Design For Package

MPD575 DFX Jonathan Weaver 1

Development History

• Originally developed by Cohort 3 students: – Bill Burnham – John Eddy – Scott Gaboury – Gunnar Ross • Edited by J. Weaver in 2005 and Anita Bersie in 2007 2

Importance of Design for Package

• DFPackage has been part of developing vehicles for a hundred years. • Package Engineering is somewhat newly recognized as a critical part of Product Design •Closely linked to ergonomics, Package Engineering is a noticeable attribute of any automobile and a successful package can mean successful sales, such as the case of the Ford Focus 3

Importance (Cont.)

• Package design is the art of creating a perception of ‘things are where they should be’ in a vehicle (including space ‘where it should be’). (The seat is the right distance from the steering wheel, the headliner is high enough, I can see the curb from here, I can see the back of my car from here…and the kid standing behind it, the door opening is wide enough, I can use the cupholder without spilling my slurpee when I put it in 3 rd gear, etc.) • Package design involves protecting real estate in the vehicle from other component’s intrusion. (the tire doesn’t go through the wheel well when I hit a bump, I can’t get in the back seat without bumping my chin with my knees, my head doesn’t rub on the headliner, the engine doesn’t come through the hood when I give it full throttle, etc.) 4

Design for Package

• Vehicle Package Engineering (VPE) facilitates the development of the entire vehicle. Vehicle Package Engineers work with all the Development teams to help the product come together as intended, defined in the Program Direction Letter (PDL) • These Development teams include: – Design and Release: Responsible for each component – Suppliers: Work with D&R activity – Vehicle Operations: Work with Manufacturing/Assembly • The forum for bringing together each Activity is the Package PAT, usually a weekly meeting, as shown in picture above 5

Occupant and Mechanical

• The Package Attribute in a vehicle is divided into Mechanical Package and the Occupant Package 6

Mechanical Package

• A Package Engineer/Designer would do an under hood or engine compartment mechanical package study – Engine decking – Hood and ground line clearances – Pedestrian crash zone – Electrical, air induction, coolant, and oil routings 7

Package Envelopes

• A Package Designer will create an envelope about some component that has motion (drive shaft, engine, tires, etc.) and store the envelope as CAD data where the Development team can readily see and assess the Package implications • Envelopes are also created by Package for engine decking (the assembly operation of installing the engine), engine roll (space occupied by the power train when under wide open throttle or shipping dynamics) and component wrapping where a 3D CAD part is made by digitally ‘wrapping’ the area to protect for some component or system. 8

Package Envelopes (Cont.)

The following slide shows a tire envelope, which is calculated based on the type of vehicle (car/truck), type of suspension (independent, 4WD, etc.), suspension parameters (turn radius, rack travel, jounce and rebound (up and down) motion of the wheel, etc.) and the size of the tire. Any component, such as a fender, that violates the Tire Clearance Envelope runs the risk of puncturing the tire, or worse!

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Package Envelope Example

Tire Clearance Envelope (transparent) Tire Envelope (Green) 10

Package Deliverables

Mechanical Package • Engine wrapping is performed by wrapping ‘plugpoints’ – the points of extremity, then a ‘wrap’ is calculated and a surface is modeled to protect for the motions a powertrain will experience (shipping, wide open throttle, etc.) 11

Occupant Package

• The Occupant Package is typically studied through a combination of manikins and digital humans • The next slide illustrates how 3D CAD models are made to take up the space that cannot be used in or about a vehicle in order to meet the Requirements or targets • It’s easy to say “we must have 40 mm above the 95%-ile Driver Manikin for headroom” but it’s hard to ‘see’ what that is without some 3D representation. 12

Occupant Package Zones

‘Up’ Vision Headroom ‘helmets’ Direct Vision Shoulder Room Hip room Pedal Zone Armrest Window Controls and Crank Handle Zone 13

What does a Package Engineer do?

• Coordinate the communication between vehicle attribute teams (NVH, Powertrain, Chassis, Body Exterior, Body Interior, etc.) to simultaneously bring to their attention where their components or areas of responsibility concerns Package Requirements • Guides the design of the vehicle system, subsystems and components by communicating Package Requirements to the Product Development teams • Aids in the effort to resolve design issues by applying CAD tools and communicating/presenting alternative solutions to Design teams (simultaneously) • Interprets customer inputs into vehicle design targets and specifications and artistically incorporates them into the Vehicle Engineering process 14

Design for Package with C3P

• Today’s Product Development is done largely with digital tools. • A part is viewed simultaneously as it is stored in the database and accessed by Engineers, Suppliers, Designers and Management. • Issues with the part are logged (tracked) and e-mails are automatically sent to the responsible parties when an issues are written 15

Design for Package Tools

Some of the many Package Engineering Tools: •Ground Clearance Tool •Pedal Package Tool •Ride Height Tool •Luggage Stack Tool •Occupant Accommodation Tool •Direct Vision Tool •Indirect Vision Tool CAD Systems •I-DEAS •CATIA •UniGraphics Human Modeling Software •RAMSIS 16 •JACK

Package Tools Examples

JACK Human Modeling studying ingress/egress (left) and reach zone (right): 17

Package Deliverables

What VPE Produces Occupant Environment Package Attribute Vehicle Architecture •Occupant Accommodation & Roominess •Ingress/Egress •Vehicle Attitude Ride Height Transmittal •Luggage, Cargo and Storage •Ground Clearance •Indirect Vision •Direct Vision •Tire Envelope & Coverage Compatibility •Digital Compatibility •Spare Tire Package & Jacking •Powertrain Package Recovery

Package Deliverables

What VPE Produces Common Supporting Processes • Verification (FDVS) • Target Setting • PAT Meetings • CAD Data Submission • Dimensional Analysis • Package Bucks • Appraisals Reporting •Internal (Local Operating Procedures) •External (Corporate Procedures, Package Study Reports, Seating Package Layouts) 19

Design for Package Escort vs. Focus

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Escort vs Focus

• A good example of a successful Package Engineering is the Ford Focus. This is a product that was designed and manufactured with strong customer input which had a great affect on the vehicle package. • The program team determined early in the PD cycle that Vehicle Package and Vehicle Dynamics were the two attributes where C-class vehicles do poorly, therefore the team set out to exceed customer expectations in these areas.

