Browse Topic: Vehicle styling

Items (85)

Early design or concept phase involve decision of key Chassis & Suspension parameters finalization, in which tire size selection is one of the most important aspect. Tire size affects overall vehicle ride & handling, steering performance and styling. In addition, it will dictate the majority of suspension packaging in subsequent design phase. An improper tire size selection can lead to major design changes in later stages and cause delay in the project deliverables. Conventional method of tire size selection mainly based on load rating using Tire standards like ETRTO, JATMA etc. is sufficient for vehicle application & basic durability point of view but lacks the insight for typical tire-rim impact failure mode. Aim of the study is to develop the methodology of predicting durability failure especially kerb strike event using simplified suspension-tire mathematical model, which will help in selection of optimal tire size or its specifications in early design phase to mitigate the impact

Atal, Abhishek, Lakhera, Vivek

N&V Component Structural Integration and Mounted Component Durability Implications

2020-01-139604/14/2020

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

Stebbins, Mark, Schudt, Joseph

A Research on Kinematic Optimization of Auto Flush Door Handle System

2020-01-062304/14/2020

A fascinating exterior appearance is one of the most important values for customers so the realization of the innovative styling has been a major topic for car makers for several years. Also, since the base of autonomous driving and electric vehicle is being expanded recently, it is essential to not only create high-tech image on a vehicle but also realize the engineering design in reality. From that point of view, the auto flush handle can be unique sales point to enhance the degree of the completion of the exterior styling. The purpose of this study is to establish the kinematic system of auto flush door handle to overcome the exterior handicaps such as not only the excessive exposure of the internal area on the deployed position but also to determine the proper operating speed. In order to resolve these issues, the Scott-Russell mechanism is applied to the auto flush handle system. The mechanism is applied to realize the straight motion so exterior quality can be improved to

Han, Jungho, Kwak, Kyoungtaek, Nam, Jinwoo, Jung, Oktae, Chung, Jinsang

New design for 2020 Mitsubishi Outlander Sport as brand awaits alliance's new platforms, products

19AUTP06_1606/01/2019

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_1205/01/2019

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 911

19AUTP01_1501/01/2019

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 styling

18AUTP10_1310/01/2018

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

HONDA 2018 ACCORD: antidote for crossover fever

17AUTP11_0311/01/2017

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 Design

2017-01-175406/05/2017

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

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 Curves

2017-01-945004/11/2017

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

A Model Based Approach for Electric Steering Tuning to Meet Vehicle Steering Performance Targets

2017-01-149303/28/2017

Subjective steering feel tuning and objective verification tests are conducted on vehicle prototypes that are a subset of the total number of buildable combinations of body style, drivetrain and tires. Limited development time, high prototype vehicle cost, and hence limited number of available prototypes are factors that affect the ability to tune and verify all the possible configurations. A new model-based process and a toolset have been developed to enhance the existing steering development process such that steering tuning efficiency and performance robustness can be improved. The innovative method utilizes the existing vehicle dynamics simulation and/or physical test data in conjunction with steering system control models, and provides users with simple interfaces which can be used by either CAE or development engineers to perform virtual tuning of the vehicle steering feel to meet performance targets. The process can be used not only in early phases of vehicle programs before

Wang, Dexin, Mao, Yiqin, Drotar, Timothy, Esser, Frank, van Dijk, Hessel, Paas, Michel

A Low Profile Loop Antenna Design for Automotive Applications

2017-01-169603/28/2017

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

A Spline-Based Modeling Algorithm for Application to Aerodynamic Shape Optimization Based on CFD Analysis

2017-01-151003/28/2017

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

Song, Kisun, Choo, Kyung Hak, Mavris, Dimitri

Multisensory Contributions to Perceived Quality and Authenticity of Materials for the Vehicle Interior

2017-01-049403/28/2017

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

Haverkamp, Michael Christian, Moos, Anja

Development of Thermoplastic Polyurethane (TPU) Material

2014-01-102704/01/2014

The enhancement of material durability is a key development theme for automakers since customers own cars longer. Research is being carried out to extend the lifetime of current thermoplastic polyurethane (TPU) materials by enhancing hydrolysis resistance while maintaining excellent low-temperature properties and scratch resistance. This development of enhanced hydrolysis resistance without degrading the melting properties of the material was achieved by introducing a new resin structure that is resistant to the invasion of water, acid, alkalis, and other substances causing hydrolysis.

Taniguchi, Daisuke, Tokuhara, Wataru, Miyake, Yuichi

Influencing Factors of Contact Force Distribution in Pedestrian Upper Legform Impact with Vehicle Front-End

2012-01-027204/16/2012

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

Nie, Bingbing, Huang, Jun, Xia, Yong, Zhou, Qing

Innovative Approaches to Global Demands of the Exterior Signal Lighting

2012-01-026004/16/2012

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 vehicles

11AEID0607_0506/07/2011

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

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.

