Browse Topic: Packaging

Items (257)
This standard is intended to demonstrate and document the control of the potential hazards from lithium cells or batteries (UN 3090 and 3480) when transported as cargo on aircraft. [still need to identify if we are addressing global (external fire) or local (battery internal failures)] This standard addresses the need to control the hazards which might arise from a failure from an individual cell by containing the hazards within the package. This specific hazards addressed within this standard are: • Uncontrolled fire • Rapid overpressure pulse within compartment
G-27 Lithium Battery Packaging Performance
Design and Development of Active On-Board Alcohol Detection System with Safety Features for Commercial Vehicles2018-01-06024/3/2018
Drink & drive has caused the increased rate of commercial vehicle accidents in the world due to the slow response to judgment and reasoning. According to research study 70% accidents are happened due to drunk & drive, it causes loss of human life and economic damage. Research has proven that drunk drivers exhibit aggressive driving behavior and apply more force during braking. While public health awareness and legal restrictions can assist in educating and discouraging people from drunk & drive, a more fool-proof method is not available in the market for commercial vehicles. Currently, a low cost, fail-safe onboard alcohol detection, and vehicle safety system is the need of the hour. This paper deals with the design & development of a low cost active onboard breath alcohol detection system and it’s on vehicle validation. Further, it explains the type of alcohol detection sensor used, controller design, logic programming and system packaging. An accurate, precise and contactless alcohol detection system and advanced safety features are the key highlights. The system has been validated on the vehicle, to check the response time & alcohol detection accuracy of the sensor, the preciseness of sensor location and safety features. Safety feature include SMS & voice call based alerts, sharing of vehicle geographical location and audio warnings inside the cabin and vehicle control features such as vehicle engine auto cut off in a stationary condition for disabling vehicle cranking and in case of moving vehicle gradually reducing engine torque to stop the vehicle. Good alcohol detection accuracy and system response time has been demonstrated in the validation of the drunk subjects.
Bakatwar, RupeshYaser, K U Syed TajJadhav, SourabhBhargava, Aashish
Active Cancellation of Exhaust Noise over Broad RPM Range with Simultaneous Exhaust Sound Enhancement2017-01-17536/5/2017
Demands for engines to operate at low-frequency firing order are increasing in the automotive market. This requirement is driven by consumer and regulatory demand for vehicles which are more efficient in the use of fuel. As a result, engine and transmission technologies have been developed which permit operation of engines with fewer cylinders at increasingly low RPM’s. The resulting low frequency exhaust noise is more difficult to attenuate than in vehicles in years past. At the same time, vehicles often have less packaging space for mufflers, when larger volume would otherwise be needed to attenuate at lower frequencies. A further challenge is the demand for increasingly refined performance sounds from the exhaust systems of premium cars despite the technical obstacles involved in even maintaining sound quality. Finally, legally permissible sound levels are decreasing in some markets. These market and regulatory demands require new solutions. Technology has been demonstrated using an ANC system. The system uses the operating principle of ANC, using a feed-forward control mechanism. This system has now been demonstrated to attenuate multiple firing orders by sound cancellation down to 1000 RPM on a 4 cylinder gasoline turbocharged engine. It has also been demonstrated to simultaneously attenuate undesirable orders and accentuate desirable orders. This has been demonstrated in a vehicle with a 4 cylinder TC engine and also in a V8 application operating in 4 cylinder mode, where such desired engine order sounds could not be expected typically.
Riddle, Jack HallBemman, Ya-JuanFrei, TomWu, SihuiPadalkar, Ishang
An Efficient Input Mobility Mapping Computational Method2017-01-18066/5/2017
The input mobility is a crucial structural parameter regarding vibro-acoustic design of industrial objects. Whatever the frequency range, the vibrational power input into a structure -and consequently the average structural-acoustic response- is governed by the input mobility. When packaging structure-borne noise sources, the knowledge of the input mobility at the source connection points is mandatory for noise control. The input mobility is classically computed at the required points as a specific Frequency Response Function (FRF). During an industrial design process, the choice of connection points requires an a priori knowledge of the input mobility at every possible location of the studied structure-borne source, i.e. a mapping of the input mobility. The classical FRF computation at every Degree Of Freedom (DOF) of the considered structure would lead to consider millions of load cases which is beyond current computational limits. This paper presents how to efficiently compute the full map of band-averaged input mobility over a Finite Elements mesh. The proposed method is based upon a modal decomposition of the structural response and analytical frequency integration; consequently, it only requires the modal basis as it is currently computed. The frequency band average allows optimizing the storage size. Since the input mobility is a real quantity, associated to each DOF of a structure, modal display tools can be used without modification. Thus, a meaningful map is provided, allowing efficient structural dynamics analysis over a broad frequency range.
