SAE 2011 World Congress

Technical Session Keynotes

Electric Collaboration - Autodesk and Tesla Motors Partner to Design the Breakthrough Model S Sedan
Ed Martin Session: B101 CAD/CAM/CAE Technology
April 14th

Ed Martin, Senior Manager of the Automotive and Transportation Manufacturing Industry Group for Autodesk will discuss his company's partnership with Tesla Motors during the conceptual design phase in production of the new Tesla Model S. Projected to be commercially available in 2012, the Model S is described as "the world's first all-electric luxury sedan" and was nominated by California Home+Design as one of the best made-in-California design innovations of the year for 2010. It is the first sedan of its class to be built from the ground up around an electric powertrain, and is capable of delivering the same zero-emission acceleration made famous by its predecessor, the Tesla Roadster, without sacrificing its roomy interior and cargo space.

Mr. Martin will describe how Autodesk and Tesla worked together to optimize and visualize the Model S design, rapidly accelerating Tesla's innovation, performance and time to market as the company expands its all-electric portfolio. He will discuss how Autodesk worked with the Tesla design team to digitally prototype multiple vehicle designs, with design review decisions made quickly and easily communicated among team members. He will also examine the unique features of the Tesla-Autodesk partnership that allowed the manufacturer to meet requirements during the Model S design phase in the critical areas of concept exploration, design modeling, visualization, and design process integration.

Other features of the Tesla-Autodesk partnership that Mr. Martin will address:

  • Reducing the time required to create high-quality imagery for clear, efficient, and effective communications
  • Ensuring that designs address both the aesthetic and functional requirements
  • Integrating with other third-party CAD applications with industry-standard data formats and optional native translators

Ed Martin
Senior Manager, Automotive & Transportation
Manufacturing Industry Group
Autodesk, Inc.

Ed Martin brings more than twenty years of automotive industry experience, including roles at an OEM and Tier One supplier, to his current role as a Senior Industry Manager for the Automotive OEM/Supplier and Transportation Equipment segments in Autodesk's Manufacturing Industry Management Group. In this role, Mr. Martin's primary focus is to help spearhead Autodesk activity in the automotive and transportation industries, including identifying and communicating solutions that enhance customer value. He is also involved in driving product strategy to meet future customer needs.

Ed Martin holds a bachelor of science degree in mechanical engineering from Kettering University and a masters degree in business administration from the University of Michigan.

Recent speaking engagements:
Tauber Institute Global Operations Conference (November 2009)

Structural Optimizations Methods and Techniques to Design Light and Efficient Vehicles
Juan Pablo Leiva, Ing. Session: B103 Design Optimization - Methods and Applications
April 12th

Juan Pablo Leiva, Ing.
President and COO
Vanderplaats R & D

Abstract - Current difficult economic environment and intense competition in the global automobile market impose automobile companies and their engineers the need to design and build vehicles that perform better that their previous models, that are lighter, more fuel efficient, more quiet, pollute less and yet be cheaper to manufacture.

In the presentation, different optimization methods and techniques that can be used to address some of these issues are discussed. Methods such sizing, shape, topology, topometry, topography and freeform optimization are described and examples on their use are presented. The paper will show that today optimization methods are mature and can be use used at different stage of the design process of vehicles.

Biography - Juan Pablo Leiva
Mr. Juan Pablo Leiva is currently the President and COO of Vanderplaats Research and Development, Inc.

Mr. Leiva has over 20 years of experience in finite elements and optimization software development. He is one of the key developer of the commercial structural optimization program GENESIS . He has published multiple papers on sizing, shape, topology, topography, topometry and freeshape optimization. He has given and/or organized multiple professional courses on the usage of structural optimization in the United States and foreign countries training several hundred engineers.

Mr. Leiva received a BS (1986) and a Engineering degree (1989) in Civil Engineering from University of Chile. In 1990 he finished a MS from the University of California, at Los Angeles (UCLA) on Structural Mechanics. He is a Senior member of AIAA and a member of SAE.

Challenges in the Development of Modern Real Time Automotive Software
Marco Di Natale Session: AE318 System Level Architecture Design Tools and Methods
April 13th

Marco Di Natale
Prof. Marco Di Natale is currently IEEE member and Associate Professor at the Scuola Superiore Sant'Anna of Pisa, Italy, in which he held a position as Director of the Real-Time Systems (ReTiS) Lab from 2003 to 2006. He received his PhD from Scuola Superiore Sant'Anna in 1991 and has been Visiting Researcher at the University of California, Berkeley in 2006 and 2008/09.

He has been selected in 2006 by the Italian Ministry of Research as the national representative in the mirror group of the ARTEMIS European Union Technology platform.

He's been a researcher in the area of real-time systems and embedded systems for more than 15 years, being author or co-author of more than 100 scientific papers. He has been winner of three best paper awards and the Archie T. Colwell award.

