Lightweight design of a suspension arm by friction stir welding

The research seeks initially to investigate why a greater shift to lightweight technologies for suspension design has not occurred already over the mass market vehicle sector. It outlines the 'knock-on' benefits of lightweight design and identifies roadblocks which hinder progress. Recent annual metrics of vehicle performance related to mass are investigated. Focusing on individual areas of the suspension, benchmarking identifies the best practice amongst current designs. Manufacturing and process engineering strategies are proposed to support the development of lightweight products with considerably improved environmental acceptability.MIG (Metal Inert Gas) welding, universally accepted as the default joining technology in this field, was found to be restrictive to progress due primarily to detrimental effects on metallurgical, dimensional and process variation on both steel and aluminium products. The latest construction materials were reviewed for suspension application, but the focus remained on proposing light weighting solutions for material generically available in economic volumes today, but with new joining technologies to overcome current restrictions in using less of these materials for each component. Following a full review of the joining technologies available for automotive suspension construction, friction stir welding (FSW) was proposed as an alternative joining technology, with FSW replacing MIG in conjunction with extruded aluminium materials. This removed the barriers incumbent in the use of MIG, which demands a more conservative, heavier design to ensure adequate service lifetime. Design concepts were engineered to take maximum advantage of the strategy of aluminium, extrusions, assembled with friction stir welding. Several viable designs were conceived, from which two were developed and compared. The optimum design was then carried forward into a manufacturing feasibility stage. The extrusions were developed for ease of manufacture, and friction stir welding trials progressed on coupons (plain plates) to ensure that the process was viable. Aluminium in the soft and hardened conditions in different thicknesses and joint configurations were successfully friction stir welded during the trial. Future work would develop the extruded aluminium arm further, into the prototype phase, with sample extrusions being manufactured, FSW welded and assembled. Prototypes would then be rig tested to ensure mechanical and durability performance prior to vehicle trials. There are also possibilities in developing high strength thin wall multi-phase steel solutions, utilising Friction Stir Spot Welding (FSSW). This welding technology enhances the selection of high strength steels, as minimal strength is sacrificed during the joining operation

The Development of a Lightweight Electric Vehicle Chassis and Investigation into the Suitability of TiAl for Automotive Applications

A lightweight chassis for a battery electric vehicle being developed at the University of Waikato was required. The chassis was designed around a predetermined body shape and suspension setup. A chassis, built from 20mm thick aluminium honeycomb sandwich panel, was designed and built to LVVTA standards allowing the car to be driven on public roads. The chassis weighs a little over a third the mass of a mass production car chassis. The car has been driven over 1800km with only one minor problem, indicating the chassis is reliable and well suited to its purpose. Titanium aluminide properties were researched to identify where titanium aluminides could be used in an automobile. Titanium aluminides have a specific strength and stiffness near to steel yet only half the density making it an ideal replacement for steel components. Automotive applications identified that could benefit from the use of TiAl include valves, brake rotors and inside 'in-wheel' electric motors

Cal Poly Supermileage Electric Vehicle Drivetrain and Motor Control Design

The Cal Poly Supermileage Vehicle team is a multidisciplinary club that designs and builds high efficiency vehicles to compete internationally at Shell Eco-Marathon (SEM). Cal Poly Supermileage Club has been competing in the internal combustion engine (ICE) category of the competition since 2007. The club has decided it is time to expand their competition goals and enter their first battery electric prototype vehicle. To this end, a yearlong senior design project was presented to this team of engineers giving us the opportunity to design an electric powertrain with a custom motor controller. This system has been integrated into Ventus, the 2017 Supermileage competition car, bringing it back to life as E-Ventus for future competitions. The scope of this project includes sizing a motor, designing the drivetrain, programing the motor driver, building a custom motor controller, and finally mounting all these components into the chassis. The main considerations in this design are the energy efficiency measured in distance per power used (mi/kWh) and the whole system reliability. Driven train system reliability has been defined as the car starts the first time every time and can complete two competition runs of 6.3 miles each without mechanical or electrical failure. Drivetrain weight target was less than 25 pounds, and the finished system came in at 20 lbs 4 oz. Due to the design difficulties of the custom controller, three iterations were able to be produced by the end of this project, but there will need to be further iterations to complete the controller. Because of these difficulties our sponsor, Will Sirski, and club advisor, Dr. Mello, have agreed that providing the club with a working mechanical powertrain, powertrain data from the club chassis dynamometer using the programmed TI evaluation motor controller board, and providing board layout for the third iteration design for the custom controller satisfy their requirements for this project

