Cover Siemens VDO Automotive aei-online org aei APRIL 2006 1 30 cover eighth-generation Honda Civic AEI's Best Engineered Vehicle 2006 setting new standards safety technology performance 30 48 62 68 78 87 97 106 112 124 132 138 147 Lighting way Exterior lighting systems contributing safety changing cars' styling Sensing change sensor use grows providing input sorts functions engineers responding design challenges standardization shared use signal output Attacking hybrid cost Hybrid-electric vehicle costs must slashed significantly technology become mainstream HEV developers reveal routes cost-reduction crusade Engineering enemy program devoid bloodshed General Motors Ford codeveloped new six-speed automatic key both companies' future vehicle plans program managers explain they'd eagerly Drivetrain advances Japan's leading companies focused development reducing size mass cost Testing rolls new generation rolling road systems helping both vehicle manufacturers race teams better simulate road conditions effect minute changes Honda Civic AEI's Best Engineered Vehicle 2006 eighth-generation model Civic re-established itself benchmark its segment setting new standards safety technology performance form vs function form function jobs distinctly different engineers design counterparts share end goal best vehicle possible Wired safety Carmakers suppliers collaborate augment drivers' skill judgment electronics Cost power safety Automotive engineers heading year's SAE World Congress sound hottest trends greatest challenges facing industry AEI 2006 Tech Awards editors Automotive Engineering International highlight innovative new products technologies display SAE 2006 World Congress based latest information provided exhibiting companies New SAE 2006 AEI continuing its preview coverage month's issue takes detailed look products services technologies displayed SAE 2006 World Congress scheduled April 3-6 Cobo Center Detroit validation OEMs developing tools engineers around world validate vehicles regulations conformity other objective subjective aspects Features 78 68 106 62 97 contents Continental aei-online org aei APRIL 2006 3 Automotive Engineering International ISSN 1543-849X April 2006 Volume 114 Number 4 Automotive Engineering International published 12 times year SAE International printed Brimfield OH Annual subscription SAE members first subscription 20 included dues additional single copies 21 North America 24 overseas Prices nonmember subscriptions 120 North America 210 overseas Periodical postage paid Warrendale PA additional mailing offices POSTMASTER Please return form 3579 Automotive Engineering International 400 Commonwealth Dr Warrendale PA 15096 SAE responsible accuracy information editorial articles advertising sections publication Readers independently evaluate accuracy statement editorial articles advertising sections publication important rely independent evaluation permission reproduce articles quantity use other media contact Publication Director Claims missing issues magazine must submitted six-month time frame claimed issue's publication date Copyright 2006 Society Automotive Engineers Inc Automotive Engineering International title registered U S Patent Trademark Office Automotive Engineering International indexed abstracted SAE Global Mobility Database Audited Department highlights Editorial Focus Global Vehicles Trucks Chicago spotlight MKS previews new Lincoln Nissan introduces spacious compact Electric drive shapes Mitsubishi CT Toyota revs new RAV4 MX-5 donates Kabura Mini gets reinterpreted Sun shines new ASC Concepts Tech Briefs Boosting range engines Bosch keeps pressure Big expectations dual clutch Valeo pushes engine valves Top-mounted solenoid makes space South Korean automakers VGT Increased cooling performance Denso Focus Electronics Freescale STMicro codevelop chips Korean automakers upgrade telematics System-level E E design needed Material Innovations BMW mixes BIW Arcelor serves steel sandwich Testing Simulation Renault F1 Team accelerates composites Researching taxicab design Manufacturing Solutions GMAW finds favor Ford high-strength steel faster path die Performance Aftermarket SAE-certified hp aftermarket Classified Advertising Product Briefs Companies Mentioned Ad Index Regulations Standards fed money fuel efficiency Insiders Insights Theodore brings 'Chris's Law' ASC Emerging Markets Ricardo-Prague outpost sees growth 92 92 95 102 102 104 120 120 145 150 155 156 157 157 158 158 160 160 6 8 10 10 18 18 20 22 26 27 28 36 36 38 40 42 42 44 46 54 54 56 59 74 74 76 contents 102 56 10 42 28 Adobe Systems, Inc Adobe Systems, Inc 6 APRIL 2006 aei aei-online org Alternative power races AEI press Audi preparing unthinkable risk its hard-earned reputation sportscar racing entering 12 Hours Sebring dieselpowered racecar major proponent diesel passenger cars Audi run its 650-hp 485-kW R10 V12 TDI diesel prototypes promote fuel-efficient technology 12-hour race Sebring test race 24 Hours Le Mans held June main reason developing Audi R10 compete 24 Hours Le Mans want world's first automobile manufacturer win diesel engine said Head Audi Motorsport Wolfgang Ullrich diesel power gaining significance European manufacturers opportunity pioneer new frontiers diesel know-how makes Audi racing effort genuine technology development program effort help promote fuel-efficient auto technology important U S market current business model professional racing built around marketing auto companies becoming interested highlighting alternativepower technologies concept alternative power racing technologies merit given increased interest government automakers suppliers consumers racing rules might pose challenge rules regulations drafted sanctioning organizations motivation technical depth design tools create specifications rules comprehend technology challenges facing automotive industry said Herb Fischel CEO Business Motorsports former head GM Racing date energyefficient environmentally friendly socially responsible motorsports priority racing sanctioning organizations Key suppliers research engineers challenged business model create new model encompasses energy environmental issues interesting racing-related alternative-power developments Since 2002 British Motorsport Industry Association MIA working Energy Efficient Motor Sport EEMS program group's short-term strategy focused introducing alternative fuels existing racing formulas regulations minimize changes encourage headto- head competition Indy Racing League competitors using 3 0-L engine fueled 10 ethanol 2006 100 ethanol 2007 EEMS initiative's long-term strategy create engine technical regulations focus energy efficiency limiting supplied fuel energy engine car making efficient use its fuel competitive advantage technology developed involves energy flow regulator monitors range fuels U S John Glenn EPA developed Green Racing concept similar MIA's energy-based approach Gasoline compete alternatives diesel hydrogen electricity engines meet national air-quality standards SAE International involved promoting alternative power