Creating an Efficient Geometrical Measurement Planning Process

<div class="htmlview paragraph">A continuously growing demand comes from the automotive industry for optimization of materials and sound insulating product packaging inside the car, so as to propose the best acoustic performance at reduced costs.</div> <div class="htmlview paragraph">A new acoustical holography system provides part of the solution to meet such a demand. The capability of measuring the acoustic field inside a vehicle with high spatial resolution makes it an advanced tool for performing extensive studies of the acoustic transparency of car openings and interior components in various environmental conditions (acoustic chamber, on road, in wind tunnel). The method allows for:</div> <div class="htmlview paragraph"> <ul class="list disc"> <li class="list-item"><div class="htmlview paragraph">Detailed localization of noise sources or leaks,</div></li> <li class="list-item"><div class="htmlview paragraph">Knowledge of the acoustic energy distribution on elementary surfaces (such as doors, windscreen, roof, sealing components, …),</div></li> <li class="list-item"><div class="htmlview paragraph">Reconstruction of the energy radiated by elementary surfaces in order to predict the acoustic pressure at driver's and passengers' ears,</div></li> <li class="list-item"><div class="htmlview paragraph">Introduction of local modifications on subsystems and components in order to predict their effect on the acoustic field.</div></li> </ul> </div> <div class="htmlview paragraph">In conjunction with some numerical prediction methods, this technique will allow to apply integrated acoustic engineering design methods for a complete understanding and control of the large variety of components and systems involved in the car performance.</div>

<div class="htmlview paragraph">Cost reduction is an essential and continuous process to meet the competitive environment of product pricing and to increase the profitability of an organization. Integrated cost reduction exercise encompass all the possible avenue., e.g. Alternate material & it's procurement system, batch size, material handling, manufacturing process improvements, logistics and finally review & make changes to derive an optimum design and cost reductions to maximum extent.</div> <div class="htmlview paragraph">This paper presents a systematic approach for achieving the cost reduction of an existing 5.7Tonnne LCV truck frame from design consideration. The methodology involves, identification of the components of the frame for the cost reduction, redesign of existing frame compatible to the cost reduction need, preliminary performance evaluation of the present frame and the cost reduction frame, redesign of the frame for the performance, detailed cost evaluation, prototype manufacturing, laboratory testing, vehicle level testing and final release for the mass production. Chassis designers contributed for major design changes to derive maximum cost reduction without compromising durability or performance deterioration due to bending or torsional stiffness changes from existing frame.</div> <div class="htmlview paragraph">After a comprehensive study, it is identified that deletion of the boxing plate and the replacement of the tubular cross members with channel type cross members will contribute for the potential cost savings of the frame. With these inputs concept design of the cost reduction frame is arrived.</div> <div class="htmlview paragraph">The important performance characteristics of a chassis frame are structural integrity (Strength and Stiffness) and durability. The existing and the cost reduction frames are evaluated based on these performance characteristics.</div> <div class="htmlview paragraph">The final design of the cost reduction frame is arrived based on CAE analysis of the frame for structural integrity, Number of iterative operations got eliminated due to the use of multidisciplinary optimization (MDO) package. Different load cases which focus on strength and stiffness of the frame are considered as an example.</div> <div class="htmlview paragraph">Bending and torsional stiffness of the existing and the cost reduction frames are also measured in the test rig. It is found that bending stiffness of the cost reduction frame is 9.15% more than the existing frame and torsional stiffness of the cost reduction frame is closer to the existing frame. It was also found that the durability of the existing and the cost reduction frame in bending is almost same. The test specifications are arrived based on strain measurements on the existing frame in our torture track.</div> <div class="htmlview paragraph">The above methodology helped us in deriving a estimated cost saving of Rs.311/- by the modified frame design. There are other intangible benefits like savings in labour cost due to elimination of the boxing plate, savings in the processing cost of boxing plate welding etc. The estimated cost savings is likely to be double of the above amount and would result in 3.5% of the Chassis frame aggregate cost.</div>

