Do you want the trunk release button in your car to be moved from an uncomfortable place under your arm, and the seat to move forward another couple of centimeters?
Previously, this was impossible - car factories reacted to the wishes of buyers for a very long time. Otherwise, they did not pay attention to requests, since in order to fulfill them, they would have to rebuild the entire workflow.
However, the design of machines for the individual needs of customers is no longer yesterday, but today. IN automotive industry Increasingly, computer simulations and virtual testing are being used instead of paper-based design and physical prototyping, everything from individual part to the car as a whole - is created on the monitor screen.
Correspondent" Russian newspaper" I was convinced from my own experience that the future lies with new technologies for product life cycle management. And it is already here. Production racing cars for Formula 1 - one of the brightest examples of the use of digital technologies in the automotive industry.
The headquarters of Red Bull Racing is located in the small English town of Milton Keynes, where the design office, test benches and production of car parts are concentrated in several buildings.
By the way, it was impossible to shoot at the factory - many technologies are secret and even during the tour are hidden behind mirrored windows. office space. Even the doors open with a fingerprint scanner. But you could ask!
And find out, for example, that the team has 700 people. That this season, almost every two weeks, about 60 people and 40 tons of cargo go to the race. Every year, in fact, a new car is created. It consists of 7,000 unique parts, while up to 30,000 design changes are developed and made per season, and only 5 months pass from an idea to a working copy.
The question immediately arises - how is such efficiency achieved? And this is where the time comes to talk about digital production. For example, painting. Did you know that decals on the body of a car cause it to become less streamlined, creating air micro-vortices that reduce speed and increase fuel consumption? So - there are technologies that allow you to make an inscription and "polish" it so that even an extra gram of gasoline is not used up. And one more nuance associated with painting - Red Bull Racing specialists with the help of software products Siemens, for example, found out that the matte or glossy paint of the car, as they say, does not affect the speed.
"The old manufacturing processes are not efficient enough to cope with the increasing complexity of the product and its personalization to individual customer requirements," says Jan Larsson, director of industry and product marketing at Siemens PLM Software. And he continues: for this you must first create digital model products - from the bolt to the final product - the machine. It is necessary to organize the process of collecting customer feedback and operational feedback with them.
And in general, the use of digital production software products is not so expensive. "For a small business, the cost will not exceed several thousand dollars. Of course, the introduction of digital technologies in large-scale production will cost more, but the gain - in increasing its efficiency, responding to the necessary changes will cover all costs," said Jan Larsson.
In a conversation with a RG correspondent, he specified: many Russian enterprises that produce complex science-intensive products, actively use digital technologies. Among them are enterprises of the aircraft industry, power engineering, and the automotive industry.
At the same time, the parallel collective work of designers and technologists in a virtual environment makes it possible to develop control programs at the same time as the part is being designed. This minimizes the production time.
And it allows you to quickly introduce completely new technologies that are still working in motorsport, but it is quite possible that they will soon be in classic automotive industries.
The automotive industry is one of key areas world economy. Annual allocations for research and innovation in the automotive industry exceed hundreds of billions of dollars. The number of jobs in the industry is over 14 million, and total assets are over $2 trillion.
Despite such impressive performance, the industry is constantly experiencing difficulties and is forced to optimize. Permanent changes and additions regarding protection environment, require an upgrade of existing models at the design stage. modern car should be based on fundamentally new developments that meet all the requirements technical progress. The continuous development of technologies in all spheres of life and the computerization of many processes are orienting manufacturers towards the creation of highly intelligent machines.
Among the challenges facing the automotive industry today is compliance with environmental regulations. Russian and foreign manufacturers aim to cut emissions and fuel consumption in half. For this, it is necessary to improve specifications cars by several times compared to previous figures: half measures are indispensable here. The gradual improvement of existing models is more labor- and time-consuming and much less effective than creating new models from scratch.
One of the innovative approaches in mechanical engineering is the use of composite and aluminum materials in the creation of the body, allowing suppliers to reduce the weight of the car by 25%.
Popularity in the automotive industry is gaining development smart cars. Every year, cars look more like personal computers on wheels. It's not just about self-driving cars. Automakers are confident that the ideal modern car must be able to do everything and be as simple as possible to manage. Most of the innovations are predominantly for concept cars, but by analyzing the technologies implemented in these devices, one can understand the direction of future developments in the automotive industry.