racing Its motorsports advisor Fishel leading work group drafting technical specifications sporting regulations group give program status report SAE Motorsports Engineering Conference December January SAE work group planning conduct workshop Autosport International England target full season competition 2008 success energy-efficient technology applied motorsports depend support participation industry drafting technical specifications sporting regulations energy environmental engineering challenges facing automotive industry staggering racing industry help accelerate development process Editorial Director editorial editorial ANTENOR R WILLEMS Executive Director KEVIN JOST Editorial Director JEAN L BROGE Senior Editor LINDSAY BROOKE Senior Editor DAVID ALEXANDER Associate Editor PATRICK PONTICEL Assistant Editor RYAN GEHM Assistant Editor MATTHEW MONAGHAN Assistant Editor MATTHEW NEWTON Editorial Assistant KAMI BUCHHOLZ Detroit Editor STUART BIRCH European Editor JACK YAMAGUCHI Asian Editor PETER WRIGHT Contributing Editor CONTRIBUTORS Dan Carney Terry Costlow Jenny Hessler Linda Trego Paul Weissler WAYNE SILVONIC Production Manager GRAPHIC DESIGNERS William L Schall Jr Lucy Matyjaszczyk THOMAS J DROZDA Publisher General Manager Corporate Sales thomasdrozda sae org MELISSA R MISHLER General Manager - Global Sales meliss sae org MARCIE L HINEMAN Associate Publisher hineman sae org CAROLYN TAYLOR Marketing Manager carolt sae org JODIE MOHNKERN Circulation Mail List Manager mohnkern sae org AEI OFFICES 400 Commonwealth Drive Warrendale PA 15096-0001 U S Web www aei-online org EDITORIAL Phone 724-772-8509 Fax 724-776-9765 E-mail aei sae org ADVERTISING Display--Lori Patterson Classified Web--Kathy Belles Phone 888-875-3976 724-772-4086 Outside U S Canada Fax 724-776-3087 E-mail CustomerSales sae org SUBSCRIPTIONS Phone 877-606-7323 724-776-4970 Outside U S Canada Fax 724-776-0790 E-mail CustomerService sae org Yazaki North America, Inc 8 APRIL 2006 aei aei-online org STEM SAE February participated speaker Partnering Results STEM Education briefing presented U S House Representatives' STEM Education Caucus Established Reps Vern Ehlers R-MI Mark Udall D-CO caucus designed address need comprehensive STEM science technology engineering mathematics education students throughout United States SAE International invited participate its award-winning World Motion AWIM program release Nation Risk report 1983 mobility industry concerned future math science education United States Considering SAE's significant experience providing lifelong learning opportunities transportation industry along successful Collegiate Design Series program society approached find ways increase student interest math science education 1990 AWIM born Since time 2 million students 15 000 volunteers participated project-based hands-on program developed pique interest elementary middle school students time might normally turn math science program successful presents engineering fun hands-on manner Students work together small teams common project requires mathematics scientific other related skills scratching few formulas coming answer AWIM involves students step process discussion Partnering Results STEM Education briefing extremely insightful informative pleased hear numerous strides made toward increasing STEM education U S Interestingly week STEM event ran across report entitled Framing Engineering Outsourcing Debate Placing United States Level Playing Field China India Duke School Engineering faculty leaders Gary Gereffi Vivek Wadhwa student researchers Ben Rissing Kiran Kalakuntla Soomi Cheong Qi Weng Nishanth Lingamneni main thrust report revolves around authors' questioning widely reported statistic that--in 2004- -the U S graduated roughly 70 000 undergraduate engineers China graduated 600 000 India 350 000 According report huge numbers engineering graduates China India included only four-year degrees three-year training programs diploma holders--and numbers compared strictly four-year graduates U S report explains vast difference population numbers alone lent itself larger numbers engineering graduates China India countries populations exceed 1 billion compared fewer 300 million U S fact authors state 1 million citizens United States producing roughly 750 technology specialists compared 500 China 200 India leads report conclude U S produces highly significant number engineers computer scientists information technology specialists remains competitive global markets Regardless situation's magnitude United States need top-notch STEM-related education exist accelerating--not only U S countries across world technology specialists involved needed global mobility industry rest assured SAE continue bring attention important issue part educate inspire students ensure bright future mobility engineering interested contributing becoming involved simply learning AWIM program please visit www sae org foundation awim SAE Executive Vice President Chief Operating Officer SAE Officers Greg W Henderson 2006 President J E Ted Robertson PE 2005 President Dr Ronald York Vice President - Aerospace Richard O Schaum Vice President - Automotive Mark R Pflederer Vice President - Commercial Vehicle Terence J Rhoades Treasurer Carol Story Assistant Treasurer Raymond Morris Executive Vice President Chief Operating Officer SAE Board Directors Joseph B Anderson Jr David J Andrea Felice Esposito Corcione Linda F Duschl Iftekhar Ibrahim Robert L Ireland Andrew J Jeffers Daniel R Kapellen Alan H Nye Eduardo Paredes Robert J Pheiffer Ronald G Rath Thomas W Ryan III Gerald S Shoemaker Arnold W Siegel Ronald R Smisek James E Smith Bharat S Vedak SAE Publications Board John R Kinstler Chairman Nicholas P Cernansky Gregory W Davis Linda F Duschl Michael D Madley Robert Noth SAE Section Activities SAE 96 sections groups located United States Canada Mexico Taiwan United Kingdom Brazil India Russia Belarus China Egypt Hong Kong Romania Italy Malaysia Ukraine Israel complete listing sections groups along respective officers www sae org sections sectlist htm SAE Headquarters Additional information regarding particular section group available SAE Headquarters Membership Section Programs focus Kemet Electronics Corp aei-online org global vehicles 10 APRIL 2006 aei global vehicles Edited Kevin Jost standard rear disc brakes instead current model's drum brakes Three cab configurations offered 2WD 4WD three trim levels three different bed sizes change current Tundra new pickup employs damper steel tailgate's hinge first 10 degrees damper activate control speed descent assist closing effort said Schrage tailgate handle optional backup camera trailer hookups easier said Jim Press President COO Toyota Motor Sales USA Dodge Rampage--Dodge resurrects Rampage name via full-size pickup concept developed unique platform Rampage's 5-ft 1 5-m cargo box features three-position tailgate fold 90 98 117 117 position ramp extended tailgate-stowed space aid loading unloading tailgate closed under-the-cargo-bed storage shelf used Separating cabin truck bed mid-gate fold forward