<div class="section abstract"><div class="htmlview paragraph">Assembly processes in aircraft production are difficult to automate due to technical risks. Examples of such technical challenges include small batch sizes and large product dimensions as well as limited work space for complex joining processes and organization of the assembly tasks.</div><div class="htmlview paragraph">A fully automated system can be expensive and requires a large amount of programming knowledge. For these reasons, ZeMA believes a semi-automated approach is the most effective means of success for optimizing aircraft production.</div><div class="htmlview paragraph">Many methods can be considered semi automation, one of which is Human-Robot-Collaboration. ZeMA will use the example of a riveting process to measure the advantages of Human-Robot-Collaboration systems in aircraft structure assembly.</div><div class="htmlview paragraph">In the assembly of the aircraft aft section the pressure bulkhead is mounted with a barrel section using hundreds of rivets. This assembly process is a non-ergonomic and burdensome task in which two humans must work cooperatively. The alleviation of such work can be achieved by using a collaborative scheme between operator and robot system. This approach uses dynamic task sharing between the operator and robot based on their skills and the process requirements. This is demonstrated by placing a robot inside section 19 on top of a lifting unit to position the counter holder while the human does the more complex task of inserting the rivet and operating the rivet tool.</div><div class="htmlview paragraph">Using dynamic task sharing and an intuitive control system, ZeMA aims to assist the operator with a collaborative robot and assistance system to improve the manufacturing quality as well as ergonomics for the human during the overhead riveting process.</div><div class="htmlview paragraph">The results are part of the European Union's Horizon 2020 research and innovation program at ZeMA and will present needs-based automation shown in the HRC riveting process.</div></div>

<div class="section abstract"> <div class="htmlview paragraph">This specification is a general level subsystem light source specification that establishes test requirements of a Gas Discharge Light Source (GDLS) subsystem for use on passenger vehicles.</div> <div class="htmlview paragraph">The completed test data to this test specification is intended to be provided to the OEM by the Tier one lamp set maker as part of the lamp assembly PPAP. Re-testing shall be required if any portion of the approved GDLS experiences a design, manufacturing or component change.</div> <div class="htmlview paragraph">This document shall be applied to systems that meet the requirements for design, performance and validation established by government standards.</div> <div class="htmlview paragraph">The subsystem is defined as the ballast, igniter and light source and shall be tested as a subsystem and considered one test sample for the entire test sequence. A failure of any component in the test sample shall constitute a failure of the entire sample. Substitution or replacement of only the light source shall be allowed during testing. Failure of the light source more than once in a tested system shall constitute a failure of the GDLS. <i>If other manufacture’s components are intended to be approved for use in the GDLS, then those possible combinations of components shall be considered a new GDLS and shall also be tested</i>.</div> <div class="htmlview paragraph">Additional testing may be required by individual OEM’s to meet specific EMC, quality, reliability and durability objectives.</div> <div class="htmlview paragraph">The following tests are to be performed under the following conditions:</div> <ul class="list disc"> <li class="list-item"> <div class="htmlview paragraph">New light source (capsule) or ballast design</div></li> <li class="list-item"> <div class="htmlview paragraph">Design or process change made to an existing capsule or ballast, which could affect the outcome of the test</div></li> <li class="list-item"> <div class="htmlview paragraph">Completion of one calendar year as noted in the “ANNUAL TESTS” Table shown in the Appendix. <i>(Note: Production process control data, collected at a shorter interval per an approved control plan, may be substituted if approved by customer’s responsible engineer and purchasing representative.)</i></div></li></ul></div>

<div class="section abstract"><div class="htmlview paragraph">The automation of assembly processes in aircraft production is, due to technological and organizational boundary conditions, very difficult and is subject to technological challenges and economical risks. The technological challenges are especially the large product dimensions as well as the high amount of variants. At the same time, aircrafts are produced in low quantities with inflexible and expensive fixtures.</div><div class="htmlview paragraph">As part of the research projects TRSE (semi-automated robot welding for single item production) and 4by3 (Modularity, Safety, Usability, Efficiency by Human-Robot-Collaboration) at ZeMA, the goal is to develop new process technologies, planning tools and adequate equipment in order to enable efficient and customized automation for various production processes.</div><div class="htmlview paragraph">The human-robot-cooperation is an approach to a required, adjusted and flexible automation. Worker and robot work together without a separating protection device in an overlapping workspace.</div><div class="htmlview paragraph">The idea is to support the worker in the production process with a sensitive robot to achieve a higher process efficiency and an improvement of quality.</div></div>

