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Obieglo, Andreas
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Conceptual Development of Automotive Forward Lighting System Using White Light Emitting Diodes

SAE International Journal of Passenger Cars - Electronic and Electrical Systems

BMW Manufacturing Co-Andreas Obieglo
Clemson University-Beshoy Morkos, Prabhu Shankar, Sudhakar Teegavarapu, Ashwin Michaelraj, Joshua D. Summers
  • Journal Article
  • 2009-01-0593
Published 2009-04-20 by SAE International in United States
This paper focuses on redesigning the headlamp subsystem functional architecture. The design involves meeting three major functional requirements: Achieving the lumen requirements according to Economic Commission for Europe (ECE) 324 regulations, Meeting the illumination pattern, and Maintaining the Light Emitting Diode’s (LED) junction temperature at 90°C. White LEDs are considered in the design to satisfy the functional requirements due to their high lumen efficacy, compact size, and long life. These benefits, when compared to existing headlight systems benchmarked, present enough potential to warrant further conceptual virtual prototyping. The prototyping focused on solutions that allowed control of sizing and numbering of LEDs, illumination pattern limits, and temperature to achieve the multiple functions a dynamic headlight system. A primary challenge in this design is to maintain the LED’s junction temperature within a recommended operational range. A conceptual design is presented with metal foam meta-material which act as both a heat exchanger to maintain the LED’s junction temperature and a structural member. The metal foam design also exploits the environmental conditions of the vehicle operation to meet the…
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Compliant Link Suspension

BMW Group USA-Andreas Obieglo
Clemson University-John C. Ziegert, Beshah Ayalew, Vincent Lee, Souharda Raghavendra
Published 2009-04-20 by SAE International in United States
This paper discusses a compliant link suspension concept developed for use on a high performance automobile. This suspension uses compliant or flexible members to integrate energy storage and kinematic guidance functions. The goal of the design was to achieve similar elasto-kinematic performance compared to a benchmark OEM suspension, while employing fewer components and having reduced mass and complexity, and potentially providing packaging advantages. The proposed suspension system replaces a control arm in the existing suspension with a ternary supported compliant link that stores energy in bending during suspension vertical motion. The design was refined iteratively by using a computational model to simulate the elasto-kinematic performance as the dimensions and attachment point locations of the compliant link were varied, until the predicted performance closely matched the performance of the benchmark suspension. A mock-up of the proposed compliant link suspension was built together with an adjustable test fixture, and experiments were carried out to validate the results from simulations. The new suspension is less complex and weighs less than the original suspension without sacrificing basic elasto-kinematic performance.
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A Morphological, Combinatory Tool for Design of Low-Gap Automotive Body Panels

BMW Manufacturing Co-Andreas Obieglo
Clemson University-Sudhakar Teegavarapu, Prabhu Shankar, Ajit S. Kanda, Beshoy Morkos, Ashwin Michaelraj, Joshua D. Summers
Published 2009-04-20 by SAE International in United States
This paper proposes a conceptual design tool that could direct designers towards concepts that lead to reduced gaps on the exterior of an automobile. Apart from the manufacturing and assembly tolerance stack up, the design and integration method of the body panels in an automobile contribute to the gap. . A benchmark study suggested cursory concepts to avoid or minimize the gaps. The proposed design tool uses a modified morphological chart approach to populate a table with concepts obtained from the benchmark study and by other means. The design tool also incorporates decision alternatives and hence is different from a morphological chart. The design tool can be used to highlight the occurrence of a high level tolerance stack up chain on the structural/mounting members. Conceptual component architectures are arranged in such a fashion to facilitate combinations through visual means. The tool enables quick, visual qualitative analyses to determine the number of interfaces, influential components, affected components, and identification of possible source of higher tolerance. A graphical representation scheme is also proposed to further visualize the…
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