Marco Di Natale has served as Program Committee member and has been organizer of tutorials and special sessions for the main conferences in the area, including the Real-time Systems Symposium, the IEEE/ACM Design Automation Conference (DAC), the Design Automation and Test in Europe (DATE) and the Real-Time Application Symposium. He also served as Track Chair for the RTAS conference, and is currently chair of the Transportation track of the DATE Conference.

He has been associate editor for the IEEE Transactions on CAD and the IEEE Embedded Systems Letters and is currently in the editorial board of the IEEE Transactions on Industrial Informatics.

Machine Health and Conditional Based Maintenance
Mark N. Pope Session: AE311 Vehicle Diagnostics
April 13th

Mark N. Pope
CCA Milford Proving Grounds Resident Manager
GM Customer Care and Aftersales

Pope began his career in the teaching field in 1976 and taught High School Chemistry and Physics for 6 years in Colorado and Nebraska. He also ventured into the sales field for a year as a representative for Mutual of Omaha Insurance Company in Colorado Springs, Colorado. He went back to his educational roots in 1983 and developed some of the first chemistry and physics educational software programs for WICAT Systems in Orem, Utah.

In the automotive field, Pope began his career on the Buick Computerized Automotive Maintenance Program (CAMS) in 1984. CAMS was the first fully utilized computerized tool to be used in automotive repair. Mark Pope has spent over twenty-six years in GM Automotive Service. Since 1984 he has been involved in designing, developing, writing, and supervising writing of User's Guides designed to inform the Service Technician on how to use various GM hardware and software products to repair vehicles. He is also responsible for the production and release of GM DVD's used in the service area including all GM Service Manuals, the Labor Time Guides, and Technical Information Software (TIS). He has also been involved the translation of GM Service Information. In 1993, he became the Resident Manager for the GM Service Technology Group (STG) at the GM Proving Grounds in Milford, Michigan. Later he held the same position for GM Service Operations, Service and Parts Operations (SPO) and currently GM Customer Care and Aftersales (CCA). In 2010, he was a member of the "White Glove - CARS Volt Dedicated Team" that was involved in the launch of the Chervolet Volt.

Mark Pope has been very involved in the Mid-Michigan SAE Section (current Program Chair) and was the 2001-2002 Chair. In 2000, he received the Mid-Michigan SAE Donald C. Scoville Memorial Award. In 2005, he received the SAE Noble R. Patterson Distinguished Section Member Award. Pope was the first Chair of the SAE Service Technology Program Office (STPO), which was later replaced by the Service Technology Program Committee (STPC). He was the Chair of the STPO for three years. He is still actively involved in the STPC. He is a past Chair SAE Sections Board and was a member of the SAE Membership Services Board for three years. He is currently a member of the newly formed SAE Membership Board. Mr. Pope has been an active member of the SAE Hybrid Standards Committee since 2005. He has written and presented papers involving service at the SAE Congress and COMVEC. He has also been involved in panel discussions at both events. For the past three years, he has been a Co-Session Organizer at SAE COMVEC for sessions on Service. He participated in the SAE Annual Planning Session that developed SAE Vision 2020. He enjoys his involvement in SAE very much and was elected to the SAE Board of Directors for 2009-2011. On the SAE Board of Directors, he has worked on the SAE Public Policy Committee and has pursued the development of possible future SAE student competitions in the area of hybrid and vehicle battery development.

Mark Pope is a native of Colorado and earned a Bachelor of Arts degree from the University of Northern Colorado in 1975 and a Master of Arts degree from the University of Northern Colorado in 1982. He has lived on the same lake for 26 years and is an active fisherman, boater, and sailor. He is a member of the Detroit Edison Boat Club and has purchased an extended cruising Motorsailor. Once a year, he hosts the Mid-Michigan SAE Governing Board meeting on an island in Lake Shannon. He also enjoys playing on a GM Proving Grounds Golf League and enjoys travel. Diane, his wife of 31 years is a middle school science teacher in an intercity school who is very familiar with the AWIM program. His oldest daughter Jennifer is a highly successful artist concerned with environmental issues and specializes in woodcut printing in Ithica, New York. The youngest daughter Jessica received a degree in teaching elementary education in 2008 and is currently an elementary education teacher in Niles, Michigan.

Systems Engineering Challenges
Session: AE312 - Systems Engineering (Part 1 of 2)
April 14th

Subramaniam Ganesan, Professor, Oakland University

Systems engineering studies the system throughout its life cycle. This includes requirements, specification, design, implementation, verification, and validation of systems, modeling, simulation, testing, manufacturing, operation, and systems maintenance. A thorough discussion on the components of the V diagram of the system engineering process will be presented.

A successful utilization of Systems Engineering will lead to reduced project cost, reduction of schedule overrun and missed performance etc. Challenges faced by systems engineering in handling complex systems under unforeseen uncertainties are presented. System design should consider also Murphy's law: Anything that can go wrong will go wrong".

This presentation will include topics such as "How Systems Engineering can help automotive Industry and defense?", "A simple look at the System Engineering organization" and "What support and resources are needed".

New and Recent SAE Brake Standards and Recommended Practices
Session: AC100 Brake Technology April 13th, 8:20 a.m.

