This study has taken place in Mullsjö at Kongsberg Automotive (KA). The purpose of the study was to evaluate how to construct an easy mountable gearknob to the lowest cost based on design and functionality by using the techniques of concept generation and sifting. The knob is intended to be integrated in a Shift-ByWire shifter and generate prototypes through SLS. Researchers followed a concept study methodology following an abductive approach, to generate an appropriate mechanical design for the gearknob. Concepts were formed by a brainstorming process, followed by weighing criteria for the knob and were finalised by evaluating the formed concepts using a Pughs Matrix constructed by the researches. Relevant literature of mechanical designs processes was reviewed to develop the theoretical framework. In addition, data was collected from Kongsberg´s computer system and unstructured interviews with employees within certain specific areas to gain additional understanding. In cooperation with supervisors, pros and cons analysis of cost, functionality and mounting capability were used to enable the researchers to draw recommendations for mechanical designs meeting the requirements of specification. The study resulted in several findings in relation to each research question. In general, a gear knob has been constructed using SLS that can be both used for mounting and demounting purposes. In addition, this construction met the specification of requirements by KA. The Printed Circuit Board (PCB) were constructed using the geometrics in the inherent components of the knob. The study further resulted in a leather gaiter that were constructed as a link between the dashboard and the knob. Results from this study imply that more screws would be used for mounting different components in the prototype phase, which will impact the view on criteria for forthcoming knobs and their mounting methods. In addition, data collection have also shown that snaps in chromium details easily break, which can also further question the use of chromium snaps for dismantling purposes. Finalised recommendations for the gearknob met the requirements of specification since researchers constructed the most simple mounting on the current surface design. Researchers conclude that these concepts are applicable and could be presented in a following prototype phase. However, if the knob is to be produced, researchers do not have enough support regarding the liquid injection moulding, which requires to be further considered. Materials will require the design constructed in this study to be modified. / Arbetet har skett i Mullsjö på Kongsberg Automotive (KA). Syftet med studien var att konstruera en lättmonterad växelspaksknopp till lägsta kostnad utifrån design och funktionalitet. Detta baserat på konceptgenerering och sållningstekniker. Knoppen kommer att integreras i en Shift-by-Wire växelspak och tillverkas i SLS prototyper. Arbetet är en konceptstudie som har följt en abduktiv ansats. Tidigare konstruktionslösningar har studerats för att få kunskap om hur en knopp utformas. Koncepten har genererats via brainstorming och har följts upp av parvis viktning. Koncepten har sedan sållats med hjälp av Pughs matris. Relevant litteratur inom produktutvecklingsprocesser samt intervjuer med anställda har gett grunden till det teoretiska ramverket. Handledare har givit sin input under hela arbetsprocessen för att hjälpa studenterna att välja rätt koncept utifrån monterbarhet, funktionalitet och pris. Studien har svarat på de tre frågeställningarna som utformats. En knopp i SLS har konstruerats utifrån enkel montering och demontering som möter företagets kravspecifikation. Kretskorten inuti knoppen har formats utefter de ingående delarnas geometrier. Vidare har övergången mellan knopp och centerkonsol resulterat i en läderdamask. Studiens resultat kan få konsekvenser i att mer skruv kommer att användas i prototypfasen vid framtida projekt. Detta kan komma att ändra synen på hur viktigt monterbarheten kan vara i kommande knoppar. Informationsinsamling har också visat att snäppen i kromdetaljer lätt går av och detta kan ifrågasätta användningen av dessa. Vid materialval rekommenderas det att se över konstruktionslösningarna då de uppnådda egenskaperna kan avvika. Arbetet har utformat konstruktionen så att det fungerar bra för SLS prototyper men studenterna kan inte garantera att dessa fungerar om komponenterna ska formsprutas.

