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    VDHS-12 Vehicle Dynamics Design Process

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    Husain Kanchwala
    This document outlines the process for designing and developing vehicle dynamics, including concept development, detail design, and vehicle tuning. In concept development, customer requirements are understood and targets are set. Concepts are generated, evaluated, and modeled. In detail design, further analysis is conducted and components are designed and prototyped. Finally, in vehicle tuning, prototypes are tested against objectives and through driver evaluations to optimize vehicle dynamics performance. The goal is to meet handling, ride, and steering targets through an analytical, testing, and refinement process.

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    © All Rights Reserved
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    VDHS-12 Vehicle Dynamics Design Process

    Uploaded by

    Husain Kanchwala
    507 views15 pages
    This document outlines the process for designing and developing vehicle dynamics, including concept development, detail design, and vehicle tuning. In concept development, customer requirements are understood and targets are set. Concepts are generated, evaluated, and modeled. In detail design, further analysis is conducted and components are designed and prototyped. Finally, in vehicle tuning, prototypes are tested against objectives and through driver evaluations to optimize vehicle dynamics performance. The goal is to meet handling, ride, and steering targets through an analytical, testing, and refinement process.

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    This document outlines the process for designing and developing vehicle dynamics, including concept development, detail design, and vehicle tuning. In concept development, customer requirements are understood and targets are set. Concepts are generated, evaluated, and modeled. In detail design, further analysis is conducted and components are designed and prototyped. Finally, in vehicle tuning, prototypes are tested against objectives and through driver evaluations to optimize vehicle dynamics performance. The goal is to meet handling, ride, and steering targets through an analytical, testing, and refinement process.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    507 views15 pages

    VDHS-12 Vehicle Dynamics Design Process

    Uploaded by

    Husain Kanchwala
    This document outlines the process for designing and developing vehicle dynamics, including concept development, detail design, and vehicle tuning. In concept development, customer requirements are understood and targets are set. Concepts are generated, evaluated, and modeled. In detail design, further analysis is conducted and components are designed and prototyped. Finally, in vehicle tuning, prototypes are tested against objectives and through driver evaluations to optimize vehicle dynamics performance. The goal is to meet handling, ride, and steering targets through an analytical, testing, and refinement process.

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    Design & Development Process for Vehicle

    Dynamics

    Vehicle Dynamics : Design & Development


    Process
    Concept Development

    Understand Customer
    requirements
    Target setting
    Concept Generation
    Concept Evaluation
    Analytical Calculations
    Initial ADAMS Analysis
    Concept 3D models
    System DFMEA
    System Specification
    finalisation

    Detail Design

    ADAMS Analysis
    Durability analysis
    DMU Packaging study
    Critical Parts DFMEA
    Tolerance Stack up
    Detailed component
    drawing
    Manufacturing
    feasibility
    Prototype development
    & build

    Vehicle Tuning

    K&C Measurement
    Vehicle Tuning trails
    Vehicle Objective
    Measurement
    Vehicle Subjective
    Evaluation
    K&C Tracking
    Jury Evaluation
    Engineering sign off

    Concept Development

    Understand Customer requirements


    Target setting
    Concept Generation
    Concept Evaluation
    Initial ADAMS Analysis
    Concept 3D models
    System DFMEA
    System Specification finalisation

    Target Setting

    Analysis of QFD requirements from customer voice


    Features / technologies to be used
    Market / Future trends
    Current / future legislative regulations
    Generation of Target Books for full vehicle ride, handling and
    steering.
    A set of subjective ratings
    Objective parameters at vehicle level
    System level parameters
    Targets are given as values, maxima, minima, or acceptable
    ranges.

    3D CAD data ( Pro E )

    Front suspension
    Lower Link , Upper link , coil springs , Anti roll bar , Front Strut ,
    Suspension bushes , ARB linkages , Torsion bars , Stub Axle , Hub ,
    bearings , Spacers , Ball Joints , Bump Stopper , Strut Top , Torsion Bar
    attachments , Coil on Shock & it mounting , Spring Aids , Shock
    Absorber , Wheel end assembly , Mounting / Attachment brackets ,
    Rear Suspension
    Leaf Springs , Coil Springs , Suspension Linkages , Shackles , U bolts ,
    Guide Plates , Suspension bushes , Spring Seats on Axle , Dead Rear
    Axle , Wheel end assembly , Hub , bearings , Shock Absorber ,
    Mounting / Attachment brackets , Rear Anti Roll bar , ARB linkages ,
    Steering System
    Steering Column , Steering Rack , Ball Joints
    Moving skeleton of front & rear suspension
    Wheel envelop
    5

