Browse Topic: Exteriors
Modern defense manufacturing and sustainment require timely engineering decisions (e.g., inspection triage, rework/accept decisions, and process adjustment) based on the as-built geometric quality. Advanced machining systems generate rich multichannel controller and sensor streams, yet accurate geometric deviation labels remain costly and delayed because they depend on downstream metrology. This paper introduces ChronosGD, a retrieval-based virtual metrology framework. ChronosGD predicts pointwise geometric deviation from multichannel time series data by: (1) retrieving the most similar historical process windows in a frozen Chronos-2 embedding space, and (2) transferring deviation information through similarity-weighted aggregation. ChronosGD avoids plant-specific gradient retraining during deployment; adaptation is achieved by refreshing a labeled historical memory as new inspected parts become available, while preserving traceability through explicit neighbor provenance.
Engineers designing pivot points for outdoor and heavy-duty equipment have long accepted the familiar routine: grease it, run it, regrease it and repeat. This approach may work well enough. But as equipment pushes into harsher environments and tighter service windows, “well enough” is no longer the standard. Maintenance-free pivots - pivots that run dry, resist corrosion and hold their tolerances through seasons of hard use - offer an increasingly compelling alternative. Designing one requires rethinking what a pivot point actually is, with most engineers focusing only on the bearing itself. While this instinct is understandable, it's also incomplete. A pivot consists of a bearing, shaft and housing working together, requiring a systems-level approach. Optimize only one element and you may still end up with a failure.
Engineers and designers might approach a new vehicle program from different angles. At Saint-Gobain Sekurit's new Imagine Lab though, the two disciplines work together from a fresh sheet when it comes to new vehicle glass and glazing options. Sekurit built the Imagine Lab co-development space with the Paris-based Meaningful design studio. The Lab is a modular space that Sekurit can set up at an OEM's design center, with stations set up to showcase Sekurit's new glass and glazing technologies. But, more than that, it's intended to be a space for free thinking, at least at first. Meaningful founder Marine RouitLeduc told SAE Media that all too often, when presented with a somewhat out-there glass idea, engineers believed that it wasn't feasible. “But they don't know all the opportunities that glass can offer,” she said. “We, with our R&D expertise, sometimes [agree] and say no, because we are an engineering company, but sometimes we [know we] can explore with them and push, a little bit, the boundaries.”
The malfunction of the aircraft windshield electric heating system, particularly arc discharge, poses a serious threat to flight safety by causing glass breakage. A systematic study was conducted on the causes and effects of arc faults on windshield structural integrity, employing macroscopic observation, microscopic analysis, and energy dispersive spectroscopy (EDS) following a windshield fracture incident. The results indicate that arc discharge typically occurs at the interface between the heating film busbar and adjacent structures. Localized high temperatures cause the outer glass to fracture, generating radial cracks. The ablation of the busbar silver coating and the carbonization of the PVB interlayer are direct evidence of arc action, whereas the heating wire remains a passive component affected by the high-temperature environment. The fault is primarily attributed to local disbonding at the busbar interface and moisture ingress. Based on the findings, recommendations are proposed for process optimization and inspection method improvement, providing a basis for the safe design and maintenance of windshield structures.
Passive fatigue can cause accidents with automated and regular vehicles. A proof-of-concept prototype [made with light-emitting diode (LED) matrices and white LED (WLED)] and a preliminary comparative usability test (N = 7) are used to study whether the active manipulation of simulated weather cues can be a potential countermeasure to passive fatigue. Participants rated system suitability, system impression, and their fatigue level similarly when they viewed a weather windshield heads-up display (HUD) versus a speedometer windshield HUD [no significant differences found and relatively small 95% confidence interval (CI) ranges around 0]. Qualitative analysis of interviews found that participants saw the potential value of the weather display and that display placement, dynamic graphics, and user activation were commonly mentioned themes. These results suggest the concept is theoretically possible, though further work is needed to prove the concept in practice.