Organized by Paul Gritt, Paul Gritt Consulting LLC

During the last 2 years, task forces and groups within the various Brake Technical committees have been working on several new brake related standards and recommended practices. This session will include short presentations be representatives of each group.

There are three objectives for this session:

  1. Update additional members of the brake community on the existence of new recommended practices and standards.
  2. Recognize the significant contributions in time and resources that many persons and companies have made.
  3. Invite additional participants to joint some of the teams whose work is not as yet completed.

The items that will be covered include:

  • Reports on:
    J-2879 Hydraulic Brake Tube Joints
    J-2928 Rotor/Drum Crack and Strength Dynamometer Test Procedure
    J-2789 Inertia Calculation for Single-Ended Inertia-Dynamometer Testing
    J-2923 Brake Drag Measurement Test Procedure For Vehicles Below 4 540 kg GVWR
  • The Current status of the work on eliminating Copper from brake linings.
  • The formation of a new task force to develop a common procedure for measuring the flow performance of master cylinders and HCU's
  • Brake Materials Environmental Task Force update
  • Brake Lining Materials Analysis Methodology Task Force update
  • Friction Materials Characterization Task Force update

Marty Kapanowski, Engineering Supervisor, Ford Motor Company
Mark Rogus, Technical Operations Manager, Link Testing Laboratories Inc.
Carlos Agudelo, Chief Engineer, Link Testing Laboratories Inc.
Steve Brown, Owner, Samarium L.L.C.
Greg Vyletel, ArvinMeritor, Inc.
Roy Link, Link Engineering Co.
Paul Gritt, Paul Gritt Consulting LLC

Numerical Simulations of Noise Induced by Flow in HVAC Ventilation Ducts
Dr. Jun Chen Session: M601 - CAE Analysis, Test Correlation and Optimization: NVH CAE (Part 1 of 2) Session 1
April 13th

Dr. Jun Chen is an assistant professor of School of Mechanical Engineering of Purdue University. He received his B.S. and M.S. in aerospace engineering from Beijing University of Aeronautics and Astronautics in China. He obtained his PhD degree in mechanical engineering from Johns Hopkins University in 2005. After that he did his postdoctoral research in Los Alamos National Laboratory. After joining Purdue in 2008, he started a new experimental group to study various flow problems. Dr. Chen's research interests are in the area of applied fluid dynamics, including development of advanced flow diagnostic techniques, unsteady flow dynamics, dynamics and structures in stratified flows, and combined experimental-numerical study of industrial flows.

Advances of Virtual Testing and Hybrid Simulation in Automotive Performance and Durability Evaluation
Dr. Shawn You Session: M501 - Load Simulation and Analysis in Automotive Engineering: Road/Lab/Virtual Test and Simulation for Vehicle Performance and Durability Evaluation (Part 1 of 5)
April 12th

Bio for Dr. Shawn You (11M-0297)
Have been working for MTS System Corporation since 1997 as a Simulation Test Consultant. Worked with OEM's and component suppliers around the world on variety of physical testing, virtual testing and hybrid simulation related projects. Received PhD degree in engineering mechanics from University of Minnesota in 1995.

Virtual testing is a method that simulates lab testing using multi body dynamic analysis software. This approach has been used more and more in vehicle design evaluation. The main advantages of this approach include that the design can be evaluated before a prototype is available and virtual testing results can be easily validated by subsequent physical testing. The disadvantage is that accurate specimen model sometimes are hard to obtain since nonlinear components such as tires, bushings, dampers, and engine mounts are hard to model. Therefore, virtual testing accuracy varies significantly. The typical virtual rigs include tire and spindle coupled test rigs for full vehicle tests and multi axis shaker tables for component tests.

Hybrid simulation combines physical and virtual components, inputs and constraints to create a composite simulation system. Hybrid simulation enables the hard to model components to be tested in the lab. As a result, it greatly reduces the requirement for an accurate analysis model and increases the chance for obtaining more accurate results.

Mechanical Hardware-in-the-Loop" (mHIL™) is one of the hybrid simulation approaches. It has been developed to enable actual physical components replacing selected components for "Real-Time" vehicle dynamic simulation. The examples of the kind of systems include Four-Corner Damper System and Quarter Vehicle System. In this approach, the virtual to physical coupling is accomplished in "real-time" allowing an accurate vehicle dynamics simulation to be conducted in a hybrid environment. The disadvantage of this approach is that the "real-time" requirement poses significant constraints on the model and test rig.

To address the limitation of real-time techniques, an alternative approach, Hybrid System Response Convergence (HSRC) method, has been developed. The HSRC method uses an iterative approach to develop a solution that satisfies the first principal condition for the hybrid system. The iterative approach allows the physical and virtual systems to run sequentially as open-loop systems, rather than simultaneously, thus avoiding the requirement to run in real-time. The disadvantage of the approach is that the iterative approach takes longer time.

