CU-ICAR: Clemson University International Center for Automotive Research

Research and leaders highlighted at VIPR-GS Research Center annual review

In February nearly 300 interdisciplinary researchers, industry leaders and government officials converged on Clemson, SC for three days of research discussions and demonstrations on the future of mobility.

The gathering was part of the annual review of the VIPR-GS Research Center, a partnership between Clemson University and the US Army DEVCOM Ground Vehicle Systems Center (GVSC) aimed at developing innovative digital engineering tools for rapid exploration and design of the next generation of on- and off-road vehicles. VIPR-GS, an acronym for Virtual Prototyping of Autonomy-Enabled Ground Systems, consists of 80 Clemson faculty from across 13 departments and more than 130 student researchers. Together, they are working on 43 active translational research projects in labs throughout South Carolina.

“Our partnership with the US Army and industry leaders helps ensure that our research is grounded in real-world application. The ability to take our foundational research and transition it into something that moves the industry forward is really meaningful.”

– Dr. Rob Prucka,
Director, VIPR-GS Research Center
Director, Deep Orange Vehicle Prototyping Program
Alan Kulwicki Professor of Motorsports Engineering

After a tour of the VIPR-GS Research Center facilities at the Clemson University International Center for Automotive Research (CU-ICAR) in Greenville, SC, the events moved to the Madren Conference Center in Clemson, SC for two days of demonstrations and presentations. In addition to sessions featuring faculty and industry professionals, student researchers had the opportunity to highlight their work during a poster display exhibition. Each presentation was aligned with ongoing research based on the key components of the VIPR-GS Research Center: autonomy, power systems, and digital engineering. In recent years some research has been tested and displayed through vehicles produced by the Deep Orange program, an accelerated and immersive vehicle concept development framework within the Department of Automotive Engineering. In partnership with GVSC and the VIPR-GS Research Center, Clemson students produced two high-speed autonomous vehicles designed for off-road, non-combat missions. These prototype vehicles will continue to serve as platforms for real-world validation of joint research projects.

Now in its sixth year, the VIPR-GS Research Center produces an impact far beyond any single project by compressing design and development timelines producing tools for smarter, faster and more cost-effective autonomous vehicles. Two critical themes of this process and the future of the VIPR-GS Research Center are digital engineering and Human Machine Integrated Formations (HMIF), the optimization and integration of technology and human capabilities. Dr. Philip Frederick, Deputy Chief Scientist for the US Army Ground Vehicle Systems Center, emphasized each discipline and the value of the VIPR-GS Research Center during his keynote address.

“As demonstrated through the recent Deep Orange projects, VIPR-GS is ideally positioned to utilize the knowledge of faculty and students, along with digital engineering and industry relationships, to not only create valuable research for today, but that continually builds for a lasting impact.”

– Dr. Philip Frederick, Deputy Chief Scientist for the US Army Ground Vehicle Systems

A common theme in the presentations was the importance of people and relationships. In addition to the touted Clemson faculty and students, GVSC and the VIPR-GS Research Center maintain strong partnerships with universities and industry leaders across South Carolina and the nation. Dr. Frederick stressed that while the research has valuable real-world applications, “it’s always the people who ultimately develop and use the technologies.” To illustrate this value, Dr. Prucka told the story of Drew Girshovich, a graduate of the Department of Automotive Engineering and Deep Orange 15 team member, who, after graduation began working for an industry partner in Greenville, SC, where he is continues to collaborate with VIPR-GS and GVSC on ongoing projects.

“The mission of the VIPR-GS Research Center is to help the US Army produce research and resources to develop better vehicles, but perhaps our most meaningful product is our students and future industry leaders. Ultimately the industry is run by people, and I couldn’t be prouder of the role Clemson plays in developing the future workforce and pushing the industry forward.”