Squeak & Rattle Simulation - A Success Enabler in the Development of the New Saab 9-5 Cockpit without Prototype Hardware

2010-01-142306/09/2010

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

Weber, Jens, Benhayoun, Ismail

Underhood Thermal Simulation of a Small Passenger Vehicle with Rear Engine Compartment to Evaluate and Enhance Radiator Performance

2010-01-080104/12/2010

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

Kumar, Vivek, Shendge, Sachin A., Baskar, S.

Anthropometry for a North American Manufacturing Population

2009-01-227406/09/2009

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

Nadadur, Gopal, Chiang, Jim, Parkinson, Matthew B., Stephens, Allison

Multi-objective Optimization of a Charge Air Cooler using modeFRONTIER

2008-01-088604/14/2008

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

Stephenson, Phil, Chen, Yang, Fateh, Nader, Parashar, Sumeet, Poian, Mauro

Design and Dimensional Engineering - a case about style parameters and engineering standards

2007-01-294411/28/2007

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

Latest Developments in Automotive Bulb Shield Design and Manufacture

2007-01-373008/05/2007

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 Tasks

2007-01-247806/12/2007

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

Reed, Matthew P., Wagner, David W.

An Interactive Approach to the Design of an Acoustically Balanced Vehicle Sound Package

2007-01-231405/15/2007

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

Wentzel, Richard E., Aubert, Allan C.

Conditions for Significant Efficiency Improvement in the Product Development Chain by the Application of Integrated Virtual Engineering

2007-01-095104/16/2007

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

Goettlicher, Christoph, Trecapelli, Anthony A.

A Study on the Analysis Method for Optimizing Mounting Brackets

2006-01-148004/03/2006

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

Chang, Hong Suk

A Decision Network Framework for Vehicle Systems Engineering

2005-01-362311/01/2005

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 Humans

2005-01-140704/11/2005

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

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 Vehicle

2005-01-043404/11/2005

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 science

AUTOFEB05_0902/01/2005

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

Kesseler, Brian

CAD CAM and Rapid Prototyping

2003-28-000308/22/2003

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 Development

2003-01-217606/17/2003

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

Friess, Martin, Bradtmiller, Bruce

Validation of Non-linear Load-Controlled CAE Analyses of Oil-Canning Tests of Hood and Door Assemblies

2003-01-060303/03/2003

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

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 Platforms

2003-01-013903/03/2003

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

Rushton, Gary, Zakarian, Armen, Grigoryan, Tigran

A New Vehicle Technology HIGHLIGHTS A heavy-duty Ram

AUTOOCT02_0510/01/2002

Chrysler Group engineers have included several firsts for the 2003 Dodge Ram 2500 and 3500 pickups, including side curtain airbags and power adjustable pedals. The 2002 Dodge Ram 1500 provided an excellent base for the 2003 Dodge Ram Heavy Duty trucks, said Rick Aneiros, Vice President of Design and Ram Design Team Leader. Chrysler Group engineers were taking into account the development needs of the heavy-duty series from the beginning of the Ram 1500 design process, he said. For example, the grille was designed to be large enough to handle the cooling needs of the larger 2500/3500 powertrains. The family resemblance is not only evident in the exterior styling of the pickups, but also under their skin, with a hydroformed frame design similar to their lighter-duty sibling. And like the 1500, the heavy-duty models incorporate enhanced safety features, several of which are firsts for the segment. The trucks feature the first heavy-duty pickup application of side curtain airbags; pre

Gehm, Ryan

SCIFI (Supporting Customer Interaction, Feedback and Information): Designing a 3D Semi-Immersive System for the Car Buying Public

2002-01-017903/04/2002

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

The Foresight Vehicle Programme - Towards Inclusion of the Styling Studio in Concurrent Development

2002-01-017203/04/2002

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.

Aerodynamic Shape Optimization Using CFD Parametric Model with Brake Cooling Application

2002-01-059903/04/2002

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 Environment

2002-01-097703/04/2002

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

Reich, Andreas, Hahn, Mathias

Thermal Performance Prediction of Front-End Heat-Exchange Modules

2001-01-176505/14/2001

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 prisms

2001-01-046003/05/2001

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 Jack

2000-01-216606/06/2000

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 Buoyancy

1999-01-196807/12/1999

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 Methods

1999-01-126803/01/1999

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”

1999-01-038403/01/1999

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

An Alternative Approach to Robust Design: A Vehicle Door Sealing System Example

97192405/20/1997

Designing a high-quality door sealing system at low cost is an economic and technological engineering challenge. Robust design is a systematic and efficient technique to meet this challenge of design optimization for performance, quality, and cost. This technique, also called parameter design, focuses on making product and process designs insensitive (i.e. robust) to hard-to-control variations called noise factors. In this paper, we illustrate and apply the principles of robust design using a response model approach to a door sealing system design problem where vehicle interior sound is the primary response being studied. The Appendix contains a glossary of all italicized words for reference.

Thomas, R. S., Ehlert, G. J.

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