Gagliardini, Laurent
FWD Halfshaft Angle Optimization Using 12 Degree of Freedom Analytical Model2017-01-17706/5/2017
This paper describes the development of an analytical method to assess and optimize halfshaft joint angles to avoid excessive 3rd halfshaft order vibrations during wide-open-throttle (WOT) and light drive-away events. The objective was to develop a test-correlated analytical model to assess and optimize driveline working angles during the virtual design phase of a vehicle program when packaging tradeoffs are decided. A twelve degree-of-freedom (12DOF) system model was constructed that comprehends halfshaft dynamic angle change, axle torque, powertrain (P/T) mount rate progression and axial forces generated by tripot type constant velocity (CV) joints. Note: “tripot” and “tripod” are alternate nomenclatures for the same type of joint. Simple lumped parameter models have historically been used for P/T mount optimization; however, this paper describes a method for using a lumped parameter model to also optimize driveline working angles. The 12DOF model results enable evidence-based decisions during the virtual vehicle phase for driveline working angles, powertrain mount rate and locations relative to P/T center of gravity. Several challenges were encountered and addressed during the 12DOF model development and correlation process, including halfshaft dynamic angle determination, P/T lateral rigid body mode frequency determination and subjective rating prediction.
Hill, WallaceKinchen, DennisGehringer, Mark A.
Development of New IGBT to Reduce Electrical Power Losses and Size of Power Control Unit for Hybrid Vehicles2017-01-12443/28/2017
One way to improve the fuel efficiency of HVs is to reduce the losses and size of the Power Control Unit (PCU). To achieve this, it is important to reduce the losses of power devices (such as IGBTs and FWDs) used in the PCU since their losses account for about 20% of the total loss of an HV. Furthermore, another issue when reducing the size of power devices is ensuring the thermal feasibility of the downsized devices. To achieve the objectives of the 4th generation PCU, the following development targets were set for the IGBTs: reduce power losses by 19.8% and size by 30% compared to the 3rd generation. Power losses were reduced by the development of a new Super Body Layer (SBL) structure, which improved the trade-off relationship between switching and steady-state loss. This trade-off relationship was improved by optimizing the key SBL concentration parameter. Size was reduced by adopting a new environment-friendly IGBT surface electrode structural design that enabled double-sided solder packaging. This approach ensured thermal feasibility caused by the higher current density due to the smaller design. A REduced SURface Field (RESURF) structure was adopted for edge termination. To improve the robustness of the breakdown voltage, an optimum RESURF concentration balance was designed which also contributed to the IGBT’s downsizing. These developments successfully reduced both the loss and size of the IGBTs, thereby reducing the size and loss of the new PCU, and helping to improve the fuel efficiency of Toyota’s 4th generation HVs.
