Transportation & Manufacturing

Intro to Manufacturing

Presenters

• Daron Fuglsang - Automotive Design Process• Justin Ashton - Body and Assembly• Cory Larson - Engine and Assembly• Evan Rortvedt - Electronics and Assembly• Ben Schlappi - Management Techniques

• Automotive Design Process• Processing Techniques• Manufacturing Management Techniques• Transportation of Manufactured Products

Main Points

Automotive Design is the first process of manufacturing a vehicle.

Automotive Design Process

Road Vehicles That Undergo The Design Process

• Automobiles• Motorcycles• Trucks• Buses• Coaches• Vans

Topics Addressed By Design team and Automotive Engineers

• Safety Engineering• Fuel Economy/Emissions• Vehicle Dynamics• NVH Engineering• Performance• Shift Quality• Durability / Corrosion Engineering• Package / Ergonomics Engineering• Climate Control• Drivability• Cost• Program timing• Assembly Feasibility

The Four Main Aspects of The Designing Process

• Exterior Design• Interior Design• Color and Trim Design• Graphic Design

Exterior and Interior Design Process

• Drawings• Drawings get approved • Clay and or digital models are designed (3D

software such as AutoCAD, and Solidworks)• Full sized version is created using CNC Milling

Machines and clay

Topics Addressed for Exterior Design

• Proportions• Shape• Surfaces of the vehicle

Topics Addressed for Interior Design

• Proportions• Shape• Placement• Surfaces for the instrument panel• Seats• Door trim panels

Color and Trim Design

• The designer is responsible for the research, design, and development of all interior and exterior colors and materials used on a vehicle.

• Designers draw inspiration from other design disciplines such as: industrial design, fashion, home furnishing, and architecture in order to address the consumers level of comfort.

Topics Addressed by Color and Trim Designer

• Paints• Plastics• Fabric designs• Leather

• Grains• Carpet• Headliner• Wood trim

Graphic Design

• The process of advertising or communication using text and images to present information.

• The design team is also responsible for creating graphics for items such as: badges, decals, dials, switches, kick or tread strips, flames, racing stripes, etc

Clay Models• Since the 1930’s automotive engineers and design teams have been using clay to show the design of a new automobile.

• Sculpting the clay to an exact replica of the new automotive design is guided by the CNC Milling machine.

• The CNC Milling Machine is a computer guided router that sculpts the detailed design into the clay model to the exact measurements put into the computer. http://www.youtube.com/watch?v=7lKg

3uC0mqw&NR=1

Conclusion Automotive Design

• Designs will continue to meet consumer’s needs– Safety – Entertainment

• Designs will be beneficial to the environment– Pollution– Materials

• Design process will become even more computer aided– CNC Milling Machine– Computer Software

Processing Techniques

• Body and Assembly • Engine and Assembly• Transmission and Axle Assembly• Brake and Assembly• Suspension and Assembly• Electronics and Assembly

Body

Body

Bodies are constructed of Sheet metal and Hydro formedMetal tubes

The tubes give the body extra rigidity and strength In higher stress areas

These areas include, rooflines,mounting points, and frame rails

Body continued

Body panels and tubes are welded together via robotic welders.

Body continued

• This is a crucial step because many cars on the road today are of a uni-body construction, meaning the frame and body are one piece.

• Human error can cause flaws and stress the integrity of the construction

Body Continued

• After the body has been manufactured it is primed then painted to protect the metal against the elements and it also gives vehicles their desirable look.

Body Continued

• After Paint, the rest of the vehicle is assembled and manufactured. The interior is installed along with other body panels.

• Body panels can be made out of several things, from sheet metal to plastics.

Body/Interior

• After all the body panels are installed, assembly line workers install pre-manufactured interior parts, form other providers.

• This allows for quicker assembly time

Conclusion Manufacturing of Body

• As robotics become more advanced the less human contact will be needed, therefore cutting down on human error.

• Different materials are being discovered and created allowing the bodies and frames of vehicle to be lighter, stronger, safer and environmentally friendly.

• New processes and techniques are being developed to cut down on time and up quality.

Engine

http://www.youtube.com/watch?v=oY2O-u0hJFk ( Ferrari Engine Production Video)

Parts like the connecting rods are made through sintering

Sintering is a process where metal powder is place into a die and put under pressure.The die is then heated and the metal powders come together to form a solid.

