1. Driving Intelligence G.VIJAY BHASKAR ASST.PROF AUTOMOBILE ENGININEERING DEPT Vehicle Body Engineering

2. Driving Intelligence UNIT I

3. Driving Intelligence Active Vehicle Safety Systems Save Lives We are on the frontier of a revolution in active vehicle safety The technology to improve vehicle stability and reduce crashes is here today Surveys indicate safety systems, like electronic stability control, are highly desired by consumers Electronic stability control saves lives and money according to the latest traffic studies Continental is actively educating key stakeholders on critical active safety technology

4. Driving Intelligence Our Industry is Under Siege

5. Driving Intelligence Crashes Cost Americans $230 Billion 6.3 million passenger vehicle crashes in 2002 $230.6 billion economic cost to society Nearly 3 million injuries and 42,815 fatalities Rollovers accounted for 82% of the increase in fatalities 95% of all crashes due at least in part to driver error 253,000 passenger vehicle rollovers Injuries declined, but fatalities increased Highest number of fatalities since 1990

6. Driving Intelligence The Motor Vehicle Safety Equipment Exists Now to Help Reduce Crashes and Rollovers It’s Called Electronic Stability Control

7. Driving Intelligence Technology is our passion but safety is our business

8. Driving Intelligence Electronic Stability Control Improves Safety We Have Safety Technology Today to Make Mobility Safer!

9. Driving Intelligence The Bottom Line Make the chassis itself electronically intelligent Raise comfort and safety to new levels without sacrifices

10. Driving Intelligence Passive Safety is Job Three The next frontier is to prevent the crash from occurring in the first place

11. Driving Intelligence Active Safety is Job One The key is to prevent the crash from occurring in the first place This is active safety

12. Driving Intelligence Opportunities in Smart Safety Systems The key is to prevent the crash from occurring in the first place

13. Driving Intelligence UNIT II

14. Driving Intelligence Automotive Safety Continuum Phase 1: Avoid problem situations.

15. Driving Intelligence Automotive Safety Continuum Phase 1: Avoid problem situations. Phase 2: Maintain control if trouble begins

16. Driving Intelligence Automotive Safety Continuum Phase 1: Avoid problem situations. Phase 2: Maintain control if trouble begins Phase 3: Protection when the crash is unavoidable

17. Driving Intelligence Automotive Safety Continuum Phase 1: Avoid problem situations. Phase 2: Maintain control if trouble begins Our Focus Should be Crash Avoidance

18. Driving Intelligence Driver Tires Brakes Steering Struts Chassis Mounts Springs Electronics Improved Safety Through Functional Integration

19. Driving Intelligence Networking Active and Passive Technologies Will Improve Safety Accident preventing systems (Global Chassis Control) Stability management systems (Electronic Stability Program, Roll Stability Control, Electronic Stability Program II) Active Safety Accident prevention Electronic brake systems (Anti-lock Brake Systems, Traction Control Systems, Brake Assist) Hydraulic brake systems (brake caliper, brake booster, etc.)

20. Driving Intelligence Networking Active and Passive Technologies Will Improve Safety Accident preventing systems (Global Chassis Control) Stability management systems (Electronic Stability Program, Roll Stability Control, Electronic Stability Program II) Active Safety Accident prevention Electronic brake systems (Anti-lock Brake Systems, Traction Control Systems, Brake Assist) Hydraulic brake systems (brake caliper, brake booster, etc.) Passive Safety Injury prevention Injury preventing systems (OOP, CV) Electronic restraints (Airbags, seatbelt tensioner,..) Intelligent restraints (Satellites, PRP) Mechanical restraints (seatbelts,..) Goal: A vehicle that prevents accidents and injuries

21. Driving Intelligence Continental Brings together Know-How in Tires, Electronics and Brake and Chassis Electronics Brake & Chassis Tires

22. Driving Intelligence Full Circle Before: the industry “needs to do more” on the safety front

23. Driving Intelligence Full Circle Before: the industry “needs to do more” on the safety front Now: we need to do more to make our technology better understood and sought after in the new vehicle marketplace

24. Driving Intelligence Our Challenge: Make Consumers More Aware of Active Vehicle Safety Develop public awareness of these possibilities to engineer a miss… Get them to buy them!

