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DEVELOPMENT OF AN EPOXY CARBON FIBER REINFORCED ROOF FRAME USING THE HIGH PRESSURE RESIN TRANSFER MOLDING (HP-RTM) PROCESS

Hexion Inc.-Cedric A. Ball, Stephen Greydanus, Ian Swentek, Kameswara Rao Nara
  • Technical Paper
  • 2020-01-0773
To be published on 2020-04-14 by SAE International in United States
Composites technology for the automotive market continues to advance rapidly. Increasing knowledge of composite design, simulation tools, new materials and process equipment are all contributing to make composites better performing and more affordable for mass-produced vehicles. In particular, the high pressure resin transfer molding (HP-RTM) and related liquid compression molding (LCM) processes are enabling manufacturers to produce complex composite parts at shorter and shorter cycle times. This paper describes the development of an epoxy carbon fiber roof frame targeted for future vehicle production. Several composite processes were considered for the roof frame. The case illustrates that when the (product) design, material and process are considered together, a high-performing, cost-efficient part can be produced. The resulting carbon fiber roof frame met all OEM performance requirements and economic targets while weighing 44% less than the original design in magnesium and 32% less on the overall assembly. The part was the first HP-RTM part successfully demonstrated in North America and stands as a model for future lightweighting developments. Of equal significance, the development process for the part involved…
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Electric Vehicle Power Transfer System Using Conductive Automated Connection Devices Infrastructure-Mounted Pantograph (Cross-Rail) Connection

Hybrid - EV Committee
  • Ground Vehicle Standard
  • J3105/1_202001
  • Current
Published 2020-01-20 by SAE International in United States
This document details one of the connections of the SAE J3105 document. The connections are referenced in the scope of the main document SAE J3105. SAE J3105/1 details the infrastructure-mounted pantograph, or cross-rail connection. All the common requirements are defined in the main document; the current document provides the details of the connection. This document covers the connection interface relevant requirements for an electric vehicle power transfer system using a conductive ACD based on a cross-rail design. To allow interoperability for on-road vehicles (in particular, buses and coaches), one configuration is described in this document. Other configurations may be used for non-standard applications (for example, mining trucks or port vehicles).
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Buzz Avoidance on Sunroof Light Sunshades: Design and Validation

Ford Motor Company-Douglas Demori, Marcos Paulo de Oliveira, Rosiane Viegas
MSX International-Douglas França
  • Technical Paper
  • 2019-36-0148
Published 2020-01-13 by SAE International in United States
Sunroof is placed in certain high-end vehicles to give user a better driving experience. All automakers are searching alternatives to reduce weight and cost in the vehicle, in which sunroofs are also impacted. Some alternatives are already applied, as a honeycomb paper used in some sunshades that presents benefits, as less weight and with a good cost reduction. Although, due the reduced weight for this part produced in this material, it shows more susceptibility to reproduce the vibration that vehicle propagates in movement, especially in bad condition roads. The sunroof assembly is dependent of the roof reinforcement and roof skin, but in this special case, the validation could be done in the components itself because the interaction of the sunshades is directly dependent of the other sunroof parts, as rails and front frame. These buzz noise in lights sunshades is perceptible when it is almost or totally close, since lighter material vibrates freely without rail anchorage, then clashing against the front frame surface. Considering the package, the key point is to design the sunshade to…
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Rattle Evaluation: Sunroof Glass Against Roof Flange

Ford Motor Company-Douglas Demori, Fernando Camargo, Karine Chagas, Marcos Paulo de Oliveira, Thais Cardoso
Webasto Roof Systems Brasil Ltda-Oswaldo Tursi Neto
  • Technical Paper
  • 2019-36-0140
Published 2020-01-13 by SAE International in United States
Sunroof is installed in the vehicles to generate a better satisfaction for customer. Normally, the glass is maintained closed or fully opened, when the user would like to exterior air to get in. The glass runs in the sunroof rail that interacts directly with the roof skin and the roof reinforcement, where the whole sunroof structure is fixed. In general, sunroofs are equipped with two stages button, were the final or second stage, more used by users, allows the glass to move until the final position directly, without stops. Even though, the first stage could move the glass according user desire. For validation, the vehicle runs in several roads in order to capture any unusual response given by the sunroof. During specific test validation created, the glass was been positioned in the critical region that by design has the minimum distance against the roof flange. Consequently, to solve the issue found, all the possible interactions were measured as the roof profile, flange height, sunroof dimensions and sunroof installation. Hence, all boundary conditions must be under…
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Chevy reveals 2020 Corvette Stingray convertible, C8.R racer

Automotive Engineering: November/December 2019

Bill Visnic
  • Magazine Article
  • 19AUTP11_14
Published 2019-11-01 by SAE International in United States

Reinforcing the Corvette's long association with astronauts, Chevrolet unveiled the convertible version of its all-new, mid-engine-layout 2020 Corvette Stingray in Cape Canaveral in early October. Executive chief engineer Tadge Juechter, underscoring the car's no-compromises performance and comparatively affordable price, called it a “no-lose proposition” for enthusiasts considering the new Corvette but also desiring a more open-top experience. When it goes into production in the first quarter of 2020, the Corvette Stingray convertible will start at $67,495 - $7,500 more than the 2020 Stingray coupe, which was widely celebrated for its aggressive $59,995 base price.