<div class="section abstract"><div class="htmlview paragraph">The increasing adoption of battery electric vehicles (BEVs), driven by the EU's target of no internal combustion engine vehicles from 2035 onwards, is driving significant changes in the automotive industry. However, the high degree of electrification and the unique low-speed acceleration behavior of BEVs therefore lead to new challenges. Measuring the drivetrain power and efficiency in a reproducible way and obtaining meaningful results is one of the challenges.</div><div class="htmlview paragraph">To address this challenge, a novel test method is developed that offers a simple and preferably modification-free approach to drivetrain power and efficiency measurements for BEVs, allowing for efficient and reproducible testing. Different paths for determining the drivetrain power with varied measurement efforts are presented and evaluated. The test method is designed to provide reliable and accurate results for BEVs.</div><div class="htmlview paragraph">In this study, the effectiveness of the test method is shown by presenting the results of tests conducted with a VW e-up! on a Vehicle-in-the-Loop test bench and comparing them with data from previous studies. The results show that this approach offers a reproducible and meaningful way to measure power and efficiency in BEV’s drivetrains.</div><div class="htmlview paragraph">In addition to the discussion of the results, insights into the measurement of BEV’s drivetrains are given. An outlook on future challenges and how to overcome these with the help of the presented test bench as well as the knowledge gained from the study completes the paper.</div><div class="htmlview paragraph">Overall, the study offers insights into the development and testing of BEVs, providing a robust and reliable test method.</div></div>

<div class="htmlview paragraph">The requirements of the link between different applications in the automotive area have been increasing rapidly during the last years. Especially the reliability of the electric/optical interface device for MOST® (<u>M</u>edia <u>O</u>riented <u>S</u>ystem <u>T</u>ransport) applications, FOT (<u>f</u>iber <u>o</u>ptical <u>t</u>ransceiver), is very important and of concern.</div> <div class="htmlview paragraph">The compliance of the required specification (for electrical or optical parameters in the entire environment) is proven by an unique and innovative procedure for automotive components. For the FOT this means also a specific and dedicated qualification procedure to evaluate the portion of the optical data transfer. Today's qualification procedures for semiconductor devices consider electrical and assembly (package) related parameters. The special optical part of the FOT (LED and photodiode) and the accompanying circuits represent a new class of parameters that have to be qualified. Presently, there is no defined standard to get an answer about the quality and reliability of those parts. Therefore, it is necessary to establish an unique standard procedure to qualify MOST devices.</div> <div class="htmlview paragraph">It is important and very useful to examine the requirements for car environment during the qualification procedure as well as the design and production process and also a parameter that represents the desired function. Otherwise it will end up into fundamental consequences for the following product development process (redesign / time shift).</div> <div class="htmlview paragraph">With the experiences from well known qualification standards and with the view of the special requirements of the FOT, there is the distinctive opportunity to establish a procedure that accommodates the particular technical demands in the application. The high benefit of this procedure is a very precise proposition about the expected product quality and reliability level.</div> <div class="htmlview paragraph">This newly developed method can be used in every area where new technologies or new processes are introduced for the first time.</div>

<div class="section abstract"><div class="htmlview paragraph">Car makers are subject to a strong regulatory pressure to make the industry more environmentally sustainable. In this context, many research and industrial activities have been concentrated in the field of sustainability through the development of innovative materials, manufacturing technologies and production processes.</div><div class="htmlview paragraph">This paper presents a tailored framework for estimating the potential of lightweighting to mitigate the Global Warming Potential (GWP) impact within the automotive sector. The framework is based on the Life Cycle Assessment (LCA) modelling of the use stage, and it is able to evaluate the effects of lightweight solutions in the application to a wide range of cars, both in terms of propulsion technologies (Internal Combustion Engine Vehicles, ICEVs, and Battery Electric Vehicles, BEVs) and vehicle segments. In addition, the assessment framework can estimate the effect of different electricity grid mixes when modelling the production of energy consumed by BEVs. The added value of the method is the ability to estimate the use stage GWP through indicators which are ready-to-use in any practical case study: starting from the knowledge of component mass only, the operation phase is easily and immediately assessed, thus limiting the inventory modelling to the sole production and End-of-Life (EoL) steps. This way, the work of the LCA analyst is greatly facilitated, with notable savings in terms of time and personnel effort.</div><div class="htmlview paragraph">The framework is validated through the application to a practical case study from literature, which deals with different lightweight measures in the application to a series of automotive components. Results highlight the potentiality of the method to perform a detailed Life-Cycle (LC) analysis, as well as the ability to identify the most profitable application fields of innovative solutions.</div></div>

