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Alumina ceramics

Morgan Advanced Ceramics' alumina ceramics feature good hardness, wear resistance, and compressive strength suitable for the automotive industry. Designed for pneumatic and water valves used with compressed air in heavy trucks, the alumina ceramics adjust various suspension levels - such as for cabs, chassis, or seats - to account for the varying loading of the trailer. They help minimize air volume consumed, allowing for better control and making cabin leveling valves more efficient.

Dynamometer systems

Mustang Dynamometer developed two engineered dynamometer systems for hybrid-electric drive testing. Hybrid-electric propulsion systems combine ac vector-controlled, electric motor power to the conventional mechanical powertrain, thus reducing demands on the engine and achieving lower emissions and improved fuel economy. By using electric motors as generators during deceleration, vehicle braking energy is recovered and stored as battery energy to be reused during peak load periods. Brake life is extended, and maintenance costs and downtime are reduced. The firm's advanced test stands, developed to test the hybrid-electric propulsion systems, use input and output variable-speed dyne motors, each in excess of 220kW (300 hp) and capable of operating in various modes of operation. Each dyne motor operates in speed, torque, or road-load simulation mode. The input motor is also designed to operate in engine emulation mode. Via a gear increaser, the variable-speed ac input dyne motor can achieve up to 12,000 rpm. The variable-speed ac output dyne motor reaches speeds of up to 4000 rpm. A Rockwell Automation controller provides all the machine logic control in addition to all the modes of operation for the variable-speed drive regulators.

Exhaust-gas-temperature sensor

An exhaust-gas-temperature sensor from NGK Manufacturing can be used to control new exhaust-gas-purification systems. The sensor can detect wide temperature ranges and has good response and reliability. To achieve these qualities, perovskite-type rare earth oxide was selected as a sensing element. The perovskite-type material functions as an insulator and also as a superconductor, depending upon the combinations of metal ion. In this case, YCrO3 was selected as a base material; wide range detection from 150 to 900°C (300 to 1650°F) and good thermal durability was obtained. These properties were enabled by a metal-sheath cable with a small diameter that was used in the sensing portion.

Over-running pulley

The over-running pulley from NTN Bearing Corp. offers a simple, robust, and compact solution to automotive accessory drive NVH issues. The firm's unique use of wrap spring clutch technology allows for a considerably smaller and higher torque capacity unit than competing solutions. The device eliminates belt chirp during large speed changes, steering wheel shutter, and belt flap noise resulting from system resonance. The unit also features an improved belt and tensioner life. The company expects the increasing use of split mass flywheels, lower idle speeds, larger alternators, and a greater sensitivity to noise-related issues to increase the use of the pulley.

HEV simulation

Opal-RT's RT-LABh is a hybrid-electric vehicle (HEV) design simulation tool. With the company's patent-pending Artemis system solver, RT-LABh can significantly speed up design simulations and can run in real time for sub-millisecond hardware-in-the-loop testing. A typical RT-LABh configuration consists of a cluster of off-the-shelf PCs linked via a 400-Mb/s IEEE 1394 FireWire.

Light simulation

SPEOS software from Optis provides engineers with the essential light simulation tool for designing and optimizing lighting systems. It allows them to model and import the lighting system files in all major CAD formats including IGES and CATIA. SPEOS gives precise photometric results such as intensity, illuminance, and colorimetry. Its real rendering feature enables designers to visualize their objects as if they were already made. A lighting scenery feature further adds to its realism by incorporating the objects in 3-D scenes. The tool is aimed at designers of headlamps and taillamps, dashboards, switches, head-up displays, and those looking to eliminate ghost light on vehicle glass surfaces.

Air-assisted injection

Orbital Combustion Process (OCP) technology from Orbital Engine Corp. uses compressed air to atomize finely the fuel as it is injected directly into the combustion chamber. Over the European emissions drive cycle, Stage 4 emissions have been demonstrated with bench aged catalysts in conjunction with a 13 to 17% fuel economy improvement. The system has the ability to run a lean stratified charge under real-world driving conditions to improve in-vehicle fuel economy. Due to the efficient fuel atomization process, an optimal spray-guided, direct-injection combustion process can be used so the spark plug and injector are closely spaced and located centrally in the combustion chamber. The low levels of emissions offered by a spray-guided system compared to a wall-guided system allow the size, and hence the cost, of the aftertreatment system to be minimized. Typically, engine-out HC levels are similar to those of a port fuel-injected engine. NOx emissions levels are reduced typically by 85% relative to port fuel-injection systems by the use of high levels of exhaust gas recirculation.

Windstop

During operation of convertibles with the top open, the airstream is led by the windshield over the vehicle, which causes turbulence from the rear into the vehicle's cockpit. The Windstop from ORIS fastens behind the front seats and prevents air turbulence inside the vehicle. The device also improves the efficiency of the car heater and reduces noise levels considerably. Even at high speeds, occupants can carry on a conversation and hear the car radio. The device is available for the Chevrolet Camaro, Chevrolet Corvette, Chrysler Sebring, Ford Mustang, Mazda Miata, and Pontiac Firebird.

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