VD - Part 01 - Automotive Design Principles

VEHICLE DESIGN
Işık University – MECH 4611
Week #1
Atabay - Istanbul Technical University 1

1886
Today ?
Course Details
Automotive Design Principles
1997

Automotive Industry & Vehicle Park (Worldwide)

Milestones of the Automotive Industry
clean,
accident-free,
autonomous
vehicles
Year
-5000 0 1769 1886 201x
Inhabitant / Motor Vehicle
Inhabitant / Motor Vehicle
7
5 Japan
3 USA
2,2
2,2
2
2,0
Germany
1
0
1975 80 85 90 95 2000 2007
Year
Reference : Tatsachen und Zahlen, 2004, S. 361 ff; VDA 2008.
Passenger Cars Worldwide
800 million passenger cars are operated today !
the same trend

is observed
in Japan
and Europe
Saturation at a
ratio of
approximately 400
to 800 cars per
1000
inhabitants
Schematic representation of the development

of the number of passenger cars operated worldwide
Reference: Guzzella, L., Sciarretta, A., Vehicle Propulsion Systems, Springer, 2007.
Historical and projected increases in global motor vehicle population
1950–2030.
Reference: Sperling, D., Gordon, D., Two billion cars driving towards sustainability, Oxford, 2009.
Chinese cars, trucks, and buses in millions, projected to 2050
Mobility
[m] Distance traveled per person per day

100,000
10,000
All mobility vehicles
1,000
Buses,
Single track Automobiles
100
Rail
Horses Air Rapid rail
Water
10
1800 1825 1850 1875 1900 1925 1950 1975 2000
Reference: Grubler, A., Nakicenovic, N., Schaefer, A., Dynamics of Transport and Energy Sytems. History of Development and
a Scenario for the Future, IIASA, Laxenburg, Austria, 1992.
Mobility - Disadvantages
Exhaust emissions
Noise Traffic jams
Waste of resources Losses of life and property

Cumulative global oil production, 1950–2030
The mismatch between those who have the oil and those who use it, 2006
Automobile Production 1920-2012
70 il. il.
M il. 3 M
,9 M 6
56 6 0
60
50000
50
40000
40
30000
Millions
30
20000
20
10000
10
0
1920 1940 1950 1960 1970 1980 1990 1997 2006 2007 2012
Reference: Verband der Automobilindustrie, 2008. [OICA]
Global Markets
“Triad” Markets (EU,
USA, J)
495 Vehicles / 1000 “Emerging” Markets
Persons**
(22 countries, India,
China, ..., TR)
5,2 Mil. 98 Vehicles / 1000 Persons**
37 Millions
5,5 Mil.
Threshold Countries
(Mexico, Brasil,
South Africa, ...)
195 Vehicles / 1000
Persons**
**Data is given for vehicles that can carry nine passengers at most.
Reference: Dünya Bankası, 2008.

Automotive Design Principles

Time Dimensions and Planning Horizons
in the Automotive Industry
Reference: Naunheimer, H. et. al., Automotive Transmissions, Springer, 2011.

Automotive Engineering
Development
In the development of the motor vehicle, there are three readily identifiable
groups of activities :
• technical innovation and refinement
• construction, configuration and styling
• methods of production, and manufacturing systems.
Reference: Happian-Smith, J., An introduction to modern vehicle design, Butterworth-Heinemann, 2001.

Production and Development
Cycles

Core of Production Activities

Car Develoment Process

Main Issues in Vehicle Design
Technical Issues
- factors related with vehicle technology
- useful volumes and load.
- speeds
- service life
Legal Issues/limits
Economic Issues
- production costs
- operation costs

Vehicle Design
Comfort Environment
150000
km
Economy Quality Active safety
Design Passive safety
Reference: IfF – TU BS
Past...
Benz Patent-Motorwagen Ford Model T

Present...
Mercedes-Benz S-Class
Porsche 911

Future... Sustainable & Safe.
E-Vehicles Accident-Free Vehicles

50 Years of Passenger Car Development
VW Beetle, 1951
Mercedes SL, 1996

"Steer-by-Wire"- Concept Vehicle
Reference: Volkswagen AG / Daimler AG (IfF Lecture Notes)

Design

Concept Election

Main Body Forms
Reference: Braess, H.H., Seiffert, U., Automobildesign und Technik, Vieweg, 2007.
Concept Sketch

Styling Studio

Model Workshop
Daimler AG

Electronic Scan/Mill system

Quick and Dirty Mock Up's

Braess, H.H., Seiffert, U., Automobildesign und Technik, Vieweg, 2007.
Interior Material and Color
Selection
Package
The ‘package’ is the industry’s term for the three dimensional (3D) view, full
sized orthogonal drawings which show the basic mechanical and ergonomic
requirements of the intended vehicle.
Braess, H.H., Seiffert, U., Automobildesign und Technik, Vieweg, 2007.
Package – Today
Reference: ATZ.
Package – Today

Powertrain Motion Envelope
Calculated Engine + Gearbox Motions Static Envelope (Geometry)
Dynamic Envelope
Reference: ATZ.
Package Example : Cooling
Reference: ATZ.
Virtual Design Elements
Proportions
Front Wheel Drive
Rear Wheel Drive
Styling Parameters as Lines or
Proportions
Exterior Design (Rear)
Grill Design – Car Front
Aerodynamic Forces & Moments
Reference : Mitschke, M., Dynamik der Kraftfahrzeuge, Springer, 2004.

Drag Coefficients of Various Bodies
Reference : Gillespie, T.D., Fundamentals of Vehicle Dynamics, SAE, 1992.

Rounding Corners
Aerodynamics
1913, Alfa Romeo
Aerodynamic Development
Interior Design
Mercedes S Class 1954
Mercedes S Class 2005

Reference: Daimler, 2005.
Interior Design
Product Histories
Product Relationships
Safety
Passive Safety
Active Safety

Basic Structure – Saloon Car

Cabriolet - Strengthening
Crash Concept Example
Reference: ATZ.

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VEHICLE DESIGN

Işık University – MECH 4611

Atabay - Istanbul Technical University 1

Atabay - Istanbul Technical University 2

Atabay - Istanbul Technical University 3

800 million passenger cars are operated today !

the same trend

Schematic representation of the development

[m] Distance traveled per person per day

Noise Traffic jams

Waste of resources Losses of life and property

Reference: Dünya Bankası, 2008.

Atabay - Istanbul Technical University 15

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

• technical innovation and refinement

• construction, configuration and styling

• methods of production, and manufacturing systems.

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

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

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

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

Atabay - Istanbul Technical University 21

Economy Quality Active safety

Design Passive safety

Benz Patent-Motorwagen Ford Model T

Atabay - Istanbul Technical University 23

Atabay - Istanbul Technical University 24

E-Vehicles Accident-Free Vehicles

Atabay - Istanbul Technical University 25

Mercedes SL, 1996

Reference: Volkswagen AG / Daimler AG (IfF Lecture Notes)

Atabay - Istanbul Technical University 27

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

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

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

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

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

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

Atabay - Istanbul Technical University 38

Reference : Mitschke, M., Dynamik der Kraftfahrzeuge, Springer, 2004.

Reference : Gillespie, T.D., Fundamentals of Vehicle Dynamics, SAE, 1992.

1913, Alfa Romeo

Mercedes S Class 1954

Mercedes S Class 2005

Atabay - Istanbul Technical University 55

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

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