<div class="htmlview paragraph">The primary motivation that drives the popularity of tube hydroforming, particularly in the automotive structural industry is the anticipation and expectation of significant savings compared to established methods, like stamping and welding. These potential savings can be divided into 6 main categories. They are capital (facilities and equipment), tooling and part costs, as well as, weight reduction, assembly simplification and performance improvement. Careful and knowledgeable consideration of these factors with the goal of achieving the best balance should lead to choosing the most advantageous manufacturing option. Overemphasis on one factor may lead to disappointing results in some of the others.</div> <div class="htmlview paragraph">This paper concentrates on the 1<sup>st</sup> 3 categories examining the impact of design decisions on overall cost. Due to the ‘newness’ of hydroforming, the possibility that design decisions made with partial knowledge may build in extra cost is higher. The latter 3 receive less attention, limited to how they relate to the cost categories.</div> <div class="htmlview paragraph">Each of the 3 cost aspects will be broken down to show how cost is incurred and give more insight into minimizing it. The tradeoff between functional features and cost will also be examined to rationalize when increasing the latter is justified by improvement of the former. This paper should help demystify a relatively new technology and facilitate understanding the most economical way to make parts for a particular function.</div> <div class="htmlview paragraph">The most knowledgeable initial decisions are essential because once a manufacturing path is chosen, changing direction is more difficult with each passing step.</div>

<div class="htmlview paragraph">Improved performance creates a need for a limited slip differential for widespread application. Existing types suffer from the disadvantage of high cost and they are generally not well suited to front wheel drive applications.</div> <div class="htmlview paragraph">The ‘Suretrac’ differential meets this enhanced requirement. In this new design torque is transmitted through the unit using a cam and follower principle. Any relative rotation of the cams on the output shafts is opposed by friction forces which generate a torque ratio between the output shafts. The design is novel in using helical faces to give large contact areas and avoid high Hertzian stresses.</div> <div class="htmlview paragraph">The performance of this type of differential differs from viscous types or traction control because the torque difference is established before any relative motion takes place. The tyre dynamics dictate the torques generated so that the differential always provides the optimum torque balance. This maintains tyre adhesion and enhances directional stability and safety.</div> <div class="htmlview paragraph">The complexity of the shapes involved precludes machining as an economic production process, so nett shape forming methods are used. This also has to apply to the prototype phase, and so simultaneous engineering has been implemented throughout the product development.</div> <div class="htmlview paragraph">The operation of the differential should normally not impinge on the driver's consciousness, so the performance can only be established by special tests carried out with full instrumentation. These tests include acceleration with the wheels on different surfaces, “split mu”, and acceleration on a curve to give unequal wheel loading. Test results are presented. Durability tests have also been completed.</div> <div class="htmlview paragraph">The differential is shown to give substantial advantages in operation, is capable of being installed in the same space as a conventional differential and has a minimum additional cost and so should gain widespread acceptance in all types of vehicle.</div>

<div class="section abstract"><div class="htmlview paragraph">Autonomous vehicle motion planning and control are vital components of next-generation intelligent transportation systems. Recent advances in both data- and physical model-driven methods have improved driving performance, yet current technologies still fall short of achieving human-level driving in complex, dynamic traffic scenarios. Key challenges include developing safe, efficient, and human-like motion planning strategies that can adapt to unpredictable environments. Data-driven approaches leverage deep neural networks to learn from extensive datasets, offering promising avenues for intelligent decision-making. However, these methods face issues such as covariate shift in imitation learning and difficulties in designing robust reward functions. In contrast, conventional physical model-driven techniques use rigorous mathematical formulations to generate optimal trajectories and handle dynamic constraints.</div><div class="htmlview paragraph"><b>Hybrid Data- and Physical Model-Driven Safe and Intelligent Motion Planning and Control for Autonomous Vehicles</b> presents a hybrid framework that combines data-driven insights with the robustness of physical models. It identifies key challenges in fusing these disparate methods and outlines potential solutions in developing robust fusion strategies, establishing generalized mixed dynamics models, and designing multi-objective robust control systems. In addition, the report explores future research directions to enhance learning efficiency, improve adaptability to rare but critical scenarios, and ultimately pave the way for secure, efficient, and human-like autonomous driving systems.</div><div class="htmlview paragraph"><a href="https://www.sae.org/publications/edge-research-reports" target="_blank">Click here to access the full SAE EDGE</a><sup>TM</sup><a href="https://www.sae.org/publications/edge-research-reports" target="_blank"> Research Report portfolio.</a></div></div>