Lightweighting of double-decker buses

The bus industry is currently undergoing extensive transformation as cities around the world push for the rapid introduction of electric buses. Lightweighting of bus structures is identified by leading experts as one of the key technologies necessary to enable and assist this revolution in the industry. Alexander Dennis Ltd. (ADL) is the UK’s largest bus manufacturer and a worldwide leader in the construction of double-decker buses. ADL consider lightweighting to be one of the three main technological pillars of the company and have thus supported various ongoing research programmes with this EngD research programme funded in collaboration with WMG, University of Warwick. This thesis summarises the outcomes of the EngD programme, the primary objective revolving around the identification of innovative yet feasible lightweighting opportunities applicable to ADL double-decker buses. A systematic review of the state-of-the-art of bus lightweighting followed by a critical analysis of ADL bus structures led to initial feasibility studies of various lightweighting opportunities which in turn led to a lightweighting proposal. An innovative lightweight upper-deck structure design was conceived, developed and proposed to ADL. The holistic redesign of the system achieved a 42% weight reduction whilst also significantly lowering the bus centre of gravity hence enabling further lightweighting of other primary structures. The redesigned upper-deck structures necessitates the novel introduction into the bus industry of two key technologies necessary for its realisation; braided fibre reinforced polymer beam structures and coated polycarbonate glazing. A study on the feasibility of utilising fibre reinforced composites to manufacture cost-effective curved structural beams was carried out. A state-of-the-art review identified a composite manufacturing process consisting of a bladder-assisted consolidation of braided commingled thermoplastic preforms as ideally suited for the bus industry. Tooling was designed and machined to allow demonstrator beams to be manufactured using the proposed method. A finite-element methodology, that would enable the design of these composite beam structures, was proposed and verified though correlation of simulation performance data with data collected from three point bend tests carried out on test beam structures. Design guidelines including considerations of manufacturing volumes and costs were prepared for use by ADL. Investigations on the feasibility of polycarbonate glazing application within the bus industry identified gaps in the knowledge of lifetime performance of polycarbonate glazing exposed to bus industry specific conditions. A novel testing set-up was designed to assess the performance of commercially available coated polycarbonate glazing exposed to a harsh daily bus washing environments. Following the successful identification of a suitable coating system, a demonstrator manufacture programme was set-up. This led to the successful manufacture and planned installation on in-service buses of polycarbonate glazing panels achieving 57% component weight reduction when compared to the current laminated-glass glazing panel

Low magnitude high frequency vibrations applied to the foot through the pedal of a human powered artificial gravity (HPAG) cycle

Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Aeronautics and Astronautics, February 2006."February 2006."Includes bibliographical references (p. 87-88).Astronauts are exposed to hazards unique to space travel. These hazards include radiation exposure and adaptation of the human body to the microgravity environment. For lunar and low earth orbital missions, the exposure period is typically less than six months and return to Earth is less than two weeks away. For travel beyond the Earth's moon, the microgravity exposure time will increase from months to years and return time will increase from weeks to months. Current countermeasures employ impact and high force loading to maintain bone health. An astronaut runs on a treadmill to impact load the weight bearing components of the musculoskeletal system. Elastic bands provide the "down" force for the astronaut while running. For high force loading, the astronaut performs a specified regimen of weight lifting exercises using resistive devices. The resistive devices provide a load in microgravity similar to that of free weights on Earth. These countermeasures have been beneficial in slowing bone adaptation, but have not stopped it. The imperceptible muscle contractions required for posture maintenance may be the absent load that the skeletal system requires to maintain bone health. Unlike the muscles that are required for impact and high force loading, the postural muscles work continuously to keep humans balanced and upright in a gravity environment.(cont.) Jumping, running and even sitting require posture maintenance. Studies have shown that low magnitude loads applied at a high frequency to the weight bearing bones have not only maintained the bone mineral density, but also more importantly, maintained the structure of the bones. This thesis demonstrates the design of a vibrating pedal that delivers a perceptible, low magnitude load at a high frequency ([approx.]30 Hz) to the foot. This design required no external power and was implemented on a Human Powered Artificial Gravity (HPAG) cycle. A device similar to the vibrating pedal device created for this research could benefit society by providing an effective therapy against the disease of osteoporosis. A vibrating pedal could easily be mounted on a stationary cycle, possibly even standard bicycle, and provide a beneficial therapy to the user.by Bruce Naakaii Ts'oh Webster.S.M

