Chassis Systems

Design
AUTE 4070U
Lecture 2

Yuping He
Ontario Tech University
September 7, 2023
3. Vehicle Development Process
Production cycle?
Development cycle?
Need
New product development

Development
cycle
Market
Production
Customer
Production
cycle

Order processing and scheduling

Order
1.1
OEM?
OEM stands for original equipment manufacturer. In the business world,
this means a company that makes a product to be sold by another
company under the OEM’s name.

Tier 1 supplier?
Partners that you directly conduct business with, including contracted
manufacturing facilities or production partners. Take, for example, a
company selling apparel: The factory that assembles that company's
cotton t-shirts is a Tier 1 supplier.

1.2
 Customer Market
orders need

Schedule Specification

Supply
Concept
components and
design
materials

Fabricate Detailed
and process design

Assemble Manufacture

Dispatch Product
introduction
Production Development
3.1 Decision Making
1) Market Analysis
o Product function, performance, safety, quality, etc.
o Cost and market share.
2) Technical Analysis
o Competitive products’ status.
o Relative standard or regulation requirements.
3) Feasibility Study Report
o Predicted products and sales match the company’s business
plan?
o Predicted products satisfy the standards or regulations?
4) Making Decision
o Product specification.
o Structures and basic parameters.
1.4
 Cruze: Chevrolet (GM)
o Engine: 1.8L
o Turbo Charger: 5.1L/100km
o Safety design: 10 airbags
o Standard OnStar, 4G LTE, Wi-Fi

Corolla: Toyota
o Engine: 1.8L
o 4 Cylinders, 16 valve engine
6.4L/100km
o Steering wheel audio controls
o Durability, reliability

Civic Sedan: Honda

o Engine: 1.8L
o 4 Cylinders, 16 valve engine
6.7L (city), 5.0L (highway)
o Continuously variable 1.5
transmission (CVT)
3.2 Design Phase
o Initial design (conceptual design schemes).
o Detailed design (structure selection, parameter calculation
and selection, testing, etc.)
o Design for manufacturing

body in white 1.6

3.3 Prototype Fabrications
o Prototype building.
o Prototype testing
o Design modification

1.7
3.4 Pilot Production
o Manufacturing plan.
o Engineering analysis
o Design improvement

1.8
3.5 Manufacturing Ramp-up and Mass Production
o Prepare mass production manufacturing plan.
o Develop required manufacturing technologies.
o Establish manufacturing equipment and assembly lines.

1.9
4. Vehicle Design Procedure
4.1 Establishment of Design Principles
o Requirements on technique, manufacturing, product cost, etc.
o Product performance measures that should be met.
o Product model variation (for larger market share).
o Performance and cost analysis (general trade-off).
o Benchmark investigation of final selected two design schemes.

benchmark investigation
Design principles are guidelines, biases and
design considerations that designers apply
with discretion. Professionals from many
disciplines—e.g., behavioral science, sociology,
physics and ergonomics—provided the
foundation for design principles via their
accumulated knowledge and experience.

1.11
4.2 Model Selection and Design Specification
o Model and structure/configuration selection.
o Calculation and selection of key technical and performance
parameters.
o Small scaled prototype development (1:5 clay model).
o Establishment of design specification: 1) design targets; 2)
product model and key parameters; 3) structure or
configuration; 4) requirements on part exchangeability; 5)
standard/regulation requirements; 6) requirements on
materials, manufacturing, and production.

1.12
1.13
Example: vehicle system design optimization

topology optimization parameter optimization

1.14
4.3 Technical Design
o Design for dimensional control.
o Inspection of kinematic relationship between relevant parts.
o Design for manufacturing and assembly:
1) Reduce the part count and types;
2) Modularize the design;
3) Strive to eliminate adjustments;
4) Design parts for ease of feeding or handling;
5) Design parts to be self aligning and self locating;
6) Ensure adequate access and unrestricted vision;
7) Design parts so they cannot be installed incorrectly;
8) Use efficient fastening or fixing techniques;
9) Minimize handling and reorientation;
10) Utilize gravity;
11) Maximize part symmetry;
12) Strive for detail design that facilitates assembly. 1.15
1.16
kinematic relationship

dimensional control 1.17

1.18
4.4 Vehicle or Assembly Overall Design
o At this point, all part and subsystem designs are completed.
o Manufacturing and design verifications are done.
o Assembly drawing is to double check the characteristic
parameters and dimensions.
o CAD techniques are widely used for vehicle or assembly
overall design.

1.19
4.5 Prototype Fabrications, Tests and Modification
Design
o With prototypes, the structure and manufacturing features of
the vehicle/assembly/part can be evaluated.
o Performance, reliability and durability of the
vehicle/assembly/part can be examined and evaluated.
o With the testing data, the satisfaction of standard or
regulations can be determined.
o Then, required modification design and relevant tests may
be conducted following the above steps.

1.20
4.6 Rapid Prototypes and Virtual Prototypes
o To date, rapid prototype techniques are used for vehicle
designs.
o CAD/CAE-based virtual prototypes are effective tools for
modern vehicle design.

1.21
4.7 Advanced Test Methods for Vehicle Design
o Hardware/software-in-the-loop real-time simulations.
o These test methods are cost-effective and safe.

1.22
4.8 Field and Road Tests
o Objective Evaluations.
o Subjective Evaluations.

1.23
1.24