Artificial Intelligence in Automobile Industry

According to Builtin, Artificial Intelligence can be defined as ,

Artificial intelligence (AI) is wide-ranging branch of computer science concerned with building smart machines capable of performing tasks that typically require human intelligence.

              From last few years Artificial Intelligence or AI became the hot topic and great career option for the many people.However, the idea of AI is not relatively new to the researchers,.There is no doubt that AI has the capability to impact our life. The question of in what level it will make an impact. And this is still in an imaginary scenario for the normal people.However, the researchers and subject matter experts can & has predicted the impact that AI will make in future. In 2018, AI expert Dr.Kai-FU Lee said that, "AI is going to change the world more than anything in the history of mankind.More than electricity."

           

            World's well known giant companies have started utilising and developing the products using AI.For example, Amazon came up with a AI based virtual assistant known as Alexa. With the combination of Sensors,cameras,Radar and Artificial Intelligence Tesla is working to develop the driverless cars,etc.

               In this article ,we will discuss in brief about the potential impact AI can make in Automotive industry. So,lets start.

# Engineering Design -

            Long back,Computer Aided Design (CAD) brought the revolutionary change in the way of creation,modification, analysis and optimization done in the designs. CAD helped to reduce the amount of time spent on manual design and drafting resulting into increased productivity,quality of design,ease of storage and document of the design records. Even though these technology greatly reduced labour work of human but its still dependent on human to create design and drafting work.

           With AI, I believe it possible to reduce more than 50 % of human intervetion in design and drafting of particular products.To understand, we will take an example of splined solid half shaft which is used in automobile differential for providing power to vehicle wheels. For CAD model, designer need to create a solid round shaft of particular length and then he will extrude the material for spline tooth creation. Suppose, with no calculations involved, designer takes appro.2 hr of time to design. Instead, with AI, we can create the CAD model of the same shaft in less than 15 minute just by entering required dimensional values like length of the shaft, diameter, spline and material details. AI will automatically generate a CAD model based on provided inputs.

            Various CAD software developers working on integration of AI in CAD softwares. In next 5-10 years, it is not surprise to see and use such a solutions in engineering design and drafting.

# Procurement -

            Procurement is an most critical and more focused function of any organisation.With  error free procurement, organisation can run its business more smoothly and can make more profits too.Artificial Intelligence already transforming procurement. With automating large time consuming processes, AI has the potential to rapidly change the procurement practices used around the world.Currently, it will be too early to say that all the procurement activities will be done by AI,because procurement is an complex,involves analytics and decision making. However, AI can be used in some lengthy and time consuming procurement activities like Spend Analysis, Vendor Search from large data,collecting market data,etc.

According to Sievo.com,below are the 7 common procurement areas where AI can be used.

7 common areas for AI in Procurement

(Source - https://sievo.com/resources/ai-in-procurement)

 

Lithium Ion Battery - Working ,Classification & Battery Cycle | Words of Engineer

If you are able to read this post on the go,on the portable devices like mobile phones or Ipads, you must say thanks to the "Lithium Ion Battery"(Li-ion ) and their developers,who worked over the years to made this happen.

Wondering,why you must say thanks to them ? Read the full article to discover the answer.

• What is Battery ? And its classification.
• Why lithium is used in batteries?
• Working of Lithium Ion Battery.
• Battery Cycle

What is Battery ?

Battery is an device which converts chemical energy directly into electric energy, which can provide power to electric portable devices like mobile phones, flashlights and even for Electric vehicles too.Fossil fuels like coal,oil,gas are currently primary energy sources and they fueled  industrial revolution and global economic growth. However,due to its finite storage, harmful effects on climate,and increased global warming made world to search for the alternative or clean fuels.

Batteries can be classified into two types based on its "re-usability".

1. Primary Battery ( Non- Rechargeable /Single use)

2. Secondary Battery (Rechargeable )

Primary batteries are designed for the use until its energy exhausted and then it is disposed.There chemical reactions can not be reversible,so they are not rechargeable. On other hand, secondary batteries chemical reactions can be reversed,which makes them rechargeable.But, because of the internal corrosion and loss of electrolyte secondary batteries can be recharged at definite battery cycles only.

Why Lithium is used in batteries ?

Following are the main reasons of using Lithium in batteries.

• Highly reactive

Lithium is highly reactive because it readily loses its outermost electron, making it easy to get current flowing through a battery.

