Driving Intelligence G.VIJAY BHASKAR ASST.PROF AUTOMOBILE ENGININEERING DEPT Vehicle Body Engineering

Driving Intelligence

G.VIJAY BHASKAR

ASST.PROF

AUTOMOBILE ENGININEERING DEPT

Vehicle Body Engineering


UNIT I


Active Vehicle Safety Systems Save Lives

• We are on the frontier of a revolution in active vehicle safety

• The technology to improve vehicle stability and reduce crashes is here today

• Surveys indicate safety systems, like electronic stability control, are highly desired by consumers

• Electronic stability control saves lives and money according to the latest traffic studies

• Continental is actively educating key stakeholders on critical active safety technology


Our Industry is Under Siege


Crashes Cost Americans $230 Billion

6.3 million passenger vehicle crashes in 2002

$230.6 billion economic cost to society

• Nearly 3 million injuries and 42,815 fatalities

• Rollovers accounted for 82% of the increase in fatalities• 95% of all crashes due at least in part to driver error

• 253,000 passenger vehicle rollovers• Injuries declined, but fatalities increased• Highest number of fatalities since 1990


The Motor Vehicle Safety Equipment Exists Now to Help Reduce Crashes and Rollovers

It’s Called Electronic Stability Control


Technology is our passion but

safety is our business


Electronic Stability Control Improves Safety

We Have Safety Technology Today to Make Mobility Safer!


The Bottom Line

Make the chassis itselfelectronically intelligent

Raise comfort and safety to new levels without sacrifices


Passive Safety is Job Three

The next frontier isto prevent the crash

from occurring in the first place


Active Safety is Job One

The key isto prevent the crash


This is active safety


Opportunities in Smart Safety Systems

The key isto prevent the crash



UNIT II


Automotive Safety Continuum

Phase 1: Avoid problem

situations.




situations.

Phase 2: Maintain control

if trouble begins




situations.


if trouble begins

Phase 3: Protection when the

crash is unavoidable




situations.


if trouble begins

Our Focus Should be

Crash Avoidance


Driver

Tires

Brakes

Steering

Struts

Chassis Mounts

Springs

Electronics

Improved Safety Through Functional Integration


Networking Active and Passive Technologies Will Improve Safety

Accident preventing systems(Global Chassis Control)

Stability management systems(Electronic Stability Program, Roll Stability

Control, Electronic Stability Program II)

Active SafetyAccident prevention

Electronic brake systems(Anti-lock Brake Systems, Traction Control

Systems, Brake Assist)

Hydraulic brake systems(brake caliper, brake booster, etc.)


Networking Active and Passive Technologies Will Improve Safety

Accident preventing systems(Global Chassis Control)

Stability management systems(Electronic Stability Program, Roll Stability

Control, Electronic Stability Program II)

Active SafetyAccident prevention

Electronic brake systems(Anti-lock Brake Systems, Traction Control

Systems, Brake Assist)

Hydraulic brake systems(brake caliper, brake booster, etc.)

Passive SafetyInjury prevention

Injury preventing systems (OOP, CV)

Electronic restraints(Airbags, seatbelt tensioner,..)

Intelligent restraints (Satellites, PRP)

Mechanical restraints(seatbelts,..)

Goal:A vehicle that prevents accidents and injuries


Continental Brings together Know-How in Tires, Electronics and Brake and Chassis

Electronics

Brake & Chassis

Tires


Full Circle

Before:the industry “needs to do more”

on the safety front


Full Circle

Before:the industry “needs to do more”

on the safety front

Now: we need to do more to make our technology better understood and

sought after in the new vehicle marketplace


Our Challenge: Make Consumers More Aware of Active Vehicle Safety

Develop public awarenessof these possibilities to engineer a

miss…

Get them to buy them!


