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A Development and Evaluation of Optimal Fingerprint Authentication Algorithm in Vehicle Use Environment

Hyundai Motor Co & KIA Motors Corp-dae sung jin, Jungduck Son, Sangwoo Jeon
  • Technical Paper
  • 2020-01-0723
To be published on 2020-04-14 by SAE International in United States
Hyundai Motor Company mass-produced the world's first fingerprint entry and start system. This paper is a study on the evaluation method to develop and verify the optimal fingerprint authentication algorithm for vehicle usage conditions. Currently, fingerprint sensors and algorithms in the IT industry have been developed for the electronic devices, and are not suitable for the harsh environment of the vehicle and the vehicle life cycle for more than 10 years. In order to optimize the fingerprint sensor and algorithm for the vehicle, this study consisted of 3way test methods. As a result, the fingerprint system could be optimized for the vehicle and the recognition rate and security could be optimized according to the sensor authentication level. Through this study, the fingerprint entry and start system achieved the recognition rate development goal (door handle sensor recognition rate: 85% or more, start button sensor recognition rate: 90% or more) and achieved security that meets European immobilizer regulation
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A Research on Kinematic Optimization of Auto Flush Door Handle System

Hyundai Motor Group-JUNGHO HAN, KYOUNGTAEK Kwak, JINWOO NAM, OKTAE Jung, JINSANG CHUNG
  • Technical Paper
  • 2020-01-0623
To be published on 2020-04-14 by SAE International in United States
A fascinating exterior appearance is one of the most important values for customers so the realization of the innovative styling has been a major topic for car makers for several years. Also, since the base of autonomous driving and electric vehicle is being expanded recently, it is essential to not only create high-tech image on a vehicle but also realize the engineering design in reality. From that point of view, the auto flush handle can be unique sales point to enhance the degree of the completion of the exterior styling. The purpose of this study is to establish the kinematic system of auto flush door handle to overcome the exterior handicaps such as not only the excessive exposure of the internal area on the deployed position but also to determine the proper operating speed. In order to resolve these issues, the Scott-Russell mechanism is applied to the auto flush handle system. The mechanism is applied to realize the straight motion so exterior quality can be improved to minimize inner gap and prevent link exposure. In…
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A study on optimization of the cross-section of door impact beam for weight reduction

Hyundai Motor Company-HEEJIN IM
  • Technical Paper
  • 2020-01-0631
To be published on 2020-04-14 by SAE International in United States
This paper focuses on the optimization of the cross section of a member type impact door beam. The cross section of the beam was parameterized by using a geometry morphing tool FCM(Fast Concept Modeler) which plug in CATIA, and the metamodel of FE analysis results was created and optimized by LS-OPT. The ANOVA analysis of results was performed to find the factor of weight reduction. And then a new cross section concept was proposed to overcome the limitation of old structure. The proposed cross section was optimized to obtain the final cross section which has a weight reduction of 10% or more.
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A Robust Methodology for Predicting the Fatigue Life of an Automotive Closures System Subjected to Hinge and Check Link Load

Ford India Ltd-Sivasankari S
Ford India Pvt, Ltd.-Nirmal Puthuvayil
  • Technical Paper
  • 2020-01-0599
To be published on 2020-04-14 by SAE International in United States
Quality in the automotive industry symbolizes the development and the manufacturing of vehicles whose specifications meet customer requirements. Among the quality issues, opening and closing effort of any closures in a vehicle is a characteristic that strongly affects the customer first opinion about vehicle design. The closure opening and closing effort is affected by different uncertainties like opening angle, load to the check-link, hinge stoppage, materials and manufacturing process. A check stop & hinge stop load durability cycle occurs when a customer opens the closures beyond the closure detent position with a force applied on the check link or hinge check stops. Due to few uncertainties like abuse opening, manufacturing imperfections, weak mounting locations, the closures will be subjected to fatigue failure. The present study is aimed to introduce a probabilistic frame-work for fatigue life reliability analysis that addresses the uncertainties associated with door opening-closing effort due to check-hinge loads, door closure opening angles and hinge stop tolerance. A fatigue life probabilistic model of various closure systems was developed using Monte-Carlo simulation, where the stress…
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Robust assessment of automotive door structure by considering manufacturing variations

FCA Engineering India Pvt Ltd-Roshan N. Mahadule
FCA US LLC-RAJ NAMINENI, Parag NITTUR
  • Technical Paper
  • 2020-01-0910
To be published on 2020-04-14 by SAE International in United States
The automotive door structure experiences various static and dynamic loading conditions going through an opening and closing operation. A typical swing door is attached to the body with two hinges and a check strap. These mechanisms carry the loads while the door is opened. Similarly, when closing the door, the latch/ striker mechanism along with the seal around the periphery of the door react all loads. Typically, computer aided engineering (CAE) simulations are performed considering a nominal manufacturing (or build) tolerance condition. This results in one loading scenario but it is found that build variations in the various mechanisms mentioned above can result in different loading scenarios which should be evaluated. This paper discusses various tolerances that should be accounted for in the CAE simulations to generate a robust door assembly.
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Evaluation of Functional Performance of Mechanism using Multi Body Dynamics Simulation