25. Driving Intelligence J.D. Power & Associates Survey Ranked Stability Control among Top 10 Desired Features

26. Driving Intelligence ESC Helps Save Lives Recent study by Mercedes indicates Electronic Stability Control can reduce single vehicle crashes by 30% 30% reduction in the U.S. could save more than 5,000 lives Same Mercedes study indicated total crashes for vehicles equipped with Electronic Stability Control were reduced by 15% Would save American public almost $35 billion Would pay for the cost of installing Electronic Stability Control on all vehicles built in the U.S. some 7-9 times

27. Driving Intelligence Bottom Line in the Mercedes Study: There was a clear drop in the accident rate after standard installation of electronic stability control

28. Driving Intelligence - In Japan - Toyota Study shows 35% reduction in single-vehicle crashes: could save more than 6,000 lives a year 30% reduction in head-on crashes could save another 2,500 lives per year 50% reduction for more severe accidents Confirms Mercedes conclusion that electronic stability control is more effective in the higher speed ranges where vehicle dynamics play a greater part and where crashes that do occur are more severe Electronic Stability Control Helps Drivers Avoid Crashes

29. Driving Intelligence - In Sweden - Swedish National Road Administration Study: Electronic stability control found to reduce accidents with personal injuries Electronic stability control should be implemented in new cars ASAP Consumers should be advised to choose cars with electronic stability control, especially in countries with wet and icy roads Electronic Stability Control Recommended For All New Vehicles

30. Driving Intelligence With fatalities overcoming the safety gains from seat belts and air bags (both passive systems), it’s now the critical time for the industry to embrace ACTIVE safety systems like electronic stability control. Using proven technology to save lives is a necessity Electronic Stability Control Saves Lives

31. Driving Intelligence Raising Consumer Awareness www.drivesaferamerica.org www.esceducation.org

32. Driving Intelligence The Technology to Help Drivers Avoid Crashes Altogether and Make all Vehicles Safer is Within Our Grasp… Are We Ready?

33. Driving Intelligence Active Vehicle Safety Saves Lives We are the frontier of a revolution in active vehicle safety Technology to save lives, help prevent rollovers and reduce crashes is here today – ESC Electronic stability control is as important to safety as airbags, ABS or seatbelts Several recent independent studies from Europe and Asia prove electronic stability control saves lives and reduces crashes and their severity Electronic stability control helps avoid crashes before they happen Actively preventing accidents significantly reduces the number of injuries and will save thousands of lives annually This proven technology is available to the North American driving public today, but most consumers are still unaware it exists

34. Driving Intelligence UNIT III

35. Driving Intelligence INTRODUCTION AERODYNAMICS : Study of forces generated by motion of air on moving body.  CLASSIFACATION OF AERODYNAMICS : external and internal, subsonic, supersonic, hypersonic  FIELDS OF APPLICATION : aerospace engineering, design of automobiles, ships, civil engineering, design of bridges etc.

36. Driving Intelligence AERODYNAMIC FORCES ON A BODY  LIFT (DOWNFORCE)  DRAG  WEIGHT  THRUST

37. Driving Intelligence HISTORY OF EVOLUTION OF AERODYNAMICS IN CARS DESIGN’S IN EARLY 20 th CENTURY :DESIGN’S IN EARLY 20 th CENTURY cars with low speeds, no aerodynamic problems.  CAR’S IN THE EARLY 50’s : CAR’S IN THE EARLY 50’s cars designed for big family’s, complete negligence of aerodynamics.  CARS AFTER 70’s : CARS AFTER 70’s fuel crisis, need of economic designs, evolution of aerodynamics.

38. Driving Intelligence WHY WE NEED TO IMPROVE AERODYNAMICS IN CARS SPEED better aerodynamics higher will be the speeds. FUEL EFFICIENCY better aerodynamics, less work for engine.