J.D. Power & Associates Survey Ranked Stability Control among Top

10 Desired Features


ESC Helps Save Lives

Recent study by Mercedes indicates Electronic Stability Control can reduce single vehicle crashes by 30%

• 30% reduction in the U.S. could save more than 5,000 lives

Same Mercedes study indicated total crashes for vehicles equipped with Electronic Stability Control were reduced by 15%

• Would save American public almost $35 billion

• Would pay for the cost of installing Electronic Stability Control on all vehicles built in the U.S. some 7-9 times


Bottom Line in the Mercedes Study:

There was a clear drop in the accident rate after

standard installation of electronic stability control


- In Japan -

• Toyota Study shows 35% reduction in single-vehicle crashes: could save more than 6,000 lives a year

• 30% reduction in head-on crashes could save another 2,500 lives per year

• 50% reduction for more severe accidents• Confirms Mercedes conclusion that electronic

stability control is more effective in the higher speed ranges where vehicle dynamics play a greater part and where crashes that do occur are more severe

Electronic Stability Control Helps Drivers Avoid Crashes


- In Sweden -

Swedish National Road Administration Study:

• Electronic stability control found to reduce accidents with personal injuries

• Electronic stability control should be implemented in new cars ASAP

• Consumers should be advised to choose cars with electronic stability control, especially in countries with wet and icy roads

Electronic Stability Control Recommended For All New Vehicles


• With fatalities overcoming the safety gains from seat belts and air bags (both passive systems), it’s now the critical time for the industry to embrace ACTIVE safety systems like electronic stability control. Using proven technology to save lives is a necessity

Electronic Stability Control Saves Lives


Raising Consumer Awareness

www.drivesaferamerica.org

www.esceducation.org


The Technology to Help Drivers Avoid Crashes Altogether and Make all Vehicles Safer is Within

Our Grasp…

Are We Ready?


Active Vehicle Safety Saves Lives• We are the frontier of a revolution in active vehicle safety

• Technology to save lives, help prevent rollovers and reduce crashes is here today – ESC

• Electronic stability control is as important to safety as airbags, ABS or seatbelts

• Several recent independent studies from Europe and Asia prove electronic stability control saves lives and reduces crashes and their severity

• Electronic stability control helps avoid crashes before they happen

• Actively preventing accidents significantly reduces the number of injuries and will save thousands of lives annually

• This proven technology is available to the North American driving public today, but most consumers are still unaware it exists


UNIT III


INTRODUCTION• AERODYNAMICS :

Study of forces generated by motion of air on moving body.

CLASSIFACATION OF AERODYNAMICS :

external and internal, subsonic , supersonic , hypersonic

FIELDS OF APPLICATION :

aerospace engineering, design of automobiles , ships , civil

engineering , design of bridges etc.


AERODYNAMIC FORCES ON A BODY

LIFT

(DOWNFORCE)

DRAG

WEIGHT

THRUST


HISTORY OF EVOLUTION OF AERODYNAMICS IN CARS

• DESIGN’S IN EARLY 20th CENTURY : cars with low speeds, no aerodynamic problems.

CAR’S IN THE EARLY 50’s : cars designed for big family’s , complete negligence of aerodynamics.

CARS AFTER 70’s : fuel crisis , need of economic designs , evolution of aerodynamics.


WHY WE NEED TO IMPROVE AERODYNAMICS IN CARS

• SPEED

better aerodynamics higher will be the speeds.

• FUEL EFFICIENCY

better aerodynamics , less work for engine.


Aerodynamics to make the efficient even more efficient!


Mythbusters – Tailgait down or up?


Mythbusters – Tailgait down or up?


AERODYNAMICS IN MCLAREN F1

SPECIFICATIONS

FRONT END

REAR END

SCOOPS

WINGS Mclaren F1


AERODYNAMIC DEVICES

• SPOILERS

• NACA DUCTS Increase rate of flow To expose air to areas not exposed to direct air

flow.


METHODS TO EVALUATE AERODYNAMICS IN CARS

WIND TUNNELS • Research tool to study effect of air moving over

a solid object.• Trial and error process.• Special pressure paints for analysis.• Detailed analysis of air flow patterns.

• Analyzing for the optimal design.


AERODYNAMIC IMPROVEMENTS IN THE CAR THAT WE ALREADY OWN

Keep your vehicle washed and waxedRemove mud flaps behind wheelsPlace license plate out of air flowAvoid roof-racks or carriersClose windows, close sunroof


CONCLUSION

• Aerodynamics in cars is a factor in the over all performance of the car, it should never be compromised.


