Slide 1

ME 531-Materials Perspective in Industrial Design

_ Energy efficient car design _1Bahar Basim- OzU Fall 2010Dr. Bahar Bamzyein UniversityMechanical Engineering

BackgroundMaterial Content of a CarDesignThe Manufacturing ProcessComponentsChassisBodyPaintInterior assemblyMateQuality ControlThe future

OutlineIn 1908 Henry Ford began production of the Model T automobile.

Based on his original Model A design first manufactured in 1903, the Model T took five years to develop.

Its creation inaugurated what we know today as the mass production assembly line.

This revolutionary idea was based on the concept of simply assembling interchangeable component parts.

Background- HistoryEnergy to produce cars/year= 0.8% to 1.5% of total energy consumed by nationEnergy to move cars/year= 15% of total energy consumed by nation

Transportation of people and goods (total)= 24% of total energy consumed by nation

Background-Energy and CarsHow to achieve energy economy

Improve engine efficiencyReduce the weight of the carAlternative engine and car designs

Background-Energy and Cars

Material Content- Contributors to the weight of car71% SteelBody shell, panels15% Cast ironEngine block; gear box; rear axle4% rubberTires; hosesBalanceGlass, zinc, copper, aluminum, polymersMaterial Content- Candidate materials for car bodies

Resistance to plastic flow

The lightest panel is with smallest (r/E1/3)Plastic yielding

We need a panel with smallest (r/sy1/2)

Material Content- Candidate materials for car bodiesMaterialDensity(d)Youngs Mod.EYield Srength syd/E1/3d/sy1/2Mild Steel7.82072201.320.53High-Strength Steel7.8207Up to 5000.35Aluminum Alloy2.7691930.660.19GFRP1.815750.730.21Material Content- Secondary propertiesPrimary:Resistance to deflectionPlastic yielding

SecondaryFracture toughnessFatigueCreepEnvironment

MaterialToughnessac (mm)FatigueCreepMild Steel100140OKOKHigh-Strength Steel10026OKOKAluminum Alloy2012OKOKGFRP3730OKCreep above 60oC

Material Content- Selection Introducing a new model of automobile generally takes three to five years from inception to assembly.

Ideas for new models are developed to respond to unmet public needs and preferences.

Trying to predict what the public will want to drive in five years is no small feat, yet automobile companies have successfully designed automobiles that fit public tastes.

With the help of computer-aided design equipment, designers develop basic concept drawings that help them visualize the proposed vehicle's appearance.

Based on this simulation, they then construct clay models that can be studied by styling experts familiar with what the public is likely to accept.

Aerodynamic engineers also review the models, studying air-flow parameters and doing feasibility studies on crash tests.

Only after all models have been reviewed and accepted are tool designers permitted to begin building the tools that will manufacture the component parts of the new model. DesignProduction Methods-Techniques

HandmadeMolding

The automobile assembly plant represents only the final phase in the process of manufacturing an automobileComponents are supplied by more than 4,000 outside suppliers, including; company-owned parts suppliersThose parts that will be used in the chassis are delivered to one area, while those that will comprise the body are unloaded at another

Production Methods- Parts The Manufacturing ProcessChassisBodyPaintInterior assemblyMateManufacturing Process-Chassis The typical car or truck is constructed from the ground up (and out). The frame forms the base on which the body rests and from which all subsequent assembly components follow. The frame is placed on the assembly line and clamped to the conveyer to prevent shifting as it moves down the line. From here the automobile frame moves to component assembly areas where complete front and rear suspensions, gas tanks, rear axles and drive shafts, gear boxes, steering box components, wheel drums, and braking systems are sequentially installed.

Manufacturing Process-Body

Generally, the floor pan is the largest body component to which a multitude of panels and braces will subsequently be either welded or bolted.

As it moves down the assembly line, held in place by clamping fixtures, the shell of the vehicle is built.

The front and rear door pillars, roof, and body side panels are assembled in the same fashion.

