A practical approach for cross-functional vehicle body weight optimization

The goal of optimization in vehicle design is often blurred by the myriads of requirements belonging to attributes that may not be quite related. If solutions are sought by optimizing attribute performance-related objectives separately starting with a common baseline design configuration as in a traditional design environment, it becomes an arduous task to integrate the potentially conflicting solutions into one satisfactory design. It may be thus more desirable to carry out a combined multi-disciplinary design optimization (MDO) with vehicle weight as an objective function and cross-functional attribute performance targets as constraints. For the particular case of vehicle body structure design, the initial design is likely to be arrived at taking into account styling, packaging and market-driven requirements. The problem with performing a combined cross-functional optimization is the time associated with running such CAE algorithms that can provide a single optimal solution for heterogeneous areas such as NVH and crash safety. In the present paper, a practical MDO methodology is suggested that can be applied to weight optimization of automotive body structures by specifying constraints on frequency and crash performance. Because of the reduced number of cases to be analyzed for crash safety in comparison with other MDO approaches, the present methodology can generate a single size-optimized solution without having to take recourse to empirical techniques such as response surface-based prediction of crash performance and associated successive response surface updating for convergence. An example of weight optimization of spaceframe-based BIW of an aluminum-intensive vehicle is given to illustrate the steps involved in the current optimization process.

VSDSS, research studies. Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Tri-level study: modification. Task 1: final report on potential benefits of various improvements in vehicle systems in preventing accidents or reducing their severity. Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Oldsmobile Omega X-body baseline weight data. Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Development of a motor vehicle materials historical, high volume industrial processing rates cost data bank (light truck). Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Body/repair shop visits to determine distribution of replacement parts sources. Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Steel optimization and substitution for 1980 Oldsmobile Omega X-body car. Final report.

National Highway Traffic Safety Administration, Office of Research and Development, Washington, D.C.

Implementation cost to consumers of Part 581 - Bumper Standard, Phase II; weight and cost study of three "X" body bumper systems; and consumer replacement cost for complete bumper systems studied. Final report.

National Highway Traffic Safety Administration, Washington, D.C.

Vehicle weight reduction study. Final report.

National Highway Traffic Safety Administration, Office of Research and Development, Washington, D.C.

Stiffness-damping matching method of an ECAS system based on LQG control

A novel method of matching stiffness and continuous variable damping of an ECAS (electronically controlled air suspension) based on LQG (linear quadratic Gaussian) control was proposed to simultaneously improve the road-friendliness and ride comfort of a two-axle school bus. Taking account of the suspension nonlinearities and target-height-dependent variation in suspension characteristics, a stiffness model of the ECAS mounted on the drive axle of the bus was developed based on thermodynamics and the key parameters were obtained through field tests. By determining the proper range of the target height for the ECAS of the fully-loaded bus based on the design requirements of vehicle body bounce frequency, the control algorithm of the target suspension height (i.e., stiffness) was derived according to driving speed and road roughness. Taking account of the nonlinearities of a continuous variable semi-active damper, the damping force was obtained through the subtraction of the air spring force from the optimum integrated suspension force, which was calculated based on LQG control. Finally, a GA (genetic algorithm)-based matching method between stepped variable damping and stiffness was employed as a benchmark to evaluate the effectiveness of the LQG-based matching method. Simulation results indicate that compared with the GA-based matching method, both dynamic tire force and vehicle body vertical acceleration responses are markedly reduced around the vehicle body bounce frequency employing the LQG-based matching method, with peak values of the dynamic tire force PSD (power spectral density) decreased by 73.6%, 60.8% and 71.9% in the three cases, and corresponding reduction are 71.3%, 59.4% and 68.2% for the vehicle body vertical acceleration. A strong robustness to variation of driving speed and road roughness is also observed for the LQG-based matching method.

