Fundamentals of Vehicle

Design
Dr. Shirish P Patil &
Dr. Kamarul Tawi
Course Objectives
Understand vehicle manufacturing organization
Understand vehicle development process
Understand vehicle systems and attributes (properties)
Learn to set performance specifications for a new
vehicle
Understand system/component contribution towards
vehicle performance
Learn to set specifications for system/component design
Learn to design components to meet specifications


Course Outline
1. Overview of vehicle design process
2. Vehicle performance specifications
3. Vehicle acceleration & powertrain design specification
4. Vehicle deceleration & brake design specification
5. Vehicle ride & chassis design specification
6. Vehicle roll-over & chassis design specification
7. Vehicle handling & chassis design specification
8. Vehicle durability & chassis design specification
9. Vehicle crash safety & body design specification
10. Design of the suspension system
11. Design of the steering system
12. Design of the body/door system
Course Schedule
Every Tuesday: classroom instruction (2 hours)
Every Thursday: group project discussion (3 hours)
Study time: approximately 4 hours/week
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%)




No.
Performance
Criteria
Level 1 Level 2 Level 3 Level 4 Level 5
1. Contributions
Does not
provide ideas
when
participating in
the group
discussion.
Rarely provides
ideas when
participating in the
group discussion.
Sometimes provides
ideas when
participating in the
group discussion. A
satisfactory group
member who does
what is required.
Usually provides
useful ideas when
participating in the
group discussion.
A strong group
member who tries
hard.
Routinely provides
useful ideas when
participating in the
group discussion. A
leader who
contributes a lot of
effort.
2. Effort in Problem-
solving
Does not try to
solve problems
or help others
solve problems.
Lets others do
the work.
Rarely tries to
solve problems or
help others solve
problems.
Does not suggest or
refine solutions, but
is wiling to try out
solutions suggested
by others.
Refines solutions
suggested by
others
Actively looks for
and suggests
solutions to
problems.

3. Attitude
Always publicly
critical of the
project or the
work of other
members of the
group. Has
negative attitude
about the
task(s).
Is often publicly
critical of the
project or the work
of other members
of the group. Is
often negative
about the task(s).
Is occasionally
publicly critical of the
project or the work
of other members of
the group. Usually
has a positive
attitude about the
task(s).
Is rarely publicly
critical of the
project or the work
of others. Often
has a positive
attitude about the
task(s).
Is never publicly
critical of the project
or the work of
others. Always has a
positive attitude
about the task(s)
4. Participation and
Working with
Others
Does not
participate,
listen to, shares
with, and
supports the
efforts of others.
Is not a good
team player.
Rarely participate,
listens to, shares
with, and supports
the efforts of
others. Often is not
a good team
player.
Often participate,
listens to, shares
with, and supports
the efforts of others,
but sometimes is not
a good team
member.
Usually participate,
listens to, shares,
with, and supports
the efforts of
others. Does not
cause ripples in
the group.
Almost always
participate, listens
to, shares with, and
supports the efforts
of others. Tries to
keep people working
well together.
Team Participation & Contribution Evaluation
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

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
Vehicle Classification
Vehicle
Type
Body Style Power Train Suspension
Passenger Car 2D/3D/4D/5D UniBody Engine: 1.0-3.0L
Trans: 5spd/Auto
Driveline: FWD
Front: McPherson
Rear: Multi-link
MPV 4D/5D UniBody Engine: > 2.0L
Trans: Auto
Driveline: FWD
Front: McPherson
Rear: Multi-link
SUV 5D Unibody or Body on
Frame
Engine: 1.8-5.0 L
Trans: Auto
Driveline:
FWD/RWD/AWD

Front: McPherson/SLA
Rear: Multi-link/Solid Axle

Luxury Car 4D Unibody or Body on
Frame
Engine: >2.5 L
Trans: Auto
Driveline: FWD/RWD
Front: SLA
Rear: Multi-link

Sports Car 2D/3D Unibody Engine: >3.5 L
Trans: 5Spd
Driveline: RWD
Front: McPherson
Rear: Multi-link
Pickup Truck 2D/4D Body on Frame Engine: >2.5 L
Trans: Auto
Driveline: RWD/AWD
Front: SLA
Rear: Solid Axle
Commercial
Truck
2D Body on Frame Engine: >5 L
Trans: Auto
Driveline: RWD

