The Art of Design Integration

J. E. “Ted” Robertson
2005 SAE President
 Scenario
• Given
– Body
– Chassis
– Engine
– Transmission
– Wheels/Tires
– Instrument Panel
– Seats
– Fasteners

• Result?
 Scenario

• Given
– Canvas
– Picture outline
– Numbered sections of the picture
– Paint brush
– Numbered paint colors

• Result?
 The Difference is . . .

• Design Integration

The design of multiple parts functioning cohesively in

harmony.

The whole is greater than the sum of the parts.

 3 Types of Designs
• A Component
– Door handle
– Solenoid valve
– Antenna
– Brake pad
– Sensor
– Paint color
• A Subsystem
– Door
– Transmission
– Radio
– Brakes
– Control panel
– Multiple colors
• An Assembly
– Automobile
– Toaster
– Painting
 What makes a great design?
• Meets requirements
– Functional
– Performance
• Fit
• Finish
• Appealing
– Looks right
– Feels right
– Sounds right
– Smells right
 Appealing
• Correct response from senses
e.g. Door handle
• Looks interesting
• Looks comfortable
• Correct height
• Fits hand (ergonomic)
• Easy entry of fingers/hand/glove
• Feels good to the touch
• Moves smoothly
• No noise
• No injector pin indents
• No part # molded in
• No parting line sharp edge
 Appealing
• Correct response from senses (cont’d)
e.g. Door
• Unlatches easily
• Swings smoothly
• Detents apparent but not too shallow or deep
• No squeaks
• No rattles
• Opens wide enough
• Closing reach acceptable
• Closing effort moderate
• Good quality closing sound
• Seals tightly – wind noise/water leaks
• Rub strips for protection
 Appealing
• Correct response from senses (cont’d)
e.g. Brakes
• Brake Feel Index (BFI)
– Pedal travel
– Force vs. deceleration
– Fade resistance
• Function of
– Pedal ratio
– Spring
– Boost
– Proportioning valve %
– Swept area
– Friction coefficients
– Caliper material
– Tires
 The difference is . . .

• Level of detail

• Basic function vs. design with style

• Left brain vs. left & right brain

 Traditional Vehicle Design Areas
• Body exterior

• Body interior

• Chassis

• Electrical

• Power train

• HVAC
 Integration Areas
• Packaging
• Thermal – cooling/heating/insulation
• Noise & vibration
• Performance – acceleration/fuel economy
• Braking
• Ride and handling
• Mass
• Cost
 Vehicle Character or Personality

• Sports car vs. family wagon

• Tuned by integration engineers

 “Integration issues are almost always at the
intersection of designs”
Total Body Chassis Electrical Power Interior HVAC
Vehicle train
Packaging

Thermal

Noise/
Vibration
Fuel
Economy
Fit

Mass

Cost
 Intersections or Nodes
• Examples
– Door to fender
– Exhaust to fascia
– Seat to floor
– Door to body opening
– I.P. to windshield & A-pillars
– Radio to I.P.
– Engine to frame
– Lamp to housing
– Tire to fender
– Wiring harness to bracket or body metal
 How Should Engineers Design?
• Engineers need to think beyond their own
specific domain – e.g. chassis
• Engineers need to be more right brained – put
some character or personality into their designs
• Have a styling person review the design or work
alongside design engineer
• Have integration engineers on a program
• Develop interface documents
 How Should Engineers Design?
(Cont’d)
• Designs should consider:
– Appearance – finish/jewel effect
– DFM/DFA
– Attachment selection (fasteners)
– Mass efficiency
– Cost effective
– Torques
– Look to nature for designs
– Look at architecture – golden ratio
– Correct proportions and shape
 Interface Document
• Contains specifications:
– Tolerances
– Gap
– Flushness
– Corrosion protection or material rules
– Isolation characteristics
– Appearance
– Attachment selection method
– Responsibilities
 Result

Quality designs that

function well and
appeal to the consumer
A Vehicle (and all consumer goods)
are Works of Art
 Thank you.
______________________

Questions ?