Powertrain Assembly Research Articles

A new vision for the automation systems engineering for automotive powertrain assembly

Pressure on the powertrain sector of the automotive industry is mounting as market demand for higher variety and lower-cost automation systems increases. To maintain the market competitiveness, design-to-market time for new products should be significantly shorter and considerable cost saving needs to be made during the design and manufacture of production facilities. Virtual construction, test and validation of systems prior to build are now identified as crucial because engineering changes owing to untested designs cannot be afforded any longer, and approved designs need to be reused more efficiently. In this article, the authors report research collaboration between Loughborough University and Ford Motor Company, to improve the current business and engineering model used in the powertrain industry. The current problems are highlighted and corresponding industrial engineering requirements are specified. The existing end-user and supply-chain interaction models are captured and new business and engineering interaction models are proposed to address the requirements. A set of engineering services required for the new interaction models is described and an evaluation approach to identify the impact of the new model on the current enterprises is explained. In addition, an overview is given on the research findings on the predicted impacts on the current businesses based on a set of evaluation criteria.

Engine mount optimisation for vibration isolation in motorcycles

This paper presents a comprehensive model to capture the in-plane dynamics of a motorcycle system to evaluate the quality of its vibration isolation, and the design of an engine mount system. The model consists of two main structural components, the frame and the swing-arm, as well as the power-train assembly, engine mounts connecting the power-train to the frame, and the front-end assembly. The model accounts for frame and swing-arm flexibility using reduced order finite-element models. The power-train assembly is modelled as a rigid body connected to the frame through the engine mounts and to the swing-arm through a shaft assembly. The engine mounts are modelled as tri-axial spring-damper systems, and the front-end assembly is modelled as a lumped mass. The complete vehicle model is used to solve the engine mount optimisation problem, so as to minimise the total force transmitted to the frame while meeting packaging and other constraints. The mount system parameters – stiffness, position and orientation vectors – are used as design variables for the optimisation problem. The imposed loads include forces and moments due to engine imbalance as well as loads transmitted due to high amplitude, low frequency bump loads, through the tyre patch. Since packaging constraints play a significant role in a motorcycle layout, it is, therefore, important to determine the displacement envelope of the power-train under extreme loading conditions to ensure clearance with other components around the power-train. A motorcycle mount system should ideally be able to isolate the frame under steady-state loading conditions and at the same time limit the maximum excursion of the power-train under transient loading conditions.

Implementing a platform strategy for a systems business via standardization

PurposeThe benefits of a platform strategy in volume product businesses are well established. Such a strategy can also pay dividends in a low‐volume systems or projects business. The benefits include increased engineering efficiency, higher solution reliability and reduced direct costs. The purpose of this paper is to describe the mechanism for the implementation of such a platform strategy via a design standardization initiative and discuss the technical challenges involved. The paper describes the case of the automotive powertrain assembly line business.Design/methodology/approachFor the past three years, the authors were an integral part of the engineering teams at four systems businesses, automotive suppliers with a global footprint, driving the process of standardization and engineering platform development. The concepts presented in the paper were developed and validated during the course of this effort.FindingsImplementation of an engineering platform can succeed via a design and work process standardization initiative embedded in a strong business context. The problems involved – technical, organizational, and cultural – must be dealt with simultaneously and comprehensively.Practical implicationsThe practical steps that need to be taken and the comprehensive approach required to implement platform concepts in a systems/projects business are highlighted.Originality/valueThere is considerable literature on the planning and design of product platforms. However, there is less discussion of how to implement these platforms in practice considering the organizational constraints and legacy products. Further, there is even less published literature on platform development for complex systems treated as products.

Frame Flexibility Effects on Engine Mount Optimization for Vibration Isolation in Motorcycles

This paper examines the influence of frame flexibility on the optimization of an engine mounting system for enhanced vibration isolation in motorcycles. A theoretical model is developed to represent the structural dynamics of an engine mount system in motorcycles. The model consists of the power-train assembly, modeled as a six-degree-of-freedom (DOF) rigid body; the swing arm assembly, connected to the power-train through a coupler shaft assembly; and the frame, connected to the power-train by elastomeric mounts and to the swing-arm through the rear suspension. Two models of the flexible frame are developed for analysis. The first model uses an equivalent stiffness matrix of the frame, derived from its finite element model, in terms of the nodes connecting the frame to the other subsystems. The second model is based on a dynamic model of the frame as well as the swing arm derived from their respective finite element models. The optimization procedure minimizes the load transmitted to the frame while constraining the engine displacement due to imposed loads within prescribed limits. The mount stiffnesses, locations and orientations are used as design variables. Examples are presented to demonstrate the influence of frame flexibility on the force transmitted to the frame.

First robotized assembly line for multivalve cylinder heads in Europe

Outlines the development of new automated assembly methods for the automotive industry currently being undertaken by ABB Flexible Powertrain Assembly GmbH based in Langenfeld, Germany. Describes the application of these jointed‐arm robots in Audi’s plant in Györ, Hungary and illustrates the benefits of the new system.