Recent studies indicate that the door system plays a significant role in the interior noise levels of newly developed vehicles. This research investigates the noise transmission paths through the door system and identifies effective strategies for improvement through a combination of door buck testing and simulation. Specifically, in this study, the finite element method (FEM) was employed for door buck simulation, and the model was validated against vibration test results. Subsequently, acoustic analysis tools were utilized to correlate with noise testing, thereby establishing a process to ensure simulation accuracy. The sound insulation performance for the main areas of the door was experimentally evaluated, and a simulation model with good correlation to these test results was developed. By utilizing both experimental and simulation results, the principal transmission paths were identified, and appropriate improvement strategies for these paths were investigated. The validated improvement strategies are intended to be applied in the development of next-generation vehicles.
Precision agriculture, also known as smart farming, was once reserved for early adopters or large-scale operations, but is now an expectation within the farming industry. Across various regions and farm sizes, smart farming techniques are changing the way crops are planted as well as how they are monitored and harvested. However, farmers today are under increasing pressure to reduce labor, decrease chemical inputs, conserve water and operate in tighter windows. Couple this with factors such as narrow seasonal windows, productivity demands and safety considerations, and the need for smarter decisions becomes imperative. Going one step further, global food demands and environmental pressures are further increasing demand for precise, accurate and intelligent farming solutions.
The payload fairing of a launch vehicle is subjected to extremely high acoustic loads, with peak levels occurring during lift-off and transonic aerodynamic regimes. The external acoustic field penetrates the fairing, producing intense internal sound pressure levels that can challenge the integrity of spacecraft components. Accurate characterization of the vibroacoustic behavior of the payload fairing and its enclosed cavity is therefore essential to ensure spacecraft survivability. The internal acoustic field is governed by the coupled dynamics of the fairing structure and the spacecraft configuration, making it critical to quantify the acoustic environment for different payload arrangements. This study presents a detailed vibroacoustic analysis of a payload fairing with multiple spacecraft configurations to evaluate the resulting internal sound pressure distribution. Vibroacoustic finite element analysis is employed in the low frequency range, while statistical energy analysis is utilized for mid and high frequency ranges. Representative models are developed, and the predicted structural and acoustic responses are validated against experimental acoustic test measurements. The validated models are subsequently extended to other spacecraft configurations to perform sensitivity studies. The influence of various parameters on the internal sound pressure levels is assessed, and the resulting perturbations across frequency bands are quantified. The outcome of this study provides a comprehensive understanding of the internal acoustic environment within payload fairing, aiding in the specification of qualification acoustic test level for spacecraft.
Helicopter tail shake constitutes a significant limitation to both passenger comfort and aircraft stability. Under powered descent conditions, elevated Angle of Attack (AoA) cause flow separation around the rotor hub and engine cowling, leading to the development of an unsteady wake dominated by large-scale turbulent structures. To support the helicopter tail shake phenomenon investigation, a dedicated Particle Image Velocimetry (PIV) experimental setup was designed in this work, together with four aerodynamic devices aimed at mitigating tail shake. These components were then tested through a wind tunnel campaign with the PIV setup. The proposed aerodynamic components were conceived to either deflect the hub wake away from the tail empennages or to decrease the Turbulent Kinetic Energy (TKE) within the wake. To achieve these objectives, a dorsal fin, a horse-collar, and two spoiler configurations inspired by automotive applications were designed and experimentally evaluated. The devices were tested both as standalone solutions and in combined arrangements on a scaled helicopter wind tunnel model featuring a rotating hub and blade shanks. The vertical velocity component, was used as an indicator of wake deflection, and the Turbulent Kinetic Energy was used as an indicator of wake turbulence. The Horse Collar and the Large Spoiler showed a reduction in both indicators suggesting possible tail shake mitigating capabilities, and additional improvements were achieved when the two devices were deployed in combination.