Other parts such as the intake manifold are casted.

After the parts are made inspection and finally assembly take place

Transmission Connects the vehicle’s engine to the drive train, uses multiple gear ratios to obtain optimum engine power under varying loads.

Housing- Is cast with Aluminum, then machined to specifications.

Oil pan and covers- Made from stamping sheet metal.

The combination of these two processesLowers the cost of these exterior parts.

Internal Gears & Differential

Internal Gears are used in Automatic and Manual Transmissions.

They change the direction of the output shaft and create different ratios.

Gears are manufactured by “cutting”Or grinding a gear blank on a CNC mill

Specialized or short production runs increase the cost of these parts dramatically.

Another factor to consider is the number of operations needed to produce the part.

Ex. GM Ring and Pinion Gears3 2 cuts

AxleShaft-made from Chrome-Moly tube

Splines- Machined with CNC mill,Then heat treated for strength.

Bearing Surface- Polished for easyInstallation.

BrakesRotors & Drums-Start with a steel blank, then machined to specification.

From top Left to Bottom Right:

Brake drums being casted with “Lost Foam Technique”

Brakes ContinuedPads- Backing-made from stamped steel. Lining Material-Ceramic or Metal fibers enclosed in a matrix. These two are then bonded together.

Shoes- Only major difference is lining is riveted to the backing.

Brakes Continued

Wheel cylinders and CalipersAre made from cast Aluminum and Then bored to accept pistons, seals, Springs.

Suspension

• The suspension of a vehicle can vary. It can have coil spring, strut, torsion bar or leaf spring, and each have their pros and cons.

• Each style of these are manufactured to each specific vehicle style. This includes the type of material and ‘spring rate’ or softness of the spring.

Conclusions toEngine, Transmission, and Suspension

Manufacturing

• #1-CNC Mills will become more complex • #2-Less skilled labor to operate needed• #3-This will be a “continuous process”• #4-Create unique ways to eliminate the

number of operations

ElectronicsThe electrical systems base components are the battery and the alternator. The alternator recharges the battery, which (battery) is used to power anything electric in the car, including starters, radios, and spark plugs. One of the more important electrical components is the ECUAlternators

Automotive air conditioning parts

Automotive battery terminals

Automotive fuses

Automotive relays Automotive switches

Automotive wire

Battery isolators Car air conditioners

Car batteries Car heaters Ignition coils

Ignition switches Power door locks

Power windows Regulators Spark plugs

Starter motors Vehicle DC motors

Sparks plugs are made up of a shell, side electrode, insulator, and center electrode.

Shell- steel is heated and extruded through a die

Side electrode-made of nickel alloy and is welded to the shell

Insulator- made of ceramic material casted in rubber molds

Center electrode- made of nickel alloy and is electric welded along the center of the insulator.

Parts are made through a continuous in-line assembly process

Manufacturing of Electronics Conclusion

• As the world is looking for petroleum alternatives, electricity is going to be playing a big role.

• More and more hybrid cars are reaching the market, and automotive electrical components are becoming more complex

• Auto makers are going to have to adjust for the new car make ups

Manufacturing Management Techniques

• Lean Manufacturing-– People are broadly trained rather than specialized– Communication is informal and horizontal among line workers– Equipment is general purpose – Work is organized in terms, or cells, that produce a group of similar products.– Supplier relationships are long-term and cooperative.– Product development is concurrent, not sequential, and is done by cross-

functional teams

Just-In-Time Manufacturing Manufacturing of parts as they are needed.

• Elimination of Waste• High Quality• Value-added manufacturing• Discovery of problems and preventing them• Large Warehouses are not necessary

Kaizen(continuous improvement)

• Base around 5 fundamentals– Teamwork – Personal Discipline– Improved Morale– Quality Circles– Suggestions for Improvement

ConclusionManufacturing Management

• Just-in-Time Manufacturing will continue to gain popularity.

• Helps cut waste material and wasted time. • Helps cut large amounts of over head. • Helps reduce the amount of raw material on

hand.

Transportation of Products

• Truck Freight • Air Freight • Sea Freight • Rail Freight

Brief History of Trucking• First started by a Frenchman in 1769 who used his

tractor to haul artillery around.• By the 1890’s many new more road worthy haulers

were developed.• After 1910 was when the common tractor trailer look

appeared.• The 1920’s brought the interstate rage which led to

bigger better trucks allowing for more freight movement and this really gave the manufacturing industry its big jump start.

