes agree well with experimental observations of oil-canning in a hood assembly. The small residual dent depth predictions are in line with experimental observations. The method using the implicit code, however, yields lower residual dent depth than that using the explicit code. Because the absolute values of the residual dent depths are small in the cases examined, more work is needed, using examples involving larger residual dent depth, to clearly distinguish between the two procedures. The analysis performed using the implicit code was significant more efficient (in terms of CPU hours) than the analysis done using the explicit code. The effects of forming strains are qualitatively examined. Forming induced thickness changes and plastic strains may not have a significant effect on oil-canning behavior, but may influence the residual dent depth strongly. Further reinforcement of the predictability of the methodology is demonstrated by an oil-canning simulation, using the implicit code, of a door assembly.
Iyengar, R. Mohan, Chang, T., Zhao, Y., Singri, M., Ilankamban, R., Perumalswami, S.
Development of Modular Electrical, Electronic, and Software System Architectures for Multiple Vehicle Platforms2003-01-01393/3/2003
Rising costs continue to be a problem within the automotive industry. One way to address these rising costs is through modularity. Modular systems provide the ability to achieve product variety through the combination and standardization of components. Modular design approaches used in development of vehicle electrical, electronic, and software (EES) systems allow sharing of architectures/modules between different product lines (vehicles). This modular design approach may provide economies of scale, reduced development time, reduced order lead-time, easier product diagnostics, maintenance and repair. Other benefits of this design approach include development of a variety of EES systems through component swapping and component sharing. In this paper, new optimization algorithms and software tools are presented that allow vehicle EES system design engineers to develop modular architectures/modules that can be shared across vehicle platforms (for OEMs) and across OEMs (for suppliers). Approaches presented in this paper use matrix clustering and graph based techniques. The application of the approach is illustrated with an example from the automotive industry on the development of a modular EES system that can be shared across multiple vehicle platforms.
Rushton, Gary, Zakarian, Armen, Grigoryan, Tigran
The Foresight Vehicle Programme - Towards Inclusion of the Styling Studio in Concurrent Development2002-01-01723/4/2002
A major activity in the development of a new car is the styling but this work has not been integrated into concurrent engineering methodologies. This paper describes ongoing work to increase the productivity and quality of styling and improving management and information flow by providing a means for r apid transformation from stylists' sketches to 3-D geometry. The result should be a less labor intensive way of generating 3-D computer m odels early in the styling process, allowing better feedback to stylists and their managers, and providing computer based geometry to engineers at a very early stage in the design lifecycle.
Newman, R. M., Tovey, M. J., Porter, C. S.
SCIFI (Supporting Customer Interaction, Feedback and Information): Designing a 3D Semi-Immersive System for the Car Buying Public2002-01-01793/4/2002
This three-year project is being undertaken at the Digital Design Studio, Glasgow School of Art in partnership with Ford of Britain, and with funding support from the British Engineering & Physical Sciences Research Council (EPSRC). The primary aim of the project is to build a prototype that will enable the car-buying public to configure and interact with a car model in a 3D semi-immersive virtual environment. The objective of this system is threefold: 1) to aid the decision-making process of buying a car; 2) to give the potential car buyer the freedom to select all aspects of the car from the colour and body style to engine size and options packages and; 3) to view and interact with their choices in a photo-realistic 3D environment. This paper outlines the context in which the system is being built and the Human Factors/HCI design approach that is being implemented in the life cycle of the project.
Benton, Beth
Aerodynamic Shape Optimization Using CFD Parametric Model with Brake Cooling Application2002-01-05993/4/2002
Revolutionary advances in computing power and software technology have fostered a new trend of integrating design and CFD analysis. This study explores the application of this new methodology to the area of aerodynamic shape optimization. The integrated process of UG, ICEMCFD, and FLUENT was developed using iSIGHT as an integration and optimization tool. Using this new methodology, a brake rotor air cooling passage shape DOE study and optimization was performed. About 35% cooling performance improvement was achieved through optimization using CFD. The advantage of CFD based design exploration is demonstrated by using this process. It shows the great potential of computer based automatic design optimization in vehicle Aero/Thermal development.