The shell of the automobile assembled in this section of the process lends itself to the use of robots because articulating arms can easily introduce various component braces and panels to the floor pan and perform a high number of weld operations in a time frame and with a degree of accuracy no human workers could ever approach

Once the body shell is complete, it is attached to an overhead conveyor for the painting process.Manufacturing Process-Pre Paint- CleaningPrior to painting, the body must pass through a rigorous inspection process.

The shell of the vehicle passes through a brightly lit white room where it is fully wiped down by visual inspectors using cloths soaked in hi-light oil.

Under the lights, this oil allows inspectors to see any defects in the sheet metal body panels.

Dings, dents, and any other defects are repaired right on the line by skilled body repairmen.

After the shell has been fully inspected and repaired, the assembly conveyor carries it through a cleaning station where it is immersed and cleaned of all residual oil, dirt, and contaminants. As the shell exits the cleaning station it goes through a drying booth and then through an undercoat dipan electrostatically charged bath of undercoat paint (called the E-coat) that covers every nook and cranny of the body shell, both inside and out, with primer.

This coat acts as a substrate surface to which the top coat of colored paint adheres.

After the E-coat bath, the shell is again dried in a booth as it proceeds on to the final paint operation.

In most automobile assembly plants today, vehicle bodies are spray-painted by robots that have been programmed to apply the exact amounts of paint to just the right areas for just the right length of time.

Considerable research and programming has gone into the dynamics of robotic painting in order to ensure the fine "wet" finishes we have come to expect.

Our robotic painters have come a long way since Ford's first Model Ts, which were painted by hand with a brush.

Once the shell has been fully covered with a base coat of color paint and a clear top coat, the conveyor transfers the bodies through baking ovens where the paint is cured at temperatures exceeding 275 degrees Fahrenheit (135 degrees Celsius).

Manufacturing Process-PaintingThe painted shell proceeds through the interior assembly area where workers assemble all of the instrumentation and wiring systems, dash panels, interior lights, seats, door and trim panels, headliners, radios, speakers, all glass except the automobile windshield, steering column and wheel, body weatherstrips, vinyl tops, brake and gas pedals, carpeting, and front and rear bumper fascias.

Next, robots equipped with suction cups remove the windshield from a shipping container, apply a bead of urethane sealer to the perimeter of the glass, and then place it into the body windshield frame.

Robots also pick seats and trim panels and transport them to the vehicle for the ease and efficiency of the assembly operator.

After passing through this section the shell is given a water test to ensure the proper fit of door panels, glass, and weather-stripping.

It is now ready to mate with the chassis. Manufacturing Process-Interior AssemblyThe chassis assembly conveyor and the body shell conveyor meet at this stage of production. As the chassis passes the body conveyor the shell is robotically lifted from its conveyor fixtures and placed onto the car frame. Assembly workers, some at ground level and some in work pits beneath the conveyor, bolt the car body to the frame.Once the mating takes place the automobile proceeds down the line to receive final trim components, battery, tires, anti-freeze, and gasoline.

Manufacturing Process-MateThe vehicle can now be started. From here it is driven to a checkpoint off the line, where its engine is audited, its lights and horn checked, its tires balanced, and its charging system examined. Any defects discovered at this stage require that the car be taken to a central repair area, usually located near the end of the line. A crew of skilled trouble-shooters at this stage analyze and repair all problems. When the vehicle passes final audit it is given a price label and driven to a staging lot where it will await shipment to its destination.