A big innovative breakthrough is observed in the development of geolocation systems and computer analysis methods: clear improvements are noticeable automotive systems navigation and security. The world's leading automakers are investing huge financial resources in the creation of user interface, with which the driver will be able to manage the flow of information without being distracted from driving.
The era of programming is leading to complete autonomy of vehicles, which requires the creation of complex codes. Of great interest are safety issues in the automotive industry. Tested and implemented systems that monitor the level of stress, as well as the degree of driver fatigue. It is expected that over time the car will acquire even greater functionality, for example, auto-steer, which will turn on if the system senses a threat to the safety of the driver or traffic.
We summarize: the main global trends in innovative transformations of cars are to change the design of the car, create an unmanned and electric transport, development of mobile service, high-tech production.
Here are some examples of innovative changes in the automotive industry:
- Evolution of manufacturability of materials;
- Engine upgrade;
- Safety;
- Compliance with environmental standards;
- Increasing comfort;
- Automation of management processes;
- Autopilot systems.
What it takes to create innovative cars from scratch
Symbiosis of CAD system (computer-aided design) and calculations of the engineering department
The integrated use of 2D and 3D technologies at the stage of prototype modeling reduces development time. The combination of models and virtualization helps to identify the characteristics of future prototypes at the initial stage of the automotive industry, reduce the cost and time of work.
Modeling
Integration of software application control systems allows:
- Reduce the complexity
- Reduce financial loss
- Increase the efficiency of the installed in the car software.
Systematization at all stages allows you to control the progress of development from the creation of the project to the end of the operational process, and provides full monitoring of shortcomings.
Process Integration
Global projects require special attention when it becomes necessary to make some adjustments and structural changes to an innovative project. For example, at the stage of conveyor assembly when installing rear-view mirrors, many options for parts are offered.
They may have different equipment:
- WITH electric drive,
- manual control,
- electric heating,
- View of blind spots, etc.
The step-by-step execution of autoassembly for each option will be different. The combination of development and regulation processes provides control over production and access to functionality from a single menu. This reduces the product readiness time and guarantees the correctness of the developed technology in the automotive industry. The integrated use of these processes will make it possible to evaluate the manufacturability of components and assemblies, as well as to identify errors or errors at an early stage (marriage or non-compliance of body parts). Thanks to this option, changes can be made at the assembly stage of cars, which greatly simplifies production.
Russian and foreign experience of innovation
The leading innovation trend in both Russian Federation, and abroad is the production of unmanned models vehicles. Such models have already carried out test trips, as well as cargo and passenger transportation.
Uber, in collaboration with Otto, has long had options for implementing such transportation. The fruitful cooperation between the two companies resulted in the emergence of an unmanned truck model and the implementation of self-guided cargo and passenger transportation.
A line of driverless buses has been launched in some European cities and in Hong Kong. They have a relatively low speed of movement - 20 km / h (for safety reasons), which is compensated by absolute safety for the natural environment.
Domestic developments connected with Russian brand KamAZ and Volgabus, which presented projects of Russian cargo drones and buses. The Kamaz project may enter the series in 2022 and will carry out cargo transportation without drivers. Model of the new unmanned bus from Volgabus should analyze online traffic situation, carry out intelligent control process through special software. Another invention from the specified company - car platform unmanned control type MatrЁshka, which will be produced in several modifications: open chassis, minibuses, trucks. According to some reports, prototypes are being successfully tested at the Skolkovo innovation center and will soon begin to run in Moscow parks and Sochi.
Despite the success of foreign and domestic manufacturers in the automotive industry, the era of unmanned vehicles has not yet arrived. Problems with safety and reliability have not yet been 100% resolved, and recent examples of unsuccessful experiments (up to death) slow down the process of introducing new technologies in the Russian Federation and in the world.
The latest case of the Tesla electric car (elon musk's ambitious project) - bright to that confirmation. Model S, which is under the control of the autopilot system, was hit by a truck on the highway, killing the driver. According to the results of the investigation, it was found that neither the driver nor the autopilot noticed the approaching car. This incident was the first accident in fatal when the car was controlled by a computer. The company acknowledged flaws in the autopilot system, although stressed that the future belongs to this innovation system management vehicle.
