PALs

Gradeability, No. of Doors, Vehicle Crash

Ride and Handling Top Speed Emission Fuel Acceleration Drive Type Seating Capacity/ Category, Head Leg Boot Target Coefficient Cooling Stopping MFDD TCD Targets and
Targets Requirements Economy 2WD/4WD Space Space Space of Drag Requirements Distance Requirements
Required Payload Segment

NVH Targets Past

data

GEOMETRIC PARAMETER
CALCULATION

Sub-system Other
Vehicle CG Articulated Packaging
Resistances ROH WB TW Location FOH Conditions Geometric
Space Parameters
TORQUE, Vehicle
POWER, BSFC Type of
FEATURES Suspension Stability
CALCULATOR Systems Sprung Unsprung
GVW FAW RAW
Mass Mass GD
Turbocharging/ Vehicle
Naturally Power Assisted/
Max. Torque Axle Type Tire Sizes Manual Steering Construction
Aspirated Type
Max. Power,
Target BSFC
Type of Front Gear Shift TM/TA,
Type of Engine and Rear No.of DMF/No-
Total Quality Target DMF
Reduction Brakes (Disc/ Speeds
Ratios Drum)

GD
ENGINE GD
Past ENGINE TRANSMISSION GD GD
COOLING AXLES CLUTCH BRAKES GD
data Past
No. of Past Past Past
Radiator data No. of Past
Cylinders data data Type of data Type of Hydraulic
Sizing Shafts data
Axle Loads Clutch Split
Displacement
Top Tank Accumulator
VEHICLE Temperature Gear Ratios Type of
Bearing Spring Pedal Load Sizing (for
SPEED Loads
CALCULATOR Firing Order Hydraulic boost)
Fan Size STEERING GD
Diameter Axle Shifting Type of
Vehicle Speed vs T,P,BSFC Housing RPMs Linkage Pedal Ratio Past
Engine RPM vs RPM Rotor Radius data
Loads
Radiator Type of Steering
Flywheel Core Size Shaft Friction Surface Pedal Free
Type of Material
Maximum Speed Inertia Axle Material Play
Type of Coolant Drum Radius
Rated Recovery Lock-to-Lock
Shaft Coefficient Pedal Angle
Speed System Type of Diameters
Aaxle of Friction Efficiency Floating/Sliding
Coolant Casing Caliper
Flow Rate HEAT LOAD Steer
GD Shaft length Torque Transmission Configuration
CALCULATOR Axle Capacity Boost Ratio
Heat Section for Maximum
Rejected Dead Axle Gear Deceleration Type of Steering
Heat Load Clamp Load Master Cylinder Gearbox
Blower Design Diameter
Past Bearing Parameters Mechanism
Motor Power data Series No. of
Release Pistons
Refrigerant Shaft Wheel Cylinder Steering Pump
HVAC GD Load Diameter
Flow Rate Bearing Pressure
CVJ type Loads Diameter of Brake
Compressor Piston (for Disc
Volumetric Peak Firing Sizing/ Release Travel LSPV Cut-in Brake) Steering
Capacity CVJ Bearing Pump Flow
Efficiency Pressure Diameter Series Rate
Diameter of Wheel
Intake Condenser Spring Cylinder (for Drum
Crankcase Sizing/ Drive Shaft LSPV Slope
Valve Volume Transmission Stiffness Brake)
Timing Capacity Diameter Cylinder Diameter
Heat Rejection
Exhaust Max. Oil Pressure, Evaporator
Valve Temperature Propeller TVD Specs. Booster Type Efficiency of Disc
Sizing/ Shaft Type Type of Shift Brake
Timing Capacity Cylinder Stroke
Mechanism Length
EGR/DOC/ Alternator Speed, Operation Pedal Return Assist Knee-point Load of
Power Propeller
POC/SCR Duct Area Shaft Spring Stiffness Booster Efficiency of Drum
Diameter No. of Brake
Exhaust Gas Min. Oil Pressure, Forks,Rods Linkage Geometry
Temperature Pedal Ratio Threshold Load
Temperature Hose of Booster
Diameter Final Drive
Synchronizer Coefficient of
Coolant Pump Friction between Steering Column
Air/Fuel Power Type Jump-in
Ratio Type of Hydraulic Ratio/ Pressure pad and disc/drum Length
Valves Lever Ratio
Oil Quantity Reflective
Fuel Intake Inertia Knee-point Coefficient of Steering Column
System Clutch Pressure Friction between Diameter
Ratio tyre and ground
Oil Pump Power
Air Filter Pressure Cone torque for Front Brake
Drop vs Flow Rate each gear Line Pressure Steering Column
Curve Energy
Engine Dissipated Drive Shaft Design
Noise
Catalytic Converter Synchronization Rear Brake
Pressure Drop vs Low Idle Time Line Pressure
Flow Rate Curve RPM