Another approach address the limitation of real-time is to use a software name OpenFresco and a predictor-corrector algorism to connect dynamic analysis software and a test system. Once the solving speed cannot meet the requirement of real time, the predictor-corrector algorism slows down the actuator to allow more time for the model to be solved. This approach is called soft real time hybrid simulation. The disadvantage of this approach is that it still requires the hybrid simulation to be conducted at the near "real-time" speed.

Virtual testing and hybrid simulation, including mHIL, HSRC, and soft real hybrid simulation, are effective tools to study vehicle performance and durability properties. These tools bring vehicle testing and modeling departments closer than they have ever been. With proper usage, these tools can provide loading and motion information of vehicle components at early development stage when a full vehicle prototype is not available.

Application of Multi-Body Simulation Methods in Development of Vehicle Ride, Handling, and Steering Performance
Max Farhad Session: M501 - Load Simulation and Analysis in Automotive Engineering: Influence of Load on Vehicle Handling/Traction/Braking Dynamics and its Control (Part 5 of 5) Session 1
April 14th

Max Farhad
General Motors Company

During the past decade, there have been significant changes in methodologies and engineering processes used to develop passenger and light-duty vehicles, particularly in the ride, handling, and steering performance areas. Economic and competitive pressures particularly relative to mass and cost, new regulatory requirements in safety, fuel economy and CO2 emissions, integration of new technologies, advancements in multi-body simulation techniques, along with the desire to engineer performance reflective of the brand character of a vehicle, constitute some of the reasons for such an evolution. The intent of this review is to highlight the current methods used in General Motors to engineer specific ride, handling, and steering performance objectives into products intended for the world markets. Some specific examples are included to further demonstrate the current state. Lastly, future challenges resulting from the electrification of the auto industry and performance advantages of the related active systems will be highlighted. Examples of such systems include electric power steering with various compensation features, active front or rear steer systems, active ride and roll, and various traction methods that need to be idealized in multi-body models in order to fully optimize their benefits and to avoid performance compromises.

Advances in Tire Modeling for Road Load Simulations
Session: M501 - Load Simulation and Analysis in Automotive Engineering: Tire and Terrain Modeling Techniques and Applications (Part 2 of 5)
April 12th

Antoine Schmeitz, TNO

In the product development process of vehicles it is current practice to use detailed multibody vehicle models to determine component loads. Mostly these vehicle models do not contain tire or road models, but are excited with experimental data at the wheel spindles. Drawback of this method is that measurements of a real vehicle must be available to do the virtual durability analyses. To solve this issue, the tires and road need to be included in the simulation model. In the last decades several tire and road models have been developed for this task. This presentation will give an overview on the state of the art tire and road modeling techniques, and standardization of measurements and validation procedures will be discussed. On the basis of a case study the application of tire and road modeling techniques for virtual vehicle durability analyses will be illustrated.

Evolution of Steel Technology to Satisfy Automotive Materials Challenges
Ronald P. Krupitzer Session: M205 - Applications of Advanced High-Strength Steels for Automotive Structures (Part 1 of 2)
April 14th

Ronald P. Krupitzer, Vice President, Automotive Market
Steel Market Development Institute

Steel has been the dominant structural material for vehicles for nearly a century. Its principle characteristics of strength, stiffness, formability, surface quality, corrosion resistance and affordability have evolved to keep pace with the changing requirements of carmakers decade after decade. However, the challenges facing automotive engineers today have become especially demanding as North American carmakers face new CAFE laws projected to require unprecedented reductions in fuel consumption. At the same time, they must continue to satisfy new standards for crash safety, handling, and NVH. In this new environment, will steel measure up? This review summarizes the continuous evolution of advanced high-strength steel properties and manufacturing processes to explain why steel has sustained its position as the dominant automotive structural material to date. Further, it explores new metallurgy, design technology, and process methods that will allow steel to remain the favored materials choice far into the future.

An Overview for Application of Modeling and Simulations in Support of Combat Vehicle Development - Past, Present and Future
Bahram Fatemi Session: M601 - CAE Analysis, Test Correlation and Optimization: Military Ground Vehicles Modeling and Simulation (Part 2 of 2)
April 14th, 9:00 a.m.

Bahram Fatemi, Ph.D.
Chief Technology Officer
US Combat Systems
BAE Systems

Dr. Fatemi is the Chief Technology Officer (CTO) for the US Combat Systems (USCS) line of business of the BAE Systems. At this position, he is responsible for coordinating all present and future technologies required to develop USCS products.

Prior to this position, Dr. Fatemi was the Director of the Modeling, Simulation and Analysis Department at BAE Systems. He received his Ph.D. in Mechanical Engineering from University of California at Santa Barbara in 1980 with emphasis in system simulation. He has been with BAE Systems since 1984. He initiated and pioneered the modeling and simulation activities at the legacy GS division of the BAE Systems in 1985 under a research and development project called "Vehicle System Modeling".

Under this project, Dr. Fatemi developed engineering simulation models to predict performance of total vehicle systems. He managed a group of over 130 engineers with most of them holding graduate degrees and over 30 of them having their Ph.D.s in different engineering disciplines. His group was responsible for all the Modeling, Simulation, and Analysis activities associated with the design and production of legacy GS combat vehicles.

