Interns / Bachelor theses topicscdhaw.tongji.edu.cn/userfiles/files/20141125... · 15/12/2014 ·...

Interns / Bachelor theses

topics

CDHAW visit 21.11.2014

update 12.12.2014

COMPLETE VEHICLE INTEGRATION

group topic

Conversion of a modern Chinese „FossilFuel“

vehicle into a BEV show car

Integrate, Design, Simulation, Build , Install.

MAGNA Systems

Demo car

• Electrification of an

conventional car by

using MAGNA

Components and

Systems

• Consideration of other

modifcations based on

the MAGNA Group

portfolio

COMPLETE VEHICLE INTEGRATION –

group topic

Description

Requirements

Contact Innovation Pillars

12/15/2014 4

• Program Management

• Target agreement • Project organization • Roles and responsibilities • Project master timing • Risk management • Meeting management • Information matrix • Reporting • Issue management • Change Management • Escalation • Lessons Learned • Project cost planning • Resource planning • Project status monthly review

• Douglas Chester, Technical Director

• +86 21 3119 6388

• [email protected]

Magna Proprietary and Confidential | Not for Distribution or Duplication


group topic PM (Program Management)

PM

CV BIW C&P EE HV EE LV Int/Ext

Description

Requirements


12/15/2014 5

• BiW Integration • BiW Modification Requirements • Redesign Floor Pan and Rear end • Simulation.

– Stiffness – Durability – Structural Safety

• BIW Integration • Packaging study • Battery attachment concept • Modification of panels in Catia • Remove rear parcel shelf ring and redesign to

reinstall panels to meet torsion and bending integrity • Underbody battery location and fixings • High voltage routing and attachments • Cooling duct locations ( wet to dry side) • Additional “ fuel door location” for fast charging port • Adapt current fuel filler for slow charging port • Modifications to engine bay longitudinal to support

new motor position • Simulation loops to meet stiffness, durability, safety,

thightness

• Gary Denton, Chief Engineer BiW & Closures

• +86 21 3119 6436




group topic BIW

Description

Requirements



group topic EE Low Voltage Electrical System

12/15/2014 6

• To show all Magna capabilities, Magna Steyr China is going to build up a pure electric vehicle (BEV), existing of Magna developed and built components and sub systems only.

Within the internship and later on a bachelor / master thesis the following issues should be worked out:

• Understand the low voltage electrical system • Chose the best components of Magna • Set up the architecture of the system • Calculate the power balance with respect to the

availability of electrical energy

• Matthias John, Chief Engineer E/E

• +86/21/3119-8112



Description

Requirements



group topic EE High Voltage Electrical System

12/15/2014 7

• To show all Magna capabilities, Magna Steyr China is going to build up a pure electric vehicle (BEV), existing of Magna developed and built components and sub systems only.


• Understand the high voltage electrical system • Chose the best components of Magna • Set up the architecture of the system • Support the set up of the driving and charging

strategy


• +86/21/3119-8112



Description

Requirements


12/15/2014 8

CHA&PWT Integration • Substitution of all conventional Powertrain parts to

the electric propulsion system

• engine bay modifications • PWT mounts • cooling system adaption • Battery cooling • HVAC system adaption • drive shafts • regen braking implementation • shifter system • Pedals • Tools

Software knowledge requirements

• Microsoft office – Proficient • Catia – Proficient

• Walter SCHIMPL, CE CHA&PWT

• +86 21 3119 6312




group topic CHA&PWT

EPA (Electric Powertrain Assembly)

Description

Requirements


12/15/2014 9

Investigation & validation of the safety & operational characteristics of a vehicle converted to EV

• Assessment of base vehicle targets • CAE analysis of base vehicle v EV version: • Safety: • Front • Side • Rear • Operational Strength • Rough Road/Fatigue • Torsion/bending • NVH • VTF/NTF • Road noise

• Antonio Maresca, CE Vehicle Functional Integration

• +86 21 3119 6279




group topic Vehicle Functional Integration

Description

Requirements



group topic EXTERIOR/INTERIOR

12/15/2014 10

Experienced in developing system requirements to satisfy product/customer personalisation requirements

