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Stepper motor

Thomson Airpax Mechatronics has expanded its product offering to the automotive design market with the 15M020D1B permanent magnet stepper motor. The motor, which measures 15 mm (0.59 in) in diameter and 15 mm (0.59 in) in length, produces more than 3.5 mN¥m (0.5 oz¥in) pull-out torque at 200 pps, outperforming other permanent magnet stepper motors in its frame size. The small size and ability to operate at low current levels make the unit suitable for applications in which space and power demands are critical. The motor gives designers a quieter, longer-life replacement for conventional brush dc motors, and through increased availability of automotive digital electronics, potential stepper designs are frequently more cost effective. Typical automotive applications include gauges and instruments as well as evolving applications based on wider, optional features.

Occupant and pedestrian protection

With the Ecofront project, TNO Automotive and its partners aim to develop a vehicle front end with improved crash performance while decreasing the mass of the vehicle. In the Ecofront, crash energy is absorbed by controlled bending of lightweight, S-shaped, aluminum elements rather than crumpling of the vehicle structure. The demanding new EEVC requirements for pedestrian protection were used to design the Ecofront, which also included styling and packaging requirements. A demonstrator vehicle front end was built to show that the technological innovations presented in this project can be achieved in a real vehicle.

Torque-limiting device

USA Tolerance Rings' European affiliate, Rencol Tolerance Rings, helped Toyota develop a tolerance ring as a solution to overload situations experienced with its electric power-assisted steering system. When the wheels strike a curb or another stationary obstacle, forces are transmitted through the rack to the drive gears, damaging the teeth and motor and causing a loss of steering control or degradation in steering performance. The tolerance ring is placed between the motor drive gear and the motor spindle and acts as a torque-limiting device. During normal operation, it will transmit the desired amount of torque. However, once the torque exceeds a predetermined limit, the tolerance ring allows the gear to slip on the spindle. When the torque level falls back into the normal operating range, the ring begins to transfer torque to the gear again. The slip is nondestructive and can be repeated thousands of times without major degradation in performance.

Boron steel

Usibor 1500 is a precoated boron steel from Usinor Auto Groupe that is used in the press-hardening process and sometimes for post quenching. The material yields good fatigue and anti-intrusion properties. It can sustain the entire press-hardening process to give finished parts good corrosion resistance. The results are close to that of a regular Zn-coated product, with low extra cost. Typical applications include anti-intrusion or flexion resistant parts such as front beams, crossmembers, B-pillars, and door beams.

Current sensor

Vacuumschmelze (VAC) presents a two-state current sensor with a dynamic measurement range that exhibits a resolution of 1 mA at low current and an accuracy of 0.5% from 1 to 100 A. The heart of both stages is the use of offset-free magnetic cores made from amorphous metal. This compact and cost-effective sensor has been designed in cooperation with a major producer of battery management systems. VAC is featuring small, PCB-mountable modules for the control of EPAS and brake-by-wire as well as high-accuracy, high-current sensors (up to 1200 A) for the integrated starter alternator. These new sensors are all based on the patented offset-free field probe technology, which for more than 10 years has proven its superiority over the common Hall-effect technology in industrial applications, according to the company.

Four-loop control

Vibration Research Corp. recently demonstrated a cost-effective solution for a four-loop, four-poster control. It is an inexpensive and easy way to perform field data replication and random tests with four independent control loops. Pictured is the control system running on a Team hydraulic system at a Spectrum Technologies facility.

Pocket-sized data acquisition

MAS Match II from V-Tech International is a pocket-sized, stand-alone, data-acquisition and online-evaluation system for long-term data and fatigue life monitoring. The device is suitable for applications in difficult-to-access areas or if space is limited. Two analog channels, completely conditioned for strain gauge applications and other analog signals, are software controlled in gain and offset, featuring a 10-12 bit resolution and a sample rate of up to 2000 samples/s. Two digital channels record discrete signals and occurrences. The standard version supports the following evaluation methods: rainflow, level crossings, range pairs, and time at level. Optional evaluation methods are transient mode with trigger, sequential peaks and troughs with master/slave, and time at level 2d. A remote control via wireless phone allows the remote extraction of data and setting of parameters.

Blast shot

Vulkan Blast Shot Technology has developed a hard stainless steel grit and stainless steel shot. Both products have been reported to reduce surface preparation and finishing if any ferrous contamination or discoloration has to be avoided. Both products are reusable up to 50 times compared to mineralic abrasives such as glass or alumina and can be used in air and airless equipment. Dust and waste development are minimized.

Traction differential

Zexel Torsen's T2-R RaceMaster traction differentials are suitable for rear-wheel-drive, truck, SUV, C-clip, and high-performance applications. The patented Equvex parallel-axis-gear configuration provides better management of gear separation forces, resulting in low backlash and quiet operation. Unlike conventional speed-sensing, limited slip differentials, Torsen T2-R is a full-time torque-sensing, torque-biasing system. Torque and differentiation are continuously managed between the two axles and biased instantaneously according to variable road conditions. The differential is preloaded and capable of remaining locked with low torque inputs, enhancing traction and mobility under extreme conditions.

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