Creation of a new design from concept to realization

The planning, design, engineering and development 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 design team led by a design manager, and they stay with the project throughout. The size of the team varies according to the progress and status of the project.The skill and judgement of the trained and experienced automotive designer is vital to the creation of any design concept.
To assist in the speed and accuracy of the ensuing stages of the design process (the implementation), some of the most advanced computer-assisted design equipment is used by the large vehicle manufacturers. For example, computercontrolled
measuring bridges that can automatically scan model 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 computeraided activities with respect to technical data processing, from idea to preparation for production,integrated in an optimum way.
Computer-aided manufacturing (CAM) Preparation of production and analysis of production processes.
Computer-integrated manufacturing (CIM) All computer-aided activities from idea to serial production.

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 motor companies of GM, Ford and Chrysler started their CAE activities as soon as computers became readily available in the early 1960s. The larger automotive companies in Europe started CAE activities in the early 1970s – about the same time as the Japanese companies.
Each new project starts with a series of detail edpaper studies, aimed at identifying the most competitive and innovative product in whichever partof the market is under review. Original researchinto systems and concepts is then balanced againstcareful analysis of operating characteristics, featuresperformance and economy targets, the projectedcost 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