– Dr. Rob Prucka,
Director, VIPR-GS Research Center
Director, Deep Orange Vehicle Prototyping Program
Alan Kulwicki Professor of Motorsports Engineering

Acknowledgment: This work was supported by Clemson University’s Virtual Prototyping of Autonomy Enabled Ground Systems (VIPR-GS) under Cooperative Agreement W56HZV-21-2-0001 with the US Army DEVCOM Ground Vehicle Systems Center (GVSC

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. OPSEC9574.

Posted in Uncategorized | Comments Off on Research and leaders highlighted at VIPR-GS Research Center annual review

Applied Research Associates, Clemson Partner to Power U.S. Army Autonomous Robot

Applied Research Associates, Inc. (ARA) and Clemson University have announced a partnership to enhance the diesel electric drivetrain of ARA’s autonomous robot. The collaboration brings together industry and academia to deliver the robotic platform to the United States Army Combat Capabilities Development Command (DEVCOM) Ground Vehicle Systems Center (GVSC).

“GVSC has been a longtime robotics partner of ARA, and this platform is a critical development in autonomous innovation,” said ARA Vice President Matt Fordham. “This partnership between industry, academia, and government is a testament to our collective commitment to growing the technology sector in and around Greenville, S.C. We are excited to leverage the expertise at the Clemson University International Center for Automotive Research (CU-ICAR) to deliver an advanced system that meets the dynamic needs of the Army.”

The research of the Virtual Prototyping of Autonomy-Enabled Ground Systems (VIPR-GS) Research Center at CU-ICAR will extend the shared research expertise with ARA and GVSC to leverage the university’s unique lab capabilities. “This partnership exemplifies the culture of innovation and collaboration at CU-ICAR. Expanding our relationship with ARA and the U.S. Army further enables us to produce meaningful research on our campus and advance the economic development mission of the university in our region,” said David Clayton, Executive Director of CU-ICAR.

“Our collaboration with ARA and the U.S. Army not only allows for an incredible real-world learning environment, but these partnerships also keep our research grounded in what matters in the industry,” said Rob Prucka, Director of VIPR-GS Research Center. “Our students and faculty are gaining invaluable industry experience while developing autonomous technologies that actively protect civilians and military personnel.”

About ARA

Applied Research Associates, Inc. (ARA) was founded in 1979, in Albuquerque, New Mexico, to offer science and engineering research to solve problems of national importance. ARA delivers leading-edge products and innovative solutions for national defense, energy, homeland security, aerospace, healthcare, transportation, and manufacturing. With over 2,000 employee-owners at locations in the U.S. and Canada, ARA offers a broad range of technical expertise in defense technologies, civil engineering, computer software and simulation, systems analysis, biomedical engineering, environmental technologies, and blast testing and measurement.

Clemson University International Center for Automotive Research

Clemson University International Center for Automotive Research (CU-ICAR) is a 250-acre advanced-technology research campus where university, industry and government organizations collaborate. The university offers master’s and Ph.D. programs in automotive engineering at CU-ICAR and is conducting leading-edge applied research in critical areas, such as advanced product-development strategies, sustainable mobility, intelligent manufacturing systems and advanced materials. CU-ICAR has industrial-scale laboratories and testing equipment in world-class facilities.

VIPR-GS Research Center

The Virtual Prototyping of Autonomy-Enabled Ground Systems (VIPR-GS) Research Center at Clemson University is a premier research initiative focused on advancing digital engineering, autonomy, propulsion systems, and virtual prototyping for next-generation military ground vehicles. In collaboration with the U.S. Army DEVCOM Ground Vehicle Systems Center (GVSC) and industry partners, VIPR-GS is driving innovation in autonomy-enabled ground systems to support the Army’s modernization priorities. VIPR-GS works closely with a diverse network of stakeholders, these partnerships facilitate the transition of cutting-edge research into field-ready solutions and accelerate the development of military and commercial vehicle technologies. VIPR-GS is committed to shaping the future of autonomy-enabled ground systems by combining cutting-edge research, digital innovation, and strong collaborations. Its ongoing efforts contribute to the Army’s Next-Generation Combat Vehicle (NGCV) program and ensure that U.S. military ground systems remain at the forefront of technological advancement.

