Creation of a new design from concept to realization

The planning, design, engineering and develop-ment of a new motor car is an extremely complex process. With approximately 15 000 separate parts,the car is the most complicated piece of equipment built using mass production methods.

Every major design project has its own designteam led by a design manager, and they stay withthe project throughout. The size of the team variesaccording to the progress and status of the project.
The skill and judgement of the trained and experi-enced automotive designer is vital to the creation of any design concept.
To assist in the speed and accuracy of the ensu-ing stages of the design process (the implementa-tion), some of the most advanced computer-assisteddesign equipment is used by the large vehicle manufacturers. For example, computer-controlledmeasuring bridges that can automatically scanmodel surfaces, or machines that can mill surfaces,are linked to a computer centre through a highly sophisticated satellite communication network.
The key terms in computer equipment are as follows:
Computer-aided design (CAD) Computer-assisted design work, basically using graphics.
Computer-aided engineering (CAE) All computer-aided activities with respect to technical data pro-cessing, from idea to preparation for production,integrated in an optimum way.
Computer-aided manufacturing (CAM) Pre-paration of production and analysis of product ionprocesses.
Computer-integrated manufacturing (CIM) All computer-aided activities from idea to serialproduction.
The use of CAE is growing in the automotive indus-try and will probably result in further widespread changes. Historically, the aerospace industry was the leader in CAE development. The three major motorcompanies of GM, Ford and Chrysler started theirCAE activities as soon as computers became readilyavailable in the early 1960s. The larger automotivecompanies in Europe started CAE activities in theearly 1970s – about the same time as the Japanesecompanies.
Each new project starts with a series of detailed paper studies, aimed at identifying the most com-petitive and innovative product in whichever part of the market is under review. Original research into systems and concepts is then balanced against careful analysis of operating characteristics, features performance and economy targets, the projected cost of ownership and essential dimensional requirements. Research into competitors’ vehicles,market research to judge tastes in future years, and possible changes in legislation are all factors that have to be taken into account by the product planners when determining the specification of a new vehicle.
The various stages of the design process are as follows:
1 Vehicle styling, ergonomics and safety
2 Production of scale and full-size models
3 Engine performance and testing
4 Wind tunnel testing
5 Prototype production
6 Prototype testing
7 Body engineering for production