All of the components that go into the automobile are produced at other sites that means the thousands of component pieces that comprise the car must be manufactured, tested, packaged, and shipped to the assembly plants, often on the same day they will be used.This requires no small amount of planning. To accomplish it, most automobile manufacturers require outside parts vendors to subject their component parts to rigorous testing and inspection audits similar to those used by the assembly plants. In this way the assembly plants can anticipate that the products arriving at their receiving docks are Statistical Process Control (SPC) approved and free from defects. Quality ControlOnce the component parts of the automobile begin to be assembled at the automotive factory, production control specialists can follow the progress of each embryonic automobile by means of its Vehicle Identification Number (VIN), assigned at the start of the production line. In many of the more advanced assembly plants a small radio frequency transponder is attached to the chassis and floor pan. This sending unit carries the VIN information and monitors its progress along the assembly process. Knowing what operations the vehicle has been through, where it is going, and when it should arrive at the next assembly station gives production management personnel the ability to electronically control the manufacturing sequence. Throughout the assembly process quality audit stations keep track of vital information concerning the integrity of various functional components of the vehicle. Quality ControlThe development of the electric automobile will owe more to innovative solar and aeronautical engineering and advanced satellite and radar technology than to traditional automotive design and construction. The electric car has no engine, exhaust system, transmission, muffler, radiator, or spark plugs. It will require neither tune-ups nortruly revolutionarygasoline.Instead, its power will come from alternating current (AC) electric motors with a brushless design capable of spinning up to 20,000 revolutions/minute. Batteries to power these motors will come from high performance cells capable of generating more than 100 kilowatts of power.Unlike the lead-acid batteries of the past and present, future batteries will be environmentally safe and recyclable. Integral to the braking system of the vehicle will be a power inverter that converts direct current electricity back into the battery pack system once the accelerator is let off, thus acting as a generator to the battery system even as the car is driven long into the future. The Future- Electric CarsBorate Operated AutomobilesDaimler Crysler- NATRIUM (Hydrogen Fuel cells))

% 50 less fuel consumption

400 miles range

No emmission, produces water

Quiet

Easy maintanance

Operates at room temperature

%40 lighter engineThe Future- Alternative FuelsThe growth of automobile use and the increasing resistance to road building have made our highway systems both congested and obsolete. But new electronic vehicle technologies that permit cars to navigate around the congestion and even drive themselves may soon become possible. Turning over the operation of our automobiles to computers would mean they would gather information from the roadway about congestion and find the fastest route to their instructed destination, thus making better use of limited highway space. The advent of the electric car will come because of a rare convergence of circumstance and ability. Growing intolerance for pollution combined with extraordinary technological advancements will change the global transportation paradigm that will carry us into the twenty-first century.

The Future- Navigation improvementshttp://www.autoteknika.com/la-auto-show-maybach-drs-concept/

The vision of this concept was to produced a mode of transportation from a coded DNA-cocoon, encased in a complex organic metamorphosis.

The powertrain on this concept is a self balancing electric drive unit that is controlled via an on-board computer that communications with the city's transport infrastructure.

Futuristic indeed! Maybach is a division of Mercedes-Benz and the Maybach DRS Concept was envisioned by Mercedes-Benz Advanced Design Center in Japan and presented at the Design Challenge at the 2010 LA Auto Show. A two wheel vehicle that sports a massive self-balancing wheel system and is housed by an organic structure.

The Maybach DRS Concept draws is inspiration from the original human powered elitist form of transportation in Tokyo during the 1870's, the human powered rickshaw. The Future- Concept Cars

ReferencesAbernathy, William. The Productivity Dilemma: Roadblock to Innovation in the Automobile Industry. Johns Hopkins University Press, 1978. Gear Design, Manufacturing & Inspection Manual. Society of Manufacturing Engineers, Inc., 1990. Hounshell, David. From the American System to Mass Production. Johns Hopkins University Press, 1984. Lamming, Richard. Beyond Partnership: Strategies for Innovation & Lean Supply. Prentice Hall, 1993. Making the Car. Motor Vehicle Manufacturers Association of the United States, 1987. Mortimer, J., ed. Advanced Manufacturing in the Automotive Industry. Springer-Verlag New York, Inc., 1987. Mortimer, John. Advanced Manufacturing in the Automotive Industry. Air Science Co., 1986. Nevins, Allen and Frank E. Hill. Ford: The Times, The Man, The Company. Scribners, 1954. Seiffert, Ulrich. Automobile Technology of the Future. Society of Automotive Engineers, Inc., 1991. Sloan, Alfred P. My Years with General Motors. Doubleday, 1963.