part cargo bed expand storage space mid-gate carbon fiber entire vehicle noted Doug Quigley Senior Manager Advanced Engineering adding strength purposes cargo bed honeycomb aluminum sandwich passenger seat 60 40 rear seats folded floor first-time pickup truck application automaker's Sto-NGo system truck forgoes B-pillars helps ingress egress power rear sliding doors applied format said Ralph Gilles Director Dodge Truck Studio adding conventional doors open 85 concept sports 5 7-L Hemi engine cylinder deactivation automaker's Multi Displacement System five-speed automatic transmission mates engine front-wheel- Vehicles unveiled 2006 Chicago Auto Show show emphasized nextgeneration upgrades new features refined technologies pickups SUVs garnering attention Trucks Chicago spotlight Toyota Tundra Toyota Tundra--Toyota designers engineers revamped new Tundra full-size pickup meet needs wants truck owners seven years consumer research dealer input Toyota's latest Tundra--reaching market 2007--rides all-new platform Tundra Double Cab 4x4 Limited -ton truck 10 000-lb 4500-kg plus towing capacity high-strength steel frame 30 greater strength layout frame changed said Mark Schrage Executive Program Manager Development Planning Operations Toyota Technical Center USA frame rail portion we've added additional reinforcements well increased width frame rail Three different engines available carryover 4 0-L V6 recently updated 4 7-L V8 new 5 7-L V8 Toyota officials releasing power torque ratings 5 7-L V8 represents largest displacement Toyota truck engine date V8 mate six-speed automatic transmission other engines using five-speed automatic Tundra brakes redesigned four-piston calipers larger--by 1 6 41 mm --vented rotors JYCO Sealing Technologies aei-online org global vehicles 12 APRIL 2006 aei drive pickup's various stowage zones result intentional design engineering considerations midgate underfloor storage low bed height enabled unique independent rear suspension unique chassis rail structure wide rail spacing noted Quigley Chevrolet Avalanche--Built General Motors' new full-size truck platform 2007 Chevrolet Avalanche offered 2WD 4WD versions Two-wheel-drive models standard 5 3-L V8 producing 320 hp 239 kW 340 lb ft 461 N m cylinder-deactivation technology known Active Fuel Management versions Vortec 5 3-L V8 both E85 85 ethanol compatible available including aluminum block engine standard fourwheel- drive models first time 2WD 4WD Avalanche models available all-aluminum 6 0-L V8 variable valve timing marks industry's first application VVT mass-produced V8 cam-in-block engine 6 0-L V8 paired Hydra-Matic 4L70 four-speed automatic transmission use fully boxed frame means 49 improvement torsional strength 36 increase bending strength addition stiffer frame vehicle's rack-andpinion steering stiff-mounted engine crossmember linear feel said Gary White GM North America Vice President Vehicle Line Executive Full Size Trucks Avalanche's suspension coil-over-shock assembly replacing previous generation's torsion bar brakes larger rotors stiffer calipers brake booster stiff-mounted dash want drive small agile-type vehicle White said New features Avalanche include optional rearview camera system optional ultrasonic rear parking assist well spring-loaded central-locking tailgate new Avalanche drops use plastic body side cladding truck showcases fully integrated plastic bumper fascias rather previous model's metal bumper systems Lincoln Navigator--A quiet ride primary engineering goal 2007 Lincoln Navigator Spray-on patches improved weld joints noise-reduction tactics paid extra attention making body fully sealed preventing sound coming vehicle said John Viera Chief Engineer Lincoln Navigator Ford Expedition Sound deadening full-size SUV 2007 using modified nextgeneration F-Series pickup truck platform improved adding insulation headliner changing carpet material adding upgrading dash insulation using thicker glass windows addition windshields supplied Automotive Components Holdings use acoustic-grade interlayer Solutia Automotive stiffer frame new body mounts isolate road noise vibration frame tube-through-tube design attaches second-generation independent rear suspension fivelink configuration fifth link controls Dodge Rampage concept Chevrolet Avalanche Lincoln Navigator global vehicles aei-online org aei APRIL 2006 13 briefs briefs fore aft movements short long arms control lateral forces upgraded suspension allows engineers optimize tuning ride comfort said Viera Navigator uses monotube shocks four corners engine 5 4-L Triton V8 six-speed automatic transmission carryovers 2006 model year Dodge Nitro--Dodge's midsize SUV entry 2007 Nitro fitted 4 0-L SOHC V6 produces 255 hp 190 kW 5800 rpm 275 lb ft 373 N m 4000 rpm 3 7-L SOHC V6 produces 210 hp 157 kW 5200 rpm 235 lb ft 319 N m 4000 rpm offered diesel engine outside North American market 2007 Available transmissions six-speed manual four- five-speed automatic commercial truck components cab use trucks said Dee Kapur President International Truck Group frame lowered its 300-hp 224-kW V8 diesel engine mated Allison 2200 RDS five-speed automatic transmission haul 2 ton tow 8 ton estimated fuel economy somewhere around 13-15 mpg standard engine International VT365 delivers 530 lb ft 719 N m concept vehicle year MXT moving pre-production stage Dodge Nitro Nitro employs independent suspension solid five-link rear suspension includes upper lower trailing arms track bar performance suspension offered Nitro R T SLT models revises sway bar springs shocks bushings Four-wheel-disc antilock brakes standard rotors inverted hat construction vent openings outboard rotor side Standard fare includes electronic stability program electronic roll mitigation International MXT--The new MXT truck features International's International MXT Karl Schmidt UNISIA Pierburg KS Bearings KS Aluminum Technology Kolbenschmidt Pierburg exactly roll tongue bearings pistons emission control products help millions powertrains perform better day gasoline diesel applications OEMs specify components improve fuel economy emissions warranty costs growing North American presence combines strengths four specialized business units six locations 30 globally Kolbenschmidt Pierburg work today Though name hard remember quality technology unforgettable Phone 248-327-9021 e-mail info pierburginc com usa kolbenschmidt-pierburg com POWER INSIDE HARD NAME EASY CHOICE Kolbenschmidt Pierburg SAE show Booth 1943 Circle 213 aei-online org global vehicles 14 APRIL 2006 aei anticipated launch date summer 2006 introduced CXT year RXT fall said Kapur MXT final product XT line crafting derivative military MXT concept pre-production vehicle year based interest customers dedication International's development team Stopping power four-wheeldrive MXT comes hydraulic brakes four-channel ABS 20-in alloy wheels shod Pro Comp 40 13 5R20 tires five-passenger four-door crew cab air suspension Mercedes-Benz R63 AMG ML63 AMG--Two 2007 Mercedes-Benz all-wheel-drive vehicles employ engine developed entirely DaimlerChrysler