The paper presents the successful drag reduction of the Racer demonstrator's rotor head through its innovative full fairing, based on a robust de-risking methodology leveraging 2D Robust Design Optimization (RDO) for airfoils, 3D CFD analysis with multiple fidelity levels, and experiments. We provide a unique end-to-end comparison across the full development cycle, correlating simulation predictions with both experimental and flight-test data. The fully faired architecture achieves a significant 42% reduction in rotor-hub form drag. At the full-vehicle level, flight tests confirm a 10% net drag reduction, including complex interactions with the airframe. This real-world measurement correlates highly with dynamic URANS predictions (11-12%), while effectively contextualizing the more optimistic 16% gains observed during static wind-tunnel and steady RANS evaluations. These findings provide a comprehensive validation of the low-drag fairing concept, offering valuable insights for the aerodynamic design of future high-speed rotorcraft.
Prior work demonstrated that acceleration washout in motion simulators produces decay-rate sensing ambiguity within the vestibular system, forcing pilots to rely on visual cues for control. While Pilot Induced Oscillation Ratings (PIORs) for flight and simulation have been matched using different sensing thresholds, a quantitative basis for the 50% reduction in the visual decay-rate threshold has remained elusive. This paper provides evidence that pilots perceive decay rate proprioceptively through stick force during both flight and simulation, rather than through vestibular or visual channels. The residues of the stick-force sensitivity transfer function reflect the amplification or attenuation of neighboring zeros and poles; when these residues fall outside the human's 30 dB tactile sensory window, the resulting decay rate becomes imperceptible. Modeling reveals that stabilization via the visual channel in simulators produces dominant mode characteristics - decay rates, frequencies, and residues - that diverge significantly from vestibular-stabilized flight. The Virtual Vestibular Cueing (VVC) technique is introduced to tune the visual channel using pseudo-vestibular rate cueing, optimally aligning the simulated dominant mode with flight-validated residues and decay rates. A preliminary fixed-base study demonstrates that VVC synchronizes performance and subjective ratings by restoring this tactile-vestibular harmony. This work establishes that handling qualities are fundamentally an Information Theory problem: Level 1 ratings occur when the residue-to-decay gradient is tuned to map the dominant mode's physical 'elbow' onto the human sensory window. This paper establishes that perceptual fidelity is not determined by the closed-loop vehicle residues, but by the force sensitivity residues. By identifying the stick-force channel as the superior conduit for this mapping, VVC allows designers to restore informational integrity in virtual environments across all axes of aircraft dynamics. VVC ensures that the visual channel supports a control strategy where the tactile feedback remains within the human sensory window, preventing the 'wrong reading' that leads to simulator-to-flight rating mismatches.
This study investigates the use of the Overset mesh method for propeller simulations in OpenFOAM and compares it with the Arbitrary Mesh Interface (AMI) approach. While AMI is well validated for rotor aeroacoustics, it is limited in handling large relative motions and complex component interactions. In contrast, the Overset method enables flexible simulation of transition kinematics using overlapping grids, though its aeroacoustic capability in OpenFOAM has not been well established. A comparative analysis was conducted on a Joby-scale five-bladed propeller at an 80° tilt angle without a fairing, representing a transition-flight condition. Aerodynamic and acoustic predictions were obtained using hybrid DDES coupled with the Ffowcs Williams–Hawkings method. Results show that the Overset method provides improved agreement with experimental thrust and torque and captures stronger leading-edge vortices than AMI. Both methods resolve blade-vortex and blade-wake interactions. However, the Overset approach produces higher broadband noise due to stronger vortices and interpolation effects, while AMI yields smoother pressure fields and clearer tonal content. In the far field, AMI better matches experimental SPL trends. Overset shows larger first-BPF SPL errors (up to 22.5 dB vs. 5.7 dB for AMI), though OASPL differences remain small. Overall, Overset is less reliable for noise prediction and more computationally expensive.