Electromechanical shift-by-wire car transmission systems make way for new innovative shifter designs such as monostable shifters that spring back to a starting position after a gear has been chosen. Unfortunately the radical change in the communication between the user and shifter has resulted in accidents due to incorrect gear selection. The inadequate usability of the monostable shifters can be attributed to the feedback it provided to users.   The aim of the thesis project was to develop a feedback concept that would improve the usability of a monostable shifter and to study if auditory feedback could be introduced to vehicle systems. By implementing design theory, benchmarking and various creativity methods five concepts with feedbacks in different modalities were developed. The concepts were evaluated in a usability study that involved 25 test participants. A review of the observations from the usability study along with an analysis of the interviews and collected data resulted in the final VRA concept. VRA was a multimodal concept with permanent visual feedback and optional auditory feedback. The shifting pattern was shown on the instrument cluster where the active gear was highlighted through light intensity, color and shape contrasts. The solid blue block, within which the abbreviation for the active gear was displayed, could be seen in the peripheral view. It was perceived as calm and helped the users navigate the shifter. A female machine voice that had a Swedish pronunciation was chosen as the auditory feedback to accompany the “P”, “R” and “D” gear selections. None of the users were indifferent towards the auditory feedback, some perceived it as caring while others found it annoying. Since the analysis did not indicate that auditory feedback was crucial, the VRA concept included an option to turn on or off the sound.   Monostable shifters behave differently compared to traditional polystable shifters, therefore with the changes in the physical movement the communication must also be reviewed. It is recommended to include the shifting pattern on the instrument cluster together with monostable shifters, as it makes up for the loss of the visual and haptic information from the physical shifter. Although the usability study showed that auditory feedback was not necessary, improvements were observed among people who favored it. The auditory information would most likely be better received if earcons were implemented instead of speech. / Elektromekaniska shift-by-wire växlingssystem tillåter nya innovativa designlösningar så som monostabila växelväljare som fjädrar tillbaka till en ursprungsposition efter varje växelval. Dessvärre har den drastiska förändringen i kommunikationen mellan användarna och systemet resulterat i missförstånd och olyckor till följd av fel växelval. Den bristfälliga användbarheten av monostabila växelväljare kan härledas till feedbacken mellan förarens handling och resultat.   Syftet med examensarbetet var att utveckla feedbackkoncept som förbättrade användbarheten av en monostabil växelväljare samt att studera om auditiv feedback kunde introduceras i förarsystem. Genom att implementera kunskaperna inom designteori, observationer från benchmarking samt diverse kreativa metoder kunde fem olika koncept presenteras. Koncepten utvärderades i en användbarhetsstudie med 25 testdeltagare.  En genomgång av observationerna från användbarhetsstudien, intervjusvaren samt dataanalysen resulterade i det slutgiltiga konceptet VRA. VRA var ett multimodalt koncept som innehöll permanent visuell feedback samt valbar auditiv feedback. Växlingsschemat visades på instrumentpanelen där den aktiva växeln markerades med hjälp av kontraster i ljusintensitet, färg och form. Förkortningarna på aktiva växel visades inuti en solid blå rektangel som var synlig i periferin. Färgen uppfattades som lugn och den starka kontrasten hjälpte personerna att navigera växelväljaren. Den auditiva feedbacken var i form av en kvinnlig maskinröst med svenskt uttal som kompletterade ”P”, ”R” och ”D” växellägena. Inga testpersoner var likgiltiga till auditiv information, vissa beskrev den som omtänksam medan andra ansåg att den var irriterande. Eftersom analysen indikerade att auditiv feedback inte var kritisk var den auditiva feedbacken valbar i VRA.   Monostabila växelväljare skiljer sig drastiskt från polystabila, därför bör kommunikationen mellan systemet och människan ses över i och med de fysiska förändringarna. Växlingsschemat bör inkluderas i instrumentpanelen i samband med att monostabila växelväljare används. Det kan nämligen kompensera bristen på den visuella och haptiska feedbacken från den fysiska väljaren.  Trots att analysen visade på att auditiv feedbak inte var nödvändig kunde förbättringar observeras bland personer som tyckte om det. Den auditiva informationen skulle mest troligt få ett bättre bemötande om earcons användes istället för tal.

