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Membranes

Versapor R and Supor R membranes from Pall Specialty Materials provide practical solutions for various automotive applications. Both membranes are FluoRepel treated for good oleophobic/hydrophobic properties. Versapor R membrane is a modified acrylic copolymer cast on a nonwoven nylon support. Supor R membrane is a modified polyethersulfone polymer cast on a nonwoven polyester support. Applications for the media include ABS brake systems, fuel tank pressure sensors, transducer protectors, electronic black boxes, electronic motors, and lighting assemblies.

Seatbelt microphone

The Seat-Belt MIC from Paragon AG is designed to improve the performance of speech recognition systems that are designed into vehicles as interfaces for the new telematics systems. This product substantially improves recognition rates, which dramatically improves the usefulness of speech recognition systems. The seatbelt microphone is the newest addition to the firm's microphones, which include the Universal MIC (replacement for applications such as GM On-Star and hands-free telephone kits); Integrated MIC, for applications in which a universal hands-free kit is integrated into the vehicle; and the Gooseneck MIC, for high-noise, truck, and off-highway equipment applications.

Dog point studs

PEM-type, high-strength, self-clinching dog point studs from PennEngineering enable reliable and secure attachment of vehicle components and can reduce the number of required parts for quicker assembly and neater, lighter component designs. The fasteners' dog point feature ensures quick nut positioning while protecting first threads from damage. The steel, stainless steel, or bronze studs are designed for automakers, Tier 1 suppliers, and aftermarket manufacturers and are suitable for various applications including bumper supports, engine brackets, airbag assemblies, and fuse terminal posts. They can be installed in metal sheets as thin as 1.3 mm (0.05 in) and are available in thread sizes ranging from #0-32 through 3Ú8-16 and M5 through M10.

Metal injection molding

Phillips Plastics has recently developed and refined its metal injection molding capabilities for functional part applications. The firm has a continuous inline furnace in a 3252-m2 (35,000-ft2) manufacturing facility that can produce parts up to 100 g with tolerances of +/-0.3%. Low-alloy steels, soft-magnetic alloys, and nonferrous alloys such as titanium and cobalt-based alloys can also be produced via metal injection molding.

High-speed video camera

Photron's Fastcam-ultima 1024 high-speed digital imaging system features high resolution and network capabilities. The camera meets the requirements of advanced applications in research and development environments of the automotive industry. It captures 1024 x 1024 pixel images at frame rates up to 500 frames/s and up to 16,000 frames/s with reduced image resolution. The electronic shutter's speed is selectable from 1 ms to 8 µs at all frame rates. Up to 63 cameras can be networked via the system's IEEE 1394 FireWire interface to provide operational flexibility. Both monochrome and high-fidelity color models are available. Windows-based software includes camera control, image capture, and file management functions. The data display includes recording rate, ID number, date/time, and recording status.

Position sensors

Piher International Corp.'s custom, long-life position sensors come in both contact and contactless versions. Contact versions are supplied with a life of up to 3 million cycles and 10 million dithers and are custom-designed to the customer's mechanical requirements. Contactless versions use giant magnetoresistive technology and have virtually unlimited life cycles. These robust products are suited for position sensing and can be supplied with up to 180° electrical angle. In addition, Piher has developed a family of lower-cost, long-life automotive products with 360° mechanical angle. Parts can be supplied with an electrical angle up to 340° and specific values at any position. Parts can be designed as a multi-position switch, a potentiometer, or a combination of both and used as either a position sensor or function control.

Variable valve lift and timing

Porsche Engineering Services' VarioCam Plus combines switchable valve lift curves with variable valve timing, allowing a variable engine (two-in-one) concept to be achieved, which yields maximum power and torque along with low pollutant emissions and low fuel consumption. This concept has been designed largely to support the inherent potential of fully variable valve timing systems. The durability of the new mechanical components is optimized, and a new Motronic engine management system is available to account for the various control functions for the variable lift switching system. The suppliers' and Porsche's production lines were adapted to the new requirements.

Aluminum engines

Power Beat International Ltd. has developed the first fully extruded internal combustion engine. Cost savings are achieved by manufacturing the engine from extruded aluminum alloy instead of using conventional casting methods. The Powerbeat Alu-X uses interlocking modules for each cylinder and to form the crankcase and envelop the crankshaft. The modules were made by sectioning extruded profiles (produced in long strips) at an appropriate length. Any number of these modules can join to make the engine block, replacing one-piece cast blocks and allowing engines of different capacities, cylinder numbers, and stroke lengths to be made from the same parts. Extruded aluminum alloy is also used for the engine head and sump plate. The piston valve bores are extruded alongside the main piston bores in the cylinder head module, which allows for a side valve arrangement. This leads to lower peak surface temperatures in the combustion chamber, reducing NOx emissions and allowing higher compression ratios without preignition. Engine assembly is quick with tie bolts instead of short studs, which hold the stressed components in compression and eliminate the need for load-bearing threaded holes within the block. Tee slots incorporated into the extrusion profile allow simple attachment and adjustment of auxiliary components and mounting of the engine. The company is developing a single-cylinder 0.2-L engine aimed at the small-engine market.

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