    CAE Analysis

    ADAMS ANALYSIS
    ADAMS Kinematics & Compliance analysis of the concepts
    ADAMS Full vehicle Ride & Handling report
    Steering column UJ Phasing
    Suspension & Steering Hardpoint attachment stiffness
    Confirm the Targets set are achievable
    Structural Analysis Report
    Front & rear suspension All components
    Front & rear wheel ends of final concept
    Dead Axle
    LHD / RHD steering system
    6

    SYSTEM SPECIFICATIONS : Suspension

    Suspension Hard Points


    Wheel geometry specification
    Wheel travels
    Spring rates
    Anti roll bar rate
    Suspension bushes
    Shock Absorber / Mcpherson strut damping rates
    Strut top mount stiffness
    Bump Stopper / Spring Aids stiffness
    Suspension Ball joint specification (angle , size , etc)
    Bearing sizes
    7

    System Specifications
    Steering
    Hard points
    Steering Geometry ,
    Steering rack travels , ratio , lock Angles
    TCD values
    Steering pump requirement / specification
    Steering Ball Joint specification (angle , size , etc) , etc
    Wheels & tyres
    Size
    Load Rating
    vertical stiffness
    Cornering stiffness
    8

    Detail Design

    ADAMS Analysis
    Durability analysis
    DMU Packaging study
    Critical Parts DFMEA
    Tolerance Stack up
    Detailed component drawing
    Manufacturing feasibility
    Prototype development & build

    Vehicle Tuning Optimization

    K&C Measurement
    Vehicle Tuning trails
    Vehicle Objective Measurement
    Vehicle Subjective Evaluation
    Engineering sign off

    10

    11

    K&C Measurement

    Vertical test:
    suspension vertical stiffness (wheel rate , ride rates) , camber change, toe change
    , castor change, wheel centre locus (longitudinal & lateral) , tire contact point
    locus , tire radial rate , track change, wheelbase change
    Roll test (with & without ARB) :
    suspension roll stiffness, roll centre height , roll steer , roll camber , castor
    change , Track change , Axle steer , wheel loads , wheel rates
    Lateral compliance test:
    lateral wheel centre compliance, steer change, camber change, roll force centre
    position ,lateral stiffness , track change
    Longitudinal compliance test:
    longitudinal wheel centre compliance, steer change, castor change, anti-dive
    tangent.
    Aligning torque compliance test:
    steer change , camber change
    Steering test:
    steering ratio, camber change, Ackermann characteristics , steering friction ,
    steering efficiency , kingpin inclination , castor , trail , kingpin offset & scrub
    radius

    12

    Vehicle Dynamics : Objective Evaluation

    Steady state Circular test ( ISO 4138) :


    To characterize vehicle balance ,grip and roll level (with and without ESP)
    Step steer (ISO 7401):
    To characterize the transient response of the vehicle to a sudden steering input including
    time delays and overshoots throughout the lateral acceleration range.
    Lateral Transient Frequency response test (ISO 8726):
    hand wheel and road wheel input angle , within the linear regime.
    lateral acceleration, yaw rate, roll rate and steering torque.
    Sinusoidal Steering Input test (ISO 3875):
    steering effort and response linearity in the on-centre region .
    Self centering (IS13057):
    To characterize the steering returnability
    Ride comfort test
    weighted RMS acceleration levels at the occupant contact points
    Steering Tests:
    To measure stationary and low speed steering efforts as per IS11948.
    Steering column tilt mechanism adjustment force.
    Temperature & Pressure mapping of the Power Assisted Steering system
    Measurement of Turning Circle Diameter (TCD)
    Straight line braking (ISO 21994) : Straight line braking performance

    13

    Vehicle Dynamics : Subjective Evaluation


    Ride Comfort :
    Primary and secondary ride, harshness
    Handling:
    On and off centre , Limit of adherence ,
    Steady State and Transient handling ,
    Straight head stability ,
    Lane change stability .
    Steering Response :
    Steering Feel ,
    Steering Effort build-up
    Braking :
    Stopping Distance ,
    Straight Line Braking Stability

    14

    Learning
    Often the difference between good vehicles and poor vehicles is
    not in the
    level of engineering and concept,
    But in the detailing that goes into the components within
    design and development.
    Parameters often important determinants of the quality of the
    vehicle
    Hysterics, stiction, friction , Joint rigidity
    This separates class leading vehicles from the competition.
    We need to incorporate this into practice for projects under
    development.

    15

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