Acknowledgment: This work was supported by Clemson University’s Virtual Prototyping of Autonomy Enabled Ground Systems (VIPR-GS), under Cooperative Agreement W56HZV-21-2-0001 with the US Army DEVCOM Ground Vehicle Systems Center (GVSC).

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. OPSEC9443.

Posted in Uncategorized | Comments Off on Applied Research Associates, Clemson Partner to Power U.S. Army Autonomous Robot

Samaritan Biologics locating at CU-ICAR

$5 million investment will create 85 new jobs

Posted in Uncategorized | Comments Off on Samaritan Biologics locating at CU-ICAR

Deep Orange 15 Unveiled

Clemson University unveiled its latest groundbreaking autonomous rescue vehicle, Deep Orange 15, on Aug. 13 at the Ground Vehicle Systems Engineering & Technology Symposium (GVSETS) in Novi, Michigan.

Deep Orange 15, an advanced, high-speed, off-road, semi-autonomous search-and-rescue vehicle, is equipped with semi-active suspension, an innovative litter-loading mechanism, a high-voltage battery, a rotating passenger seat to assist victims and a series hybrid powertrain. The vehicle is the 15th created as part of Deep Orange, Clemson’s flagship student vehicle prototype education program, where master’s students in the University’s Department of Automotive Engineering work with industry professionals to strategize on the customers’ needs, develop unique concepts and engineer and build each vehicle from scratch.

Sponsors of Deep Orange 15 are: Clemson’s Virtual Prototyping of Autonomy-Enabled Ground Systems program (VIPR-GS); U.S. Army’s DEVCOM Ground Vehicle Systems Center (GVSC); Brembo; Fox Racing; and North American Rescue.

With the support of these organizations, Clemson students apply research topics that not only help advance autonomy technology but also help students gain hands-on skills to expand their experience and knowledge.

Robert Prucka, the faculty lead on Deep Orange 15, said the team is excited to unveil the vehicle.

“Our Deep Orange students collaborated across an 18-month period to develop this autonomous, high-speed, off-road relief vehicle from the ground up,” said Prucka, the Alan Kulwicki Professor of Motorsports Engineering. “Getting the opportunity to show our work and research at the GVSETS symposium provides our students with an understanding of the significance of these new technologies and the opportunity they are receiving from being a part of the Deep Orange program.”

GVSC is a major Deep Orange sponsor and is hosting the symposium at which Deep Orange 15 is being unveiled.

David Gorsich, the chief scientist at GVSC, emphasized that the deployment of autonomous vehicles is a priority for the U.S. Army.

“Through our digital transformation, virtual prototyping and digital engineering practices will enable us to design ground vehicles from a formations perspective and understand how specific technologies provide warfighting capabilities up-front, long before we go into production decisions,” he said. “The modeling and simulation done at Clemson and the teamwork in programs like Deep Orange are exemplars of how the Army Futures Command shapes the future.”

The Deep Orange program at Clemson is set up to create advanced vehicles for the vehicle sponsor and prepare students for future success.

Among them is Anirudda Joshi, a student pursuing a master’s degree in automotive engineering and serving as the engineering project manager for Deep Orange.

“Deep Orange’s product is not only the vehicle but also the student,” Joshi said. “It has been an honor to take part in Deep Orange 15. The hands-on engineering experience is beyond anything we would have received from the classroom alone. We look forward to sharing what we have created.”

The focus is on all aspects of automotive engineering, which helps students develop and hone their skills to prepare them for jobs at major automotive original equipment manufacturers and their suppliers.

Following the graduation of the student team, the Deep Orange 15 vehicle will stand as a unique and advanced research asset for Clemson University, propelling it to the forefront of autonomous high-speed off-road research.

The vehicle will serve as a validation and verification tool for the complex dynamic modeling of autonomous vehicles in challenging terrains and as an advanced deployment platform for pioneering control algorithms and energy management strategies for off-road vehicles.