Prior to joining BAE Systems, Dr. Fatemi was with NUTECH Corporation in San Jose, California for four years. At NUTECH, he was responsible for developing simulation capabilities and qualifying Nuclear power plants to earthquakes and other dynamic loads.

State-of-Art of Moiré Method and Applications to Shape, Displacement and Strain Measurement
Yoshihara Morimoto Session: M107 - Optical Measurement and Nondestructive Testing Techniques in Automotive Engineering
April 14th, 8:00 a.m.

Yoshihara Morimoto - Moire Institute Inc., Senior Research Engineer

Moiré method is useful to measure the shape and the whole-field distributions of displacement and strain of structures. There are many kinds of moiré methods such as geometric moiré method, sampling moiré method, Fourier transform moiré method, moiré interferometry, shadow moiré method and moiré topography. Grating method analyzing directly deformation of a grating without any moiré fringe pattern is considered as an extended technique of moire method. Phase analysis of the moire fringe patterns and the grating patterns provides accurate measurements of shapes or displacement and strain distributions. Some applications of these moiré methods and grating methods to dynamic shape and strain distribution measurements of a rotating tire, sub-millimeter displacement measurements from long distance for landslide prediction, real-time shape measurements with micro-meter order accuracy, etc. are shown.

Yoshiharu Morimoto (Nickname: Harry Moiré) graduated MC of Osaka University, Japan in 1968. He is JSME Fellow and SEM Fellow. He was a member of SEM Executive Board, Chairman of ACEM and President of JSEM. He retired from Wakayama University, Japan in 2009 and now he is Professor Emeritus at Wakayama University. He established Moiré Institute Inc. in 2009 and he is now Representative Director. His major field of study is experimental mechanics and image processing. His current interests are measurements for shape, deformation, stress and strain using moiré method and phase-shifting digital holographic interferometry.

Fatigue for Anthropomorphic Testing Devices
Session: M602 - CAE Durability Analysis & Applications (Part 1 of 2)
April 13th, 8:00 a.m.

Darrell F. Socie, Professor, University of Illinois

Most people reading this will recognize the anthropomorphic testing device in the title as a dummy. Fatigue analysis has traditionally been very much like the title, why do something simple when you can ask an expert to make it more complicated? But, today most durability decisions are being made by non-experts. In the current environment of ever decreasing numbers of fatigue experts, when is a simple fatigue analysis good enough? This presentation provides a number of examples where simple fatigue analysis and analysis tools have been used to solve more complex problems.

Composites for Automotive Engine Applications
Session: M306 - Automotive Composites
April 12th, 1:00 p.m.

David A. Nash, Dana Corporation, Chief Engineer

A Perspective on Model Validation and Validated Models
Vicente Romero Session: IDM107 - Reliability and Robust Design in Automotive Engineering: Model Validation and Verification
April 12th

Vicente Romero
Sandia National Laboratories, Albuquerque, NM

What constitutes a "valid" model? What does the model validation process involve? These questions are still being resolved by the modeling and simulation community. Even the definition of 'model' is still under debate (which of the equations, input parameters/uncertainties, discretization aspects, boundary conditions, etc. in a particular model validation activity are part of the 'model' being validated?). Besides definitions of 'model' and 'model validation', this talk considers some fundamental issues in modeling and prediction that bear on the viability of model validation formulations, metrics, and criteria (i.e., the structure of the validation proposition and the type and threshold of evidence for or against a model's indicated suitability for a given prediction purpose). Related items of model builder's risk vs. model user's risk, Type X and Y validation errors, strong and weak models, traveling and non-traveling models, data conditioning, and model conditioning will be discussed. The author's particular paradigm of "real space" model validation will be described, citing technical, pragmatic, and philosophical rationale from validation experiences in the areas of heat transfer, solid and structural mechanics, irradiated electronics, and combustion in fluids and solids.

Vicente Romero has been with Sandia National Laboratories for 23 years. He is currently in the Model Validation and Uncertainty Quantification group in the Engineering Sciences Directorate. He has a modeling background in optical, thermal, and fluid systems, specializing in complex coupled systems and applications where statistical or stochastic behavior is important. Dr. Romero also has extensive experience in developing and applying optimization and uncertainty quantification techniques for model validation and risk assessment and reduction in nuclear weapon systems subjected to stressing thermal-mechanical-electrical-radiation environments.

Leading in Crazy Times
Theresa Rich Session: IDM202 - Management and Leadership in Engineering and Manufacturing Organizations
April 12th, 11:00 a.m.

Theresa Rich, General Motors Company, Global Change Management & Organizational Development

Leading during normal times is plenty challenging. Leading in crazy times requires extra understanding and skill. This presentation explores how you and your team can be your best, regardless of what craziness may be going on around your organization, your team members, and you.

Roadmap for Lean Transformation
Session: IDM201 - Key Success Factors of Lean Manufacturing Implementation and Global Supply Chain

Ravi Anand, Isoftwareworks, Principal Consultant

Lean manufacturing is the latest business mantra for doing more with less. Almost all manufacturers worldwide have tried to implement Lean Manufacturing with varied degree of success. Some have had very little or no success and given up on the methodology.

