VEHICLE DESIGN

&
CAD
Işık University - AUE 421

Week #2

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 1886

Today ?

Automotive Design Principles

Vehicle Types & Platforms
Standards & Regulations

1997

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Comfort

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 Natural Frequencies

Vehicle Body

Human

Wheel
Seat

Natural Frequency

Reference : Guney, A., Vehicle NVH Lecture Notes, 2012.

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 Vibration and Sound

Reference : Guney, A., Vehicle NVH Lecture Notes, 2012.

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 Vehicle Vibrations
Cabin

Seat

Seat suspension

Cabin suspension

Body springs and dampers

Tires at wheels

Reference : Guney, A., Vehicle NVH Lecture Notes, 2012.

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 Vehicle Vibrations

Reference : Guney, A., Vehicle NVH Lecture Notes, 2012.

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 Transfer Mechanisms of Sound and Vibration
(Example)

Reference : Guney, A., Vehicle NVH Lecture Notes, 2012.

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 Acoustic Sources in Passenger Cars (Pass-by
Noise)
Exhaust Pipe
Exhaust Pipe Ending
1% 4%
24%
Engine and Transmission

71%
Tire Rolling Noise

Reference : Braess, H.H., Seiffert, U., Handbuch der Kraftfahrzeugtechnik, Vieweg, 2003.
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 Pass-By Noise Measurement

Reference: Happian-Smith, J., An introduction to modern vehicle design, Butterworth-Heinemann, 2001.

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Environment

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 Shift in types of vehicles in the future as
petroleum supplies diminish

EVH : Fuel Cell Electric Vehicle «FEV»

EVB : Battery Electric Vehicle «BEV»

Reference: Fuhs, A.E., Hybrid Vehicles and the Future of Personal Transportation, CRC Press, 2009.
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 Mileage and emissions from road transport
(Germany 1960–2008)

Reference: Pistoia, G., Electric and Hybrid Vehicles, Elsevier, 2010.

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 CO2 Emissions
Total CO2 Emissions
≅ Year CO2 Emissions – Human generated
Biomass Year
Combustion
Vegetation Other
Passen Heavy
Oceans Big Ships ger
Air Commercial
traffic Cars Vehicles
transport
Energy Biomass
Production Combustion

Industry
Soil Household, Small Consumers
Human generated
CO2 Emissions

Reference: Verband der Automobilindustrie, 2008.

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 Exhaust Emission Limits – Passenger Cars
1,13 1,13 3,16 3,16 0,18
[g/km]
1992/93
1996/97
2,3
2000
2,2
2005
0,7 Euro 5 2008

0,56
0,5 0,08

0,15 NOX
0,2 HC 1,0 1,0 1,0
0,3 0,05

0,25 0,64
0,15 NOX
0,1 HC 0,5 0,5
0,025
0,06 NOX
0,075 HC
0,005

Particulate
Matter
Reference: Baden-Württemberg Germany – Çevre İdaresi Birimi, 2004.
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 Recycling

Material
Material Anteil am
Percentage Auto [%] Recyclingquote
in Automobile[%] Recycle Percentage [%] [%]

Stahl
Steel 53 98 -100
Gußeisen
Cast iron 12,5 98 -100
andere Metalle
Other metals 5,2 95
Gummi
Elastic materials (tires) 5 95
Kunststoffe
Plastics 9 60
Glas
Glass 4 5-10
andere Materialien
Other materials 11,3 ~10
Insgesamt
Total 100 ~75

Reference: Institut der Deutschen Wirtschaft, Köln, 2003.