Here are some of the challenges Deep Orange 15 was designed to address:

Natural Disaster Relief and Reconnaissance Mission

● A natural disaster, such as a hurricane or an earthquake, changes the topography of the area and puts numerous people in immediate danger. The vehicle and two passengers must get to the scene within the golden hour (hour of time in which medical assistance is crucial for survival), create a digital map of the area, and make it back autonomously with the injured person and one passenger while the original driver stays behind at the scene to help others who are in need of assistance.

Off-Road Terrain Rescue Mission

● A dehydrated hiker is stranded in a rocky area with a broken leg and needs medical attention. The vehicle must get to the hiker through the rocky terrain and get back to its original location unmanned while the driver assists the hiker in the back of the vehicle on a rescue litter.

Posted in Uncategorized | Comments Off on Deep Orange 15 Unveiled

Clemson University and EY US to develop ‘edge-case’ autonomous racecar

GREENVILLE – Clemson University has collaborated with professional services firm Ernst & Young LLP (EY US) to advance autonomous vehicle (AV) technology to be used by competitors in the Indy Autonomous Challenge. Thirty teams from 39 universities across the world have registered to compete in the first high-speed head-to-head autonomous race at the Indianapolis Motor Speedway (IMS).

High-speed racing requires lightning-fast reflexes and advanced driver training to both optimize vehicle performance and maneuver around other drivers at similarly high speeds. These extreme — or edge-case — scenarios offer a rare testbed to develop and validate automated driving technology.

Through Deep Orange, one of Clemson’s flagship programs, automotive engineering students will develop the high-speed, self-driving, open-wheel racecar as part of their two-year graduate studies. Undergraduate and graduate teams from other universities will develop the driverless car software, which will then be imported and run on the Clemson-designed vehicle. The project aims to advance driverless technology for passenger cars and equip Clemson automotive engineering students with direct experience in the field.

“We see a lot of opportunities in the mobility sector, but we need a talented workforce to overcome the current challenges and propel autonomous forward into adoption,” says Steve Patton, EY Americas Mobility Leader. “Working alongside the engineering students at Clemson has given me a positive outlook on the future of innovation and the future of our workforce.”

In addition to being a lead sponsor of Deep Orange 12, EY US is providing thought leadership and professional seminars to the student team on topics driving the future of the mobility industry including the automotive value chain, emerging ecosystems and new business models.

Deep Orange 12 is part of Clemson University’s long-running Deep Orange rapid prototype vehicle program housed at the Clemson University International Center for Automotive Research (CU-ICAR). Now in its 12th year, the program addresses technology challenges facing the mobility industry with an innovative concept vehicle. Deep Orange develops the next generation of engineering leaders through an immersive educational experience within the Department of Automotive Engineering.

Deep Orange 12 addresses two major challenges affecting the automotive industry today: connectivity and automation. For optimum safety and efficiency, self-driving vehicles will need to receive and process incredible amounts of data, from infrastructure and satellites to other vehicles on the road. Research also shows a strong need for more — and more frequent — high-visibility demonstrations of autonomous technology in action to drive public acceptance and use.

For this project, Clemson students must not only replace the driver’s interactions with the vehicle using electronic steering, brake and throttle controls but also design a complex set of perception sensors and on-board computers that analyze the racing environment. These systems include a suite of lidars, radars, cameras and high-precision GPS systems that mirror the way human drivers receive and process information, which is then used to locate vehicles on the track and strategize how to beat the competition. The Deep Orange 12 student team is also designing a powertrain specifically around the requirements of autonomous racing.

“The extreme engineering behind motorsports has often been used as a testbed to push the boundaries of consumer vehicle technology,” says Robert Prucka, Deep Orange 12 faculty lead and Kulwicki Endowed Professor in Motorsports Engineering with the Robert H. Brooks Sports Science Institute and associate professor with the Clemson University Department of Automotive Engineering. “This is an incredible opportunity for students to not only work with advanced racing technologies but have a hand in driving solutions for one of the most pressing engineering challenges facing the mobility industry today.”