Qian, Cheng
Simulating the Diffuse Interior Lighting Situation and Examining Its Results in a Virtual Reality Environment2002-01-09773/4/2002
To produce an appealing ambient interior lighting design, the illumination inside a car is generated by diffuse reflections at the surfaces of the interior. So the complete illumination set can be determined by using all light sources and the attributes of the surface materials of the interior geometry. Normally, the early concept phase of the car is ideally to integrate the interior lighting in the styling of the car. But in this phase it is nearly impossible to measure and optimize the interior light due to continuous changes in car interior styling. An approach of simulating the diffuse illumination situation of car interior by using a radiosity method is presented. Then the results of the radiosity calculation are prepared in order to use them in a virtual reality environment. First the physical basics and their numerical implementation are shown. Then the material attributes, which are essential for calculation and their measurement based on real materials, are presented. Third we give a discussion which advantages we have by presenting the calculation results in virtual reality. At last, results of the radiosity calculation are demonstrated and are compared with measurement values to estimate this simulation method.
Reich, Andreas, Hahn, Mathias
Thermal Performance Prediction of Front-End Heat-Exchange Modules2001-01-17655/14/2001
The application of high performance engines and climate control systems, coupled with constraints relating to vehicle styling, aerodynamics and underbonnet packaging, continues to present demanding thermal management challenges in the design and layout of the front-end cooling module. Several computational fluid dynamics techniques are now available to assist in this design and packaging process, but many of these require a high level of specialization from the user. The work reported here outlines a relatively simple 1-dimensional technique to aid in the analysis and optimization of the cooling pack configuration. The tool can be used interactively by a multi-skilled vehicle engineer throughout the entire design and development of a new vehicle.
Jones, M. R., Fletcher, D. W.
REFLEX: TECHNOLOGY TO MEET STYLE Introduction to 4 & 5 mm prisms2001-01-04603/5/2001
4 & 5mm reflex prisms are newborn options in automotive lighting design. They are very useful for new styling configurations, especially when mixed with optics. But 4 & 5mm reflex patterns can create defaults directly linked to these prisms' size. These defaults can be sink marks or surface distortions. They affect the photometrical output and the overall aspect of molded lenses. Thus the 4 & 5mm reflex prisms' use requires an increased precision regarding the effective optical angles in order to obtain a photometrical quality comparable to the one with conventional size of prisms (2.38mm).
Iatan, George, Caire, Bernard, Pichot, Frédérique
Proactive Human Factors Engineering Analysis in Space Station Design Using the Computer Manikin Jack2000-01-21666/6/2000
In this case study, a human factors analysis was carried out in the preliminary design phase of the Cupola, a European Space Agency (ESA) module for manned space flights for the International Space Station (ISS). The manikin software Jack® was used early in the design process before any flight hardware production. All Cupola astronaut tasks were evaluated in a virtual environment of the Cupola. Methodological aspects concerning the analysis are described, e.g. file processing, use of coordinate systems and the use of a prior task analysis. Results show that the thorough manikin analysis supported with the hierarchical task analysis results, was an important help in the design process.
Sundin, Anders, Örtengren, Roland, Sjöberg, Hans
Development and Initial Testing of a Space Suit Simulator for Neutral Buoyancy1999-01-19687/12/1999
The Maryland Advanced Research/Simulation (MARS) Suit is designed to be a low-cost test bed for extravehicular activity (EVA) research, providing an environment for the development and application of biomedical sensors and advanced EVA technologies. It is also designed to be used in gaining more experience with human-telerobotic interactions in an integrated EVA worksite. This paper details the first generation MARS Suit (MX-1) design, describes the low-cost development process, and presents results from ongoing suit testing, as well as plans for future work.
Shook, Lauren S., Akin, David L.
Assessing Automotive Audio System Visual Appearance Attributes Using Empirical Methods1999-01-12683/1/1999
Human factors engineers typically concern themselves with issues of product functionality measured in terms of users’ task completion times and/or error rates. However, a product is not only a means to accomplish specific goals but a perceptual object whose sensory attributes mediate a certain “look and feel.” The present study sought to identify the visual appearance attributes of automotive audio systems that impact qualitative response to products. Results revealed specific visual appearance attributes that contributed separately to the perception of stylish appearance, 3D shape, visual complexity and cost/quality.
Kleiss, James A., Enke, Gerd
The Development of the “Line-Beam Headlamp”1999-01-03843/1/1999
Many types of low profile headlamps have been developed to meet the great demand to improve both aerodynamics and styling. However, none have resolved the principal subject, “the compatibility of light-efficiency and styling”. Our innovative development is the super -low profile headlamp system, which contains totally unique reflectors. The special combination of reflectors is designed to generate beam pattern. To achieve this innovation, the precise light control technology and the research for optimal headlamp beam pattern were essential. The head-lamp performance was examined by our original computer simulation system. As a result, this headlamp is only 30mm high and it has extremely high light efficiency. It also provides excellent headlamp performance, in regards to the bright foreground illumination, long distance visibility and accurate glare control.
Oyama, Hiroo, Kawaguchi, Yoshifumi
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