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DFSS Approach for Evaluating Damage Resistance of Molded-in-Color Interior Trim and its Effect on the Customer Perceived Quality Experience

FCA US LLC-Sumant Joshi, Ewa M. Lebert
  • Technical Paper
  • 2020-01-1102
To be published on 2020-04-14 by SAE International in United States
Molded-in-color thermoplastics used in vehicle interior trim applications have functional requirements for both performance and appearance. Material selection for interior components, such as door panels, door sills, console panels, hard trim and instrument panels, take into consideration these aspects for meeting functional as well as perceived quality requirements. Polyolefin-based materials are commonly used in these applications and can vary from unfilled polypropylene copolymers to highly engineered systems designed for occupant impact applications. While the material performance of these different approaches is well understood, maintaining the appearance of components influences the customer perceived quality experience. The material performance assessments quantifying this experience can be related to measurable color durability metrics that include resistance to damage, fade, fluid/chemical, soiling and cracking. The customer perceived quality of interior materials that is reflected in JD Power IQS question INT40 “Materials Scuffs/Soils Easily” has been further evaluated in this paper using statistical analysis and Design for Six Sigma (DFSS) tools. To facilitate a JDP INT 40 improvement initiative, an in-depth narrative analysis was done to identify the most susceptible interior…
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Parametric Modelling and Performance Analysis of HVAC Defroster Duct Using Robust Optimization Methodology

FCA Engineering India Pvt Ltd-Nagababu Garikipati
FCA Engineering India Pvt, Ltd.-Mohsin Khan
  • Technical Paper
  • 2020-01-1250
To be published on 2020-04-14 by SAE International in United States
Thermal comfort and safety of automotive passengers are the most important factors in the development of the automotive HVAC system. HVAC system is responsible for the demisting and defrosting of the vehicle’s windows and for creating/maintaining a pleasant environment inside the cabin by controlling airflow and temperature. Fog or ice which forms on the windshield is the main reason for invisibility and leads to major safety issue to the customers while driving. It has been shown that proper clear visibility for the windshield could be obtained with a better flow pattern and uniform flow distribution in the defrost mode of the HVAC system and defrost duct. Defroster performance has received significant attention from OEMs to meet the specific global performance standards of FMVSS103 and SAE J902. Therefore, defroster performance is seriously taken into consideration during the design of HVAC system and defroster duct. The HVAC unit provides hot air to the defroster duct which is blowing high velocity air to the windscreen to clear the frosting. Currently as a traditional defrost duct design process, multiple…
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Optimization of engine mounting system for first gear marching judder

Tata Motors Ltd-Shreyash Borole, Sandip Hazra, Dhananjay Gadve
Tata Motors, Ltd.-Sagar Ramchandra Deshmukh
  • Technical Paper
  • 2020-01-0416
To be published on 2020-04-14 by SAE International in United States
Normal engine mounting system is designed to bear loads of powertrain in all driving conditions and also isolate the vibrations of powertrain. Softer mounts are good for vibration isolation but it is not recommended to have softer mounts because durability will be affected adversely. Optimum stiffness needs to be finalised which will have balance between durability and performance. In addition to durability many performance parameters needs to be checked during the time of development. This study includes the development of engine mounting system for elimination of drive away judder in first gear. Maximum peak torque value for the drive-away event: typical value is 80Nm - 120Nm. In the worst case, this peak torque can reach a maximum of 170Nm depending on maneuver. RPM is around 1100-1200. Steering wheel, instrument panel and whole vehicle cabin will vibrate for few seconds and then vehicle will run smoothly. To eliminate this issue various iterations were done in the mounting system and solution is selected which has no marching judder in 1st gear. A 16DOF rigid body model is…
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Footrest Design to Reduce Lower Leg Injury in Frontal Crashes

General Motors do Brazil-Tsuguo Eduardo Kimura, Gilvan Prada Rossi, Paulus Hanser de Freitas
  • Technical Paper
  • 2019-36-0090
Published 2020-01-13 by SAE International in United States
The frontal impact is the most common vehicle crash type in accidents involving cars. During a vehicle frontal impact, the injuries are caused by occupant body moving forward and impacting the vehicle interior parts. The performance of the vehicle body and the interior parts design may influence on the occupant injury levels. Injuries in the occupant lower body are usually affected by the vehicle lower body deformation and the design of the interior lower parts (lower instrument panel, pedals, floor and footrest). When the purpose is to reduce the injury of a specific body region, the modification of the interior part design can be more effective in terms of impacts in mass, costs and development time than a modification in the vehicle body. The objective of the study was to develop a new footrest design to reduce the injury level of the left driver leg in a frontal crash condition. It was also evaluated the influence of the vehicle body deformation on the driver leg injury. There were manufactured footrest prototypes with different shapes and…
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Implementation, Improvement and Statistical Validation of Scoring by Milling Process on an Instrument Panel with In-Mold Grain Lamination