Lean Manufacturing is a straightforward approach that can be applied to a process to remove all non value adding activities. It comprises of a set of tools and principles that can be used by anyone willing to improve the process. If it is so simple, then why do companies fail during Lean implementation?

It is crucial to understand that Lean implementation is a different way of doing things in a work area. It is a change that needs to be managed and planned for. Lean Transformation is a journey that improves how work is done. When done right, lean impacts everyone and improves processes throughout the enterprise.

This presentation provides a Roadmap to Lean Transformation as a step by step approach to Lean implementation. The key question of how to make Lean Manufacturing work will also be addressed.

New Component Developments for Improvements to Future Mobile Air Conditioning Systems
Bill Hill Session: HX104 New Approaches to Future Mobile Air Conditioning System Design
Tuesday, April 12th 10:00

Bill Hill, Engineering Specialist, MACRAE, LLC

Bill summarizes the papers of this session along with providing some insight to how these papers apply to the future developments for Mobile Air Conditioning systems. He will also provide some background to explain the reasons for these new developments in component technologies for automotive air conditioning systems.

William Hill is an engineering specialist in automotive Heating, Ventilation, and Air Conditioning (HVAC). Currently he is working as a consultant with MACRAE, LLC. From 1968 to 2009 he worked for a number of divisions of General Motors, lastly as a Technical Fellow in the HVAC area. During this time he also spent five years working for Zexel Corporation (a Japanese HVAC component manufacturer). William is actively involved in SAE committees. He has chaired five major SAE Cooperative Research Programmes over the last nine years and has been a session chair for the Climate Control Sessions at SAE Congress for the last ten. He is currently a Co-Chair of the SAE Interior Climate Control Standards Committee and for the last five years has helped to organise the SAE Alternative Refrigerant System Symposium. In 2008 William received the EPA Climate Protection award, having previously received it in 2005. In the same year he was a runner-up for SAE Environmental Excellence in Transportation and received the GM Research Most Valuable Colleague Award. In 2007 he received the SAE Forest R McFarland Award. He has been a judge at Future Truck and Future Car events sponsored by the US Department of Energy as part of the PNGV programme and has 11 patents or patents-pending in the HVAC area.

Driveline Warm-Up Systems
Dario Bettio Session: HX103 Energy Efficiency of Thermal Systems
Thursday, April 14th 1:00 - 1:30 p.m.

Dario Bettio, Product Engineering Manager, Dana Holding Corporation

Global legislative changes to reduce emissions and social awareness of the need to minimize fuel consumption have been key contributors in the effort to increase vehicle efficiency.

Consumers are witnessing improvements in engines, transmissions, addition of gas-electric hybrid, electric and plug-in hybrid vehicles to automotive fleets worldwide.

This presentation reviews current trends and options considered in the ongoing effort by vehicle manufacturers to quickly reach optimal engine and transmission operating temperatures.

Dario Bettio is Product Engineering Manager at Dana Holding Corporation. His background includes over 25 years experience in the design and development of automotive components.

He holds a B.Sc. in Mechanical Engineering from UMC in Sao Paulo, Brazil and an MBA in Production and Industrial Operations from FGV in Sao Paulo, Brazil. He is also a Professional Engineer and Project Management Professional (PMP).

Mr. Bettio has been an SAE member for over 20 years and is co-inventor in three patents. In his current role he is responsible for the development of products to improve powertrain efficiency such as transmission and engine active warm-up, cooling systems and its components.

Bashar S. AbdulNour Session: HX 104 New Approaches to Future Mobile Air Conditioning System Design
April 14th 1:00 p.m.

Bashar S. AbdulNour, Ph.D.
Manager, Thermal Systems Analysis and Validation
General Dynamics Land Systems

The origins of automotive Climate Control date back to the inception of the automobile. Climate Control is considered as a defining vehicle attribute and, hence, critical to brand image and customer satisfaction. In recent years, the pace of development in Climate Control system performance, features, and complexity followed the rapid pace of advancements in science and technology. Climate Control and passenger comfort became a reflection of personal comfort, convenience, and luxury across all vehicle lines. Recent innovations include muti-zone Climate Control and human thermal comfort. As a result, much focus and increased demand are placed by vehicle manufacturers on Climate Control engineering.

The continued expansion in the use of modeling and simulation (M&S) tools and methodologies in design and development pushed the pace even further in order to decrease the time-to-market and reduce cost by replacing expensive prototyping and testing. Sophisticated models are being used to characterize individual feelings based on human thermal physiology and the environment, thus enhancing thermal comfort modeling capabilities. The aggressive use of M&S for virtual prototyping and certification will allow for more design iterations yielding optimized performance, reduced power consumption, and better quality.

Going forward, there is yet another phase to follow. Alternative mobility such as hybrid electric vehicles (HEV) and fuel cell vehicles (FCV) have their unique thermal management issues; specifically, climate control and powertrain cooling applications. To maintain the same level or performance and quality expected by the end customer, the Climate Control system of HEV and FCV will have to adopt to include innovative solutions that allow for lower energy consumption and more energy generation.