UNIT IV


Back

Driving IntelligenceBack



FRONT ENDFRONTAL PRESSUREPRESSURE DIFFERENCEMINIMISE FRONTAL AREAREDUCE cd

Back


SCOOPS

ENGINE COOLING INCREASESFLOW

RATE OF AIR

Back


REAR ENDREAR VACUMFLOW DETACHEMENTTURBULANCE

Back


WINGS

PRODUCE DOWNFORCE

REDUCE DRAG

Back


Back



COEFFICIENT OF DRAG

Drag = 1/2xd x Cd x A Xv2

Measure of aerodynamic

efficiency.

Back


SPECIFICATIONS• EngineType:V12

• Curb Weight : 1100 kg.

• Displacement:6064 cc

• Horsepower:627 bhp @ 7400 rpm

• Torque:479 lb-ft @ 4000 rpm

• Performance0-60 mph:3.2 sec

• 0-100 mph:6.3 sec

• Top Speed:240 mph /hr

BACK


Some Background...Cars at first were built entirely of wood, and later of wood frames with steel body panels.

In the early 1900’s, the idea of a body-on-frame design came about.

These vehicles hadThese vehicles hada load-bearing chassisa load-bearing chassisthat supported all thethat supported all themechanical partsmechanical partsand a body usual madeand a body usual madeof steel.of steel.

Ford Model TFord Model TCourtesy Car Body DesignCourtesy Car Body Design

http://www.carbodydesign.com/articles/2005-04-13-chassis-history/2005-04-13-chassis-history.phphttp://www.carbodydesign.com/articles/2005-04-13-chassis-history/2005-04-13-chassis-history.php


Moving Forward...

Heavy-duty vehicles like trucks and busses still use the idea of body-on-frame.

Regardless of the construction technique, steel is still the predominant material used in automotive frames.

Today, most smaller Today, most smaller vehicles such as small vehicles such as small SUV’s and sedans use a SUV’s and sedans use a unibody (or monocoque) unibody (or monocoque) construction.construction.

Honda Civic FrameHonda Civic Framehttp://automobiles.honda.com/images/2009/civic-sedan/safety/safety-header.jpghttp://automobiles.honda.com/images/2009/civic-sedan/safety/safety-header.jpg


A Quick Comparison

MonocoquesMonocoques

Typical Ladder FrameTypical Ladder Frame


What it’s all AboutToday, the new revolution in car design is the use of new materials in the vehicle structure.

As fuel economy restrictions become tighter, manufacturers must find new ways to meet them.

This has led them away from using so much steel in the vehicles, and more and more are moving towards aluminum.

The central theme of our project was to compare The central theme of our project was to compare these new lightweight aluminum cars to their these new lightweight aluminum cars to their steel predecessors and see if anything is being steel predecessors and see if anything is being sacrificed and/or gained.sacrificed and/or gained.


A Basic Comparison

Two common alloys used in car manufacturing:For Aluminum: AA 5182

For Steel: AISI 1020

SteelSteel AlAl

Yield Yield StrengthStrength

(MPa)(MPa)294.8294.8 395395

UTS (MPa)UTS (MPa) 394.7394.7 420420

Hardness Hardness (HB500)(HB500) 104104 5858

Data Courtesy efundaData Courtesy efundahttp://www.efunda.com/materials/alloys/carbon_steels/show_carbon.cfm?ID=AISI_1020&prop=all&Page_Title=AISI%201020http://www.efunda.com/materials/alloys/carbon_steels/show_carbon.cfm?ID=AISI_1020&prop=all&Page_Title=AISI%201020

http://www.efunda.com/materials/alloys/aluminum/show_aluminum.cfm?ID=AA_5182&show_prop=all&Page_Title=AA%205182http://www.efunda.com/materials/alloys/aluminum/show_aluminum.cfm?ID=AA_5182&show_prop=all&Page_Title=AA%205182


Properties

Density of Steel: 7.88 g/cm3

Density of Aluminum: 2.7 g/cm3

Aluminum is about 3 times lighter than steel per unit volume, but can be made just as strong using certain alloys/shapes/bonding methods.

