Close-Range Photogrammetry Approach for the Virtual Prototyping of an Automotive Magnetorheological Semi-active Differential

First target of this paper is to describe the design of an automotive semi-active differential based on the use of a Magneto-rheological Fluid (MRF). The MRF allows to control the locking torque and, consequently, to improve the vehicle handling. Second target is to propose a method grounded on a Close-Range Photo-grammetry approach for the CAD modeling phase of the device ideated, alternative to the use of the typical Reverse Engineering (RE) techniques. In fact, although a Reverse Engineering process allows the complete 3D reconstruction of the external surfaces and features of a real object, it could often take a lot of time and, in some cases, could be affected by some approximations or errors. To evaluate the goodness of the procedure adopted, the MRF LSD geometry was reconstructed also by means of the Reverse Engineering techniques applied to the physical prototype of the new device ad hoc created. Lastly, the results of the FEM analysis carried out to validate the design process and the methodology ideated and adopted were showed.