39. Driving Intelligence Aerodynamics to make the efficient even more efficient!

40. Driving Intelligence Mythbusters – Tailgait down or up?

41. Driving Intelligence Mythbusters – Tailgait down or up?

42. Driving Intelligence AERODYNAMICS IN MCLAREN F1  SPECIFICATIONS SPECIFICATIONS  FRONT END FRONT END  REAR END REAR END  SCOOPS SCOOPS  WINGS WINGS Mclaren F1

43. Driving Intelligence AERODYNAMIC DEVICES SPOILERS NACA DUCTS  Increase rate of flow  To expose air to areas not exposed to direct air flow.

44. Driving Intelligence METHODS TO EVALUATE AERODYNAMICS IN CARS  WIND TUNNELS Research tool to study effect of air moving over a solid object. Trial and error process. Special pressure paints for analysis. Detailed analysis of air flow patterns. Analyzing for the optimal design.

45. Driving Intelligence AERODYNAMIC IMPROVEMENTS IN THE CAR THAT WE ALREADY OWN  Keep your vehicle washed and waxed  Remove mud flaps behind wheels  Place license plate out of air flow  Avoid roof-racks or carriers  Close windows, close sunroof

46. Driving Intelligence CONCLUSION Aerodynamics in cars is a factor in the over all performance of the car, it should never be compromised.

47. Driving Intelligence UNIT IV

48. Driving Intelligence Back

49. Driving Intelligence Back

50. Driving Intelligence Back

51. Driving Intelligence FRONT END  FRONTAL PRESSURE  PRESSURE DIFFERENCE  MINIMISE FRONTAL AREA  REDUCE cd REDUCE cd Back

52. Driving Intelligence SCOOPS  ENGINE COOLING  INCREASESFLOW RATE OF AIR Back

53. Driving Intelligence REAR END  REAR VACUM  FLOW DETACHEMENT  TURBULANCE Back

54. Driving Intelligence WINGS  PRODUCE DOWNFORCE  REDUCE DRAG Back

55. Driving Intelligence Back

56. Driving Intelligence Back

57. Driving Intelligence COEFFICIENT OF DRAG  Drag = 1/2xd x Cd x A Xv 2  Measure of aerodynamic efficiency. Back

58. Driving Intelligence SPECIFICATIONS EngineType:V12 Curb Weight : 1100 kg. Displacement:6064 cc Horsepower:627 bhp @ 7400 rpm Torque:479 lb-ft @ 4000 rpm Performance0-60 mph:3.2 sec 0-100 mph:6.3 sec Top Speed:240 mph /hr BACK

59. Driving Intelligence Some Background... Cars at first were built entirely of wood, and later of wood frames with steel body panels. In the early 1900’s, the idea of a body-on-frame design came about. These vehicles had a load-bearing chassis that supported all the mechanical parts and a body usual made of steel. Ford Model T Courtesy Car Body Design http://www.carbodydesign.com/articles/2005-04-13-chassis-history/2005-04-13-chassis-history.php

60. Driving Intelligence Moving Forward... Heavy-duty vehicles like trucks and busses still use the idea of body-on-frame. Regardless of the construction technique, steel is still the predominant material used in automotive frames. Today, most smaller vehicles such as small SUV’s and sedans use a unibody (or monocoque) construction. Honda Civic Frame http://automobiles.honda.com/images/2009/civic-sedan/safety/safety-header.jpg

61. Driving Intelligence A Quick Comparison Monocoques Typical Ladder Frame

62. Driving Intelligence What it’s all About Today, the new revolution in car design is the use of new materials in the vehicle structure. As fuel economy restrictions become tighter, manufacturers must find new ways to meet them. This has led them away from using so much steel in the vehicles, and more and more are moving towards aluminum. The central theme of our project was to compare these new lightweight aluminum cars to their steel predecessors and see if anything is being sacrificed and/or gained.

63. Driving Intelligence A Basic Comparison Two common alloys used in car manufacturing: For Aluminum: AA 5182 For Steel: AISI 1020 SteelAl Yield Strength (MPa)294.8395 UTS (MPa) 394.7420 Hardness (HB500) 10458 Data Courtesy efunda http://www.efunda.com/materials/alloys/carbon_steels/show_carbon.cfm?ID=AISI_1020&prop=all&Page_Title=AISI%201020 http://www.efunda.com/materials/alloys/aluminum/show_aluminum.cfm?ID=AA_5182&show_prop=all&Page_Title=AA%205182

64. Driving Intelligence Properties Density of Steel: 7.88 g/cm3 Density of Aluminum: 2.7 g/cm3 Aluminum is about 3 times lighter than steel per unit volume, but can be made just as strong using certain alloys/shapes/bonding methods. Because of this, AL parts can be thicker, and thus stronger, than their steel counterparts, all while weighing less.