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Implementation and Experimentation of Effective Clog Removal Method in Tractors for Enhanced Condenser Life and Air Conditioning Performance During Reaper Application

Mahindra & Mahindra, Ltd.-Gurpreet Singh, Prabhakaran Arumugam, Rakesh Sharma
Mahindra Research Valley-Shreekant Srivastava
Published 2019-10-11 by SAE International in United States
Tractors in the field are exposed to adverse operating conditions and are surrounded by dust and dirt. The tiny, thin and sharp broken straw and husks surround the system in reaper operation. The tractors which are equipped with air conditioning system tend to show detrimental effects in cooling performance. The compressor trips frequently by excess pressure developed in the system due to condenser clogging and hence cooling performance is reduced considerably. The air conditioning performance reduces due to the clogged condenser located on the top roof compartment of operator’s cabin, which is better design than keeping in front of radiator where clogging happens every hour and customer need to stop the tractor to clean it with specific blower. The present system is designed keeping condenser at the top of the roof where heavy particles won’t reach easily, So, condenser choking/clogging is observed every 2 hours, this makes the operator to perform repetitive cleaning operations with specific equipment and is a time-consuming process. The present system utilizes the condenser fan operating logic to eliminate this issue…
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Study of Energy Absorbing Front Cabin Mount, Its Stiffness Balance with Chassis and Test Correlation in Frontal Impact of Commercial Vehicle Cabin

Mahindra & Mahindra, Ltd.-Avinash Dhole, Rishi Shrivastava, Chetan Raval
Published 2019-04-02 by SAE International in United States
During design and development of a cabin for any commercial vehicle, meeting the strength requirements of front impact as per Indian regulation (AIS-029) is a very critical milestone. AIS-029 regulation consists of three destructive tests, i.e. Front Impact Test (Test A), Roof Strength (Test B) and Rear Wall Strength (Test C). Study of energy absorbing front cabin mount, its stiffness balance with chassis and CAE correlation with physical test is demonstrated in this study. [1]
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Automatic Speech Recognition System Considerations for the Autonomous Vehicle

Ford Motor Co., Ltd.-Joshua Wheeler
Published 2019-04-02 by SAE International in United States
As automakers begin to design the autonomous vehicle (AV) for the first time, they must reconsider customer interaction with the Automatic Speech Recognition (ASR) system carried over from the traditional vehicle. Within an AV, the voice-to-ASR system needs to be capable of serving a customer located in any seat of the car. These shifts in focus require changes to the microphone selection and placement to serve the entire vehicle. Further complicating the scenario are new sources of noise that are specific to the AV that enable autonomous operation. Hardware mounted on the roof that are used to support cameras and LIDAR sensors, and mechanisms meant to keep that hardware clean and functioning, add even further noise contamination that can pollute the voice interaction. In this paper, we discuss the ramifications of picking up the intended customer’s voice when they are no longer bound to the traditional front left “driver’s” seat. Considerations are made to the possibilities of new microphone construction and layouts to provide coverage for all potential passengers, and cost-efficient minimal microphone packages are…
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Aerodynamic Analysis of Passenger Car with Luggage Carrier (Roof Rack)

Pranav Anil Hol
Automotive Research Association of India-Mohammad Rafiq Agrewale
Published 2019-01-09 by SAE International in United States
Any change is vehicle exterior design, affects the aerodynamics characteristic. Generally different types of roof racks are attached on passenger vehicles to carry luggage which affects aerodynamic drag. The objective of this work is to perform aerodynamic analysis of ground vehicle with roof rack to investigate the change in drag coefficient. First, the aerodynamic analysis of a baseline passenger car model is performed with and without generic benchmarked roof rack at 100 kmph. Further analysis is carried out with different new designs of roof racks. Based on simulation result, a scaled down prototype model is fabricated and validated by using a wind tunnel test for optimum suitable case. The modelling of the vehicle is done in CATIA tool and simulation is carried out by using ANSYS Fluent. The results show maximum drag reduction of around 9% with new design of roof rack as compared to the benchmarked roof rack which improves the fuel economy around 18% when compared to a benchmarked roof rack.
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Explosion in compute power enables automated driving

Automotive Engineering: September 2018

Sam Abuelsamid
  • Magazine Article
  • 18AUTP09_04
Published 2018-09-01 by SAE International in United States

This summer I've been reading a preview copy of Autonomy: The Quest to Build the Driverless Car. Penned by former GM R&D chief Larry Burns with co-author Christopher Shulgan, the book is both a personal memoir and a chronicle of the birth of the modern automated vehicle. It's been more than a decade since I first rode in an AV, the Chevrolet Tahoe dubbed “Boss” which was built by the Tartan Racing team from Carnegie Mellon University.

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