The application of Advanced Driver Assistance Systems (ADAS) in commercial vehicles marks significant challenges in mechanical design and digital validation of externally mounted sensor systems. Blind Spot Assist (BSA), a radar-based ADAS feature, depends on accurate sensor alignment and stable bracket mounting to ensure reliable detection of objects within the vehicle’s blind spots. the exposure to dynamic loading environments, BSA radar brackets must be designed to withstand operational vibrations and also should comply with international automotive standards, including ISO 16750-3 [1, 7], which outlines test procedures of mechanical vibration and shock.
This paper describes a digital approach for the development of BSA radar brackets, incorporating system-level design thinking, flexible-body simulation, and vibration analysis. The method is combination of physical behavior with simulation techniques to study bracket behavior for dynamic loads and identifying probable sources of structure resonance and the interaction of the system with neighboring systems or components.
A multi-dimensional design process is highlighted, where multiple iterative modeling, cross-functional teams brainstorming, and virtual validation enables the efficient exploring of alternate designs. The framework supports countermeasure studies such as geometry optimization, boundary condition refining, and system decoupling, with digital development.
This approach is applicable for a wide range of ADAS sensor mounts challenges faced in heavy-duty vehicles, where the packaging constraints, harsh operating conditions, and NVH (Noise, Vibration, Harshness) requirements must be considered. This paper shows a replicable model for engineering teams to improve sensor stability, reduce physical testing and simulation cycles, and ensure compliance with vibration standards from the design evolved from simulations.