• Lighter in weight

Lithium is lighter in weight than Lead,which is needed for portable devices.

• Higher Energy Density

Lithium has energy density higher almost twice than nickel cadmium. Energy density is the amount of energy in given mass.

• Low self discharge

Compared to nickel cadmium,lithium has self discharge less than half.

How Li-ion battery works ?

Li-ion batteries consist of Anode, Cathode ,Separator, Electrolyte & two current collectors( Positive & Negative). Both the Anode & Cathode has the capability to store the Lithium ions.

Electrolyte is used to carry Lithium ions from anode to cathode & vice versa through separator.Below image shows the working of Li-ion battery.

Flow of Lithium Ions -

        State                                        From                                To

   While Charging              -            Cathode         =>         Anode

   While  Discharging        -            Anode            =>         Cathode

Image Source - http://large.stanford.edu/courses/2010/ph240/nie1/

Battery Cycle

According to the Apple, Apple Li-ions batteries work in battery cycles. One charge cycle is completed when you have discharged 100 % of your battery capacity but not necessarily all from one charge. For example, suppose you have used 75% of your battery capacity one day & charged again to 100% battery capacity.On next day, you have used 25% means you have discharged total 100 % of battery capacity in 2 days & this is considered as one complete battery cycle.

One Cycle

Charges

+100%

Discharges

-75%

+75%

-25%

+25%

One charge cycle is completed after you’ve discharged 100% of your battery’s capacity.

Source : https://www.apple.com/batteries/why-lithium-ion/

Common Facts about Li-ion Batteries -

1. First commercial Lithium Ion battery was made by Sony corporation in 1991.

2. For safety reasons,while travelling by flights,spare or uninstalled lithium metal or lithium-ion batteries are must be removed from check in baggage and should kept with passenger in carry on baggage.

For more engineering related posts, keep visiting 'Words of Engineer'

Portal Drop Axle | Words of Engineer

Portal  Drop Axle

Generally, vehicles can be classified into two groups based on its application area-

1. On-Highway Vehicles

2. Off-Highway Vehicles

Simple explanation of difference between On Highway and Off Highway vehicles is, On highway vehicles are used on normal terrain and Off Highway vehicles are used in rough terrains like rocky, mud, agriculture land,mining and construction sites,etc.

The concept of power transfer from engine to wheel is same in both vehicle types and done via Engine, Gearbox, Driveshaft, Axle and finally to wheel.Definitely, specifications of those drivetrain components may vary depending on the requirements of On Highway and Off Highway vehicles.Gear Reduction,ground clearance,speed are the few examples of requirements.

From drivetrain components,axle is the only component which is directly in contact with wheels and used to transfer power to wheels. There are different types of arrangement between Axle and wheels are available for On Highway and Off highway vehicles.

In On highway vehicles, Axle tube centerline and Wheel centerline is mostly same,i.e.No offset between them.

Normal Axle Layout

Whereas,in Off Highway vehicles, sometimes,there is offset (usually above ) in axle tube centerline and Wheel centerline.This distance between the two centerlines is called as "Drop Distance" and measured in mm.

Portal Drop Axle 

Along with the drop distance,these Drop axles has simple gearbox installed at both wheel ends which is used as gear reduction. So, these axles are also called as "Two Stage Reduction axles".
First reduction occurs in differential by Ring & Pinion drive gear and second reduction is done at wheel end by simple gearboxes.

Portal Drop Axle Graphics

( Image Source - Pinterest

Image Credit - Respective owners )

There are various advantages of Portal Drop Axles, which made Off Highway vehicles to adopt this design,and are mentioned below -

Advantages of Portal Drop Axles -

1. Two Stage Reduction

Due the addition of gear reduction at wheel end, torque reduction strain on other drivetrain components can be lowered,which provides room for design of  smaller size Ring and pinion gears, differential case for same gear reduction.

2. Ground Clearance

As compared to normal layout, Portal axles provides higher ground clearance to the vehicles as size of differential is reduced,axle tube and differential case are mounted above the wheel centerline.

Disadvantages of Portal Drop Axles -

1. Slightly Increased maintenance cost.

Due to increase in number of gears in axle, oil needed for the lubrication is increased, which also needs periodic check of oil at every 8000-10000 km.

2. Not easy for installation

Portal Drop Axles are not easy to install, expertise is needed for correct installation to avoid potential safety and cost issues.