Stainless steel sandwich

The Cambridge University's Gordon Laboratory, in collaboration with Fibertech and the Defence Science and Technology Laboratory in the UK, has developed a novel melt spun fiber bore called 'Fibrecore', fabricated entirely from stainless steel with thin faceplates. Fibrecore is typically manufactured by 5mm-long and 70μm thick stainless steel fibers, produced by a melt overflow process. Its entirely metallic construction allows spot welding and tungsten inert gas welding without difficulty. Fibrecore exhibits different energy absorption mechanisms such as core cushioning, core-faceplate delamination, and plastic faceplate deformation, often in a concertina-like fashion. Its low-cost, high structural efficiency and good energy absorption characteristics make it attractive for a range of commercial and military applications. Such applications being evaluated include vehicle body panels, exhaust system noise reduction, low cost filters, and lightweight physical protection. In addition to these characteristics, Fibrecore exhibits properties such as corrosion protection, vibrational damping, and thermal insulation, which also extend its applications.

Características físicas, somatotipo e desempenho de corredores de 100 e 400 metros no Rio Grande do Norte

Objective: The aim of the study was to investigate physical characteristics and to examine association between somatotype and performance in collegiate runners of 100 m and 400 m. Methods: The sample, male runners (n=39) competing at the regional level in the state of Rio Grande do Norte, Brazil, had height, body mass, skinfolds, limb circumference and skeletal breadths measured. Then, the somatotype was calculated by Health-Carter method. Races (100 m and 400 m) were held to assess athletic performance. Descriptive statistics were calculated for the total sample, as well as for the 100 m and 400 m groups, and established four subgroups, named quartiles. For analysis between groups of runners (100 m x 400 m) was used Student's t test for independent samples. To examine the relationship between the race times and anthropometric variables, was used the Pearson correlation test. The somatotype dispersion distance and somatotype spatial distance were calculated among subgroups. One-way analysis of variance, the Wilcoxon test followed of Tukey post test, and correlation analysis were used with a significance level of p<0.05. Results: Somatotype with mesomorphy and ectomorphy dominance was exhibited by 100 m and 400 m athletes. Endomorphy was low in both groups, especially in 400m runners, who had more elongated body types than 100 m runners. When separately compared by athletic performance quartile, 100 m sprinters of better qualifications (G100-G1) had somatotype with dominant mesomorphy, whereas 400 m runners had somatotype with dominant ectomorphy. A significant correlation (r = -0.55, p=0.008) between calf circumference and 100 m race times was observed showing the importance of muscularity, whereas a significant correlation was found between height and 400 m race times (r = -0.53, p=0.02) showing the importance of linearity. Conclusion: Runners of 100 and 400 may show differences in physical characteristics, depending on the level of athletic performance. Anthropometric periodic evaluations may help in the training process of these athletes. However, more specific assessment parameters should be taken into account, because somatotype by itself has not power to predict whether an individual will succeed in racing speed

Design, Simulation und Erprobung einer aktiven Sitzaufhängung für Nutzfahrzeuge

Nutzfahrzeuge müssen oft durch sehr unebenes Gelände gefahren werden. In diesem Fall wird der Fahrer starken Vibrationen ausgesetzt, die von der Fahrzeugkarosserie durch die Sitzaufhängung auf ihn wirken. Um diese Schwingungen zu verringern, werden die Sitzaufhängungen in der Regel mit Feder-Dämpfer-Systemen ausgerüstet. Jedoch erreichen die passiven Systeme vor allem bei niederfrequenten Schwingungen ihre physikalischen Grenzen. Eine wesentliche Verbesserung des Sitzkomforts kann unter solchen Anregungsbedingungen nur mit einer aktiven Sitzaufhängung erreicht werden. In diesem Beitrag wird ein neuartiges aktives System für die Sitzaufhängung auf Basis von elektrorheologischen Flüssigkeiten vorgestellt. Außerdem werden die theoretischen Grundlagen für die Modellierung der beschriebenen aktiven Sitzaufhängung dargestellt. Anschließend werden die Simulationsergebnisse mit den Messergebnissen unter realen Betriebsbedingungen verglichen. Die Repräsentation der Ergebnisse mit Hilfe der im Bereich der Sitztechnik weit verbreiteten SEAT-Werten (Seat Effective Amplitude Transmissibility) zeigt das Potenzial des entwickelten Systems zur aktiven Reduktion der Schwingungsbelastung des Fahrers und ermöglicht seine objektive Bewertung.

Ford Escort GL baseline weight data. Final report.

National Highway Traffic Safety Administration, Washington, D.C.