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 Environmental Measures – Automotive Technology
Fuel
- Fuel type, quality Driver
- Autonomous systems
Engine - Driver assistance
- Cold / Hot operation optimization
- Efficiency optimization Body
- Engine-Gearbox harmony - Light weight
- Alternative fuels and propulsion techniques – materials and design
Measures related with engine peripheral units techniques
- Aerodynamic
optimization

Converters and filters Powertrain

Chassis (Susp., Brakes, in
Steering) - Selecting gear ratios
Exhaust system - Determining the number of
- Rolling Resistance
- Light weight gears
- Powertrain efficiencies

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Economy

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 Internal Combustion Engine (ICE)
Energy Usage

30% Heat to cooling water

30% Heat to exhaust gases

Fuel energy 100% ICE 5% Heat radiation

5% Friction

30% Usable mech. energy

Reference: Gevatter, H.J., Grünhaupt. U., Handbuch der Mess- und Automatisierungstechnik im Automobil, Springer, 2006.
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 Typical ICE
(Internal Combustion Engine)
Characteristic

Reference: Happian-Smith, J., An introduction to modern vehicle design, Butterworth-Heinemann, 2001.

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 Increasing efficiency of U.S. cars and light trucks, 1975–2004.
Fuel economy stagnation after 1985

Reference: Sperling, D., Gordon, D., Two billion cars driving towards sustainability, Oxford, 2009.
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Quality

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 Reliability Theory – Bathtub curve

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

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 Reliability Theory – Bathtub curve
Early Failures:
Early failures section is characterized by a declining failure rate. The risk of a part failing
decreases with time. These early failures are caused mainly by production and assembly
errors. Early failures can be countered by corresponding quality assurance.

Random Failures:
Random failures have a constant failure rate. The failure risk of a part is thus always the
same. The risk is usually relatively low. These random failures are caused e.g. by
operating errors or dirt particles.

Wearout and Fatigue Failures:

In the failures due to wear and fatigue section, the failure rate increases sharply. The
failure risk increases for a part as its service life increases. The failures occurring here
are, for example, caused by fatigue fracture, ageing, pitting or wear. This section is the
most interesting for the design engineer, since the service life of a part is largely
determined by this section. It can therefore be substantially improved by taking special
account of the possible causes of failure and designing the parts accordingly − service
life calculation.

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

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 ?

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 Driver Type in Terms of Powertrain
Loading in a Passenger Car

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

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 Service Life of Passenger Car and Commercial Vehicle
Transmissions under Different Operating Conditions

Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

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 Misuse Powertrain

Reference: ATZ
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Vehicle Platforms & Types

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 Independent Automotive
Manufacturers
„Traditional“ Manufacturers
60

(prediction)
Indian and Chinese
50 Manufacturers
40 India , e.g. :
• TATA
30
52 China, e.g. :
20 12 • Geely
6 • Brilliance (BMW-Partner)
10 16 • Jiangling (Landwind)
12 11
0

2010
1964

1999

2006
Independent Automobile Manufacturers (2006)
Euro-USA-Japan-Korea Europe
• GM - Opel - Vauxhall - Saab - Isuzu - Suzuki - Subaru - Daewoo • VW - Audi - Seat - Skoda – Bentley
• Ford - Jaguar - Volvo - Mazda - Land Rover -Bugatti - Lamborghini
• Daimler(Chrysler) - Mitsubishi • Fiat - Alfa Romeo - Lancia - Ferrari
• PSA - Peugeot - Citroen
Korea Japan
• Renault - Nissan (Japan)
• Hyundai - Kia • Toyota - Daihatsu
• BMW – Mini – Rolls Royce
• Honda
• Porsche

Reference: VDA, IfF – TU BS, AP 2005, Accenture, Global Insight 2007.

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Automotive R&D Expenses 2007

8,4*
8,1
7,5

4,8
4,3
4,0

* Billion US Dollars

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 Passenger Cars (Press nominations)

Lower Higher
Mini Small Mid
Mid Mid

Ford KA Ford Fiesta Audi A3 Audi A4 Audi A6

Smart Fiat Punto BMW 1 BMW 3 BMW 5
Mini Cooper Opel Corsa Mercedes A Class Mercedes C Class Mercedes
VW Lupo VW Polo VW Beetle Honda Accord E Class
. .
. . VW Golf VW Passat .
. . .
. .
. .
. .
.
Cabriolet
Luxury Sport Off-road Van
s