That's about " Portal Drop Axle" from Words of Enginner.

Product Design Development In 5 Stage Gates | Words of Engineer

Product Design Development In 5 Stage Gates

In Product Lifecycle (PLC), we understood about the different life phases of product which are namely Pre-Introduction, Introduction, Growth, Maturity, Decline and Extended Growth. Success of any product lies in its successful design and development. As you may aware, design development of any product involves plenty of engineers from almost all departments of organization to work on it. This make design development huge and complex process. Question may arise here that, do we have solution for this? Answer is ‘Yes, we have solution, by systematic division, monitoring and tracking of work any major task can be accomplished. Considering this, many organisations have adapted ‘Stage Gate Process’. 

Stage gate is the project management technique in which project/program is divided in different stages with management decision review/approval points called as gates. Over the years, there are many concepts of stage gate process are developed by the experts, but traditional process is ‘5 Stage gate process’. 

In this 5 Stage gate process, total project (from Customer RFQ to Production release) is divided into 5 stages with 5 approval gates, those are mentioned below –

Stage-0                 Discovery

Stage-1                 Scoping

Stage-2                 Build Business Case

Stage-3                 Development

Stage-4                 Testing & Validation

Stage-5                 Launch

 Stage Gate Process

 (Image Source - https://creately.com/diagram/example/jlgeb7gf1/Stage-Gate+Process?utm_source=pinterest&utm_medium=social&utm_campaign=pinblock )

      Further this individual stages has many tasks under it which needs to be completed by different departments on schedule timelines. Above mentioned is the traditional 5 stage gate process, however every organisation has their own terminologies for each stage gate.So, that's about 5 Stage Gates process.

Business Screening Document | Words of Engineer

Business Screening Document -

Every company has their defined organisation management structure and this management team is responsible for creating a strong relationships with employees, shareholders and the customer.
Introduce and embrace fundamental and new company values among them.
Predicting the future market, guiding the company for its products to sustain in the market .Also increase company market growth in terms profit and reputation and so on responsibilities.

What is Business Screening Document (BSD) ?

When any company receives Request for quotation for the business opportunity from any other company or person.Before sending quotation to customer, receival company's Business development team has to present the opportunity in front of the company management team.So that management team can share their views on the opportunity and provide decision to proceed for this business or not.

What information this document has ?

To keep uniformity in Business Screening , company create a standard document which will be used for all the Business Screenings.

This document consists of below points -

1. Customer

2. Relation with customer

Management needs previous relation history of customer with the company in terms of engineering, quality,sales, purchasing, payment.

3. Customer Product details

In this section, overall information of final customer product is given like market need of product, features of the product, competitors having similar products,expected sales volume.

4. Sales region

 Not every product is suitable for all the region's of world.For example- Supercar can not be used in off highway roads. So,sales region and customers and company's presence in that region is an important factor.

5. Customer's Program timeline

Sometimes customer wants to launch product in market too quickly.It is important to know timelines,so that company's engineering and plant capabilities can be adjusted accordingly.

6. Annual Sales volume

Annual sales volume are need to plant capabilities and manpower management also for calculating expected overall company sales volume for the year.

7. Purchasing Terms

Purchasing terms explains,what type of purchase customer wants, one time purchase agreement or the agreement with timely scheduled.

8.Packing and shipment terms

What of packing and ways of shipment is expected from customer is explained in this section.

9.Payment terms

Payment Terms are mutually agreed by both the companies and varies from customers to customers. Sometime payment made on credit base or debit base depending upon the customer relations with company, discuss done on agreement signing.

10.Expected revenue generation

Considering the expected annual sales, expected revenue of before and after tax is calculated for the financial year.

11. Risk involved,if project taken

For any business opportunities,there are some Risk involved in it.In this section,Risk involved in the project is explained.This is  depends upon many factors like product, customer, market need and so on.

12. Risk involved,if project not taken

As Risk involved if project taken, there are also Risk involved if project not taken. For example - Competitors may get a business with customer and possibility of overtaking share of existing businesses.

13.Future Opportunities

Opportunity opens the doors to new opportunities !  Probable new business opportunities with this business are explained in this section.

So, above all information is mentioned in business screening is tool for management to decide why the opportunity or business is needed for company. After business Screening is done,if management provides approval then quotation can be sent to customer.