Millions of fans watch motorsports events every year, and an undeniable part of the appeal are the skills and personalities of the drivers themselves, according to Prucka. With more advanced sensors, software and connectivity, the results of Deep Orange 12 could produce additional driver safety and crash-prevention benefits for today’s racing series.

“Even a fraction of a second can make the difference between a near miss and a collision, especially at racing speeds,” says Prucka . “By making competitor information available to the racecar through connectivity, the technologies we are developing can provide advanced collision warning to drivers behind the wheel.”

By collaborating with industry leaders such as EY US, students gain unique hands-on experience and expertise that lead to successful careers after graduation. Over two years, students gain business acumen and hands-on experience in vehicle design, development, prototyping and production planning. Students develop comprehensive technical knowledge as well as valuable “soft skills” that are often overlooked in traditional engineering programs.

Deep Orange relies on a network of equipment, software, facilities and professionals to help students deliver their prototype vehicle within just two years. With EY US as primary sponsor, supporting partners include Energy Systems Network, Indianapolis Motor Speedway, Specialty Equipment Market Association (SEMA) and the Robert H. Brooks Sports Science Institute.

“Our goal with Deep Orange is to shape the next generation of engineering leaders with real-world projects that prepare them to develop solutions to tomorrow’s mobility challenges,” says Chris Paredis, BMW Endowed Chair in Automotive Systems Integration and Deep Orange Program Director. “A project as complex as engineering a high-performance racecar with state-of-the-art autonomous technology makes for a once-in-a-lifetime learning experience. Our students earn both the skills and confidence to innovate and improve the interconnected mobility systems of the future.”

Announced in late 2019 at the SEMA Show in Las Vegas, the Indy Autonomous Challenge is a $1.5 million university prize competition organized by Energy Systems Network and IMS to win the world’s first head-to-head, high-speed autonomous race on October 23, 2021. IMS hosts the annual Indianapolis 500, the largest single-day sporting event in the world.

The competition has attracted university teams from around the world, all of which are developing their own driverless vehicle algorithms. After extensive simulation testing and validation, each team’s code will be used to control a vehicle for the race at IMS’s 2.5-mile oval track. The vehicle used by these race teams will be based on the prototype developed in the Deep Orange 12 program at CU-ICAR.

While engineering students drive each Deep Orange project, they benefit from Clemson’s world-class cabinet of cross-disciplinary researchers within the Department of Automotive Engineering. Students also utilize the University’s state-of-the-art automotive facilities and testing equipment for the project, operating out of the 9,000-square-foot AVX Mobility Systems Innovation Lab on the CU-ICAR campus.

END

About EY
EY is a global leader in assurance, tax, strategy, transaction and consulting services. The insights and quality services we deliver help build trust and confidence in the capital markets and in economies the world over. We develop outstanding leaders who team to deliver on our promises to all of our stakeholders. In so doing, we play a critical role in building a better working world for our people, for our clients and for our communities.

EY refers to the global organization, and may refer to one or more, of the member firms of Ernst & Young Global Limited, each of which is a separate legal entity. Ernst & Young Global Limited, a UK company limited by guarantee, does not provide services to clients. Information about how EY collects and uses personal data and a description of the rights individuals have under data protection legislation are available via ey.com/privacy. For more information about our organization, please visit ey.com.

Deep Orange
Deep Orange is a flagship program of Clemson University’s two-year master’s program focused on systems integration in automotive engineering. The program provides students with experience in market analysis, concept exploration, vehicle design, prototyping and manufacturing while balancing costs and design targets in an aggressive timeline. The innovative vehicle prototype program encourages students to push the boundaries of conventional design and engineering.

Clemson University International Center for Automotive Research
The Clemson University International Center for Automotive Research (CU-ICAR) is a 250-acre advanced-technology research campus where university, industry and government organizations collaborate. CU-ICAR offers master’s and Ph.D. programs in automotive engineering and is conducting leading-edge applied research in critical areas, such as advanced product-development strategies, sustainable mobility, intelligent manufacturing systems and advanced materials. CU-ICAR has industrial-scale laboratories and testing equipment in world-class facilities.