<div class="htmlview paragraph">Current and proposed legislation regarding gaseous emissions has adversely affected the fuel economy of certain gasoline engines. Recent economic and environmental developments such as the fossil fuel shortage have improved the potential for the use of diesel engines as the power plant for small commercial vehicles and possibly certain passenger cars.</div> <div class="htmlview paragraph">Many variables affect fuel economy comparisons. Most of these variables can be associated with either the vehicle design or operation.</div> <div class="htmlview paragraph">The objectives of this paper are to relate fuel economy claims with a variety of cycles and to show how some of these claims can be justified. Also, to show how some of the more impressive diesel over gasoline economy claims relate more to the real world than comparisons based on EPA and SAE cycles.</div> <div class="htmlview paragraph">EPA originally started with one cycle and later split it into city and highway driving, to better cover the real world. SAE now has three cycles which represent a broader range of habits and requirements. There is still room for improvements at the low speed, short trip in cold weather, end of the scale. Also, the high volume of small Commercial vehicles such as Pick-Ups, Vans, Taxis, etc. need attention.</div> <div class="htmlview paragraph">To appreciate the significance of comparing the real world to SAE cycles, we must be familiar with “typical vehicle fuel economy as influenced by trip length” (<span class="xref">1</span>) <span class="xref">*</span>, “fuel savings potentials in short trip cold weather service” (<span class="xref">2</span>), and “other published statistics” (<span class="xref">3</span>) that have SAE level research and credibility.</div> <div class="htmlview paragraph">These papers show the results of surveys describing how up to 80% of trips and 50% of the auto fuel consumed are associated with trips of 10 miles or less.</div>

<div class="section abstract"> <div class="htmlview paragraph">Because of the intense focus on fuel economy and fuel emission standards, it has become imperative to optimize vehicle drivetrains. In light of this, component efficiencies have become an important factor in the drivetrain decision-making process. It has therefore become necessary to develop a universal standard to judge transmission efficiency.</div> <div class="htmlview paragraph">This SAE Recommended Practice specifies a test procedure which maps torque transmittal efficiency and parasitic losses for manual transmissions. The application of this document is intended for manual transmissions used in light (class 4) through heavy truck applications with both simple and compound ratio structures.</div> <div class="htmlview paragraph">This document is separated into two parts. The first compares input and output torque throughout a specified input speed range in order to determine the overall transmission efficiency. This test is used to evaluate all forward gears; testing in reverse is optional. The second procedure measures parasitic losses experienced at zero output torque over a range of operating speeds. A procedure for further reduction of this data into a loaded efficiency from gear and bearing systems is also provided.</div></div>

<div class="htmlview paragraph">A presentation of the factors considered in the development and implementation of digital instrumentation on agricultural tractors. Market and economic conditions that affect the content and functions of digital instrumentation will be discussed. Test and development of the components, relative to state-of-the-art design will be presented.</div> <div class="htmlview paragraph">Market acceptance, training and service considerations after product release will be reviewed.</div> <div class="htmlview paragraph">The impact on product planning and future applications of similar systems will also be discussed.</div>

<div class="htmlview paragraph">The car manufacturing process benefits from a competition between different materials that have to fulfil such demands as lightweight, comfort and safety. For ecological and economical reasons low vehicle weights minimise the energy consumption necessary for transportation.</div> <div class="htmlview paragraph">High strength steels enable to lower body weight by reducing sheet thickness and increase car safety by excellent crash behaviour. A very important contribution to vehicle safety and value maintenance during the whole life cycle is the use of galvanised steel sheets to prevent corrosion and premature failure of crash relevant body components.</div> <div class="htmlview paragraph">Up to date the high standards in corrosion protection and appearance of the exposed car body in the automotive industry are verified by extensive surface coating processes, applied to the body in white by batch processes. Continuous coil coating of galvanised sheet steel is an extremely efficient alternative to the currently used surface finishing processes. The range of possible coil-coating systems expands from spot weldable thin film coatings over EDP-replacements to complete body paints.</div> <div class="htmlview paragraph">Thin film precoated, galvanised steel sheets are comparably or easier to process in terms of formability and weldability as well as adhesive joining than their uncoated counterparts. Furthermore they yield better application properties like enhanced corrosion protection, especially in cavities. This results in a possible elimination of secondary corrosion protection measures and leaner production processes. Thus, by avoiding, or shifting environmentally sensitive processes to the steel supplier it is possible to slim down the production efforts for high quality automotive vehicles.</div> <div class="htmlview paragraph">Precoated steel sheets offer a high potential to optimise car production in terms of environmental aspects and economical benefits.</div>