Product Life Cycle ( PLC) | Words of Engineer

  
Product Life Cycle ( PLC) 

 In our busy lives, we use thousands of products on everyday basis. Have you ever wondered about product life cycle? Like human being, product too have their life cycle phases. PLC defines the complete cycle of product from its launch in market to elimination from the market. PLC is one of the important concepts for companies to decide/approve company products portfolio expansion, reviewing the scope of product or to verify products success in market, etc.

 The general phases in product life cycles are namely - 

1. Introduction

2. Growth

3. Maturity

4. Decline

   Above are the typical life phases of the product but it is not guaranteed that every product will attend all the phases. The performance of product is depends upon its need, demand and other factors too play a vital role in product life cycle and they are seen from a market point of view but there are lot more activities happens before product launched in market, as an engineer, we should aware about those behind the scenes. All the things happens behind the Introduction stage are falls in stage called as Pre-Introduction Phase.

So, for engineering perspective, typical product life cycle consists of -

1. Pre-Introduction

2. Introduction

3. Growth

4. Maturity

5. Decline

As you seen in illustration, additional Stage shown and named as 'Extension Phase. This phase can be achieved by continuous improvement in product,excellence in service,improving sales and marketing strategies.

Engineering Design Process | Words of Engineer

Engineering Design Process

We all studied general engineering design process,that consists of below steps -

1 - Find Problem or Need
2 - Gather required information
3 - Find all possible alternative solutions
4 - Select Best solution among them
5 - Build the solution (Prototype)
6 - Test and evaluate solution
7 - If result is satisfactory then release solution, if not repeat steps from 1 to 6.

But in actual engineering design process,there many steps involved and every organisation have their own engineering design process, almost similar to each other with the foundation of general engineering design process.

 Here, I'm writing about engineering design process I understood from my experience.

Flow Chart -1

Explanation -

1. As shown in flow chart, firstly customer approaches multiple organizations by providing some requirements of product needed for their vehicle. Let's say, OEM requires tires for their new vehicle, so OEM will approach different organizations having expertise in tire manufacturing.

2. After receiving the request and basic requirements, tire manufacturer starts engineering activities and create concept drawing, CAD model of new tire and submit it to OEM for review.

3. OEM reviews the concept design. If design approved, they provide detailed tire requirements of vehicle to selected tire manufacturing company. If design not approved, tire manufacturing company still has chance to submit another concept design unless and until OEM did not approve any other tire manufacturers concept design.

4. Considering concept design approved scenario we will understand next steps. After receiving detailed requirements tire manufacturer starts working on detail drawing. As product (tire) manufacturer, they are responsible for all engineering design calculation & validation, but OEM also takes part in this.

5. Now, after engineering design validation, tier manufacturer submits final detailed prototype design drawings to OEM for review.

6. If any design changes received, that changes need to accommodate and re-submit the updated Prototype design drawings to OEM. If no design changes received from OEM, tire manufacturers are ready to release Prototype drawings and prototype build is carried out.

7.After prototype build, there are tested in engineering labs as well as actual field environment where final vehicle will be in operation.

8. If results vary from requirements all the activities from detail prototype drawing to engineering lab and field test will be carried out again until the results meet the requirements. If both the engineering lab and actual field results meets the desired vehicle requirements, all prototype drawings are released for production.

Part Development Track Template | Program Management Tool | Words of Engineer

Part Development Track Template 

After Bill of materials of product has been finalised,it will be released in engineering product data management and ERP systems.Product engineer hold the ownership and responsibility to create a part development track template of product using released Bill of materials and only authorised person to update any changes in it.

As we know for successful launch of product, Program management is responsible to keep an eye on the status of each aspect of the program,to facilitate this every company create standard tracking or monitoring templates for important program aspects. So,this is one of the standard templates with the main objective to provide purchase engineers a single glance view of the parts to plan purchasing activity and for project management team to track/monitor the purchasing status of all required parts.

Basically, this is one of the tools of program management which consist of all parts needed to build a final product with details like part level, part number,part name,qty,parts item commodity,make or buy decision, drawing release ,PR,RFQ,PO,PPAP statuses of all parts.

For prototype stage,all parts must be available before the scheduled proto build dates to avoid a launch schedule delay or the probable business losses.

Below shown simplest part development track template format shows the engineering, purchase and quality department tracking points, if required we can add other functional departments tracking points also.