Dr. Bashar AbdulNour is currently the manager of the Thermal Analysis and Validation Group at General Dynamics Land Systems in Sterling Heights, Michigan, which is a leading global defense contractor and manufacturer of ground combat vehicles. He leads a large team of engineers working on the design and development of thermal systems of all types of military vehicles. His areas of expertise are Computational Fluid Dynamics (CFD) and thermal management, both analysis and testing.

Dr. AbdulNour holds three graduate degrees from Michigan State University including an M.S. and a Ph.D. (1990) in Mechanical Engineering. After graduation, he became an Assistant Professor of Mechanical Engineering at the University of Wyoming. He joined Ford Motor Company in 1993 where, for fifteen years, he developed extensive knowledge of vehicle climate control and powertrain cooling engineering, as well as the technical methods used in product development. His hands-on work with analysis and simulation tools and methodologies, technology development, and testing techniques applied to automotive thermal systems earned him diverse engineering and management expertise with progressive responsibilities.

Dr. AbdulNour has over 50 published journal and conference papers. He has been the chairman of fifteen technical sessions at national and international conferences. He has been the co-organizer of the Climate Control Session of SAE International Congress since 2001, and was the technical keynote speaker in 2010. His involvement with SAE also includes contributing to the Thermal Management Activity Committee and Vehicle Thermal Management Systems (VTMS) conferences.

Advances in Modeling and Simulation of Vehicle Thermal Management Systems
Ben Zandi Session: HX101 Thermal System Components
Thursday, April 14, 8:00 a.m.
Ben Zandi
Founder, Chairman, and CTO
LES International LLC

Speed and accuracy are of paramount importance in the modeling and simulation of vehicle systems and components. Today's commercially available thermal/flow analysis software packages either offer speed or sacrifice speed for accuracy: 1) approximate modeling using one-dimensional (1D) simplistic network solvers (flow and thermal) for quick prediction of flow and thermal fields, or 2) detailed modeling using complex and sophisticated three-dimensional (3D) heat transfer and computational fluid dynamics. The first approach provides the simulation speed, sacrificing accuracy and can possibly lead to oversimplification, while the second approach offers accuracy at the cost of speed. Therefore, the analyst is often forced to make a choice between the two approaches, or find a way to link or couple the two methods. The linking between one-dimensional and three-dimensional models using separate software packages has been attempted and accomplished for a number of years with some frustration. This coupling procedure involves a very tedious and time-consuming task of interfacing between the two packages made more difficult by the lack of access to the source code. Furthermore, there may be issues relating to overall convergence, as well as the convergence of each solver, which can lead to compromised accuracy. For a truly coupled approach, modifications to the source code of the solvers would be required if the analysts had access to it.

This presentation discusses the advantages and shortcomings of each methodology and offers a hybrid approach to bridge the gap between "speed" and "accuracy". A complete thermal modeling and simulation methodology is introduced offering a variety of approaches for modeling complex systems and components. This avoids any of the unnecessary "overhead" associated with a single modeling approach type. As an example, by allowing the combination of a full three-dimensional analysis in the radiator and the use of a network-based approach for pipes and pumps, the analyst can study the effects of orientation, fouling and related environmental conditions within the radiator and its effect on the complete system. The ability to combine these modeling approaches within a single system model allows one to employ the right tool for the job. This greatly reduces the model development / analysis time allowing for the timely generation of results from which informed design decisions can be inferred. This modeling approach is demonstrated though 1D/3D examples analyzed using the ADFlo software package.

Dr. Ben Zandi is the Founder, chairman and the Chief Technology Officer (CTO) for TES International, LLC; a Michigan-based company that provides state-of-the-art engineering software and consultation services. Established in 1994, TES specializes in electronics cooling, thermal management and structural/vibrational/shock analysis for the aerospace, automotive and electronics industries. Ben has been the Principal Investigator on several government-sponsored research projects (through the US ARMY) that resulted in the development of multiple CAE packages currently marketed by TES; including ElectroFlo (coupled 3D Thermal/Electrical/CFD analysis of electronic components, boards systems and racks), and ADFlo (modeling and simulation platform for vehicle thermal management).

Prior to TES, Dr. Zandi was the thermal specialist for e3 Engineering, where he was responsible for thermal analysis and design of automotive electronic components and systems.

Dr. Zandi received his Ph.D. from the University of Tennessee in the area of numerical heat transfer and fluid flow - involving coupled electrical, thermal and CFD solutions of electronic systems and subsystems.

