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Sheet metal hydroforming

Siempelkamp Pressen Systeme (SPS) is actively pushing forward new technological concepts that have been developed and refined from classical tube hydroforming. One of these concepts, sheet metal hydroforming, is being developed by SPS in cooperation with the University of Dortmund. Sheet metal is forced into a die cavity by water at high pressure. The sheets will take the shape of the die contour and retain this shape durably with repeatable accuracy. The first machine will be supplied by SPS this year. Fundamental research on the forming process of large workpieces or of material with forming properties is necessary so that this technology can lead to series production.

3-D mechanical design

SolidWorks Corp.'s powerful SolidWorks software is a 3-D CAD solution for the mainstream mechanical design market. Its innovative, intuitive design capabilities and integrated add-on solutions save time and are easy to use. The company's latest solution is based on its core product SolidWorks 2001.

Onboard data acquisition

Soltec/Kyowa's Model DIS-3000A is a fourth-generation, compact, onboard vehicle and HYGE sled data-acquisition system. This 16- or 32-channel system withstands 100 g. Built-in, isolated signal conditioning is provided for each channel to measure acceleration, voltage, and event inputs of onboard vehicles involved in front barrier and side impacts, rollover tests, and HYGE sled measurements for seatbelt and airbag testing. Operating on an internal rechargeable battery, the less than 10 lb (4.5 kg) unit amplifies analog signals sent from sensors, digitizes them with 12- or 16-bit resolution, and stores them in a large, nonvolatile 1 MS/channel memory that provides 50 s of data when sampling at 20 kHz. External power is not required for measurement and data collection. On-site post test analysis can be performed with a laptop PC and an array of crash test software.

Data-transfer software

Sony Precision Technology America's PCscan III is a software package that enables data transfer from the company's data recorder to an IBM-PC/AT or compatible for display and analysis. The software and integration product provides for data uploading or concurrent recording to notebook, PC, or workstation. Multichannel and wide-band measurement data are directly transferred to the computer's hard disk and can be displayed instantly on the screen. The software includes high-speed tape search, a data export function that supports formats commonly used in data analysis, and waveform and numerical display of loaded data for improved efficiency of analysis. The various functions are controlled quickly and easily by click-and-drag operations.

Fuel economy simulation

Southwest Research Institute (SwRI) has created the Vehicle System Model (VSM), an engineering software tool and database that will provide a modular approach to simulating vehicle fuel economy and performance. VSM, jointly developed with a major automotive manufacturer, features two operating modes: a rigorous, high-fidelity, forward-looking model architecture and a high-speed, backward-looking model architecture.

Through-hole LEDs

Stanley Electric's new through-hole AlGaInP LED series delivers 10-15x brighter lighting than conventional through-hole LEDs, which reduces the amount of components necessary to achieve equivalent lighting levels and, thus, the total cost of lighting. The high-visibility LED series features a typical luminous intensity of up to 5000 mcd (20 mA), depending on color, and comes in three colors with a 10° viewing angle. Its advanced LED die is composed of aluminum, gallium, indium, and phosphate (AlGaInP) as opposed to a typical GaAsP LED. The LEDs are suitable for both indoor and outdoor applications with an operating temperature range of -40 to +85°C (-40 to +185°F), including use for automotive interior lighting in instrument clusters and audio or HVAC systems as well as a replacement for incandescent bulbs in automotive taillamps and other external vehicle lights. The LEDs meet similar lighting requirements in RVs, trucks, and forklifts.

Grit blast manipulator

Sulzer Metco's RotaBlast rotating grit blast manipulator helps to ensure effective treatment of cylindrical components by continuously rotating the grit blast nozzle during precoating preparation of both internal and external surfaces, eliminating the need to rotate the component. Its ability to ensure maximum reliability and efficiency of the grit blast process makes it suitable for preparing automotive engine block cylinder bores for plasma spray coating and for allowing OEMs to automate their thermal spray processes to a greater degree than before.

Stress testing

Thermotron Industries' AST-8 is a compact system for performing highly accelerated life testing on automotive components. The small, portable unit is able to pass through a standard door opening. It is designed to reduce utility consumption and lower operating costs. The firm's multi-axis vibration table and rapid thermal change rate system provide a suitable environment for ruggedizing product designs. Product temperature change rates exceeding 70°C/min (158°F/min) can be achieved throughout a range of -100 to +200°C (-148 to +390°F). Vibration levels in excess of 50 g rms covering a broad frequency spectrum are transmitted directly to products under test.

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