<p>This thesis was done at DaimlerChrysler AG in Stuttgart,Germany. The aim of the thesis is to develop an algorithm for controlling a motor used in a Shift-by-Wire System. The control algorithm is to be implemented in a prototype car for further testing. The Shift-by-Wire System can be described as follows: An electrical actuator is mounted in an automatic gearbox to select gears instead of the gear stick. The actuator is controlled by a microcontroller, which runs a control algorithm. The position of the actuator is measured with a linear position sensor and sent to the controller.</p>

This thesis deals with the development of a specification regarding a push-button, which will be used to control the gear-shifting function in an automobile. In addition to this the author will describe different techniques and theories that have been helpful in achieving data and results for the specification. Kongsberg Automotive AB, is located in Mullsjö, Sweden, the company supplies parts to the automotive industry. In the research and development department, R&amp;D, there is a group that works with development of Shift-By-Wire systems. In an automobile with a Shift-By-Wire system the communication between the gear-shifter and the gear-box occurs electronically. The mechanical link is, in most cases, taken away and replaced by the digital system. Within this group an internal Kongsberg project is in motion dealing with the development of a number of gear-shifters, finalizing in the mounting of the shifters in a Smart Car. These concepts will be displayed to customers by Kongsberg as a demonstration of what the company has to offer. To be able to decide what appears in the specification the author has done a thorough push-button examination. Tightness is one of the most important elements in a push-button; it determines what the push-button conveys and its character. The choice of mechanical solution will affect both the tightness and the character of the push-button. To illustrate this, the author has chosen to use a version made of silicon rubber. The silicon rubber part is ordered from a supplier company specializing in customer-specific push-buttons. The method is simple, cost-effective, enables regulation in tightness, compressive force, illumination, density, repelling liquids, penetrating objects and other parameters. All of these properties are desirable when developing push-buttons. The specification consists of seven chapters. The first chapter describes the document. Chapter two is an introduction chapter. The following three chapters present the requirements made concerning the product. The sixth chapter concerns laws and regulations and the seventh and last chapter is an appendix. The requirements concerning the product consist of functional, qualitative and electrical requirements. Belonging to the functional requirements are the following: stroke, force, illumination etc. To the qualitative requirements belong: performance, reliability, applicability etc. The electrical requirements consist of preparing the button for Kongsbergs own patented sensor system. The specification will be handed over to Kongsberg on the finalization of the thesis. The result will work as a template, with the intent that the document is to be used and followed up by the company. The functional and qualitative requirements and data have been assumed by the author and will later be tested, followed up and if necessary altered by Kongsberg. / Detta examensarbete behandlar framtagandet av en kravspecifikation för en knapp som skall användas till att styra växelfunktionen i en bil. Utöver detta går författaren in på olika tekniker och teorier som har hjälpt till att nå resultaten i kravspecifikationen. Kongsberg Automotive AB ligger i Mullsjö, Sverige, företaget levererar delar till bilindustrin. På utvecklingsavdelningen finns det en grupp som jobbar med utveckling inom Shift-By-Wire system. I en bil som använder ett Shift-By-Wire system sker kommunikationen mellan växelväljaren och växellådan elektroniskt. Den mekaniska länken är i många fall helt borttagen. Ett internt Kongsbergprojekt pågår inom denna grupp som behandlar att ta fram ett antal växelväljare som skall monteras in i en Smart Car. Dessa koncept skall visas upp mot kunder till Kongsberg, som en demonstration på vad företaget har att erbjuda. För att bestämma vilka krav som ska finnas med i kravspecifikationen har författaren gjort en grundlig ”knapp-undersökning”. Tryckkänslan i knappen är ett av de viktigaste momenten, den avgör till stor del vad knappen förmedlar och vilken karaktär knappen får. Valet av mekanisk lösning i knappen kommer till stor del att påverka knappens karaktär och tryckkänsla. Författaren har valt en silikongummivariant som exempel och bygger upp knappens karaktär runt denna grund. Silikongummidelen beställs av ett leverantörsföretag som specialiserar sig på kundspecifika knappar. Metoden är enkel och kostnadseffektiv och gör det möjligt att styra parametrar som tryckkraft, tryckkänsla, belysning, täthet, tålighet mot inträngande föremål och vätskor och diverse annat. Alla dessa egenskaper är önskvärda vid utveckling av en knapp. Kravspecifikationen består av sju kapitel. Det första kapitlet redogör kortfattat för dokumentet. Nästa kapitel är ett inledande kapitel. Sedan följer tre kapitel där de olika kraven på produkten läggs fram. Det sjätte kapitlet berör lagar och regleringar och i det sjunde och sista kapitlet kan man hitta bifogade dokument. De olika kraven består av funktionella, kvalitativa och elektronikrelaterade krav. Till de funktionella hör slaglängd, krafter, belysning o.s.v. De kvalitativa kraven utgörs av parametrar som prestanda, tillförlitlighet och användbarhet. Det största elektronikkravet ligger i att förbereda knappen för Kongsbergs egna patenterade variant av sensorering. Kravspecifikationen kommer att överlämnas till Kongsberg vid examensarbetets slut. Resultatet blir en typ av mall, med avsikten att dokumentet skall kunna användas och vidareutvecklas av företaget. De funktionella och kvalitativa kraven och data som författaren har antagit kommer att testas, vidare arbetas och vid behov ändras av företaget.