subsidiary AMG R63 AMG based R-Class ML63 AMG variant MClass SUV naturally aspirated AMG 6 3-L V8 produces 503 hp 375 kW 6800 rpm 465 lb ft 630 N m 5200 rpm redline 7100 rpm AMG's V8 features four valves cylinder variable valve timing actuating bucket tappets magnesium dual-path intake manifolds closed-deck aluminum engine block cast-in steel reinforcements racing-inspired bedplate design rather individual main bearing caps production engine first AMG V8's cylinder bores use TWAS twin wire arc sprayed technology reducing friction 10 according Robert Allan Manager AMG TWAS finishing process makes running surfaces twice hard conventional cast-iron cylinders Bosch 9 7 microprocessor manages fuel injection ignition valve timing variable intake manifold well thermostat AMG engine mates seven-speed automatic transmission Nissan Quest--A complete interior overhaul exterior alterations including new grille bumper fascia represent largest mid-cycle investments Nissan history said Brad Bradshaw Vice President General Manager Nissan Division 2007 Nissan Quest minivan interior includes new instrument panel relocated gauges central position driver well new third-row fold-flat spring-assisted seat design featuring integrated auto-folding headrests help designers engineers create improved interior customer validation sessions undertaken different evaluations ranging seat folding using knobs switches engineers often focused often overlook typical customer views vehicle's ease use said Carla Bailo Director Vehicle Program Management Nissan Technical Center North America Lexus ES--The fifth-generation Lexus ES arrives 350 2007 sports 3 5-L V6 engine compared previous-generation ES 330's 3 3-L V6 produces 25 power- -218 vs 272 hp 163 vs 203 kW --and 7 torque--254 lb ft 344 N m 4700 rpm vs 236 lb ft 320 N m 3600 rpm first time ES offers optional glass roof extends entire passenger cabin provides fixed skylight rear passengers sliding sunroof passengers welded-steel bands 6 150 mm wide link B-pillars give glassroof vehicle added rigidity impact protection according Hiroyuki Hirata Chief Engineer ES 350 car 108 lb 49 kg heavier ES 330 due part body reinforcements side-impact protection help offset added mass reinforcements vehicle shed mass other areas new six-speed transmission 10 lb 4 5 kg lighter previous-generation vehicle's fivespeed automatic Kia Multi-S concept--Kia Motors America unveiled its Multi-S concept vehicle--the S stands Sporty Spacious Smart designed combine features crossover vehicles upscale leisure SUVs Multi-S evidence Kia's future design direction said Len Hunt Executive Vice President COO Included safety features electronic stability control six full-length side-curtain airbags active front-seat head restraints adaptive headlamps tire-pressure monitoring Power Multi-S comes 2 4-L four-cylinder gasoline engine mated five-speed automatic transmission manual shift mode Leather suede seating accommodates seven passengers Overhead dual full-length glass moonroofs HVAC system extends three rows seating large center console luggage box overhead console provide storage space Mercedes-Benz R63 AMG Nissan Quest interior Lexus ES 350 Kia Multi-S concept MathWorks, Inc aei-online org global vehicles 16 APRIL 2006 aei fold-flat second- third-row seats offer flexible cargo storage Multi-S features latest interface technology iPods MP- 3s PDAs cell phones notebook computers rear entertainment system USB port complements 6 1- channel premium surround-sound audio system Hyundai Entourage Accent- -Hyundai showed its first minivan Chicago Sharing lot engineering features recently launched Kia Sedona Entourage only available long-wheelbase form rear fascias different instrument panel distinguish vehicles option packages vary Power comes Hyundai's allaluminum 3 8-L DOHC 24-valve Lambda V6 first Azera puts 242 hp 180 kW 251 lb ft 340 N m engine features timing chains scheduled maintenance instead belts V6s must replaced set intervals Entourage certified Ultra Low Emission Vehicle Research Hyundai showed safety number priority minivan owners Standard safety features Entourage include ESC traction control system ABS tire-pressuremonitoring system active head restraints dual airbags seat side-impact airbags side-curtain airbags Asked possible four-wheeldrive version John Krafcik Vice President Product Development Strategic Planning said choice ESC AWD hard case AWD deal AWD only helps accelerating few safety situations benefit stepping throttle terms bang buck ESC Hyundai unveiled 2007 threedoor Accent body bending stiffness 39 previous generation stiff structure enabled engineers tune Accent better both comfortable ride responsive handling GS three-door features unique steering rack sportier feel four-door GLS SE trim sport-tuned suspension featuring 24 stiffer 11 stiffer rear spring rates larger stabilizer bar unique strut valving larger wheels tires Accent SE delivers 70 increase roll control GLS exceeding roll stiffness Hyundai Tiburon SE Mass-market performanceorientated vehicles debuting show included Dodge Caliber SRT4 Honda Civic Si Sedan Mitsubishi Galant Ralliart Dodge Caliber SRT4--The 2007 Caliber SRT4 employs 2 4-L DOHC 16- valve turbocharged inline four-cylinder engine producing estimated 300 hp 224 kW 6000 rpm 260 lb ft 353 N m 2000 6000 rpm aluminum block specially machined increased water oil flow unique cast pistons move iron cylinder liners engine Honda Civic Si sedan--Marking first time Honda Civic Si available four-door sedan shown Chicago probably 95 you'll highperformance 2007 car sale fall said John Mendel Senior Vice President American Honda Motor Co Civic Si Sedan concept shares basic powertrain components coupe including 197-hp iVTEC engine six-speed manual transmission limited-slip differential said Mendel Mitsubishi Galant Ralliart--The 2007 Mitsubishi Galant Ralliart midsize sedan powered 258-hp 192-kW 3 8-L V6 engine features sport-tuned suspension 18-in alloy wheels unique aero treatment its attributes introduces first factoryinstalled Rockford Acoustic Design premium audio system includes FM CD MP3 playback capability six-disc in-dash CD changer linear eightchannel amplifier producing 360 W Kami Buchholz David Alexander Hyundai Entourage Hyundai Accent Dodge Caliber SRT4 Honda Civic Si sedan Mitsubishi Galant Ralliart 3M Automotive Division aei-online org global vehicles 18 APRIL 2006 aei MKS previews new Lincoln clean simple styling concept Lincoln MKS hints future direction brand's next-generation full-size luxury sedan Peter Horbury Executive Director Ford North American Design describes MKS clutter excess Flanking grille adaptive lighting system light-emitting diodes illuminate sequentially steering wheel turned Other adaptive technologies shown MKS include passive entry system recognizes driver automatically unlocks car well activating personal settings mirrors seats radio temperature Bluetooth technology used transmit cell phone calls vehicle's 14-speaker 500-W DVD surround- sound system MKS showcases next-generation Lincoln Mobile Media System 8-in LCD touch screen