65. Driving Intelligence The Cost Issue While Al may seem like a miracle metal for car production, there is a reason not all cars are made from Al... It costs a lot more than Steel.

66. Driving Intelligence The Move to Aluminum The first production vehicle to move to an Al frame was the Audi A8 in 1994. This allowed Audi to make their full-size car lighter than the competitions (BMW, Mercedes,Lexus...), thus giving them the edge in performance & handling. This comes at a price premium though, for instance compared to a Lexus LS460 (Steel framed) which costs around $65,000. The A8 starts at $75,000 Audi A8 Lexus LS460

67. Driving Intelligence An Increasing Trend http://www2.prnewswire.com/mnr/duckerworldwide/37515/

68. Driving Intelligence Cars Utilizing Al Frames Audi A8 Jaguar XJ Corvette Z06 Honda NSX Audi A2 Audi R8

69. Driving Intelligence Weight The most obvious advantage to using aluminum in place of steel in cars is aluminum weighs less. Cars with Mostly Al Space Frames

70. Driving Intelligence Safety Not too many safety tests have been performed on Al framed vehicles due to their usually higher price. However, the Audi A2 is an inexpensive compact car that has been tested, and received overall favorable reviews compared to its steel bodies counterparts.

71. Driving Intelligence Some other advantages... There are some manufacturing methods that can only be done with aluminum, such as extrusions. These extrusions allows the Al Space Frame to have about half the amount of parts as a traditional steel monocoque. Because of all this, Al is already a cheaper material to use for low volume production cars (under 100,000 units a year or so).

72. Driving Intelligence A Few Other Facts... Today, the average car contains about 200 pounds of aluminum parts. Aluminum space frames (like that from Audi), contain fewer parts and fewer connection nodes, which helps keep production costs lower.

73. Driving Intelligence UNIT V

74. Driving Intelligence In The Future While Aluminum may be the wave of the future for now, some exotic car companies are already looking ahead to composite materials. Take for example Porsche Carrera GT, which used a completely Carbon-Fiber monocoque construction in addition to Carbon-Fiber body panels. Because of this, the curb weight of the car was only 3000 lbs., even with a 5.7L V-10 engine powering it. http://andrewbeard.wordpress.com/2009/05/11/technology-carbon-fiber-monocoque-chassis/ Porsche Carrera GT http://upload.wikimedia.org/wikipedia/commons/thumb/6/65/Porsche_Carrera_GT_- _Goodwood_Breakfast_Club_%28July_2008%29.jpg/800px-Porsche_Carrera_GT_- _Goodwood_Breakfast_Club_%28July_2008%29.jpg http://upload.wikimedia.org/wikipedia/commons/thumb/6/65/Porsche_Carrera_GT_- _Goodwood_Breakfast_Club_%28July_2008%29.jpg/800px-Porsche_Carrera_GT_- _Goodwood_Breakfast_Club_%28July_2008%29.jpg

75. Driving Intelligence References Building an aluminum car http://www.allbusiness.com/professional-scientific/scientific-research-development/443897-1.html http://www.allbusiness.com/professional-scientific/scientific-research-development/443897-1.html History of Automobile Body and Chassis http://www.carbodydesign.com/articles/2005-04-13-chassis-history/2005-04-13-chassis-history.php http://www.carbodydesign.com/articles/2005-04-13-chassis-history/2005-04-13-chassis-history.php Automobile Bodies: Can Aluminum Be an Economical Alternative to Steel? http://www.tms.org/pubs/journals/JOM/0108/Kelkar-0108.html Different Types of Chassis http://www.autozine.org/technical_school/chassis/tech_chassis2.htm Aluminum Versus Steel http://www.travistrailer.com/public/pag16.aspx http://www.travistrailer.com/public/pag16.aspx