• The rest is history

Brief History of Railroad

• The U.S. system was based off of England’s developing system as it competed against the canal system.

• In the 1860’s the first Transcontinental Railroad was built across America allowing freight and manufactured parts to be moved from coast to coast again giving the manufacturing industry a jump start.

Brief History of Sea Freight

• The idea to use ships at sea to move and transport goods has been around since man has discovered that wood floats and was able to create the first crude rafts.

• The sea created almost no limitations, for water came into contact with all major cities and their industries.

Brief History of Air Freight• Ever since long distance flight was capable, the

promoters of aviation looked for practical uses for the airplane.

• They came up with the idea to use them to carry freight.

• The first couple of tries were only somewhat successful but after some modifications in the 1920’s, it opened up a new door in merchandise and manufactured goods transportation. It allowed businesses to be more efficient.

• The rest is history

Rail FreightMost economical for large and heavy freight.And if you are close to a rail head at pick up and drop off points.

Truck FreightNo restrictions on size, location or destination.Typical price range is $100 to $250.Average lead-time is 1 to 3 weeks.

Air Freight-The transportation of manufactured goods through air is an economical way for fast over seas shipment.Air Freight cost can be $250 or more.-It has no limitations, due to road, rail or land. That is needed is a big flat area to land and take off.

C - 17

MRAP being loaded on C-17

Sea Freight• Shipping manufactured

goods by sea is very cheap for transporting large amounts of freight at one time to the same location over seas.

Petroleum Alternatives• Currently our country is in a big Go Green trend• Engineering new environmentally friendly ways to power vehicles.• Current alternative include

– Alcohols - ethanol and methanol. – Compressed natural gas (CNG) - natural gas under high pressure. – Electricity - stored in batteries. – Hydrogen - a very special type of gas. – Liquefied natural gas (LNG) - natural gas that is very, very cold. – Liquefied petroleum gas (LPG) (also called propane) - hydrocarbon gases under low pressure. – Liquids made from coal - gasoline and diesel fuel that doesn't come from petroleum. – Biodiesel - a lot like diesel fuel, but made from plant oil or animal fat.

• Change the manufacturing process of vehicles– Need to accommodate new assembly machines and the like

Petroleum Alternatives• Hybrid Vehicle- A vehicle that combines two or more power sources to

provide power.– Reduce emissions, and improve mileage

Hydrogen Vehicle- Turn hydrogen to power trough either combustion, or use of fuel cell.- Combustion- hydrogen is burned in the engine- Fuel Cell- hydrogen is combined to produce water and electricity.

Conclusion-What Lies in the future of Manufacturing and Transportation

• More hybrid vehicles will be put on the market, including commercial vehicles.

– Freightliner offers hybrid trucks

• Hydrogen power will be explored and introduced as well to commercial vehicles.

– Currently fuel cells are being tested in aircraft by Boeing– Being used in Buses as well

Ideally every vehicle in the future will be running on some sort of renewable petroleum alternative fuel.

References• Valuebasedmanagement.com

http://www.madehow.com/Volume-1/Spark-Plug.html

http://www.globalsources.com/gsol/I/Automotive-Electronic-manufacturers/b/2000000003844/3000000151410/-1.htm

http://www.answers.com/topic/trucking-industry-2

http://en.wikipedia.org/wiki/Rail_transport_in_the_United_States

http://www.century-of-flight.net/new%20site/commercial/history%20of%20air%20freight.htm

http://auto.howstuffworks.com/engine6.htm

References• Valuebasedmanagement.com

http://www.madehow.com/Volume-1/Spark-Plug.html

http://www.globalsources.com/gsol/I/Automotive-Electronic-manufacturers/b/2000000003844/3000000151410/-1.htm

http://auto.howstuffworks.com/engine6.htm

http://youtube.com/watch?v=0YgxRanYd6E

http://youtube.com/watch?v=sRKL6hDng-Q

http://youtube.com/watch?v=mJkdk50zjuE

References

• Enterprise Automotive Systems• Currie enterprises• Yukon axle• Allison transmission• KP Metallurgical Casting Company Limited• Wilwood• Stop-Tech• Holden Manufacturing