Audi A8 Aston Martin Audi TT Roadster BMW X 5 Renault Espace

BMW 7 Ferrari F430 BMW Z4 Mercedes M Class Mercedes V Class
Mercedes S Class Porsche 911 Mercedes SLK Ford Explorer Chrysler Voyager
Jaguar XJ8 Porsche Cayman Porsche Boxster Jeep Wrangler VW Sharan
Lexus LS 400 . . Land Rover Opel Zafira
. . .
. . . Range Rover .
. .
. .
.
.
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Passenger Car Variants

Sharing parts !

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 Modularity

Renault Modus

Reference: Happian-Smith, J., An introduction to modern vehicle design, Butterworth-Heinemann, 2001.

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Road Vehicle Classification

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 The Motor Vehicle

A motor vehicle or road vehicle is a self-propelled wheeled vehicle that does not
operate on rails, such as trains or trolleys.

The vehicle propulsion is provided by an engine or motor, usually by an internal

combustion engine, or an electric motor, or some combination of the two,
such as hybrid electric vehicles and plug-in hybrids.

For legal purposes motor vehicles are often identified within a number of vehicle
classes including automobiles or cars, buses, motorcycles, off highway vehicles,
light trucks or light duty trucks, and trucks or lorries. These classifications vary
according to the legal codes of each country. ISO 3833:1977 is the standard for
road vehicles types, terms and definitions.

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ISO 3833:1977

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ISO 3833:1977

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ISO 3833:1977

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ISO 3833:1977

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ISO 3833:1977

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ISO 3833:1977

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ISO 3833:1977

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2002/24/EC
2007/46/EC

Class L Vehicles
Motor vehicles with less than 4 wheels;
· L1 stroke volume smaller than or equal 50 cm3, max. Speed
50 km/h, 2 wheels
· L2 stroke volume smaller than or equal 50 cm3, max. Speed
50 km/h, 3 wheels
· L3 stroke volume more than 50 cm3, max. Speed more than
50 km/h, 2 wheels
· L4 stroke volume more than 50 cm3, max. Speed more than
50 km/h, 3 wheels
· L5 stroke volume more than 50 cm3, max. Speed more than
50 km/h, 3 wheels, loaded weight max. Smaller or equal 1000
kg.

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2002/24/EC
2007/46/EC

Class M vehicles
Motor vehicles with min. 3 or 4 wheels, good for passengers;
· M1 max. 8 seats incl. Driver and max. Weight 3500 kg.
· M2 more than 8 seats incl. Driver and max. Weight 5000 kg.
· M3 more than 8 seats incl. Driver and max. Weight more than 5000 kg.

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2002/24/EC
2007/46/EC

Class N vehicles
Motor vehicles with Min. 3 or 4 wheels, min. Weight 1000 kg. , good for carry goods;
· N1 loaded weight smaller than or equal 3500 kg.
· N2 loaded weight between 3500 kg – 12000 kg.
· N3 loaded weight more than 12000 kg.

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2002/24/EC
2007/46/EC

Class O vehicles
Trailer or semi-trailer – no engine, no motor.;
·O1 loaded weight smaller than 750 kg. One axle.
·O2 loaded wieght smaller than or equal 3500 kg. Excl. O1.
·O3 loaded weight between 3500 kg – 10000 kg.
·O4 loaded weight more than 10000 kg.

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Turkish Automotive Industry

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Turkish Automotive Industry 1960-2010

1960-1970 Assembly License

Protected
Market
1970-1980 Development of Localization
Component ind.