Designation of Complex Assembly Products under USDA's BioPreferredSM Program
Session: SDP112 - Green Chemistry for Automotive Applications
April 14th

Jeff Goodman, Chief of USDA's Environmental Management Division

Jeff Goodman serves as Chief of USDA's Environmental Management Division. His responsibilities include managing USDA's hazardous materials management program, focused principally on Superfund cleanups, overseeing the Department's sustainability programs such as energy and water conservation, and directing the BioPreferredSM program to increase government and commercial sales of biobased products. Jeff is an environmental engineer with over 36 years of experience. Prior to joining USDA six years ago, he worked for 23 years as an environmental consultant. During this time he managed a wide variety of projects for both public and private clients including environmental policy analyses, hazardous waste site investigations, and the conduct of over 700 environmental due diligence audits of manufacturing facilities in most major industrial categories. Jeff began his career at the U.S. Environmental Protection Agency where he developed strategies to implement the Clean Water Act, a legislative proposal for Superfund, and approaches to hazardous waste management regulations under the Resource Conservation and Recovery Act.

Evolution of Testing Technology and Impact on Hardware-In-the-Loop Applications
Mina Khoee-Fard Session: AE108 Hardware-in-the-Loop Technology for Embedded Software Development and Testing
April 13th

Mina Khoee-Fard - General Motors Company

Vehicle electrical architecture has evolved in the last two decades. Increasing number of vehicle functions, features, multiple network protocols, and numerous vehicle variants have demanded the testing technology of the past to change dramatically. Application of Hardware-In-the-Loop for embedded software development, verification and validation spans from component level, to domain specific subsystems to system and vehicle level. While there are similarities in methodology for set-up of HIL applications for component level to subsystem to system level, there is an increasing level of complexity at each level with respect to both HIL and test environment. The complete setup of HIL systems goes beyond the HIL hardware and software. Plant modeling is a critical part of setup for HIL applications. The requirements for plant modeling are different for every vehicle domain such as body, chassis controls, active safety, hybrid and powertrain with different requirements and unique challenges. In addition, component level vs. integration level software verification poses different requirements for plant modeling environment. The approach to the plant modeling environment for each level of testing is based on the component, subsystem, or system level requirements under test and verification. Proper setup of HIL environment enables the test engineers to develop automated tests for software verification. While test automation setups have some common requirements for different levels of testing, complexity of each level of testing poses specific requirement for test automation setups. Methodological approach to HIL setup from hardware, software to modeling environment to test automation will enable early software verification in the lab environment. In addition, complex vehicle feature and functions of future such as various hybrid technologies, advanced driver assistant systems including semi-autonomous driving require proper approach and infrastructure to testing methodology today as enablers for facing the complexities of the future.

Reflections over the Development of ISO 26262
Joseph D. Miller AE300 -Safety Critical Systems (Part 2 of 2)
April 14

Joseph D. Miller, TRW Automotive US LLC

How did the US get involved in the ISO 26262 development?
What happened at that first meeting in Berlin?

  • Who participated?
  • Why did the US lose the first vote?
What were the significant evolutions of the standard during its 5 years of development?
  • Scope
  • Hardware metrics
  • Software tables
  • Proven in Use
  • Guideline
What are expectations of the National Academy of Science (NAS)?
What will happen next?
On the Thermo-Mechanical Fatigue of Tool Steels
Prof. Farhad Rezai-Aria Prof. Farhad Rezai-Aria
Ecole des Mines d'Albi, France

Many industrials components are subjected to complex thermal and mechanical loadings. Under such critical conditions, materials might experience cyclic micro or macro yielding. Different approaches are in general employed to characterize the material or components behavior and damage development. These approaches can be divided into isothermal and non-isothermal philosophies.

Forming tools - in particular the hot forming tools - are strategic assets in industrial production. During the production of a given part, the surface of these tools experiences a non-isothermal thermo-mechanical loading due to heat transfer, deformation energy and frictions forces. While thermo-mechanical loading generally leads to the initiation of cracks, in many cases the friction forces promotes cumulative shear plastic straining, localized micro rupturing and micro-cracking as a mechanism for formation of debris.

Thermo-mechanical loads are usually calculated using thermo elasto-visco-plastic constitutive laws. Some recent development in heat-checking (multi-axial loading and cracking) will be addressed. The transient between multi- to uni-axial cracking will be discussed. The effect of the environment on the thermal fatigue behavior will be presented.

Both isothermal and thermo-mechanical fatigue will also be addressed. The effect of the SEN thickness on isothermal crack propagation will be presented. In-situ crack observation and crack propagation in isothermal and thermal fatigue are used for crack tip displacement measurements, which constitute the crack propagation driving force.

Dr. Farhad Rezai-Aria is a full Professor at Ecole des Mines d'Albi, Centre ICA, in France since 1997. He is also the head of the "SUMO Group" (French acronym for Surface/Machining/Materials/Tools) in the recently created Institut Clément Ader.

He has received his BSc from Sharif University of Technology Iran in 1976 and his PhD from Ecole des Mines de Paris (Materials Centre) in 1986, where he researched on the elevated temperature isothermal and thermo mechanical fatigue of superalloys.

From 1988 to 1997 he was the head of the High Temperature Fatigue group on superalloys and MMCS in the Mechanical Metallurgy Laboratory under Prof. B. Ilschner (?), at the Materials Department of the Swiss Federal Institute of Lausanne (EPFL).