Pressure-Crank High Idle Sleeve

Angle Curve RPM Force

Turbocharger Vacuum Shift

Specifications Available Impulse

SUSPENSION GD
Past
CRASH AND
data SAFETY GD
Suspension Wheel Rate Bouncing Scrub Past
Hard Points Front Frequency Radius data BODY AND
CHASSIS GD
Suspension Average Height of
Wheel Rate Pitching Deceleration of
Geometry/ Frequency Toe Crush Can Past
Rear the Vehicle
Layout data
Spring Roll Center Crush Can Natural frequency Chassis
Stiffness Stance Height Camber Body Loads
Length of Restraint Loads
Required System
Damping Front Rear
Coefficient Travel Travel Castor
Space in Front Time to Contact
with Restraint Material used Type of Body
of Engine Construction
Natural Frequency System
Rear Travel Rear Travel
of Suspension
Space in Rear Restraint Method of joining Chassis
of Engine Slack ELECTRICAL Past
of sections Frame
Section AND data
ENGINE ELECTRONICS
Average Vehicle Bumper GD
INTAKE Force required for Beam Sub-frame Method of joining
Crush Stiffness Sections
for sheet metals
Intake Clean Side
Depression Hose Diameter ENGINE Swan Neck Restraint Battery
EXHAUST Offset Specific Capacity
Stiffness Bending Stiffness Torsional Stiffness
Dust Holding Transmission
Capacity Loss Back Muffler Volume Anchorage Crush Can Battery Size
Pressure Zone Minimum Global
Stiffness Minimum Global
Flow Natural Bending Torsional
Uniformity Frequency Frequency Frequency
Index No. of Distance between Alternator
Pipe Sensor dummy and steering Capacity
Hangers Coordinates
Mode Diameter wheel
Air Filter Critical BIW Panel
Volume Shapes Sections Thicknesses
Rubber
Hanger Natural
Dirty Side Hose Stress Stiffness Frequency
Diameter Distribution Mechanism
Selection Glass Thickness
Hanger
Locations Mode
ENGINE Shapes
MOUNTING GD
Past Transmission
data Loss Flow Uniformity
Type of Index of Catalytic
No. of Mounts Converter
Mounts
Insertion Loss
Mount Mount
Positions Orientation Exhaust Pipe
Temperature
Mass Flow Rate Distribution
Mount TRA Direction
Stiffness
Catalytic Converter Stress
Engine Firing Recommended Load-in Distribution
maximum TRA
Frequency
frequency
 PALs FEATURES

Vehicle Category, Vehicle Stability

Segment Systems

Crash Type of
Targets and Suspension
Requirements

Turbocharging/
Cooling Naturally Aspirated
Requirements

Power Assisted/
TCD Manual Steering

Drive Type Axle Type

(2WD, 4WD,
FWD, RWD)
Vehicle
Construction Type
Boot
Space
Tire Sizes

Leg
Space Gear Shift
Quality Target

Head TM/TA,
Space No.of
Speeds

Target Coefficient
of Drag Type of Engine

No. of Doors, DMF/No-DMF

Seating Capacity/
Payload
Type of Front
and Rear
Brakes (Disc/
Drum)