Increase in
1980-1990 Modernization
Capacity Transition
Period
Up-to-date Up-to-date
1990-1995 Model
Model Export

Free Market 1995-2000 Full integration

Manufacturing Base

Global Research & Development, Design

2000-2012 & Technology Management,
Competition
Intellectual & Industrial Property

TARGET FOR 2012 : CENTER of EXCELLENCE

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 Turkish Automotive Industry
%85 of
Automotive
Suppliers in
Marmara Region

ISTANBUL

Izmit
Adapazar ı
Gölcük

Bursa Ankara
TTF
Eskişehir

Izmir
Konya
Aksaray

Antalya Adana

Temsa

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Standards and Directives

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Please visit web sites of : OSD, TAYSAD, ODD

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Technical Standards & Regulations
Coming from EU

Application Steps
1. Translation of Standards : TSE (Türk Standartları
Enstitüsü)
2. Decleration of Regulations : Ministry of Science, Industry
and Technology – (Official Journal : Resmi Gazete)
3. Approval : Ministry of Science, Industry and Technology
4. Assignment of Technical Service Personal and Lab's.

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 Directives
16 41 78/1015 Motosikletlerde Gürültü
sıra ECE R EEC No İsim
No
17 45 - Far Silicili Araçlar ve Onayı
1 - 70/222 Araç Arka Plakalarının Bağlanması 18 46 71/127 Geri Görüş Aynaları
19 49 88/77 Dizel Motorları Egzoz Emisyonu
2 - 78/316 Araçların İç Donanımları (Göstergeler,
İkaz Lambaları)
20 51 + 59 70/157 Gürültü ve Egzoz Sistemi
3 3 76/757 Sinyaller ve Lambalar
21 52 - 8-18 Kişilik Araçların
4 9 70/157 Üç tekerlekli Araçlarda Gürültü Konstrüksiyonu
5 11 70/387 Kapı Kilit ve Bağlantıları 22 58 70/221 Arkadan Çarpma ve Yakıt Tankları
6 13 71/320 Frenler
23 63 - Mopedlerde Gürültü
7 18 74/61 İzinsiz Kullanmaya Karşı Önlem
24 67 - LPG Kullanan Araç Ekipmanları
8 22 - Koruyucu Başlıklar Onayı
9 24 72/306 Dizel Motorlarında Duman Testi 25 83 70 / 220 Egzoz Emisyonu
10 25 78/932 Koltuk Başlıkları
26 84 80/1268 Yakıt Tüketimi
11 26 74/483 Dış Çıkıntılar
12 27 - Üçgen Reflektörler 27 85 80/1269 Motor Güçleri

13 28 70/388 Kornalar 28 92 - Motosiklet Susturucuları

14 35 - Pedal Konumları 29 96 77/537 Traktörlerde Egzoz Emisyonu
15 39 75 / 443 Geri Vites, Hız Ölçümü 30 101 - Karbondioksit ve Yakıt Tüketimi
Ölçümü
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 Max. Weights Min. Engine Powers
(DIN 70010)
Höchstlast
Max. Weight min.Engine
Min. Motor-
leistung
Power

Tractor + Trailer (5 Axle)

40 t 176 kW

Articulated Bus
28 t 124 kW

Truck (3 Axles)
26 t 106 kW

Truck (2 Axles)
18 t 75 kW

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 Permissible Weights and Dimensions - (Commercial Vehicles)

2 Axles 18 t

12 m
All Types
Top. 40 t
Road Train

18,75 m 4m

Tractor + Trailer 40 t

16,5 m 2,55 m
Articulated Bus

28 t

18 m
Reference: 96/53/EG v. 25.7.96 Yönetmeliği ve Alman Otomobil Üreticileri Birliği (VDA) Yıllık Bülteni 2006.
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Vehicle Subsystems

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 Subsystem Weght * 100 %
Powertrain Overall Weight

Engine + Mounts
Clutch + Gearbox +
Shafts + Joints + Dif.
Fuel + Fuel system +
Fuel tank
Powertrain

Exhaust System

Subsystem Weght * 100 %

Chassis Overall Weight

Steering system

Front suspension

Rear suspension
Chassis

Brake system

Tires & Rims

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Subsystem Weght * 100 %
Body Overall Weight

Body
Part – Subsystem – System Weights

Seats
Body

Windows and Glasses

Other
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