CAE, VE Commercial Vehicles Ltd-Tanmay Jain
VE Commercial Vehicles Ltd-Srinivas Kurna
  • Technical Paper
  • 2020-01-0474
To be published on 2020-04-14 by SAE International in United States
Functional performance of mechanism plays a vital role in attracting the customer concentration towards the product. It is first interface for interaction with customer. Hence it is important to evaluate the functional performance at the time of design phase itself in order to eliminate the possibility of increase in proto-builds. Functional performance of a mechanism comprises of:- • Mechanism should perform its function for which it is designed. • Effort required to perform the function • Ease of functionality. Evaluation of such parameter at the design stage involves many assumptions and this brings chance variables in the methodology. In order to eliminate these assumptions we have developed a methodology using the multi body dynamic model of mechanisms like gear shifting mechanism and cabin door outer handle mechanism. We have evaluated the effort and displacement required to drive the mechanism and correlated the results with the practical testing about 90%. We have also utilized this methodology to quickly optimize the existing design and reduced the effort and displacement
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A finite element design study and performance evaluation of an ultra-lightweight carbon fiber reinforced thermoplastic composite vehicle door assembly

Clemson University-Anmol Kothari, Aditya Yerra, Madhura Limaye, Sai Aditya Pradeep, Gaurav Dalal, Gang Li, Srikanth Pilla
Honda R & D Americas Inc-Skye Malcolm, Duane Detwiler
  • Technical Paper
  • 2020-01-0203
To be published on 2020-04-14 by SAE International in United States
The ever-growing concern to reduce the impact of transportation systems on environment has pushed automotive industry towards fuel efficient and sustainable solutions. While several approaches have been used to improve efficiency, the light-weighting of automobile components has proven broadly effective. A substantial effort is devoted to lightweight body in white which contributes ~35% of total weight of the vehicle. Closure systems, however, have been often overlooked. Closure systems are extremely important as they account for ~ 50 % of the structure mass and have a very diverse range of requirements including crash safety, durability, strength, fit, finish, NVH, and weather sealing. To this end a carbon fiber reinforced thermoplastic composite door is being designed to enable 42.5% weight reduction for an OEM’s mid-size SUV steel door. In this work, several novel composite door assembly designs are developed by using an integrated design, analysis and optimization approach. A design optimization is performed to satisfy static load case requirements which represent daily use and misuse. The crashworthiness of the door assembly is assessed by considering three non-linear…
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The Aural Discomfort Analysis and Control In the Instant the Door Closes

Geely Automobile Research Institute-Mao Guang Jun, Youqiang Cao PhD, Jun Zhang PhD, Kaige Zhang PE, Gang Yang MD
  • Technical Paper
  • 2020-01-1260
To be published on 2020-04-14 by SAE International in United States
With the improvement of the vehicle air leakage performance, the aural discomfort phenomenon appeared in the instant the door closes. The studies for closing door sound quality have been occurred, but there is little literature on the study of the aural discomfort due to the air pressure fluctuation over a very short period of time. In this paper, the relationship between the air leakage under positive pressure and the aural discomfort based on the air pressure fluctuations in the instant the door closes was systematically studied through a large number of objective test and subjective evaluation of the vehicles. And this paper theoretically deduces the relationship of the air pressure fluctuation inside the car with the closing door speed, the ratio of door area to passenger compartment volume, the vehicle air leakage, the cross-sectional area of the vehicle, the decompression air vent area at the moment the door closes. Then the objective test data and CAE analysis validate completely the inference. In this paper, it puts forward the human aural comfort air pressure threshold value…
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Design optimization of passenger door in bus.

Daimler India Commercial Vehicles Ltd-Harikrishnan Srinivasan
Daimler India Commercial Vehicles Pvt Lt-Anil Kumar Cherukuri, Ananda S
  • Technical Paper
  • 2020-01-0909
To be published on 2020-04-14 by SAE International in United States
There are certainly many ways to achieve light weight within the strength and safety requirements. Common ones are to completely replace the existing material with higher yield strength material with a possible reduction in section thickness. The other one is to selectively replace conventional steel at specific areas. While the first approach with homogenous material has certain advantages in procurement and manufacturing, it is not optimal in the design perspective and results in higher costs. so same discussed here the approach of weight optimization by multi material for our passenger door leaf assembly.
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Robustness Design to Avoid Noise on Exterior Handle System

Ford Motor Company-Douglas Demori, Júlio Magalhães, Cristiane Carla Gonçalves, Helano Santos
  • Technical Paper
  • 2019-36-0137
Published 2020-01-13 by SAE International in United States
Squeak and rattle are two undesirable occurrences during component operation and during vehicle driving condition, resulting in one of the top complains from costumers. One common grievance could happen during the user exterior handle operation and during side door closing. The exterior handle system during the operation could generate a squeak between interface parts, if materials and geometric tolerances was not been carefully designed. Also, vibration generated during door closing effort, might generate squeak between parts since the reinforcement for exterior handle touches the outer sheet metal internally. For this reason several guidelines might be included to avoid potential noise condition for this system during vehicle lifetime as correct material reduce friction between parts, taking into consideration the geometric condition between parts. Plus, coupling system on handles two pieces should also be evaluated to avoid squeak during use. Not less important, if required anti-shock material system may be applied to eliminate a clash produced between parts during excessive vibration. It is extremely important to evaluate the environment that the vehicle will be exposed since the…
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