Modern automotive industry reached unprecedented levels. Latest developments amaze with the courage of fantasy and the skill of embodiment, they seem fantastic. It will soon become clear what innovations will enrich the automotive industry of the future.
Manufacturing process represents a set of actions, as a result of which raw materials or semi-finished products entering the plant are converted into finished products (into a car) (Fig. 2.1). Manufacturing process car factory includes receiving blanks, different kinds their processing (mechanical, thermal, chemical, etc.), quality control, transportation, storage in warehouses, assembly of the machine, its testing, adjustment, shipment to the consumer, etc. The whole set of these actions can be carried out either at several plants (in cooperation), or in separate shops (foundry, mechanical, assembly) of one plant.
Rice. 2.1. Scheme production process
Technological process the part of the production process that is directly related to the sequential change in the state of the object of production (material, workpiece, part, machine) is called.
Changes in the qualitative state relate to chemical and physical properties material, shape and relative position of the surfaces of the part, appearance production object. The technological process includes additional actions: quality control, cleaning of workpieces and parts, etc.
The technological process is carried out at the workplace.
workplace called a plot production area, equipped in accordance with the work performed on it by one or more workers. The completed part of the technological process, performed at a separate workplace, by one or more workers, is called OPERATION. The operation is the main element of production planning and accounting. For example, see fig. 2.2.
Rice. 2.2. Hole drilling; pressing the bearing onto the shaft
The operation can be performed in one or more setups.
Statutory called the part of the operation performed with the unchanged fixing of the workpiece to be processed or the assembly to be assembled. For example, Fig. 2.3.
here the stepped roller is machined on a lathe in two setups.
Position each of the various positions of the invariably fixed workpiece relative to the equipment on which the work is being done is called. For example,
Shoulder milling is performed in two positions; the part is fixed on a turntable mounted on the table of the milling machine.
transition called a part of the operation, which concludes the processing of one surface with one go or several simultaneously operating tools with a constant mode of operation of the machine. When changing the surface to be machined or the tool when machining the same surface or changing the operating mode of the machine when machining the same surface and with the same tool, new transition. The transition is called simple if the processing is carried out by one tool, complex - when working with several tools. For example,
disk processing is performed in several transitions.
Passage one movement of the tool relative to the workpiece is called.
The transition is divided into steps.
Reception is a complete set of individual movements in the process of performing work or in the process of preparing for it. For example, the example of disk processing discussed above includes the following techniques: take a part, install it in a chuck, fix the part, turn on the machine, bring the first tool, etc.
Reception elements- these are the smallest for measuring the fate of the working reception in time. The breakdown of the transition into techniques and elements of the technique is necessary for the rationing of manual work.
To complete a technological or production process, a certain time is required (from the beginning to the end of the process) - this is a cycle.
Cycle- the period of time required to manufacture a part, assembly or entire machine.
We present to you new technologies in the automotive industry, which in soon can become an integral part in the automotive industry. Superplastics are the birth of a new era.
Superplastics.
When it became possible to weave carbon threads into various materials, became possible creation heavy duty plastics. Such materials are capable of withstanding high impact forces while being significantly lighter than conventional impact parts. in collisions and contribute to weight savings.
Some Western companies are working on the development of a hybrid material - plastic with a steel cable woven into it. This inexpensive material will be used in the creation of body elements, interior decoration, bumpers. Such heavy-duty reinforced superplastics do have high strength, but so far they do not look very beautiful. This shortcoming will most likely be corrected soon.
Charging from a rolling car.
Hybrid cars are still not as popular as they deserve to be. And all because there are such harmful snobs in the world who constantly piss off that the battery charge is not enough for a full trip. Plugging such skeptics into the belt should be developing infrastructure and an increasing volume of batteries. A number of leaders in the auto industry, such as Audi, BMW and Mazda, are working on an interesting development - a generator to generate electricity for a battery that is driven by the rolling of a car while driving.
Electric motors in hubs.
In the “shaggy” years, Ferdinand Porsche was already thinking that the electric engine of the car should be located in the hubs, which would greatly expand the space in the car for passengers and the battery. Until now, this idea is in the air, but manufacturers are afraid to position the motors this way, because an increase in unsprung weight can affect handling and smoothness when driving on dusty and gravel roads. However, Protean Electric and Lotus Engineering are conducting research in which two identical Lotus vehicles are tested by company employees for maneuverability and handling.