A demonstration ride shows the glare-free, game-changing power of adaptive driving beams, already available in Europe. An approval test from NHTSA is proving difficult for OEMs to pass. I'm riding in the second row of a Lincoln Navigator fitted with Forvia Hella's adaptive driving beam (ADB) headlight system. The low- and high-beams are on, blasting everything in front of us for between 350 and 500 feet (122 and 152 m) with a bright, daylight-temperature LED light. Even traffic and street signs at the edges of the road, which normally aren't as well illuminated, are bathed in brightness. A car pulls out in front of us, and the system instantly adjusts, creating a tunnel of unlit space on and just next to the vehicle ahead. So even though we still have high beams on the rest of the road, that driver isn't facing the harsh glare that is the No. 1 complaint about today's high-intensity headlight systems.
Welcome, once again, to our annual digital-only issue. We remain committed, of course, to our eight print issues each year, but letting the benefits of digital media come to the fore is always its own fun challenge. No matter what your role is, you should find something engaging and educational among these virtual pages. We've got videos, animations and other multimedia components for you to click on and learn from in this issue. My personal favorite example in here of a video replacing a thousand words can be found in our cover story. It's not like the text is indecipherable, but simply seeing how adaptive headlight beams adjust where they throw their high beams so as to not blind other drivers in almost all situations is just cool. Headlight technology has come a long, long way in the last decade, from the low lights of old helping clear a path home to today's often-annoying high beams that may provide extra safety to the driver, but make the blood of oncoming drivers run dry.
The transformation of the Subaru Outback from wagon to SUV is complete. While the wagon was a perfectly capable off-road machine, the new Outback gets a boxier exterior (possibly an homage to the boxer engine) and Wilderness-trim level-first platform upgrade. During a recent drive program in Northern California, I had the opportunity to test the increased capability of the vehicle firsthand.
MSIL (Maruti Suzuki India Limited), India’s leading automotive manufacturer, offers a diverse range of SUVs (Sports Utility Vehicles) in its portfolio. Traditionally, SUVs are associated with an assertive stance and a commanding road presence; however, this bold design language often compromises aerodynamic drag performance. Over the past decade, demand for this segment has surged, while CAFE (Corporate Average Fuel Economy) regulations have become increasingly stringent. To address this growing market need, MSIL conceptualized a new SUV - Victoris - targeted to deliver best-in-class aerodynamic efficiency in MSIL SUV portfolio. This paper details the aerodynamic development process using CFD (Computational Fluid Dynamics) and full-scale WTT (Wind Tunnel Testing). Initially, the aggressive styling of Victoris negatively impacted drag performance. Strategic exterior surface refinements and integration of aero components enabled recovery of aerodynamic efficiency. Key interventions included redesigned front and rear bumpers, roof-end treatment, quarter spoiler profiling, bumper corner vents, and aero-cut alloy wheels. Victoris successfully retained its bold styling while meeting ambitious aerodynamic targets. The optimized aerodynamic silhouette comprising hood-to-windshield transition, roof contouring, backdoor spoiler, and side body profiling - along with underbody elements such as covers, strakes, and air curtains improved drag performance by 14% compared to the initial design. Achieving this improvement required significant shape modifications and aero part additions without compromising SUV identity. This paper explains how these measures were implemented and the resulting airflow characteristics.
Weather-strip sealing systems are critical to automotive closure performance, influencing water- and dust-tightness, aerodynamic noise control, and overall NVH quality. Conventional validation often relies on flat or straight JIG-based tests that inadequately represent the curved, angled, and non-uniform geometries of real closures such as doors, tailgates, hoods, roofs, and fixed or movable glass. This disparity limits the predictive accuracy of sealing performance in actual vehicles. This study proposes a vehicle-integrated validation framework that mirrors true geometric and contact conditions. The methodology combines finite element analysis (FEA) of both flat JIG and full-vehicle CAD geometries with experimental JIG tests, establishing a baseline for pressure distribution, compression load, and sealing contact behavior. A comparative analysis highlights significant deviations between flat-section predictions and vehicle-specific closure profiles. Results demonstrate that the integrated method more accurately reflects sealing efficiency, sound transmission loss, and long-term deformation, offering improved reliability for early-stage NVH optimization and product qualification. The findings recommend incorporating vehicle-profile-based validation into standard development practice for automotive weather-strips.
Items per page:
50
1 – 50 of 4040