Kimura, KeisukeRahman, TasbirMisumi, TadashiFukami, TakeshiHara, MasafumiKawaji, SachikoMachida, Satoru
Experimental Investigation with R1234yf Condenser Airflow Blockages of Non-Hotspot and Hotspot Objects to Impact on A/C System Performance2016-01-02554/5/2016
This paper addresses R1234yf A/C system performance impacted by condenser airflow passage blockages of nonhotspot and hotspot objects. With the modern vehicle design trend, more and more chances exist in blocking condenser airflow passages by objects such as TOC (transmission oil cooler) or fine grills etc. These objects create hotspots and narrowed airflow passages to the condenser and result in A/C performance degradation. It is important to understand the specific area of the condenser which is most impacted by a blockage so this area can be avoided in the design/packaging of front end components. In addition, it is important to understand the magnitude of performance loss associated with the specific areas of blockage. As a result of this understanding, optimal design locations for these blockages (including hotspots and grilles) can be proposed in order to mitigate the impact on A/C cooling performance. The study indicated that blocking condenser airflow passages by both the hotspot and non-hotspot objects results in A/C performance degradation, i.e. increasing evaporator discharge air temperature and raising up compressor discharge pressure and temperature. With non-hotspot object blocking, the A/C performance with idle conditions has less impact than that with driving conditions. No significant difference for A/C performance impact between vertical and horizontal blockage was found. Hotspot object blockage located at the bottom of the condenser shows worse A/C performance than blockage located at the top of the condenser. A/C performance further degrades as the hotspot object temperature increases. From the study, it is concluded that in order to minimize A/C performance impact from condenser airflow passage blockages, the blocking object located at the top of the condenser is the better choice than that at the bottom of the condenser, assuming the blockage is unavoidable altogether. Thus, the larger grille opening should be reserved for the bottom of the condenser, and any hotspots should be at a low temperature if possible.
Zheng, Yinhua
Bow-Free Tri-Component Mechanically Pre-Stressed Failure-Oriented-Accelerated-Test (FOAT) Specimen2015-01-25519/15/2015
In some today's and future electronic and optoelectronic packaging systems (assemblies), including those intended for aerospace applications, the package (system's component containing active and passive devices and interconnects) is placed (sandwiched) between two substrates. In an approximate stress analysis these substrates could be considered, from the mechanical (physical) standpoint, identical. Such assemblies are certainly bow-free, provided that all the stresses are within the elastic range and remain elastic during testing and operation. Ability to remain bow-free is an important merit for many applications. This is particularly true in optical engineering, where there is always a need to maintain high coupling efficiency. The level of thermal stresses in bow-free assemblies of the type in question could be, however, rather high. High thermal stresses are caused by the thermal contraction mismatch of the dissimilar materials of the assembly components and occur at low temperature conditions. These stresses include normal stresses acting in the component cross-sections and interfacial shearing and peeling stresses. The normal stresses in the component cross-sections determine the reliability of the component materials and the devices embedded into the inner component (package). The interfacial stresses affect the adhesive and cohesive strength of the assembly, i.e. its integrity. It should be pointed out that although the assembly as a whole is bow-free, the peeling stresses in it, whether thermal or mechanical, are not necessarily low: the two outer components (substrates) might exhibit appreciable warpage with respect to the bow-free inner component (package). While there is an incentive for using bow-free assemblies, there is also an incentive for narrowing the temperature range of the accelerated reliability testing: elevated temperature excursions might produce an undesirable shift in the modes and mechanisms of failure, i.e. lead to failures that will hardly occur in actual operation conditions. Failure oriented accelerated test (FOAT) specimens are particularly vulnerable, since the temperature range in these tests should be broad enough to lead to a failure, and, if a shift in the modes and mechanisms of failures takes place during significant temperature excursions, the physics of such failures might be quite different of those in actual operation conditions. Mechanical pre-stressing can be an effective means for narrowing the range of temperature excursions during accelerated testing and, owing to that, - for obtaining consistent and trustworthy information. If pre-stressing is considered, the ability to predict the thermo-mechanical stresses in the test specimen is certainly a must. Accordingly, the objective of this analysis is to obtain simple, easy-to-use, physically meaningful and practically useful closed form solutions for the evaluation of stresses in a bow-free test specimen of the type in question. The emphasis is on the role of compliant attachments, if any, between the inner and the two outer components. The developed model can be used at the design and accelerated test stages of the development of bow-free electronic and optoelectronic products. The compliant attachments, if any, could be particularly comprised of beamlike solder joint interconnections that, if properly designed, have a potential to relieve the thermal stresses to an extent that the low-cycle-fatigue state-of-stress is avoided.
Suhir, EphraimBensoussan, AlainNicolics, Johann
Six-unit (6U) CubeSats are recognized as the next nanosatellite to be considered for standardization. The CubeSat standard established by California Polytechnic University (Cal Poly), which applies to 1U–3U sizes, has proven to be a valuable asset to the community. It has both provided design guidelines to CubeSat developers and a consistent, low-risk interface to launch service providers. This has ultimately led to more flight opportunities for CubeSats. A similar path is desired for the 6U CubeSat. Through this process of standardization, a consistent, low-risk interface for the 6U needs to be established.
