AEI's What's New at SAE 2002
Die-face design
AutoForm Engineering's AutoForm-DieDesigner software for rapid die-face design and optimization improves quality, cost, and lead times in the design of sheet-metal parts and stamping dies. Tooling engineers can create fully parametric die-face designs rapidly from CAD surface data and can immediately try out and optimize their designs with integrated stamping simulation modules. Key features include fully automatic and semi-automatic design of binder and outer/inner addendum using profiles, easy part and tool modifications (morphing), automatic fill of holes and double-attached parts, and export of tool surfaces to CAD. For typical automotive parts, the complete die face can be created in only 60 min.
Exhaust gas aftertreatment
AVL List GmbH has developed heavy-duty diesel engines complying with Euro 4 emissions legislation without the use of particulate traps or DeNOx catalysts. The technology builds on advanced fuel-injection equipment combined with AVL's combustion knowledge and holistic development approach. A dynamically controlled EGR system is applied. An Oxicat is added to compensate for production tolerances affecting the lube-oil control. Test results show a 20% margin to the legislated emissions limits. On-road fuel consumption is similar to current Euro 3 compliant engines. The technology is also applicable to off-road engines to meet Tier 3 requirements.
Interior impact
A turnkey solution for interior impact testing from BIA is capable of FMVSS201 interior impacts at 42 km/h (26 mph), 10 kN (2250 lbf), and 1% accuracy. Impact test parameters are configurable by entering the required test conditions into a Windows-based control system and leading the robotic-type impactor to the desired impact point. The test system comes complete with PC-based controls, a laser positioning system, photography equipment interface, and an integral hydraulic system. The only facility requirement is electrical power. By adding an optional high-speed impactor, the system can simulate pedestrian impacts.
Sound and vibration measurement
With Version 6.1 of PULSE, Brüel & Kjær's sound and vibration measurement platform offers spatial transformation of sound fields such as near-field acoustical holography on data generated by the Acoustic Test Consultant for near-field analysis and source location. It also features steady-state response analysis and arbitrary waveforms on PULSE; multiple-input, multiple-output analysis (supported by Modal Test Consultant) and a new version of operational modal analysis; envelope analysis using amplitude demodulation (e.g., for the diagnosis of roller bearing elements and the identification of gearbox faults); PULSE Interface to Sony SIR-1000 Software that allows data to be read directly into PULSE on a PC from a Sony tape streamer via a standard SCSI interface; and all-in-one input/output module up to 102.4 kHz.
Tire and wheel mounting
Burke E. Porter Machinery Co. has extended its expertise into tire and wheel mounting systems, which include a range of systems such as wheel soapers, wheel loaders, online vision error proofing, weigh stations, turnovers, an active ring inflator, and patented single/double robotic tire mounters. The firm's robotic mounting permits each tire and rim combination to have its own specific routine for tool position, tip angle, starting position, and tool-rotation pattern. An industrial PC with touch-screen operator panel provides clear and simple graphics to guide users through setups, operation, and diagnostics. No robot language is required once the system is set up.
Data acquisition
ViewDAQ is real-time display software for use with Campbell Scientific's CR5000 and CR9000 data-acquisition systems. With drag-and-drop functionality and other easy-to-use design features, it is suitable for creating scenes that provide real-time display of data during vehicle testing. Screens can be configured with any combination of dials, gauges, compasses, thermometers, LEDs, strip charts, and other display elements. Control features such as flags, switches, potentiometers, and variable settings can also be incorporated into the screens to provide real-time control. Operation of the units with or without ac power or a PC makes the systems effective in either portable or stationary applications. The CR9000 features a maximum throughput of 100 kHz. The CR5000 is a self-contained, stand-alone unit with 40 single-ended (20 differential) analog inputs, two pulse counters, two continuous analog outputs, four switched voltage excitations, four current excitations, and eight digital I/Os.
