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Stebbins, Mark
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N&V Component Structural Integration and Mounted Component Durability Implications

General Motors LLC-Mark Stebbins, Joseph Schudt
  • Technical Paper
  • 2020-01-1396
To be published on 2020-04-14 by SAE International in United States
Exterior component integration presents competing performance challenges for balanced exterior styling, safety, ‘structural feel’ [1] and durability. Industry standard practices utilize noise and vibration mode maps and source-path-receiver [2] considerations for component mode frequency placement. This modal frequency placement has an influence on ‘structural feel’ and durability performance. Challenges have increased with additional styling content, geometric overhang from attachment points, component size and mass, and sensor modules. Base excitation at component attachment interfaces are increase due to relative positioning of the suspension and propulsion vehicle source inputs. These components might include headlamps, side mirrors, end gates, bumpers and fascia assemblies. Here, we establish basic expectations for the behavior of these systems, and ultimately consolidate existing rationales that are applied to these systems. We consider a simple two degree-of-freedom system subject to a base excitation consisting of masses attached via springs and dampers. Component mode decoupling, vibration amplification and basic design guidance relationships are suggested.
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Customer Perception of Road-Induced Structural Feel

General Motors LLC-Mark Stebbins, John Cafeo, Mark Beltramo
  • Technical Paper
  • 2020-01-1080
To be published on 2020-04-14 by SAE International in United States
Structural feel, or “vehicle feels solidly built” is a subjective measure that traditionally has been assessed by technical experts and executives. Vehicle programs’ timing and viability can be affected by these assessments. Objective measures would improve the vehicle development process. The first step in developing objective measures is to assess whether road-induced structural feel can be sensed by the customer. To this end, an internal drive clinic was conducted and proved to be an effective approach for obtaining customer perception of structural feel. Vehicles that spanned a range of excellent to poor structural feel were chosen by experts as part of the experimental design. The non-expert participants rank-ordered the vehicles’ structural feel performance in the order determined a priori by the experts. Results also indicate that the question “vehicle feels solidly built” is a good overall question for assessing structural feel.
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Dynamic Impact Transient Bump Method Development and Application for Structural Feel Performance

General Motors LLC-Mark Stebbins, Daryl Poirier, Rene Robert, Andrew Hornbrook
  • Technical Paper
  • 2020-01-1081
To be published on 2020-04-14 by SAE International in United States
Road induced structural feel “vehicle feels solidly built” is strongly related to the vehicle ride [1]. Excellent structural feel requires both structural and suspension dynamics considerations simultaneously. Road induced structural feel is defined as customer facing structural and component responses due to tire force inputs stemming from the unevenness of the road surface. The customer interface acceleration and noise responses can be parsed into performance criteria to provide design and tuning vehicle integration program recommendations. A dynamic impact bump method is developed for vehicle level structural feel performance assessment, diagnostics, and development tuning. Current state of on-road testing has the complexity of multiple impacts, averaging multiple road induced tire patch impacts over a length of a road segment, and test repeatability challenges. A transient impact response method is developed that consists of a totally observed single input at the tire interface and vehicle response, enabling time or frequency domain data processing with minimal signal processing errors. This method is adapted to the ADAMS multi-body dynamics CAE environment. Simplified vehicle integration concept case studies are assessed…
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Estimation of a Structure's Inertia Properties Using a Six-Axis Load Cell

University of Cincinnati-Mark Stebbins, Jason Blough, Stuart Shelley, David Brown
Published 1997-05-20 by SAE International in United States
A new method to estimate a structure's inertia properties using a prototype load cell designed to measure all loads and moments applied to a structure is presented. This prototype six-axis transducer approach employs 32 piezoelectric sensing elements which are arranged to form the load cell. These redundant measurements are used to determine the principal forces and moments from an overdetermined set of equations. Calibration of this multi-crystal load cell is performed with a fixture that utilizes a calibration mass and quasi-free-free boundary conditions. The resulting calibration matrix is a 6×32 transformation from the coupled measurements to a decoupled set of pseudo measurements consisting of the forces acting on a structure. With this transducer and its calibration matrix, a system's inertia properties can be estimated. A thorough discussion of both the calibration and inertia estimation procedure with a experimental test case is presented.
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