• Personalisation is catering for the individual requirements of both drivers and passengers to increase their comfort levels


SMARTER

• Drivers seat can be adjusted to suit individual requirements for position, heating and cooling, massage.full leather seating

• Rear seat recline for added comfort. Fully leather

• HVAC airflow is variable for each seating position to allow for occupant climatic comfort

• Steering wheel 4 way adjustment and tilt features for driving and ingress/egress convenience. Fully heated with full control of all car features

• Cooling feature in glove box/centre console/underfloor for food and beverages

• Individual DVD screens for passengers enjoyment

• Variable ‘mood’ lighting according to occupants disposition

• Ian Barton – Chief Engineer Exterior/Interior Systems

• Telephone Number - 0086 - 15618045961


SAFER

Single topics

Description

Requirements


12/15/2014 12

• Optimize pedestrian model for head or leg impact BiW Modification Requirements

• Develop Optimization at MSC – Investigate Optimization processes data – List possible tools – Create report to discuss current

industry tools – Investigate possible design variables – Investigate optimization tools to complete a simple

optimization. – use at least 2 different simulation tools – Investigate robustness analysis – Investigate realistic optimization areas – Investigate and understand 1 aspect of China NCAP

Pedestrian testing

• Morphing – Develop morphing procedure

• Use HyperMorph • Use LsPrePost • List possible tools – Create report to discuss current

industry tools • Integrate morphing process in optimization process

– MSC Requirements of Student • Understand Explicit finite element analysis • Able to create simple crush box analysis • Understanding and interest in Automotive engineering. • Understanding and interest in statistics • Understanding and interest in material science


CV Topics – Optimization / Morphing

SAFER

• Antonio Maresca, CE Complete Vehicle

• +86/21/3119-6279


Description

Requirements


12/15/2014 13

• Investigate forming data. • Implement real world work hardening from stamping

process into CAE modeling techniques to improve correlation.

• The aim to allow reduction of material thickness to reduce overall vehicle mass.

• Investigate forming data • Investigate incremental forming data • List possible tools – Create report to discuss current

industry tools • Investigate mapping forming data to pressed panel mesh. • Investigate one step forming data • Investigate difference between incremental forming and one

step forming. • Discuss processes for hot forming simulation • Investigate and understand 1 aspect of China NCAP Adult

Occupant Protection (Front Impact / Side Impact)

• MSC Requirements of Student • Understand Explicit finite element analysis • Able to create simple crush box analysis • Understanding and interest in Automotive engineering • Understanding and interest in materials science


SAFER

CV Topics – Forming / Stamping

Correlated to test

OneStep data included

No Stamping data


• +86/21/3119-6279


Description

Requirements


12/15/2014 14

• Space Optimize Complete vehicle model • Implement real world work hardening from stamping

process into CAE modeling techniques to improve correlation.

• The aim to allow reduction of material thickness to reduce overall vehicle mass.

• Develop Topology Optimisation at MSC • Investigate Topology Optimisation processes data • List possible tools – Create report to discuss current

industry tools • Investigate possible design variables and various load

cases • Investigate and explain Multi Disciplinary Optimisation

(MDO) • Investigate Topology optimisation tools to complete a simple

topology optimisation. – use at least 2 different simulation tools

• Investigate topology optimisation using implicit analysis • Investigate topology optimisation using explicit analysis • Discuss positive’s and negatives for implicit and explicit

analysis • Investigate and understand 1 aspect of China NCAP Adult

Occupant Protection (Front Impact / Side Impact)

• MSC Requirements of Student • Understand Implicit and Explicit finite element analysis • Able to create simple crush box analysis • Understanding and interest in Automotive engineering. • Understanding and interest in statistics • Understanding and interest in material science



• +86/21/3119-6279


CV Topics – Topology Optimization

Original Design

Optimization Results

Design Space

Description

Requirements


12/15/2014 15

• Newly available material in China • Implement the material characteristics into CAE

modeling. • The aim to allow reduction of material thickness to

reduce overall vehicle mass whilst meeting current NVH targets.