interface DVD navigation tri-zone climate control audio connectivity vehicle information functions concept sedan fitted 4 4-L DOHC 32-valve V8 engine produces 315 hp 235 kW 4500 rpm 320 lb ft 434 N m 3000 rpm engine mated six-speed automatic transmission active all-wheel drive MKS employs independent suspension MacPherson strut rearward- facing lower L arms stabilizer bar independent rear suspension multilink coil-over-shock stabilizer bar oversized gauges inspired precision watches set dash panel covered suede seats adjust 14 ways Both driver passenger seats heated cooled Kami Buchholz Peter Horbury introduced MKS concept North American International Auto Show Nissan introduces spacious compact Sentra taking step class 2007 Nissan executives recognized opportunity add entry-level vehicle lineup vehicle selected fill void Versa inexpensive--expected start around 12 000--great care taken focus quality Versa called Tiida Japan based Nissan's global B platform shared Renault Clio extensive number common parts across platform allowed costs kept precisely profitable North American version price point couldn't profitably compete said Jed Connelly Sr Vice President Sales Marketing Nissan North America keeping costs major focus development process thought making interior spacious comfortable possible Nissan claims best-in-class interior length 72 3 1836 mm overall length vehicle only 169 1 175 9 4295 4468 mm hatchback sedan versions respectively long interior result short overhangs stretched wheelbase 102 4 2600 mm wheelbase helps give Versa surprising amount rear legroom its 38 0 965 mm surpasses 2006 Maxima's 36 5 972 mm Rear knee room 25 6 650 mm exceeds its competitors including Ford Focus hatchback's 21 5 546 mm Hyundai Elantra sedan's 22 1 562 mm maximize interior space A-pillar touchdown point placed directly wheel result small side window added improve driver visibility addition interior spaciousness great care taken maximize comfort hard cheap plastics typically entry-level cars replaced soft-touch materials hip points rear chair height ease ingress egress rear hip point actually higher rear passengers look don't claustrophobic tied-in feeling said Orth Hedrick Regional Product Manager Versa enough room fuel tank far forward beam axle result cargo space small car fairly impressive Cargo volume hatchback 16 9 ft 0 48 m rear seats 13 8 ft 0 39 m sedan seats fold flat feature 60 40 split seats supplied INSA larger other compact cars due space afforded larger interior seat although it's unique Versa Tiida actually big Maxima seat said Hedrick sit don't feel you're cramped tiny little seat need maximize interior space called completely new compact engine design big design attributes engine its compact size said Hedrick New Nissan intake exhaust rear Typically we've exhaust result able compress exhaust system save little bit money spend interior Versa slotted below Maxima Nissan's lineup giving presence compact vehicle segment makes 9 total vehicle sales U S ZF Friedrichshafen AG aei-online org global vehicles 20 APRIL 2006 aei continuously variable transmission CVT Versa expected deliver 38 mpg Xtronic CVT operates via use belt pulleys varying working diameters pulleys transmission eliminates steps gears keeping engine its optimum power range resulting smoother efficient operation ways CVTs relatively invisible technology certainly compared hybrids attention said Jack Collins Vice President Product Planning Nissan North America CVTs offer exceptional benefits terms efficiency driving feel refinement Versa's CVT offers 8-10 improvement fuel economy four-speed automatic according Collins Nissan investing 800 million upgrade its plant Aguascalientes Mexico production Versa begin 2006 plant currently builds Nissan Sentra U S market production grow 70 200 000 units today 350 000 units 2007 hatchback Versa sale June '06 United States sedan follow late winter Matt Monaghan 1 8-L dual overhead cam inline four-cylinder engine estimated generate 120 hp 90 kW 5200 rpm 125 lb ft 169 N m 4800 rpm Three transmissions available standard six-speed automatic fourspeed electronically controlled automatic overdrive Nissan Xtronic CVT small car Versa surprising amount rear legroom--38 0 965 mm --made possible extended wheelbase Versa's interior designers avoided inexpensive hard plastics typically entry-level vehicles instead using soft-touch materials armrests dashboard door panels Electric drive shapes Mitsubishi CT electric motor housed inside wheel gives Mitsubishi Concept CT all-wheel drive requiring various traditional pieces hardware design flexibility Mitsubishi In-Wheel Electric Vehicle MIEV doesn't require direct mechanical attachments said Daniel Sims General tery pack generator 40-kW output in-wheel motor produces 20-kW output four-door hatchback concept vehicle's total peak power 100 kW 134 hp design influenced highperformance urban scooters Japan elsewhere Concept CT based all-new platform presently used North America said O'Connell adding next paragraph book terms MIEV technology first shown A-segment concept vehicle 2005 Tokyo Motor Show Concept CT's interior features flat floor well fold-flat seats rear seats upright position folding seat bottoms seat backs center console spotlights iPod-style controls includes fingerprint identity recognition center steering wheel fixed place rim wheel rotates around display MIEV information said O'Connell Access vehicle via standard-opening doors butterfly rear doors Kami Buchholz MIEV technology Concept CT provide cruising capability high capacity power short bursts needed acceleration Manager Mitsubishi R D America's Design Studio MIEV technology eliminates driveshafts electric motor hardware that's associated universal joints transfer case prop-shafts added David O'Connell Chief Designer California design studio Concept CT uses 1 0-L three-cylinder gasoline engine producing 67 hp 50 kW drive rear wheels generator used charge lithium-ion bat Delphi Corp aei-online org global vehicles 22 APRIL 2006 aei Failing fear opposition its nearly five-year-old second-generation RAV4 plate Toyota aiming fences its newest version small SUV pumped-up 2006 model sports power under redesigned enlarged form Performance enhancement important priority RAV4 development program said Executive Chief Engineer Kiyotaka Ise during presentation media Santa Barbara CA ardent fan Tokyo Giants baseball team fan Yogi Berra aphorisms observe lot watching handful Berra-isms pitched explaining examining understanding markets RAV4 offered guided SUV's development V6 power United States easy call quickly understood roomier interior order Europe other hand power roominess seat fuel efficiency handling version region smaller powerful sportier feel though U S version better handling current-generation offering Toyota says its previous life RAV4 offered only I4 its new life V6 Toyota revs new RAV4 2GR-FE 3 5-L dual VVT-I unit used Avalon available mates fivespeed automatic generates 269 hp 201 kW 6200 rpm--more competitors' V8s according Toyota-- 246 lb ft 334 N m 4700 rpm unit features