Posted in Uncategorized | Comments Off on Clemson University and EY US to develop ‘edge-case’ autonomous racecar

CU-ICAR expands industry offerings with Technology Neighborhood III

U.S. Economic Development Administration providing $2M for neighborhood’s first building

GREENVILLE, S.C. – Home to 21 global businesses, the Clemson University International Center for Automotive Research (CU-ICAR) is expanding its footprint on the 250-acre campus with a new technology neighborhood, Technology Neighborhood III. The first building in the neighborhood will be a multi-tenant 40,000-square-foot high-bay facility supported by $2 million in funding from the U.S. Economic Development Administration (EDA).

“As a contributor to the state’s knowledge economy, world-class facilities like those at CU-ICAR are critical. TN3 will support our students, researchers and industry partners with an innovative environment in which to prosper,” said Clemson President Jim Clements. “We are so appreciative of the continued support from our partners at the EDA for believing in our vision and providing funding to support these efforts, which will in turn allow us to support South Carolina’s economy.”

On Thursday, Dana Gartzke, assistant secretary of commerce for economic development, had an opportunity to tour the CU-ICAR campus and award Clemson with the $2 million EDA grant.

“Working alongside the City of Greenville, the state of South Carolina and our partners in Washington D.C. makes it possible for Clemson to provide state-of-the-art facilities that will help our strategic corporate partners grow and flourish,” said Angie Leidinger, vice president for External Affairs. “CU-ICAR has continued to grow since its inception 15 years ago from an automotive focus to be inclusive of the mobility industry in response to the needs of industry. This expansion is a further testament to our ability to support our partners, our state and our students.”

The building is designed to accommodate new and growing companies in the Upstate. The building aims to fill a void in the local real estate market for high-quality multi-purpose facilities that can accommodate a range of businesses, from startup companies to established firms in the automotive, transportation, manufacturing and engineering support service industries.

Technology Neighborhood III is CU-ICAR’s first new neighborhood in 15 years. First announced in 2003, CU-ICAR was founded to be an advanced-technology neighborhood where academia and industry converge. CU-ICAR announced the opening of its first building in 2007 and finished its sixth building in Technology Neighborhood in 2016.

“From OEMs to suppliers in automotive, aerospace and beyond, our global reputation is directly tied to our ability to support Clemson’s partners and advance economic development in South Carolina,” said Jack Ellenberg, associate vice president of Corporate Partnerships and Strategic Initiatives. “CU-ICAR is a unique research park in that it’s not just a location, it’s a campus with active academic programs where companies can interact with other organizations, outstanding researchers and Clemson students, making it an asset to Greenville, our development allies and the state.”

The facility is planned as a multi-tenant high-bay, flexible laboratory and office building shell project intended for business tenants. Anticipated businesses located in the building may have high-bay spaces in 5,000 to 6,000 square foot bays for laboratory, small-scale distribution, engineering/ technical services, etc. with truck access at the rear. It is anticipated that some tenants may desire office spaces located in the front areas of the building.

LICAR LLC, an entity of the Clemson University Land Stewardship Foundation ( CULSF), will be the developer and owner of the facility. CULSF is an independent, non-profit entity that seeks to support Clemson through the development of real property in ways that to maximize the educational, research and economic development mission of the University.

Clemson University International Center for Automotive Research
The Clemson University International Center for Automotive Research (CU-ICAR) is a 250-acre advanced-technology research campus where university, industry and government organizations collaborate. CU-ICAR offers master’s and Ph.D. programs in automotive engineering and is conducting leading-edge applied research in critical areas, such as advanced product-development strategies, sustainable mobility, intelligent manufacturing systems and advanced materials. CU-ICAR has industrial-scale laboratories and testing equipment in world-class facilities.