One of them is equipped with hub motors. According to the test results, it turns out that for the average driver the difference is imperceptible. Small flaws in the management are eliminated by small suspension adjustments. the average driver will not notice the performance degradation associated with the extra unsprung weight, and due additional setting will help to overcome most of the side effects associated with handling.
Nickel-zinc batteries.
Modern urban heavy traffic requires fuel economy. A common thing today is to turn off the engine in a traffic jam or at a traffic light so as not to “smoke the sky”. The trouble is that lead acid battery under the hood is not able to withstand several aggressive stop-start cycles - it quickly discharges if you didn’t have time to ride, but started several times in a row. This problem was solved back in 1901, when Thomas Edison came up with nickel-zinc.
Such a battery does not lose discharge so quickly if you are forced to turn off and start the engine several times in a row. In addition, these batteries are longer term services. Modern company Power Genix claims nickel-zinc batteries weigh half as much for twice the run time. In addition, they are more environmentally friendly in terms of disposal.
Today, the car market is in the midst of fierce competition, because leading brands are making a lot of efforts to offer the customer quality product corresponding to all modern requirements. In this regard, the world market offers the end user a really good range of rubber, which will impress even the most demanding customer.
That is why manufacturing companies are so interested in developing new technologies in the field of car tires, which will allow in the near future to occupy a worthy market niche.
Let's consider what innovations the leaders of mechanical engineering have prepared for their consumers.
Goodyear technical innovations
American Goodyear company once again surprised world manufacturers with the Triple Tube innovation, which could be seen for the first time at the presentation of the well-known motor show in Switzerland. The main achievement of scientists is automatic control air volume inside the tire depending on the type pavement, which will provide the potential owner of this product with additional stability on the road in a variety of situations.
Automatic adaptation provides three different modes tire performance while driving.
- The first one introduces the technology additional stability on the road, as well as automatic vehicle roll resistance, which provides elevated level tire elasticity. It significantly improves the machine's maneuverability on dry surfaces and reduces the length stopping distance, which is achieved due to the increase in the area of contact between the tire and the road.
- The second is equipped with technology for additional vehicle maneuverability in adverse weather conditions, which is implemented in the process of counteracting tire slip. This system provides for a narrowing of the contact area, which, in turn, leads to an automatic increase in its diameter.
- The third mode is relevant during fast driving car and is automatic procedure changing the shape of the wheel to the so-called "conical", which significantly increases the grip of the tire in sharp turns and provides the car with additional maneuverability and stability on the road.
It is also impossible not to highlight the concept of tires BH03, which is another achievement of the Americans. This technology provides for the possibility of producing rubber, which is able to generate electricity on its own, which leads to automatic charging of the car battery directly while driving.
French Michelin Leader Achievements
The engineers of the French company Michelin also do not sit idly by, and today they offer the world market a production technology Michelin tires Tweel, which does not require air at all. The structure of the new wheel consists of a solid metal structure and many polyurethane spokes, which completely solves the problem of wheel punctures, as well as their regular pumping. On numerous studies the innovation has proven time and time again that, overcoming metal spikes, the car continues to move confidently. To date, the company has announced production exclusively for commercial transport, but the creators assure that in the near future we will be able to see this innovation on cars.
Japanese Contribution to the Innovative Progress of Mechanical Engineering
Scientists were no less progressive Japanese company Bridgestone who developed unique technology production of tires Nano-Pro-Tech. It allows you to control numerous properties of the structure and composition of the tire at the molecular level. Thanks to this innovation, it is possible to regulate the content of the components that are part of the rubber and actively interact with each other. This, in turn, provides vehicle benefits such as improved tire traction, reduced gas mileage, shorter braking distances and more, which brings the product to a new level of vehicle stability, safety and maneuverability on the road.
Considering all the above enumeration of scientific and technological progress, we can conclude that the main engine innovative technologies in the field of automobile tire production is high level competition in this industry. This trend will always serve excellent engine to increase the range and improve the quality of products of world manufacturers of car tires, the main goal of which will be the maximum satisfaction of the needs of the end customer. And this means that in the near future we will be able to learn about new achievements and innovations in the field of mechanical engineering.