DEVELOPMENT OF NORTHROP-GRUMMAN MARK VIIE TRAINING UNIT AND WIRELESS VIDEO SYSTEM FOR USE IN IMMERSIVE ENVIRONMENTS

A training unit has been developed that allows NVESD researchers to develop training simulations within virtual environments to enhance infantry skill and awareness. A ground station was developed to house a computer, power system, and video transmission system. This station will allow for a remote operator to wirelessly send a video/audio stream to the handset. The ground station also allows the use of external video and audio inputs to be sent using onboard converters. Different wireless frequencies were evaluated to determine the best for long-range transmission of content. A handset was developed from a carbon fiber prototype shell. The handset features a video receiver, display, power system, OSD system, and external video inputs. The user can view transmitted video and audio while obtaining real-time GPS feedback from the OSD. The alternate video input allows the handset to be used within the virtual environments developed at the University of Kentucky’s Center for Visualization for virtual environments. This thesis will present the research conducted in order to develop Mark VIIE training unit including the requirements for the project, the desired functionality, the NVESD provided equipment, the analysis of the prospective components, the design of custom fabricated parts, and the assembly and integration of the components into a complete system

Strike 3000: Standing Electric Trike

In the past decade there has been much research conducted on maintaining a healthy lifestyle, even in sedentary activities. It is clear to see this trend in the rising popularity of standing desks, ergonomic mice and keyboards, and the plethora of applications that remind the user not to stay inactive for too long. Ken Howes suggests that this revolution be brought to the world of motor vehicles with his proposed concept of the Strike 3000: an electric-powered three-wheeled vehicle that keeps the operator in a standing position while still maintaining all of the functionality and reliability of a standard automobile. To accomplish this goal, the members of Team 4 conducted thorough technical research into existing patents, competitive designs, and literature concerned with the essentials in designing a vehicle. With the information that was gathered, Team 4 then began to generate design concepts for every component of the vehicle including the chassis, steering, braking, suspension, etc. Together the team generated over one-hundred and fifty concepts. The team also conducted a Quality Function Deployment comparison to create a visual representation of how each component of the vehicle will help meet the wants of the sponsor as well as a comparison between the Strike 3000 and other competitive products. This gave the team a better understanding of what components were important to focus on and which could be sacrificed in order to improve the most essential parts. After the foundation work of the design was completed, Team 4 and Ken Howes collaborated to design a chassis to the aesthetic standards of Mr. Howes’ proposed design while making necessary revisions to keep the design technically acceptable. At the start of the second semester, Team 4 had sent out a final design and engineering drawing to a local welder for construction of the chassis. They ordered all the parts to be implemented into the vehicle. When the chassis arrived they began assembling the vehicle in the Kirk Machine Shop so that custom parts, such as suspension mounts and tie rods could be welded and modifications to the chassis could be made accordingly. The team was able to finish the construction with a lot of help from Nick Ladyga, a member of the team who lead the build effort. The motor was not able to be installed by the time of the Design Showcase but with technical documentation and guidance the team will be able to help Mr. Howes complete the vehicle in a short amount of time

Advanced Mobile Robotics: Volume 3

Mobile robotics is a challenging field with great potential. It covers disciplines including electrical engineering, mechanical engineering, computer science, cognitive science, and social science. It is essential to the design of automated robots, in combination with artificial intelligence, vision, and sensor technologies. Mobile robots are widely used for surveillance, guidance, transportation and entertainment tasks, as well as medical applications. This Special Issue intends to concentrate on recent developments concerning mobile robots and the research surrounding them to enhance studies on the fundamental problems observed in the robots. Various multidisciplinary approaches and integrative contributions including navigation, learning and adaptation, networked system, biologically inspired robots and cognitive methods are welcome contributions to this Special Issue, both from a research and an application perspective

Construction, Operation and Maintenance of Network System(Junior Level)

This open access book follows the development rules of network technical talents, simultaneously placing its focus on the transfer of network knowledge, the accumulation of network skills, and the improvement of professionalism. Through the complete process from the elaboration of the theories of network technology to the analysis of application scenarios then to the design and implementation of case projects, readers are enabled to accumulate project experience and eventually acquire knowledge and cultivate their ability so as to lay a solid foundation for adapting to their future positions. This book comprises six chapters, which include “General Operation Safety of Network System,” “Cabling Project,” “Hardware Installation of Network System,” “Basic Knowledge of Network System,” “Basic Operation of Network System,” and “Basic Operation and Maintenance of Network System.” This book can be used for teaching and training for the vocational skills certification of network system construction, operation, and maintenance in the pilot work of Huawei’s “1+X” Certification System, and it is also suitable as a textbook for application-oriented universities, vocational colleges, and technical colleges. In the meantime, it can also serve as a reference book for technicians engaged in network technology development, network management and maintenance, and network system integration. As the world’s leading ICT (information and communications technology) infrastructure and intelligent terminal provider, Huawei Technologies Co., Ltd. has covered many fields such as data communication, security, wireless, storage, cloud computing, intelligent computing, and artificial intelligence. Taking Huawei network equipment (routers, switches, wireless controllers, and wireless access points) as the platform, and based on network engineering projects, this book organizes all the contents according to the actual needs of the industry