This thesis was done at DaimlerChrysler AG in Stuttgart,Germany. The aim of the thesis is to develop an algorithm for controlling a motor used in a Shift-by-Wire System. The control algorithm is to be implemented in a prototype car for further testing. The Shift-by-Wire System can be described as follows: An electrical actuator is mounted in an automatic gearbox to select gears instead of the gear stick. The actuator is controlled by a microcontroller, which runs a control algorithm. The position of the actuator is measured with a linear position sensor and sent to the controller.

Constantly growing demands from the costumers in the Automotive industry forces the subcontractors to seek alternative ways to compete. One parameter of quality is the components tolerance against NVH(Noise, Vibraion &amp; Harshness) aspects. Kongsbergs Automotive has developed a new gear shifter platform (Shift-by-Wire) that is sold to Alfa Romeo and used in of their car models. However, the company is not pleased with the components sound quality, therefore the main purpose of this thesis is to develope a number of concepts that is supposed to enhance these NVH-aspects. To get an understanding of the problem an analysis of the causes of the emitted sound has been done parallell to a product decomposition, function decomposition and a Ishikawa-diagram. Together with these methods has a litterature study been performed to get familiar with the physics of an impact and especially the emittment of noise. The concepts has been generated through a combined brainstorming and brainwriting session. A number of concepts has been developed that should reduce emitted noise. To evaluate the concepts generated has well proven methods for screening been used, such as: analysis of pros and cons, feasibility analyis and Go/No-Go. The definite concept uses a method that absorbs the kinetic energy induced by the user through a built-on component and an energy absorbing foam. The idéa is that the built-on component and the foam should transform more of the kinetic energy to heat energy. The consequenses of this study is that the company now has a fully applicable concept to evaluate the idés effectiveness regarding reduction of noise. Next step is to make a prototype and evaluate the idéa. Since the making of a prototype has not been done, the biggest restriction in the thesis  is that the developed concept is not evaluated regarding its effectiveness of reduction of noise.

<p>Shift-by-Wire is about replacing the mechanical link between the automatic transmission and the shift lever with an electromechanical system. This will make new safety functions possible and assist the driver in other ways. </p><p>To do this, an actuator with a brushless DC motor is built into the transmission. It controls the position of the shift valve, which decides the driving position. </p><p>This thesis concerns the controlling of the brushless DC motor. This is done by programming a shift control unit with a Motorola HC12 microcontroller. The performance of the motor is then tested and evaluated.</p>

Shift-by-Wire is about replacing the mechanical link between the automatic transmission and the shift lever with an electromechanical system. This will make new safety functions possible and assist the driver in other ways. To do this, an actuator with a brushless DC motor is built into the transmission. It controls the position of the shift valve, which decides the driving position. This thesis concerns the controlling of the brushless DC motor. This is done by programming a shift control unit with a Motorola HC12 microcontroller. The performance of the motor is then tested and evaluated.