Design Optimization of Scooter Engine Hanger for Maximizing Stiffness to Weight Ratio2015-01-13664/14/2015
In scooters, the engine is a dynamic component. It is directly connected to the rear wheel and it also acts as a swing arm. Such behavior of an engine entails a requirement of a dynamic link connecting it to the frame. The link employed for this is an engine hanger. An engine hanger sustains a direct load and vibrations from the engine and allows swinging motion of the engine, thereby reducing the vibrations generated by the road undulations. The length of the engine hanger is chosen to minimize the transmission of forces generated by the rear wheel and engine arrangement to the chassis. Whereas, its shape is dictated by the forces acting on it, manufacturing process, available packaging space and its manufacturing cost. An engineer aims at developing an engine hanger that can withstand such loads and vibrations, as well as optimize its weight to meet the cost target. Improper design may lead to failure of the part in running condition. This research aims at optimizing the shape of an existing engine hanger, in order to minimize its weight without compromising on the required stiffness and at the same time ensuring manufacturability, strength and low cost. Packaging constraints, boundary and loading condition have been carried over from an existing design. The design has been modified for achieving the optimum balance between strength and cost. The design is then further validated and analyzed keeping all the manufacturing constraints and packaging space in mind. The results provide a better understanding of the distribution of stresses in the engine hanger and the effects of the manufacturing process on its shape, size and cost. The study of stress distribution helps in formulating designs with minimum weight as well as meeting the required stiffness criteria and cost target.
Koli, AnshulChandel, IshanBalasubramaniam, Viswanathan
Advanced Close Coupled SCR Compact Mixer Architecture2015-01-10204/14/2015
Future Diesel emission standards for passenger cars, light and medium duty vehicles, require the combination of a more efficient NOx reduction performance, a significant reduction of fuel consumption along with the opportunity to reduce the complexity and the package requirements to facilitate it. Recent activities on catalytic products allows for the SCR active compounds to move from the ceramic substrate located in the underbody to the DPF substrate already located in a close coupled position to achieve the benefit of the highest temperature. This newly developed SCR-coated DPF has massively improved the potential of NOX reduction. As published in the SAE-2014-0132 “advanced compact mixer: BlueBox” [1] it is crucial to inject Adblue®/DEF with a very high mixing performance level. The benefit of using the SCR-coated DPF in combination with a high performance compact mixer has been demonstrated [2] [3], however new vehicle platform development increases the challenge for exhaust system packaging constraints. The purpose of this paper is to show different exhaust design architectures incorporating a dedicated compact mixer matching compactness, weight and mixing performance. In more details, depending on the DOC and SCR-coated DPF geometrical arrangement from “Axial” to “U-turn” (180 degree from inlet to outlet) [4] [5] passing through an “L-shaped” (90 degree) each system requires a specific flow management in order to get high mixing performance and related high NOx reduction potential. High mixing performance is managed using dedicated mixer designs where the cavity behavior is improved using enhanced CFD simulation. The paper will specifically give a focus on the proposed “V-shape” about 135 degree angle between the DOC inlet and the SCR-coated DPF outlet which is appropriate for a transversal engine installation in a medium size compact car. The benefit of the installation of the entire aftertreatment system in close coupled position looking at NOx reduction together with CO2 control will be demonstrated.