new high-output lowfriction cylinder head roller-follower rocker arms concave camshafts open valves faster hold open longer Preliminary fuel-efficiency numbers V6 2WD 20 28 mpg city highway Toyota expects rate V6 30 standard engine refined version carryover 2AZ-FE 2 4-L VVT-i I4 166 hp 124 kW packs additional 5 hp 3 7 kW Torque remains 165 lb ft 224 N m 4000 rpm DOHC 16-valve powerplant employing aluminum block magnesium head higher compression ratio its predecessor 9 8 1 vs 9 6 1 other engine features counter-rotating balance shafts plastic intake manifold electronic throttle control I4 mates four-speed automatic five-speed V6 electronically controlled uphill downhill shift control uses lock-up torque converters 24 29 mpg 2WD fuel efficiency I4 highest class excluding hybrids according Toyota Both engines meet ULEV-II emissions standard Although uses existing albeit refined engine RAV4 nearly other way new model developed new platform Ise said work project began early 2002 Japan taking lead development though Japan considered Previously unavailable V6 offered new RAV4 engine features variable valve timing intelligence both intake exhaust cams new RAV4 longer wider taller previous model Henkel Corp aei-online org global vehicles 24 APRIL 2006 aei secondary market RAV4 executive chief engineer spent lot time United States targetsetting purposes U S -based Toyota engineers large hand ensuring SUV's suitability U S conditions Toyota's Japan design center won styling responsibilities against groups United States Europe added Michael O'Brien National Product Planning Manager Toyota Trucks Mexico Planning noted Ise worked greater degree difficulty typical program head tightly control costs keep sticker low 2006 RAV4 base grade four-cylinder engine MSRP 20 300 4x2 model greatly enhancing vehicle terms refinement power other parameters leaps typical Toyota redesign programs said drove old RAV4 think totally different car companies O'Brien said class class noted first-generation model began bang launched 1996 since decline relative competitors segment RAV4 first car-based SUV sold U S revolutionized SUV market according Toyota started innovators really lost ground RAV4 said O'Brien job entails understanding market translating product requirements basic configuration product basic features price position etc new RAV4 offered three grades accommodating engine drive configuration twoor four-wheel drive available electronic on-demand 4WD system replaces previous full-time AWD viscous-coupling system first small SUV segment available third-row seating except sport model larger refined interior enabled 14 5-in 368-mm increase vehicle length 181 1 4597 mm Width height increased 3 2 81 mm 0 6 15 mm respectively RAV4 features advanced chassis systems including all-new independent suspension rear well electric power steering EPS Toyota SUVs RAV4 full panoply company's Star System includes ABS electronic brake force distribution vehicle stability control traction control brake assist VSC vehicle stability control enhanced interfaces new EPS system dc motor gear-reduction system built steering gear housing Greater use high-strength steel reinforced structures enhance body rigidity responsive steering lower levels NVH Sales RAV4 began late December 2005 Competitors include Honda CR-V Ford Escape Chevrolet Equinox Jeep Liberty Hyundai Santa Fe RAV4 built Japan Patrick Ponticel new rear shown suspensions said Toyota provide better handling RAV4 rack new electric power steering system mounted frame bushings enhance driver road feel third row seats available first time RAV4 Federal-Mogul SPG global vehicles MX-5 donates Kabura Mazda developed new rear-wheeldrive coupe concept basic underpinnings its MX-5 roadster Kabura concept strays traditional 2 2 seating unique 3 1 configuration eases vehicle entry exit capitalizing power-operated freestyle rear door It's fresh way creatively using space free-style door slide inconspicuously car seamless glass surface extends cowl B-pillar Behind Bpillar two-piece glass hatch hinges roof's glass panel pivot upward serve roof spoiler vent air interior increase rear headroom glass panel contains photovoltaic solar cell help control ambient interior temperature recharge battery concept's 2 0-L four-cylinder derivative engine used MX-5 Miata mated six-speed manual transmission Suspension double wishbone multilink rear Kami Buchholz Concept Kabura's name taken Japanese term howling arrow signaling start battle free-style door shown its retracted state unique feature Kabura body said Franz von Holzhausen Director Design Mazda North American Operations guided project opening passenger door free-style door push button retracts 6 150 mm rear quarter-panel cavity increased ingress-egress path serves full-size rear seat located behind passenger seat Designers able provide full-size seat fuel tank located behind driver side rather driveshaft jump-seat located behind driver Both rear-seat front-seat passenger identical leg shoulder headroom designers minimized instrument panel positioned passenger seat 6 150 mm ahead driver's seat Kabura's windshield forward portion roof integrated ll vision clearer global vehicles Mini gets reinterpreted Displaying bit sporty flair functionality Mini Concept Detroit unveiled earlier year drops usual Bpillar adds other features entering exiting loading car easier cargobox's floor cover--when swiveled upward--serves partition passenger area luggage compartment pulled rearward added length floor cover serves temporary locking dock roof's rear section opens aid loading needs interchangeable stamped plastic storage box--measuring length height rear side window--fits window opening seats mounted center console via load-bearing extensions rotate inward moved forward electric motor assistance help rear-seat occupants enter exit Once rear passengers seated seats automatically return original position Rear-seat backrests folded flush luggage compartment floor Mini's next production vehicle resemble Detroit study lot said Jim McDowell Vice President Mini U S noting similar concepts shown Frankfurt Tokyo It's shell that's appeared third time time it's completely rebuilt said McDowell Mini's chrome side air vent surrounds fold form cupholders--keeping drinks cool air conditioning beverages warm heat engaged concept Mini lot ideas production car said McDowell Kami Buchholz Mini Concept Detroit features front-hinged engine compartment roof box carrier wheels bolting points connection flanges permit exchangeable design elements DuPont thermoplastic EE Products include Crastin PBT resins hydrolysis resistant low warp grades Great connectors sensors control modules Thermx high performance polyester higher temperatures surfacemount Pb-free applications drop-in existing PBT molding tools Zenite LCP resins best high temperature resistance excellent dimensional stability creep resistance Inherently flame retardant electronic connectors Zytel HTN high performance polyamide chemical heat moisture resistance plus processability New grades surface-mount Pb-free applications