Fundamentals of Vehicle Design

1. Fundamentals of Vehicle Design Dr. Shirish P Patil & Dr. Kamarul Tawi

2. Course Objectives • Understand vehicle manufacturing organization • Understand vehicle development process • Understand vehicle systems and attributes (properties) • Learn to set performance specifications for a newvehicle • Understand system/component contribution towards vehicle performance • Learn to set specifications for system/component design • Learn to design components to meet specifications

3. Course Outline • Overview of vehicle design process • Vehicle performance specifications • Vehicle acceleration & powertrain design specification • Vehicle deceleration & brake design specification • Vehicle ride & chassis design specification • Vehicle roll-over & chassis design specification • Vehicle handling & chassis design specification • Vehicle durability & chassis design specification • Vehicle crash safety & body design specification • Design of the suspension system • Design of the steering system • Design of the body/door system

4. Course Schedule • Every Tuesday: classroom instruction (2 hours) • Every Thursday: group project discussion (3 hours) • Study time: approximately 4 hours/week

5. Evaluation Criteria • Final written project report including weekly log of activities (40%) • Final project presentation (15%) • Mid-term project presentation (5%) • Team participation & contribution (40%)

6. Team Participation & Contribution Evaluation

7. Project Description • Each team (5 students) will choose a passenger vehicle to be engineered • Team will decide the performance specifications for the vehicle • Team will design the specifications for the powertrain/brake/suspension/body system so that vehicle specifications are satisfied

8. Requirements for the Report • List of specifications for cost, weight, acceleration, braking, ride, handling, roll-over, crash safety and durability. Method of setting each specification • Design of powertrain system properties to meet acceleration specification • Design of brake system properties to meet braking specification • Design of suspension & steering system properties to meet ride, handling, roll-over and durability specification • Design of body system properties to meet crash-safety specification • Design of door system properties to meet door closing effort specification

9. Vehicle Classification

10. How to prepare vehicle specifications? • Understand what your customer desires • Understand what your competition offers • Understand government regulation

11. Team Exercise • Pick a vehicle you plan to design • Write vehicle specifications by studying 2 or more competition vehicles (study dealer specs., do internet search, etc.)

12. Cost Specification • What is the intended selling price of the car? • How many units do you plan to sell? • Will you make any profit?

13. Weight Specification • What is intended gross vehicle weight (GVW)? • How many passengers? • What is the luggage capacity? • Weight distribution?

14. Geometry Specification • Wheelbase? • Tread? • Ground clearance? • Tire size?

15. Acceleration Specification • 0 to 100 km/h in how many seconds? • Engine torque/power? • Transmission speed? Auto or Manual?

16. Braking Specification • Deceleration level required? • Stopping distance from 100 km/h? • Dry surface/Wet surface?

17. Ride Specification • Desired ride frequency? • Desired passenger acceleration on an average road surface?

18. Roll-over Safety Specification • What is the max lateral acceleration the vehicle will sustain?

19. Handling Specification • Minimum turning radius? • Understeer or oversteer? • Steer gradient?

20. Durability Specification • What is the desired life of a suspension component?

21. Crash Safety Specification • What is the average deceleration experienced during frontal crash?

22. Organization of an Automaker Suppliers Manufacturing & Assembly Vehicle Engineering Leadership Sales & Marketing Finance After Sales Service Dealer Network

23. Concept to Customer Process Customer Requirements Vehicle Program Regulations Vehicle Engineering Manufacturing & Assembly Sales Service

24. Organizational Responsibility

25. Vehicle Development Organization Vehicle Development Organization Product Engineering Vehicle Engineering Styling Body Engineering Chassis Engineering Powertrain Engineering Climate Control Engineering Electrical Engineering Package Engineering Weight Engineering Safety Engineering Vehicle Dynamics Vehicle Durability Vehicle NVH Vehicle Thermal&Aero Prototype Planning/Test Exterior Styling Interior Styling

26. Product Engineering

27. Vehicle Engineering

28. Styling

29. Vehicle Development Process Vehicle, System & Component Spec Concept Evaluation To Meet Spec Program Approval Prototype Design & Testing Production Design & Testing Fix Problems Before Production

30. Vehicle Development Process

31. Vehicle Systems & Attributes Vehicle Systems Attributes • Cost • Weight • Package • Safety • Dynamics • Durability • NVH • Styling • Body • Chassis • Powertrain • Climate Control • Electrical

32. Function of Vehicle Systems

33. Vehicle Attributes