Front: SLA
Rear: Solid Axle

How to prepare vehicle
specifications?
Understand what your customer desires
Understand what your competition offers
Understand government regulation
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.)
Cost Specification
What is the intended selling price of the
car?
How many units do you plan to sell?
Will you make any profit?
Weight Specification
What is intended gross vehicle weight
(GVW)?
How many passengers?
What is the luggage capacity?
Weight distribution?
Geometry Specification
Wheelbase?
Tread?
Ground clearance?
Tire size?
Acceleration Specification
0 to 100 km/h in how many seconds?
Engine torque/power?
Transmission speed? Auto or Manual?
Braking Specification
Deceleration level required?
Stopping distance from 100 km/h?
Dry surface/Wet surface?
Ride Specification
Desired ride frequency?
Desired passenger acceleration on an
average road surface?
Roll-over Safety Specification
What is the max lateral acceleration the
vehicle will sustain?
Handling Specification
Minimum turning radius?
Understeer or oversteer?
Steer gradient?
Durability Specification
What is the desired life of a suspension
component?
Crash Safety Specification
What is the average deceleration
experienced during frontal crash?
Organization of an Automaker
Leadership
Vehicle
Engineering
Sales
&
Marketing
Manufacturing
&
Assembly
Finance
After
Sales
Service
Dealer
Network
Suppliers
Concept to Customer Process
Customer
Requirements
Regulations
Vehicle
Program
Vehicle
Engineering
Manufacturing
&
Assembly
Sales
Service
Organizational Responsibility
Organization Responsibility Examples
Central
Leadership
Run the company profitably
Provide leadership for the future
Provide initiatives to build
Eco-friendly cars
Finance Raise & provide funds to run
operations
Provide loans to
customers for purchasing
vehicles
Vehicle
Engineering
Engineer the vehicle to meet
customer specifications and
regulatory requirements
Design & test parts and
vehicles to meet specs.
Manufacturing &
Assembly
Manufacture parts & assemble
vehicles
Manufacture stamped
body panels & engine
castings
Sales & Marketing Gather customer specifications Set customer wants
After Sales
Service
Provide after sales customer
service
Ensure availability of
replacement parts
Dealer Network Sell & service cars
Suppliers Manufacture parts & assemble
systems
Design/test/manufacture
parts
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
Product Engineering
Organization Responsibility
Body Engineering
Develop exterior sheet metal and interior trim to meet
engineering and cost specifications
Chassis Engineering
Develop suspension/steering/brake/frame system
components to meet engineering and cost specifications
Powertrain Engineering
Develop engine/transmission/driveline/fuel/exhaust system
components to meet engineering and cost specifications
Climate Control
Engineering
Develop HVAC system components to meet engineering
and cost specifications
Electrical & Electronic
Engineering
Develop electrical/electronics/entertainment system
components to meet engineering and cost specifications
Vehicle Engineering
Organization Responsibility
Package Engineering
Ensure all systems and components fit in the vehicle
Weight Engineering
Ensure all systems and components meet weight spec.
Safety Engineering
Ensure that the vehicle meet the regulatory safety spec.
Vehicle Dynamics
Ensure that the vehicle meet the regulatory/customer ride
& handling spec.
Durability Engineering
Ensure that the vehicle meet the customer durability spec
Vehicle NVH
Ensure that the vehicle meet the customer Noise,
Vibration & Harshness spec.
Prototype Planning/Test
Plan & manage prototype builds and testing
Styling
Organization Responsibility
Exterior Styling Develop exterior sheet metal Class I (Styled)
clay surface
Interior Styling Develop interior trim Class I (Styled) clay
surface

Vehicle Development Process
Vehicle,
System &
Component
Spec
Production
Design &
Testing
Prototype
Design &
Testing
Program
Approval
Concept
Evaluation
To
Meet Spec
Fix Problems
Before
Production
Vehicle Development Process
Process Outcome Activities Examples
Prepare Spec. Final vehicle,
system &
component spec.
Hold customer clinics
Benchmark vehicles
Study regulations
0 to 100 kmph in 9 sec
Investment cost < $ 500M
no structural failure < 150,000 km
Concept
Evaluation
Data required to
make decisions
Design feasibility studies
Cost feasibility studies
Is acceleration spec. possible?
Is investment target possible?
Program
Approval
GO or NO GO
decision
Program meeting

Prototype Design
& Testing
Data required for
80% confidence
in the design
Part design
Manufacturing & Assembly
Testing
CAD surface or solid with drawings
soft tooled part & pilot plant assembly
CAE/Lab/Proving Ground testing
Production
Design & Testing
Data required for
99% confidence
in the design
Part design
Manufacturing & Assembly
Testing
CAD surface or solid with drawings
hard tooled part & plant assembly
CAE/Lab/Proving Ground testing
Fix Problems
before Launch
100% confidence Final fixes by launch team

Vehicle Systems & Attributes
Vehicle
Systems Attributes
Body
Chassis
Powertrain
Climate Control
Electrical
Cost
Weight
Package
Safety
Dynamics
Durability
NVH
Styling
Function of Vehicle Systems
Vehicle System Function
Body Provide durable attachment for other major systems
Provide safe and pleasant seating environment for all passengers
Protect passengers from crashes
Chassis Provide capability to steer the vehicle
Provide capability to brake the vehicle safely
Provide isolation between road and passengers
Powertrain Provide capability to accelerate the vehicle by transferring torque to wheels
Provide capability to control vehicle speed
Meet regulatory exhaust requirement
Climate Control Maintain comfortable temperature distribution for passengers
Provide windshield defrost capability
Electrical & Electronics Provide power supply where needed
Provide desirable entertainment system
Provide functional censors and controls
Vehicle Attributes
Vehicle Attributes Description
Cost Lowest production, assembly and distribution cost compared to
competitive vehicles
Weight Lowest curb weight compared to competitive vehicles in its weight class
Package Best use of the space to provide comfort and amenities to passengers
Safety 5* crash rating from the Federal Motor Vehicle Safety Standard (FMVSS)
Dynamics Best ride & handling performance compared to competitive vehicles
Durability Highest reliability and high mileage durability compared to competitive
vehicles
NVH Lowest noise, vibration and harshness compared to competitive
vehicles