Zytel EMX EMI shielding resins design flexibility plastic protecting against electromagnetic interference control modules world doesn t forgive failure need know connectors control modules switches sensors miss live hot aggressive environment 150 000 miles need protected Talk high-performance cost-effective materials technology work best application need market fast need partner concept commercialization Dial DuPont First 1-800-441-0575 visit automotive dupont com information full range DuPont EE solutions Copyright 2005 DuPont Rights Reserved DuPont Oval Logo DuPont miracles science Crastin Thermx Zenite Zytel registered trademarks trademarks DuPont its affiliates Circle 227 aei-online org global vehicles 28 APRIL 2006 aei American Specialty Cars CEO Paul Wilbur team way future vehicles include ball cap bottle sun block gloveboxes ASC earlier year unveiled new prototype vehicles showcasing company's expanding portfolio power-folding roof systems debuted carbon-fiber-intensive sports car concept perhaps Offered durable fabric folds accordion-style three depending vehicle size stackable hard panels bidirectional roof units fold exposing interior's occupants varying degrees sky push button TriLite concept minivan roof panels Lexan GLX polycarbonate latest InfiniVu materials choice Sun shines new ASC Concepts Buckmaster said compromise terms vehicle styling Wilbur explains InfiniVu system retains vehicle's body pillars roof-crush characteristics side-airbag positioning maintained ASC touted its carbon-fiber design manufacturing prowess Diamondback Viper car's decklid roof panel hood rockers assorted ultimate idea portable cookery based compact SUV Cosmos TriLite concepts based Hummer H3 Toyota Sienna respectively show potential applications InfiniVu roof-system architecture InfiniVu based set common components electronic hardware controls helps keep costs low said ASC Vice Chairman Chris Theodore key functional enabler horizontal header located D-pillar tracks way roof slides forward provides rear-loading access Theodore noted InfiniVu system scalable across vehicle sizes currently targeted SUV crossover minivan segments Developed collaboration GE Plastics Automotive clear Lexan offers weight savings 50 potentially greater shatter resistance compared glass panels ASC offers its InfiniVu materials suite roof-systems applications Lexan coated Exatec 900vt abrasion- weather-protective material prototype panels thermoformed GE Plastics' Netherlands facility production panels injection molded noted Derek Buckmaster GE Plastics Automotive Global Marketing Manager advantage Lexan formed match contours roof's leading trailing edges body trim constructed using ASC's patent-pending Omni-Carbon compression- molding process Wilbur claims reduces molding cycle times 80 versus traditional autoclave processes Diamondback's 615-hp 456-kW V10 developed conjunction McLaren Performance Technologies display ASC-Suzuki Wave based Suzuki's Grand Vitara SUV Developed ASC's Huntington Beach CA studio Wave ultimate vehicle sports-fan tailgate parties Its rear section slides body fitted barbeque grill refrigerated cooler Lindsay Brooke ASC's new power-folding roof systems fabric-based Cosmos shown Hummer H3 Trilite Toyota Sienna aimed SUVs crossovers minivans Diamondback Viper rolling showcase potential applications ASC's proprietary Omni-Carbon carbon-fiber process well McLaren Performance Technologies' engine tuning development capabilities Designed ASC's Huntington Beach CA studios Suzuki Grand Vitara-based Wave concept features slide-out barbeque cooler module KOAASHOW 2006 Lighting way 30 APRIL 2006 aei aei-online org Lighting way brighter future vehicle lighting design engineering promised next decade development aspects automotive lighting become rewarding increasingly complex challenge need combine styling systems technology safety issues particularly pedestrian safety years vehicle exterior lighting add-on feature--a practical necessity efforts give headlights styling identity particularly expensive cars 1930s 1940s quadruple rectangular designs introduced 1950s 1960s trend towards hiding behind flaps tucking via pop-up motorized systems Oldsmobile Toronado Triumph TR7 TR8 Fiat X1 9 although Cord hiding its headlamps 30 years 1940s though Tucker its Cyclopean eye central headlight illuminated steering turned 10 demonstrated new dimension lighting technology late 1960s Citroen's DS 21 SM steering-directed high Lighting Exterior lighting systems contributing safety changing cars' styling Stuart Birch way beams during mid-to-late 1990s headlamps vehicle lighting general began new significant role overall design integration parallel realization lighting systems safety vehicle fitted Headlamps play key role both passive active safety motor vehicles--especially comes accidents involving pedestrians said Dr Roland Lachmayer Head R D Lighting Hella 70 pedestrian accidents primary contact zones corners vehicle's end HBPO frontend joint venture Hella Behr Plastic Omnium developing new approaches entire front-end module improve pedestrian protection applying Hella's expertise headlamp optimization behavior headlamp compared tennis racket soft middle hard edges greater value must placed space controlled displacement absorption impact energy explained Lachmayer added Hella aiming improve energy absorption headlamps via design changes including housing projection module result changes maximum force arising case thigh impact accordance Directive EEVC WG 17 Headlamps play key role passive safety motor vehicles--especially comes accidents involving pedestrians said Hella's Lachmayer Automotive Lighting Lighting way 30 APRIL 2006 aei aei-online org Lighting way brighter future vehicle lighting design engineering promised next decade development aspects automotive lighting become rewarding increasingly complex challenge need combine styling systems technology safety issues particularly pedestrian safety years vehicle exterior lighting add-on feature--a practical necessity efforts give headlights styling identity particularly expensive cars 1930s 1940s quadruple rectangular designs introduced 1950s 1960s trend towards hiding behind flaps tucking via pop-up motorized systems Oldsmobile Toronado Triumph TR7 TR8 Fiat X1 9 although Cord hiding its headlamps 30 years 1940s though Tucker its Cyclopean eye central headlight illuminated steering turned 10 demonstrated new dimension lighting technology late 1960s Citroen's DS 21 SM steering-directed high Lighting Exterior lighting systems contributing safety changing cars' styling Stuart Birch way beams during mid-to-late 1990s headlamps vehicle lighting general began new significant role overall design integration parallel realization lighting systems safety vehicle fitted Headlamps play key role both passive active safety motor vehicles--especially comes accidents involving pedestrians said Dr Roland Lachmayer Head R D Lighting Hella 70 pedestrian accidents primary contact zones corners vehicle's end HBPO frontend joint venture Hella Behr Plastic Omnium developing new approaches