• To compare two C-class vehicles, we use the Escort, as the Focus was also dubbed the ‘Escort replacement’. The following data show Package improvements. 21

Front Headroom Rear Headroom Front Shoulder Room Rear Shoulder Room Front Hip Room Rear Hip Room Front Seat Compartment Volume (liters) Rear Seat Compartment Volume (liters) Front Belt Height Sgrp-Front Sgrp-Rear Overall Vehicle Length (to show similarity)

Escort vs. Focus

Escort (mm)

993 935 1310 1324 1276 1256 1406 1069 417 241 274 4437

Focus (mm)

997 978 1364 1362 1262 1312 1416 1128 414 292 330 4440 22

Design for Package

•When Designing for Package in Product Development, the Vehicle Package attribute can mean a great success if done right! •Good Package Engineering is gets noticed: “…Lincoln and Mercury customers will see that doing business with a premier consumer company gives them products that are priced, packaged, and serviced right," said Mark Hutchins, Lincoln Mercury president. - June 30, 2000, MOTOR TREND NEWS.

“Ford's packaging engineers have wrought a minor miracle in the rear of the new Expedition.” – August, 2002, CAR AND DRIVER.

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Design for Package

• The Ford Focus is the first vehicle ever to receive, both the North American Car of the Year and the European Car of the Year awards. North American Car of the Year 2000: A jury of 47 independent journalists from Canada and the United States selected Ford Focus as the North American Car of the Year. They selected

Focus because it set a new standard for the small car segment.

• European Car of the Year 1999: Fifty-five journalists in 21 countries voted in the 1999 COTY program and 42 of the 55 journalists scored Focus as their first choice. Focus scored 444 points to the second-place winner's 272.

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Design for Package

Focus is a winner

North American awards

• Automobile Journalists Association of Canada awarded 3 Best New Car Awards 1999: Focus ZTS accepted the winners' hardware for Best New Family Sedan (under $25,000), and Best New Economy Car went to Focus LX. In a tie for first place (with Honda Civic SiR), Focus ZX3 completed the hat trick in the Best New Sports Coupe Category. • Popular Science 1999 "Best of What's New" Grand Award: The editors of popular science review thousands of new products, technology development and scientific achievements. One hundred products are selected for distinction as "Best of What's New." Ten Grand Awards are given across 10 categories-Focus won the Grand Award in the Cars category. 25

Design for Package

Focus is a winner • "Since Focus was launched in Europe in 1998, it has received critical acclaim for many of its attributes, including styling, driving dynamics, interior space and safety," says Scarpello. • Road & Track Ten Best: Ford Focus was named one of the "Ten Best" vehicles in 1999. • Detroit Free Press Car of the Year: Ford Focus was named "Car of the Year" by auto critic Tony Swan of the Detroit Free Press. "I'm also impressed by this car's blend of supple ride and responsive handling, which

conspire to give it a comfort quotient that's near

the head of its class," said Swan. • The Detroit News Personal Favorite: "Of all the new

passenger cars introduced this year by American, European and Asian manufacturers, the Focus

may be our personal favorite. It comes in three distinctly different body styles-a sporty coupe, a more conservative sedan and a practical station wagon…

Even the Japanese could learn something from this well-executed small car."-The Detroit News

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Design for Mechanical Package Example: Powertrain Packaging Strategy

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Overview of Powertrain Packaging Strategy

• Wrapping the vehicle around the Powertrain, change what the customer sees on the outside • Identifies preferred/standardized locations for powertrain components, systems & subsystems for basic architectures (FWD, RWD, AWD) • Use common Powertrain package units across multiple vehicle platforms and programs 28

Goals of Strategy

• Reduce the number of engine and transmission variants at use in vehicles at Automotive Manufacturing Company • Reduce the number of unique Powertrain calibrations (hardware, processor, code, & settings) at Automotive Company • Support common vehicle under hood layout & improve component re-use • Simplify assembly and service procedures by placing items in standard locations under hood

Example: Under hood package locations, Strategy A.

Washer Fluid Mount Alternator Power Radiator Steering Vehicle Front PS Reser voir Air Box 29

Powertrain System Content

Red Circled Items are Included in Strategy

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Desired Benefits of Strategy

• Simplified commodity planning and vehicle matching (stress common, resist added complexity) • Improved networking, work with vehicles as partners instead of powertrain customers • Clarify the overall powertrain strategy for Automotive Company so ground level engineers are more empowered 31

Potential Barriers to Strategy Success

• Cynicism – “We’ve been advocating wrapping vehicles around Powertrains for years, it hasn’t happened yet.” • Organizational Inertia – Vehicle teams perceived as customers who demand and get what they want, “they won’t change” • Management Culture – Must overcome traditional politics and adjust decision making behavior to enable successful implementation of under hood packaging initiative 32

Design for Package References

• • Mechanical Engineering Design, November, 2002 • Auto News, June, 2000 • • • Car and Driver, August, 2002 www.stereographics.com

www.jacksolutions.com

www.memagazine.org/supparch/medesign/puttim g/putting.html

• www.view.iao.fhg.de/aboutview.htm

• The Detroit News, January, 2000 33