GEOMETRIC PARAMETER
CALCULATION

Vehicle
Resistances

Other Geometric
Parameters

Sub-system
Packaging Space

Articulated
Conditions

FOH

CG Location

TW

WB

ROH

FAW

GVW

RAW

Sprung Mass

Unsprung Mass
Gradeability,
Acceleration Emission Vehicle
Top Speed GVW Fuel Tire Sizes Resistances
Required Requirements Economy

TORQUE,
POWER, BSFC
CALCULATOR

Max. Torque
Max. Power,
Target BSFC

Total
Reduction
Ratios

T,P,BSFC Total Reduction Rated Vehicle

vs RPM Ratios Tire Sizes Speed Resistances

VEHICLE
SPEED
CALCULATOR

Vehicle Speed vs
Engine RPM

Maximum Speed

Vehicle No. of Doors,

Category, Seating Capacity/ Blower Vehicle Speed vs
Segment Payload Motor Power Engine RPM

HEAT LOAD GEOMETRIC DATA: Surface Area,

GD Thickness, Tilt Angle for the following
CALCULATOR
components: Windshield, Driver Side
Glass Panels, Passenger Side Glass
Panels, Rear Glass Panel, Roof,
Heat Load
Floor, Doors, Firewall, Rear Wall,
Insulation Panels
Turbocharging/ Max. Torque Vehicle No. of Doors,
Naturally Emission Max. Power, Type of Engine Category/ Seating Capacity/
Requirements
Aspirated Target BSFC Segment Payload

Past ENGINE
data

No. of Volumetric Peak Firing

Cylinders Efficiency Pressure

Intake Valve Crankcase

Displacement Timing Volume

Exhaust Valve Max. Oil Pressure,

Timing Temperature
Firing Order
EGR/DOC/ Alternator Speed,
POC/SCR Power
T,P,BSFC
vs RPM Exhaust Gas Min. Oil Pressure,
Temperature Temperature
Flywheel Coolant Pump
Inertia Air/Fuel Power
Ratio

Blower Motor Fuel Intake Oil Quantity

Power System
Oil Pump Power
Coolant Air Filter Pressure
Flow Rate Drop vs Flow Rate
Curve Engine
Noise
Heat Catalytic Converter
Rejected Pressure Drop vs Low Idle
Flow Rate Curve RPM
Rated
Speed Pressure-Crank High Idle
Angle Curve RPM

Refrigerant Turbocharger Vacuum

Flow Rate Specifications Available
 Heat
Rejected by Transmission Vehicle Speed vs Coolant Rated
Engine Heat Rejection Engine RPM Flow Rate Speed

GD
ENGINE
COOLING GEOMETRIC DATA: Packaging
Past Limits, Effective Grill Opening Area,
data Radiator-Condenser-Fan Layout,
Air Velocity
at Radiator Position of Radiator with respect to
Engine
Radiator
Core Size

Fan Size
Diameter

Top Tank
Temperature

Type of Coolant
Recovery System

Refrigerant
Flow Rate Heat Load

GD
HVAC
Past
data GEOMETRIC DATA: Packaging
Compressor Sizing/
Capacity Space Available, Condenser-
Radiator-Fan Layout, Seating Layout

Condenser Sizing/
Capacity

Evaporator Sizing/
Capacity

Duct Area

Hose
Diameter

Type of
Valves
 Total TM/TA,
Total T,P,BSFC Reduction Gear Shift No.of
T,P,BSFC Reduction Drive Type vs RPM Quality Target
vs RPM Axle Type Ratios Speeds
Ratios 2WD/4WD

GD
AXLES TRANSMISSION GD
Past Past
data No. of data
Shafts
Axle Loads

Gear Ratios
Bearing
Loads
Shifting
Axle RPMs
Housing
Loads
Shaft
Type of Material
Axle
Shaft
Type of Diameters
Aaxle
Casing
Shaft length
Axle
Section for Gear
Dead Axle Design
Parameters
Bearing
Series Shaft
Bearing
Loads
CVJ type
Bearing
CVJ Series
Diameter
Type of Shift
Drive Shaft Mechanism
Diameter Operation

