Product Planning Styling Engineering & Development Prototyping Testing

Powertrain & Chassis Engineering

  • Powertrain
  • Chassis Engineering

Powertrain in Model Developing

Powertrain development, including fine-tuning of engine, transmission and system control , plays a crucial role in the model building process; and it is closely related to a vehicle’s fuel consumption, emissions and maneuverability. In light of future requirements for performance, environmental protection and energy legislation, powertrain technologies receive continuous improvement. New technologies such as electronic throttle control, turbocharger, variable valve timing and exhaust gas recirculation are introduced while transmissions evolve toward 6AT and CVT designs to comply with future fuel consumption regulations.

Powertrain Design and Development

Powertrain design focuses on the compatibility of engines and vehicles that makes sure the engines matches the vehicle layout perfectly while taking vibration noise, maintainability, safety and dynamic clearance into consideration.

1. Engine concept and design

Engine designs can usually be broken down into fifteen subsystems: cylinder heads, cylinder blocks, lubrication systems, valve systems, breath systems, main moving, cooling systems, ignition systems, accessories, intake systems, exhaust systems, timing systems, fueling systems, EMS systems and turbocharger systems.

2. Analysis of competing engines

Learn about the strength and weakness of competing engines though comprehensive analyses and comparison on design features and characteristics for the engineering team to refine future products.

3. Engine design

The foundation of engine design is the detailed analyses on basic concepts and power requirements. The analyses comprise of 3D conceptual design, 2D detail design, CAE analyses, control system and overall vehicle compatibility. Engines currently under development are all equipped with a turbocharging system to meet the performance demand; as such the durability of exhaust manifolds becomes more crucial. The exhaust manifolds must be able to work normally under the temperature of a fully loaded engine and to meet the stress specification of material strength.

4. Transmission matching

In order to successfully equip transmission systems on various car models, compatibility tests and optimization design are required to achieve the best balance between fuel consumption and power output.

5. Powertrain Labs

A full range of equipment and resources are introduced for development, fine-tuning and durability tests of the powertrains and completed vehicles for guaranteed quality and reliability. The current testing resources include Rig/Bench testing platforms, engine testing facilities as well as emission and fuel consumption labs, among others.

   

6. Powertrain tuning

Powertrain tuning is necessary after completion of powertrain matching to satisfy the requirements on performance, thermal effects, fuel consumption, emission, drivability and regulations of respective target markets.

Powertrain tuning is divided into two major parts: Tuning of the Engine Management System (EMS) and the Transmission Management System (TMS). Apart from separate basic tuning of engines and transmission units on dynamometer, the scope of vehicle tuning also examines the combination of engines and transmissions under various running conditions and checks for efficient energy consumption and optimum performance of powertrain under various working conditions. Powertrain tuning of a vehicle includes exhaust gas pollution and fuel consumption tuning, subjective and objective driving ability tuning, three extreme conditions field tuning test (High temp, High dust, High altitude) and extreme cold and an emissions regulation endurance test.

         
     

Chassis system design and development at HAITEC involves the following main areas: Chassis package design, chassis analysis, layout design, part design, prototyping and test assembly, design verification, and new technology/template R&D. Development cost, delivery time and quality management are also practiced for chassis components.

The complete R&D process from chassis design through to actual vehicle testing at HAITEC is shown in the design and integration of the suspension system, steering system, braking system,transmission system and suspension provides a demonstration of R&D expertise. These areas are summarized below:

1. Suspension system design and integration

An appropriate suspension arrangement is designed to meet the specified performance, space and cost requirements. CAE virtual prototyping, DMU's package and dynamic gap validation, installation and maintenance procedure validation, and mule prototyping are used to design a suspension system that delivers the required vehicle performance along with the ride and controllability expected for the vehicle variant.

2. Steering system design and integration

The steering system must meet requirements for ergonomics, collision safety, space restrictions, field of view, targeted performance of steering stability, maneuverability, handling and minimum turning radius. The suspension system and engine room layout controllability and engine compartment layout are then taken into account to design a steering system and geometric arrangement that meets safety characteristics and NVH requirements.

3. Braking system design and integration

The braking system must meet the requirements for regulations of the individual market, and driving comfort of ergonomics, stepping feedback and stiffness. Efforts are made at reducing braking noise and vibration sensitivity while ABS anti-locking brakes are fitted as standard to deliver the design for a safe, reliable and controllable braking system.

4. Transmission, gearshift and pedal mechanism design and integration

The transmission system must provide a suitable joint between the engine and the gear box. The design of the pedal mechanism must meet layout regulations, collapse requirements during collision as well user comfort requirements while also being strong, safe, comfortable and cost-effective. In designing the gearshift mechanisms, appropriate styles must be developed for automatic and manual transmissions as well as one that provides precise gear shifting and feedback.