Michelin, JoelNappez, PhilippeGuilbaud, FredericHinterberger, ChristofOttaviani, EricGauthier, CatherineMaire, PhilippeCouturier, Thierry
New Low Packaging Acoustic Solution for Air Intake Line2015-01-16654/14/2015
Noise is one of the key nuisances from which the car is the source. One of those noise sources, the air induction line of the Internal Combustion Engine (ICE), can use some noise attenuation systems as damping isolated volumes (called resonators), or porous ducts, before the air filter. Those solutions can attenuate designated frequencies or range of frequencies. The issue is that those solutions can be bulky, especially for resonators, expensive or even generate some drawbacks on performances. Elements like hot air ingestion, pressure drops or even generation of new noises are some significant areas where performances can be deteriorated through the implementation of such acoustic device on the air induction line. It has then invented and developed a brand new type of acoustic device, designed to ensure optimal performances for a very low packaging. This solution preserves performances and cost, and tend to cope with most of the drawbacks of usual technologies. This paper describes and explains the design process, the evaluations methodology and results done to identify the optimum product. Then, this optimized concept has been benchmarked versus conventional technologies, both on a test bench as well as on engine bench to assess its performances. Results on intake noise attenuation, acoustic emissivity, pressure drops, temperature elevation and size has finally shown a best-in-class solution, able to overpass usual technologies on all those fields. This leads to an essential solution, saving space and noise emissions, ideal to cope with latest Noise Emission Regulations and challenging packaging constraints.
Arnault, NicolasBaudet, AdrienBecker, Nicolas
Surface Fatigue Design Method for Automotive Components Subjected to Torsional Vibrations in Modern Engine Applications2014-32-002611/11/2014
Nowadays the challenge in design of auxiliary devices for automotive small engines is focused on packaging reduction and on the increase of the performance. These requirements are in contrast to each other and in order to fulfil the project specifications, new and more refined design tools and procedures need to be developed. This paper presents a calculation loop developed by Pierburg Pump Technology Italy S.p.A. (PPT). It supports the design of a variable displacement oil pump component for engine applications. The work is focused on the fatigue life evaluation of a joint, which transmits the drive torque from the engine to the oil pump. The aim of the procedure is to calculate the onset of the surface fatigue phenomenon in the hexagonal joint which drives the oil pump, taking into account the axes misalignment and the flat-to-flat clearance. The study has involved several matters, experimental measures, CFD, MBA and FEM analyses. A calculation procedure has been set up in order to consider all the necessary loads applied on the joint. The CFD analysis defines the hydraulic resistance loads on the pump. The FEM analysis is used to define the joint contact behaviour in terms of stress and strain and the surface pressure on the driving surfaces. The MBA defines the dynamical behaviour of the joint and it works out the load time history. The input shaft rotational velocity is imposed. It is obtained via experimental measures of the rotational velocity taken on the fired engine. The presented surface fatigue analysis method is a hybrid methodology which involves several calculation software packages and experimental data. The method is useful to design and verify drive joints subjected to torsional vibration, which typically undergo the pitting phenomenon. In the end, this new design tool in the PPT know how portfolio has led to a better products knowledge and to time-to-market reduction.
Franceschini, AlessandroPellegrini, EmanueleSquarcini, Raffaele
Fatigue Based Optimization of Cast Iron Bracket Depending On Proving Ground Data2014-01-23099/30/2014
Nowadays, a lightweight component design plays a significant role in both cost of a vehicle and fuel economy in competitive heavy duty truck industry. This paper describes the optimization study of an Anti-Roll Bar (ARB) bracket used in a heavy duty truck. ARB system is used to avoid rolling of a vehicle. In order to measure real forces acting on ARB links, calibration study is performed in laboratory conditions. According to this study, measured strains are correlated with theoretical strain-force curve. After the correlation study, fatigue based topology optimization is made on ARB cast iron bracket according to correlated Road Load Data (RLD) which is performed at Proving Ground. Most of the optimization studies in the literature depend on maximum static loading condition. However, many components or structures in the industry subjected to fluctuating loads when they are in service condition. Small loads in a fluctuating load domain may cause potential danger in the design because there will be damage accumulation on the part when those loads are repeated. The failure of components under cyclic load is called fatigue which plays important role in the design. In this study packaging volume, different road profiles, fatigue cycle limits, material of bracket and manufacturing constraints are taken into consideration. Compared with initial design, the weight of ARB bracket is reduced by 25% while keeping the fatigue life in an acceptable level.