Propeller No. of
Shaft Type Forks,Rods

Propeller Synchronizer
Shaft Type
Diameter
Reflective
Inertia
Final Drive

Cone torque for

each gear
GEOMETRIC DATA: Packaging
Space Available, GVW, FAW, RAW,
Articulated Conditions (Laden, Synchronization
Unladen, Steering Angles), Wheel Time
Base, Track Width, Tire Sizes
Sleeve
Force

Shift
Impulse

GEOMETRIC DATA: Packaging

Space Available, Tire Sizes
 Total
Reduction T,P,BSFC Shifting Vehicle
Ratios vs RPM Gear Ratios RPMs Stability Maximum
Stopping MFDD Speed
Systems Distance

CLUTCH GD
BRAKES GD
Past Past
Type of data
Clutch data
Type of Hydraulic
Split
Type of
Spring Accumulator
Pedal Load Sizing (for
Hydraulic boost)
Type of
Linkage
Pedal Ratio
Rotor Radius
Friction Surface
Material
Pedal Free
Play
Coefficient Drum Radius
of Friction Pedal
Efficiency Floating/Sliding
Torque Transmission Caliper
Capacity
Boost Ratio
Maximum
Clamp Load Deceleration
Master Cylinder
Diameter
Release No. of
Load Pistons
Wheel Cylinder
Diameter
Diameter of Brake
Release Travel Piston (for Disc
LSPV Cut-in Brake)

Spring Diameter of Wheel

Stiffness Cylinder (for Drum
LSPV Slope Brake)
TVD Specs.
Booster Type Efficiency of Disc
Brake
Pedal Return Assist
Spring Stiffness Knee-point Load of
Booster Efficiency of Drum
Pedal Ratio Brake
Threshold Load
of Booster
Coefficient of
Hydraulic Ratio/ Friction between
Lever Ratio Jump-in
Pressure pad and disc/drum

Clutch Knee-point Coefficient of

Ratio Pressure Friction between
tyre and ground
Spring Front Brake
Assistance Force Line Pressure

Energy Rear Brake

Dissipated Line Pressure

GEOMETRIC DATA: Packaging

GEOMETRIC DATA: Packaging Space Available, Brake Pedal and
Space Available, Clutch Pedal and Lever Geometry, Kerb Weight, GVW,
Lever Geometry, GVW FAW, RAW, Wheel Base, Height of
CG, Deflection of spring Laden and
Unladen conditions.
Power Assisted/
Manual Steering
Ride and Type of Crash
TCD Drive Type Handling Targets and
2WD/4WD Suspension Requirements
Targets
Vehicle
Speed vs
Engine RPM Type of
Tire Sizes Target Vehicle
Suspension Coefficient of Construction
Drive Type Drag Type
2WD/4WD

STEERING GD SUSPENSION GD BODY AND

CHASSIS GD
Past Past
data data Past
Type of Steering data

Chassis
Suspension Bouncing Body Loads Loads
Lock-to-Lock Hard Points Frequency
Angle

Suspension Pitching Material used Type of Body

Steer Geometry/
Configuration Frequency Construction
Layout

Type of Steering Stance Method of joining Chassis

Gearbox Spring of sections Frame
Mechanism Stiffness Section
Front
Steering Pump Travel Sub-frame
Damping Sections Method of joining
Pressure Coefficient for sheet metals
Rear Travel
Steering
Pump Flow Natural Frequency Bending Stiffness
Rate of Suspension Torsional Stiffness
Scrub
Radius
Cylinder Diameter Wheel Rate Minimum Global Minimum Global
Front Bending Torsional
Toe Frequency Frequency
Cylinder Stroke Wheel Rate
Length Rear Critical BIW Panel
Camber Sections Thicknesses

Front
Linkage Geometry Travel Castor
Mechanism
Selection Glass Thickness
Steering Column Rear Travel Roll Center
Length Height

Steering Column
Diameter
GEOMETRIC DATA: Packaging GEOMETRIC DATA: Total Length,
Space Available, Total Length, FOH, Total Height, FOH, ROH, Wheel
Steering Column ROH, Wheel Base, Track Width, CG Base, Track Width, CG Height, GVW,
Drive Shaft Design Height, GVW, FAW, RAW, Sprung FAW, RAW, Sprung Mass, Un-sprung
Mass, Un-sprung Mass Mass, Seating Layout, Trims Details

