Mario Hirz

An approach of multi disciplinary collaboration in conceptual automotive development

Conceptual automotive development processes are characterised by a wide range of different working fields and influencing factors, which leads to the participation of several departments, engineering service provider and component supplier. An important factor for a successful development states an optimised interaction of the different involved parties and departments based on efficient collaborative development processes, using computer aided tools, methods and strategies. The present publication treats the development of an integrated approach for the automotive concept phase, which is based on an integrated virtual product representation model. This model enables access of all involved parties and consists of several interlinked modules to cover the requirements in view of product structure management, geometry creation and functional simulation.

An Application of Enhanced Knowledge-Based Design in Automotive Seat Development

Management of product complexity in virtual development establishes as an important challenge that has to be considered to ensure efficient product creation. The main goal is to provide a virtual environment, which allows the simultaneous definition, representation, verification and alignment of involved components. As a key aspect of the present publication, an integrated approach based on a novel configuration of a design-related master model that connects different development disciplines is introduced. Several methods are integrated to this approach and support a continuous efficient development even in early phases. The paper completes with an exemplary application in automotive seat development, representative as one of the complex disciplines in automotive engineering.

Knowledge-Based Design

The chapter “Knowledge-Based Design”, covers the use of template models, integrated calculation and simulation procedures, and automated routines to support product design. Knowledge-based design enables the collection, storage and re-use of expert knowledge, as well as the subsequent integration of know-how into development processes. Using examples from component and assembly development, the chapter elaborates on the potential of enhanced parametric-associative design and knowledge-based engineering used in combination with simultaneously linked calculation procedures.

Car side window kinematics

It is a demanding and time-consuming task to construct the side window mechanism of a car such that the deflections along the seals are minimized. The reason for this is that the window surface S delivered by the stylist, will in general not be movable in a proper way: It is required that the surface tightly moves along the seals. Deflections will necessarily occur no matter how much effort the engineer invests. This article describes how to find a spatial motion that minimizes seal deflection for some given automobile side window surface. Necessary but acceptable modification of the stylists surface S is also addressed, as well as the lifting mechanism design. It is argued that our systematic approach offers considerable savings compared to the prevailing trial-and-error approach.

Evaluation of Angular Sensor Systems for Rotor Position Sensing of Automotive Electric Drives

The objective of this paper is the generic approach for assessment and evaluation of different position sensor technologies used for automotive electric traction drive applications. The information of the position angle is essential for the robustness and the quality of the control respectively the reliability of the overall electrified powertrain. The rotor position sensor is a key component, which has to be considered with best application’s usage. A systematic testing within automotive requirements can support the technology selection as well as the performance evaluation in a very early stage of the electric drive system development. First an overview about automotive relevant rotor position sensors is given. Based on this the testing parameter, the test bench capabilities and a test result of a selected end of shaft position sensor is described.

Modeling Techniques in CAD

The chapter “Modeling Techniques in CAD”, includes a detailed introduction of design methods within the CAD environment. Structures and strategies of wireframe, surface and solid modeling are presented and discussed in terms of their application in collaborative product development processes. Beyond the application of primary CAD functionalities, this chapter uses specific examples from the automotive industry to present a variety of methods for the efficient creation of mechanical components and assemblies.

Potential of the 50cc Two Wheeler Motor Vehicle Class in Respect of Future Exhaust Emission Targets

Future emission regulations for two wheeler vehicles driven by small capacity engines will include the cold start characteristics and the durability behavior. [1] Based on the European homologation cycle ECE R47 and an additional cold start test cycle, a number of scooters driven by 50cc engine concepts in combination with different exhaust gas after treatment strategies have been analyzed and evaluated. The test series have been performed with the help of a CVS measurement system according the European homologation instruction and in addition with the help of an online emission recorder measurement.

Flow and Engine Test Bench Development of Crankcase Supercharged Four Stroke Engine with Oil Separating System

An efficient and low cost way to supercharge a four stroke engine is to use the bottom side of the piston to increase the volumetric efficiency. In comparison to naturally aspirated (NA) engines, this supercharging concept pre-compresses the intake air in the crankcase resulting in a significant increase of torque and power output. On a prototype engine fundamental research activities were carried out on a driven flow test bench to optimize the volumetric efficiency by varying the influencing parameters. Subsequently the characteristics of different mixture preparation concepts (carburetor and fuel injection system) in combination with the treated supercharging concept have been studied during the development phase on engine test bench.

Sensor and object recognition technologies for self-driving cars

Autonomous driving functions for motorized road vehicles represent an important area of research today. In this context, sensor and object recognition technologies for self-driving cars have to fulfill enhanced requirements in terms of accuracy, unambiguousness, robustness, space demand and of course costs. The paper introduces different levels of automated driving functions according to the SAE standard and derives requirements on sensor technologies. Subsequently, state of the art technologies for object detection and identification as well as systems under development are introduced, discussed and evaluated in view of their suitability for automotive applications.

Generative engineering design methodology used for the development of surface-based components

ABSTRACTThe presented paper introduces a methodology of Generative Engineering Design of surface-based components in the automotive development and its general use. In addition, the required tools for the application of the presented method within complex CAD systems are described and discussed. Application of presented methodology is shown within the development of an exemplary class A surface of a sport vehicle front part. In the context it is shown, that Generative Engineering Design methodology provides an automatic adaptation of detailed design in case of styling modification, leading to automatically recreated linked features, e.g. component boundaries, if designers styling (CAS) is changed.