Posted in Uncategorized | Comments Off on CU-ICAR expands industry offerings with Technology Neighborhood III

Fall 2020 Update

Posted in Uncategorized | Comments Off on Fall 2020 Update

Clemson University recognized for innovation in engineering education

Posted in Uncategorized | Comments Off on Clemson University recognized for innovation in engineering education

Clemson University automotive engineers invent ‘single-shot’ manufacturing technology

New technology that was invented at Clemson University could help reduce the time and cost it takes to manufacture components that are composed of different materials and need to be joined together, researchers said.

Even better, the process could be automated with the help of artificial intelligence, they said.

Srikanth Pilla, right, and Saeed Farahani inspect some of the parts they created as part of their research into hybrid single-shot manufacturing of metals and composites.

Srikanth Pilla and Saeed Farahani are calling their technology “hybrid single-shot manufacturing of metals and composites.”

It’s aimed at streamlining the manufacturing of some components, such as the center consoles in high-end cars, said Pilla, the Jenkins Endowed Professor in the Department of Automotive Engineering and the founding director of Clemson Composites Center.

One of the goals is to reduce the cost of making vehicles lighter, which improves their mileage and helps automotive companies meet federal fuel efficiency standards. But researchers said the technology could be used in a variety of industries, including home appliance manufacturing.

The technology could be ready for the manufacturing floor in as little as two years, Pilla said.

When some parts are made conventionally, one machine stamps sheet metal into the desired shape, and another machine creates polymer or composite parts. Then the pieces are bonded together with glue.

In hybrid single-shot manufacturing, it’s all done in one machine. The technology can be used in existing equipment, obviating the need for major capital investment, Pilla said.

The new method could reduce infrastructure costs and cycle time, while helping ensure that the pieces are mistake free and fit snugly together.

Pilla illustrated the work with a half-moon-shaped piece of polymer that was embedded in a rectangular piece of sheet metal.

“We are shooting the polymer into the sheet metal, and that is deforming the sheet metal,” he said. “While it’s deforming, it’s also bonding to the sheet metal. So, it’s one single operation.”

Farahani moved to Greenville from Tehran Polytechnic to work under Pilla as a Ph.D. student at the Clemson University International Center for Automotive Research.

“When I found this research topic in the literature, I thought, ‘This is going to be perfect for me,’” Farahani said. “My academic background is metal forming, but my experience is mostly on composite and plastic tool design. So with this subject, I can combine these two together.”

Pilla said the team’s approach to the research is unique.

“Maybe one or two research groups in the world have been working on this, but they are all looking at it from the metals side,” he said. “We actually flipped the problem, and we said, ‘This one people will do, and it’s easy to do because sheet metal has a pretty established methodology.’

“Also, my expertise is in polymers and composites, so it makes sense to investigate the problem by flipping it.”

As part of the research, Farahani built a “concept design tool,” and covered it with sensors that measure everything from temperature to pressure. He also created his own software that allows researchers to create a computer model of the machine’s process, also called a “digital twin.”

The digital twin coupled with artificial intelligence is playing a crucial role in teaching the machine to operate on its own.

For the tool to learn, it needs to make mistakes. But allowing the tool to run hundreds of cycles would be too expensive.

Instead, researchers have conducted a limited number of experiments with the machine. Now they are feeding data from the experiments into the machine’s digital twin, along with physics-based models that helps the machine understand its limitations.

“We are saying that science has limits, and these are the limits for you,” Pilla said of the message to the machine. “Then the machine will know what it’s capabilities are and accordingly it will try to learn by itself.”

The research helped Farahani secure his Ph.D. in automotive engineering in December. He is continuing this work as a postdoctoral researcher in Pilla’s lab to further refine the digital twin.

Researchers also plan to test the new technology at the Clemson Composites Center with the goal of making real components.

Read more:

https://newsstand.clemson.edu/clemson-university-automotive-engineers-invent-single-shot-manufacturing-technology/

Posted in Uncategorized | Comments Off on Clemson University automotive engineers invent ‘single-shot’ manufacturing technology