Because of this, AL parts can be thicker, and thus stronger, than their steel counterparts, all while weighing less.


The Cost IssueWhile Al may seem like a miracle metal for car production, there is a reason not all cars are made from Al... It costs a lot more than Steel.


The Move to AluminumThe first production vehicle to move to an Al frame was the Audi A8 in 1994.

This allowed Audi to make their full-size car lighter than the competitions (BMW, Mercedes,Lexus...), thus giving them the edge in performance & handling.

This comes at a price premium though, for instance compared to a Lexus LS460 (Steel framed) which costs around $65,000. The A8 starts at $75,000

Audi A8Audi A8

Lexus LS460Lexus LS460


An Increasing Trend

http://www2.prnewswire.com/mnr/duckerworldwide/37515/http://www2.prnewswire.com/mnr/duckerworldwide/37515/


Cars Utilizing Al Frames


WeightThe most obvious advantage to using aluminum in place of steel in cars is aluminum weighs less.

Weight Comparison Among Full-Size Luxury Cars

0325650975

1300162519502275260029253250357539004225455048755200

BMW 7-Series Mercedes S-Class

Audi A8 Jaguar XJ

Cu

rb W

eig

ht

(lb

s.)

Cars with Mostly AlCars with Mostly Al

Space FramesSpace Frames


SafetyNot too many safety tests have been performed on Al framed vehicles due to their usually higher price.

However, the Audi A2 is an inexpensive compact car that has been tested, and received overall favorable reviews compared to its steel bodies counterparts.


Some other advantages...There are some manufacturing methods that can only be done with aluminum, such as extrusions.

These extrusions allows the Al Space Frame to have about half the amount of parts as a traditional steel monocoque.

Because of all this, Al is already a cheaper material to use for low volume production cars (under 100,000 units a year or so).


A Few Other Facts...

Today, the average car contains about 200 pounds of aluminum parts.

Aluminum space frames (like that from Audi), contain fewer parts and fewer connection nodes, which helps keep production costs lower.


UNIT V


In The FutureWhile Aluminum may be the wave of the future for now, some exotic car companies are already looking ahead to composite materials.

Take for example Porsche Carrera GT, which used a completely Carbon-Fiber monocoque construction in addition to Carbon-Fiber body panels.

Because of this, the curb weight of the car was only 3000 lbs., even with a 5.7L V-10 engine powering it.

http://andrewbeard.wordpress.com/2009/05/11/technology-carbon-fiber-monocoque-chassis/http://andrewbeard.wordpress.com/2009/05/11/technology-carbon-fiber-monocoque-chassis/

Porsche Carrera GTPorsche Carrera GThttp://upload.wikimedia.org/wikipedia/commons/thumb/6/65/Porsche_Carrera_GT_-_Goodwood_Breakfast_Club_http://upload.wikimedia.org/wikipedia/commons/thumb/6/65/Porsche_Carrera_GT_-_Goodwood_Breakfast_Club_

%28July_2008%29.jpg/800px-Porsche_Carrera_GT_-_Goodwood_Breakfast_Club_%28July_2008%29.jpg%28July_2008%29.jpg/800px-Porsche_Carrera_GT_-_Goodwood_Breakfast_Club_%28July_2008%29.jpg


ReferencesBuilding an aluminum carhttp://www.allbusiness.com/professional-scientific/scientific-research-development/443897-1.html

History of Automobile Body and Chassishttp://www.carbodydesign.com/articles/2005-04-13-chassis-history/2005-04-13-chassis-history.php

Automobile Bodies: Can Aluminum Be an Economical Alternative to Steel?http://www.tms.org/pubs/journals/JOM/0108/Kelkar-0108.html

Different Types of Chassishttp://www.autozine.org/technical_school/chassis/tech_chassis2.htm

Aluminum Versus Steelhttp://www.travistrailer.com/public/pag16.aspx

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Driving Intelligence G.VIJAY BHASKAR ASST.PROF AUTOMOBILE ENGININEERING DEPT Vehicle Body Engineering