AEI's What's New at SAE 2002
Spinforming systems
Integrated spinforming systems from Hess Engineering are used for high-volume automotive exhaust component production. The precise, economical metal-forming technology can accommodate concentric-, eccentric-, and oblique-axis designs. Benefits include cost savings of 30%, no welding, low tooling cost, high material yield/reduced scrap, weight reduction, flexible manufacturing, and high reliability.
Pyrotechnic activator
To help prevent serious neck injuries during a typical rear impact, Hirtenberger Automotive Safety has developed a pyrotechnic activator for crash-active headrests. In the case of a rear impact, the device moves the headrest toward the occupant's head in less than 20 ms. Due to the quick and reliable reaction achieved by using pyrotechnics and sensors, the system presents a significant improvement in comparison to conventional systems. The system also is easily reloadable and, therefore, cost competitive. By launching the system in the new BMW 7 Series, the company is the first supplier of a pyrotechnic anti-whiplash system.
Engine development
IAV Automotive Engineering's FI2RE is a tool for engine research and development. It increases the flexibility of injecting and igniting fuels for diesel, gasoline, or natural gas. The unit is capable of up to five injections per cylinder, per 720° crank angle. The injections are also capable of being simultaneous on several different cylinders. The FI2RE can be used for up to eight cylinders on gasoline engines (injection and ignition) and up to 12 cylinders when used on diesel engines. It can be controlled by any CAN communication controller. The field of application for the FI2RE ranges from emissions research and testing to the evaluation of new unconventional injection and ignition sequencing, such as rate shaping or microinjections. The tool's structure and software are fully flexible and may be customized. The product is based on a Motorola MPC555 controller.
X-by-wire
Intensa offers a toolbox of mechatronics solutions for the next X-by-wire generation. The steering, throttle, brake, shift, and suspension control systems will replace traditional mechanical hardware with highly reliable networks of actuators, control units, sensors, wiring, and communication protocols such as Time-Triggered Protocol or FlexRay. The company also features programs covering control unit housings for accommodation of the PCB with precision insert-molded, multi-pin connectors and provides bondable, insert-molded solutions for miniature noncontacting sensors (e.g., pedal and throttle position sensors). In addition, Intensa and its manufacturing partners offer gold-plated contact pins for improved conductivity as well as completely sealed housing and wire harness designs.
Pressure sensors
Kavlico's P155 and P195 high-performance pressure sensors are suitable for a variety of motorsports applications. Engine builders and dynamometer operators also use the sensors for applications such as manifold absolute pressure, boost pressure, oil pressure, fuel pressure, nitrous oxide bottle pressure, hydraulic-brake pressure, air-suspension pressure, pneumatic-system pressure, and aerodynamic pressure. The sensors feature stainless steel housings, male or female process connectors, EMI and RFI protection, O-ring options for process media compatibility, and pressure ranges from 0-100 kPa (0-15 psi) through 0-20,700 kPa (0-3000 psi) gauge, absolute or sealed. They also provide a linear voltage output of 0.5 to 4.5 V dc and install easily due to their small size and weight.
Intake manifold
Keihin Corp. is producing a composite intake manifold for the Honda Civic to accompany the one already being produced for the Honda Accord. Both plastic manifolds are part of complete intake-manifold assemblies supplied by Keihin. By using a composite material, the company was able to work with Honda in achieving a higher level of shape complexity and part integration, thus gaining easier assembly and reduced cost. Keihin also offered engineering support and worked with other suppliers to meet the high level of quality and refinement required by the customer for the new material.