GEOMETRIC DATA: Packaging

Space Available, Articulated
Conditions, FAW, RAW, CG Height,
Wheel Base, Track Width, Tire Width
 No. of Volumetric No. of Rated
Cylinders Efficiency Cylinders Speed

Intake Valve Displacement Volumetric

Displacement Timing Efficiency

Rated Fuel Intake Catalytic Converter Exhaust

Speed System Pressure Drop vs Valve
Flow Rate Curve Timing

Air Filter Pressure Pressure-Crank Exhaust Gas

Drop vs Flow Rate Angle Curve Temperature
Curve

Turbocharger Air/Fuel
Specifications Ratio
GD
ENGINE
INTAKE GD
Past ENGINE
data EXHAUST Past
data
Intake Clean Side
Depression Hose Diameter Back Muffler Volume
Pressure
Dust Holding Transmission
Capacity Loss
No. of
Hangers Pipe
Flow Uniformity Natural Diameter
Index Frequency
Rubber
Hanger Natural
Air Filter Mode Stiffness
Volume Shapes Frequency

Hanger
Dirty Side Hose Stress Locations Mode
Diameter Distribution Shapes

Transmission
Mass Flow Rate Loss Flow Uniformity
Index of Catalytic
GEOMETRIC DATA: Packaging Converter
Limits Insertion Loss

Exhaust Pipe
Temperature
Mass Flow Rate Distribution
NVH Targets Displacement

Catalytic Converter Stress

Load-in Distribution
No. of T,P,BSFC
Cylinders vs RPM
GEOMETRIC DATA: Packaging
Limits, Tail Pipe layout
ENGINE
MOUNTING GD
Past
data

No. of Mounts Type of

Mounts

Mount Mount
Positions Orientation

Mount TRA Direction

Stiffness

Engine Firing Recommended

maximum TRA
Frequency frequency

GEOMETRIC DATA: Packaging

Limits, Powertrain Mount Orientation,
Powertrain Mass, Maximum allowed
displacement of CG, MOI of
Powertrain
 Crash
Targets and
Requirements

CRASH AND GD
SAFETY
Past
data
Average
Deceleration of Swan Neck
Offset
the Vehicle

Crush Can Natural frequency

Length of Restraint
Required System

Space in Front Time to Contact

of Engine with Restraint
System
Space in Rear
of Engine Restraint
Slack
Average Vehicle Bumper
Force required for Beam
Crush Stiffness

Height of Restraint
Crush Can Specific
Stiffness

Crush Can Anchorage

Stiffness Zone

Distance between
dummy and steering Sensor
wheel Coordinates

GEOMETRIC DATA: GVW, Space

Available, CG Height, Seating Layout
 Vehicle No. of T,P,BSFC
Category, Displacement
Segment Cylinders vs RPM

ELECTRICAL Past
AND
ELECTRONICS data

Battery
Capacity

Battery Size

Alternator
Capacity
 GVW PALs FEATURES

All PALs All Features

GD
MASS
DISTRIBUTOR Past
data

Subsystem Subsystem Subsystem Subsystem Subsystem Subsystem Subsystem Subsystem MASS

1 2 3 4 5 6 7 8 TARGETS

Parameter 1

Parameter 2

Parameter 3

Parameter 4

MASS
MODEL (DLL)

Actual Mass = Sum

of Mass of each
parameter

Mass to be
If Actual Mass < reduced = Mass
Mass Target Target – Actual
Mass

Mass within Target

GD
COST
TARGETS Past
data

Subsystem Subsystem Subsystem Subsystem Subsystem Subsystem Subsystem Subsystem COST

1 2 3 4 5 6 7 8 TARGETS

Parameter 1

Parameter 2

Parameter 3

Parameter 4

COST
MODEL
(ENCRYPTED
DLL)

Actual Cost = Sum

of Cost of each
parameter

Cost to be reduced
If Actual Cost < Cost
= Cost Target –
Target
Actual Cost

Cost within Target