Ford Motor Company-Caio V. Bertolini, Fábio Koki, Renato Veiga, Leandro Quinelato
  • Technical Paper
  • 2019-36-0155
Published 2020-01-13 by SAE International in United States
This paper starts describing the in-mold grain lamination and bilaminated film cover when applied to instrument panels with seamless passenger air bag doors. It then offers a comparison between two different PAB door weakening processes, the laser scoring and the scoring by milling. It further discuss the scoring by milling process and analyses its implementation on a real case instrument panel. In the implementation case, the scoring pattern is checked against a pre-defined engineering specification and correlated to the results of a drop tower test, which shows the force necessary to break the PAB door. Three iterations are performed until the results for scoring pattern and breaking force are achieved. The breaking force results are then statistically validated against the specification and capability analysis.
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SAE J2450 Supplemental Training Document

Vehicle E E System Diagnostic Standards Committee
  • Ground Vehicle Standard
  • J2450/1_201910
  • Current
Published 2019-10-31 by SAE International in United States
This supplement, which is a living document, is meant to provide both clients and translation suppliers with some suggestions for integrating SAE J2450 into their business practices. It is intended for the use of clients, trainers who wish to develop new evaluators, and those who wish to self-train.
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Crew Station Lighting - Commercial Aircraft

A-20A Crew Station Lighting
  • Aerospace Standard
  • ARP1161B
  • Current
Published 2019-10-18 by SAE International in United States
This SAE Aerospace Recommended Practice covers the recommended requirements for the lighting and characteristics of instruments; information plates and displays, emergency, cautionary, advisory and status displays; circuit breaker and toggle switch positions; and the recommended requirements for the utility lighting system.
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Design Guidelines for Fiberboard Materials

Textile and Flexible Plastics Committee
  • Ground Vehicle Standard
  • J1774_201909
  • Current
Published 2019-09-25 by SAE International in United States
This document provides information on the various fiberboard products, which are available for automotive application. It is intended to give engineers and designers a better understanding of product usage, characteristics, properties and industry terminology. The following sections cover these topics: 2 General Product Information 3 Design Characteristics 4 Physical/Mechanical Properties 5 Fiberboard Definitions In sections 2, 3 and 4 the fiberboard products are categorized. These sections give an overview of product types, with general information about characteristics and properties. In cases where product categories encompass more than one material or material grade, ranges were established to cover all of the products in that category. The individual companies that supply fiberboard products should be consulted for specific information about a particular product or application.
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Flight Deck Lighting for Commercial Transport Aircraft

A-20A Crew Station Lighting
  • Aerospace Standard
  • ARP4103A
  • Current
Published 2019-09-17 by SAE International in United States
This document recommends design and performance criteria for aircraft lighting systems used to illuminate flight deck controls, luminous visual displays used for transfer of information, and flight deck background and instrument surfaces that form the flight deck visual environment. This document is for commercial transport aircraft except for applications requiring night vision compatibility.
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A Resonant Capacitive Coupling WPT-Based Method to Power and Monitor Seat Belt Buckle Switch Status in Removable and Interchangeable Seats

SAE International Journal of Advances and Current Practices in Mobility

Ford Motor Co.-Mark Cuddihy
Solace Power Inc.-Brian Pottle
  • Journal Article
  • 2019-01-0465
Published 2019-04-02 by SAE International in United States
In this study, we present an intelligent and wireless subsystem for powering and communicating with three sets of seat belt buckle sensors that are each installed on removable and interchangeable automobile seating. As automobile intelligence systems advance, a logical step is for the driver’s dashboard to display seat belt buckle indicators for rear seating in addition to the front seating. The problem encountered is that removable and interchangeable automobile seating outfitted with wired power and data links are inherently less reliable than rigidly fixed seating, as there is a risk of damage to the detachable power and data connectors throughout end-user seating removal/re-installation cycles. The present study tackles this issue through outfitting three removable and interchangeable rear seat assemblies with resonant capacitive coupling wireless power transfer as to power each rear seat across a variable gap between the interior paneling and that side of the seat closest to the interior paneling. A fundamental design challenge this system presented was the need to develop a rugged method to account for different sizes of seating, and hence…
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