Kosar, FatihYegin, Mehmet BurakDogru, OkanAkarsu, Cüneyt
Innovative Concept of Front Disc Brake Module with Weight Reduction and Cost Optimisation2014-01-25059/28/2014
The customer satisfaction index is higher for disc brake systems because of the advantages like less reaction time, shorter stopping distance and improved pedal feel compared to drum brake system. In current competitive market scenario and as per customer requirements, front disc brake module is becoming necessary. The brake system design is challenging task due to stringent performance meeting criteria and packaging constraints with weight optimization. Brake disc is very important component in the brake system which is expected to withstand high braking torque and dissipate heat during braking event. In existing car to replace front drum brake with disc brake module, vehicle needs to undergo legislative verifications and certifications with respect to pedal effort, stopping distance and circuit failed conditions etc. This paper explains development of disc brake system with novel brake disc during transition to switch from drum to disc brake with respect to packaging constraints, which has met all the performance in competitive price. In Conventional disc brake system, brake rotor has hat type construction which is complicated considering design complexity and takes higher manufacturing lead time. Innovative concept of front disc brake (Patented by Tata Motors) with straight brake rotor was evolved and later on designed with respect to packaging constraint. Number of manufacturing steps for this brake disc rotor is drastically reduced, resulted in less manufacturing time with cost & weight reduction. Digital thermal performance evaluated in house, fine-tuned and verified by correlating with test data available for existing design and then applied for new design.
Shah, AsheshPatil, SanjayAbhyankar, Umesh
Development of an Integrated Box SCR System for China IV On-Highway Applications2014-01-15394/1/2014
To satisfy China IV emissions regulations, diesel truck manufacturers are striving to meet increasingly stringent Oxides of Nitrogen (NOx) reduction standards. Heavy duty truck manufacturers demand compact urea SCR NOx abatement designs, which integrate injectors, NOx sensors and necessary components on SCR can in order to save packaging space and system cost. To achieve this goal, aftertreatment systems need to be engineered to achieve high conversion efficiencies, low back pressure, no urea deposit risks and good mechanical durability. Initially, a baseline Euro IV Urea SCR system is evaluated because of concerns on severe deposit formation. Systematic enhancements of the design have been performed to enable it to meet multiple performance targets, including emission reduction efficiency and low urea deposit risks via improved reagent mixing, evaporation, and distribution. Acoustic performance has been improved from the baseline system as well. The optimized system improved ammonia uniformity, eliminated urea deposits, improved NOx conversion efficiency while satisfying existing EU III installation packing space. This development demonstrates that good system performance can be achieved despite the challenges of meeting multifaceted and often-conflicting performance targets. System perspectives combined with assessment and understanding of unique components is critical to achieving aggressive performance targets while reducing development time for urea SCR systems.
Long, Shun HongTang, LianhuaYan, GuodongNiu, BenZheng, GuanyuWang, FengshuangZhang, SuyingZhang, JianhuaTao, Jianzhong
Design and Optimization of Planetary Gearbox for a Formula Student Vehicle2014-01-17804/1/2014
This paper presents the method of designing an optimized light weight, cost effective planetary gearbox for a Formula Student vehicle. The gearbox has a high speed functioning capability, in addition to the compact size and light weight. The iterative optimization procedure used provides a technique for selecting the best possible configuration of the gearbox. Conventional gearboxes used for this purpose are generally two step reduction gearboxes, which are bulkier in terms of weight and volume. Also, a review of the existing market reveals that the planetary gearboxes manufactured in India are not capable of handling high speeds, thus rendering them futile for racing applications. The target reduction ratio for the gearbox is a fixed parameter. The method involves design and optimization of the gear-train with the calculated ratio. A detailed algorithm has been used, which involves developing a mathematically modelled code for deciding gear characteristics, physical modelling using CAD, and structural testing of the same through simulation, with repeated iterations with a target to reduce both weight and volume. The program used has been modelled on the theoretical data acquired through perusal of available literature. The selection of bearings have been made after calculating the forces acting on the bearings, followed by market research to select bearings with the requisite load capability. The shafts for the gears have also been designed according to force calculations, followed by structural analysis. The casing for the gears is constructed around the gear-train for efficient packaging and validated through static structural simulation. A preliminary thermal analysis has been completed to verify the design according to thermal considerations. The result of the same has been presented.
Bakshi, SoovadeepDhillon, ParveenMaruvada, Teja
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