• Develop methodology to simulate Quiet Steel Behavior in CAE Simulation

• Investigate material properties. • List possible tools – Create report to discuss current

industry tools. • Investigate possible design variables and various load

cases • Investigate effect of different design parameters to develop

a design guideline for this material. • Structure, NVH and Safety load case investigation and

correlation.

• MSC Requirements of Student • Understand Implicit and Explicit finite element analysis • Understanding and interest in Automotive engineering. • Understanding and interest in statistics • Understanding and interest in material science



• +86/21/3119-6279


CV Topics – Quiet Steel

CV Topics – Software Knowledge requirements

Software knowledge

– Minimum requirements

• Microsoft office – Proficient

• Hyperworks – Proficient

• Lsdyna - Proficient

– Additional desired Knowlege

• LSopt

• LSTasc

• RADIOSS

• PAMCRASH

• MADYMO

• VRD – Genesis

• Hyperworks – Optistruct

• AutoForm

16 Author Disclosure or duplication without consent is prohibited

Description

Requirements


12/15/2014 17

AWD (All Wheel Drive) Systems • Create a design guide line to minimise the conflict of

objectives in on- and off-road performance

• Summarize the performance targets and methods to proove them

• Show the interrellation between on- and off-road behavior

• Analyse active and passive systems to improve both performances (on and off road)

• Suggest a modular setup of systems providing a cost efficient step by step improvment of performance

Software knowledge requirements • Microsoft office – Proficient • Catia – Proficient

• Walter SCHIMPL, CE CHA&PWT

• +86 21 3119 6312



CHASSIS & POWERTRAIN Topic - AWD

Description

Requirements


E/E Topic - High Voltage Safety Implementation

12/15/2014 18

• More and more the trend is going into the direction of electric driving, either combined with a combustion engine as hybrid vehicle (HEV) or as pure electric vehicle (BEV).

• Any way, inside and underneath the car high voltage components are implemented and mounted.

• To deal and work with those high voltage components means high risk for health and even for life.


• Collecting all Chinese regulations regarding high

voltage safety • Process for being beware of High Voltage Safety

during the whole development process • Development of a guideline/checklist for all high

voltage safety related topics to take care of along the development process


• +86/21/3119-8112



Description

Requirements


E/E Topic - Voice Control

12/15/2014 19

• One of the reasons for severe accidents is the distraction of the driver while doing inputs into the HMI.

• There are voice recognition system available in the

market which are working properly in an office or home environment.


• Find and choose a voice recognition system and

adapt it to the HMI of a vehicle. • Run the system and make it work under noisy

conditions


• +86/21/3119-8112



Source: BMW AG

SAFER SMARTER

Description

Requirements


E/E Topic - Process Development

12/15/2014 20

• To develop a modern vehicle within short time and under a big cost pressure efficient development processes are needed.

• To review, slim down and finally to improve all

processes, is one of the most important issues within a company


• Collect, understand and review all E/E related

processes inside Magna Steyr China. • Come up with proposals for improvements • Create a masterplan including all processes, tasks,

delivery lists, checklists…


• +86/21/3119-8112



SMARTER AFFORDABLE

Description

Requirements


Interior - Exterior Trim Mold Flow

12/15/2014 21

CAE tool used for the design of injection molded parts and tooling.

Mold flow analysis


SMARTER

• Can save in costs and timing

• No proto type tooling needed

• Study can be used by CV for crash testing whilst part is still being developed

• Tooling trails faster as gates in right position and right settings (shot size, pressures, cooling times

• Can be used to change materials with minor modifications to tooling

• Ian Barton – Chief Engineer Exterior/Interior Systems

• Telephone Number - 0086 - 15618045961


SAFER

Fill pattern

Pressure at VP changeover

Pressure at

injection location

Temperature at the flow front

Interns / Bachelor theses topicscdhaw.tongji.edu.cn/userfiles/files/20141125... · 15/12/2014 ·...

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