entire front-end module improve pedestrian protection applying Hella's expertise headlamp optimization behavior headlamp compared tennis racket soft middle hard edges greater value must placed space controlled displacement absorption impact energy explained Lachmayer added Hella aiming improve energy absorption headlamps via design changes including housing projection module result changes maximum force arising case thigh impact accordance Directive EEVC WG 17 Headlamps play key role passive safety motor vehicles--especially comes accidents involving pedestrians said Hella's Lachmayer Lighting way aei-online org aei APRIL 2006 33 Lighting way E-Class headlamps adapt prevailing driving weather conditions country motorway modes system includes active- cornering-light functions plus enhanced fog lamps Altogether system incorporates five light functions combined bi-xenon technology country mode nearside curb widely brightly lit driver's range vision increased 10 m 33 ft motorway mode sees xenon low-beam output upped 35 38 W car reaches 90 km h 56 mph 110 km h 68 mph range nearside lamp increased create uniform cone light 120 m 394 ft center cone providing 50 m 164 ft improved visibility compared conventional low beams Mercedes-Benz's active light function offered since 2003 its angle changed 12 15 fog nearside headlamp swivels 8 nearside lowers cone height resultant wider beam reducing glare major player sector Automotive Lighting AL established 1999 50 50 joint venture Bosch Magneti Marelli totally controlled Magneti Marelli incorporates former Seima Group company well placed advantage move glass plastic headlamp lenses opened major styling options provided opportunity use technology automotive art form AL emphasizes importance rear lamp design LEDs create light voltageinduced recombination processes semiconductor layer says AL emitted light determined its color internal structure LED Compared conventional incandescent bulbs main advantages LEDs long life 100 000 h low energy consumption small module depth switch-on time short providing safety benefit event emergency braking light intensity adjustable brake pressure facilitating adaptive rear lamps speed 120 km h 75 mph LED stoplamp provide 6 6 m 22 ft extra braking distance following vehicles says AL LEDs offer vast variety fascinating innovative styling possibilities Bi-color LED Passat AL started LED rear lamp production Peugeot 307CC 2003 company developed first bi-color LED rear lamp dual-chip package position brake indicator functions Volkswagen Passat 2005 introduction AL claimed world market leader exterior LED applications company states working unspecified customers pre-development LED functions headlamps Introduction new technology started AL sidemarker function Cadillac DTS headlamp year Daytime running position lights next applications LED technology says company Xenon technology brought major changes automotive lighting industry 1991 AL pioneer its application production cars new Alfa Romeo 159 uses AL's xenon system triple cylinder optics providing inside story latest Mercedes-Benz E-Class offers Ambient Lighting providing glare-free illumination interior uses LEDs door-handle recesses footwells plus luminous panels roof liner Mercedes states its use illumination enhances driver's operating perceptive safety during darkness Ambient Lighting said psychologically biologically stimulating effect driver improve performance potential new S-Class interior lighting soft colors provide mood ambience Hella developed car's plastic light guides overall length 5 m 16 4 ft particular challenge meet differing location-dependent brightness requirements overall impression uniform steady interior illumination light sources LED modules flexible printed circuit board light fed both sides according length guide explained Hella spokesman wave-like decoupling structure directs light fed side exits interior via molded-on lens Hella's light guides used Mercedes-Benz S-Class's Ambient Lighting Volkswagen EcoRacer research sports car LED headlamps turn indicator lamps developed Hella headlamp modules depth only 55 mm 2 2 facilitates design opportunities Particularly cars short body overhang conventional headlamps installed significantly higher drive axles says VW flatness LED headlamps lower position feasible Alfa Romeo 159's triple-cylinder optics Automotive Lighting Lighting way 34 APRIL 2006 aei aei-online org Lighting way distinctive front-end appearance AL describes its high-performance bixenon projector unit core module adaptive lighting systems innovation introduced 2003 BMW 3 Series functionality steadily enhanced dynamic curve lighting static bend lighting motorway city poor weather functions applications AL developed electronic control units ECUs evaluate range dynamic driving parameters including steering angle yaw rate vehicle speed well electromechanical actuators control low- high-beam swivel other leading lighting systems suppliers AL developed pedestrian-friendly headlamp absorb impact energy company states Europe 7000 pedestrians cyclists die year result collisions vehicles 400 000 injured Cleaning glare past decade Europe xenon headlamps required law ECE 45 48 controlled AVAC automatic vertical aim control fitted cleaning system main reason cleaning reduce glare experienced oncoming vehicles AL produces static nozzles positioned bumper hydraulically operated telescopic nozzles technology other powerful headlights available night vision Working cooperation Mercedes-Benz AL developed company describes statement world's first active IR lighting system latest S-Class giving effect invisible high-beam lights driving low beam providing major improvement active safety Safer driving central theme Valeo's R D programs year's Frankfurt Motor Show company unveiled its V360 360 vision around vehicle demonstrator equipped variety driverassistance systems including advanced lighting technologies According company latest studies conducted drivers Europe Asia U S clearly show driver expectations future car design relate primarily safety particular active safety collision avoidance lighting technology V360 includes Beamatic high- low-beam automation switching automatically according traffic conditions XtraVue IR night vision system designed provide night-time vision equivalent high beam driving low-beam mode adaptive rear lamps MicroOptics LED technology providing homogenous luminous surface both optimum visibility design freedom Bending lights 90 better visibility Valeo's xenon dynamic bending light systems adopted Audi BMW Citroen Opel VW company claims 90 improvement driver visibility curves bends via its latest generation bending-light technology dynamic bending light system works both high low beam uses motorized xenon modules swivel horizontally 15 direction straight ahead optimal angle swivel headlamp determined ECU processes data supplied speed steering angle sensors real time Added visibility driver provides increased reaction time making both smoother safer driving use dynamic bending lights systems its xenon technology continue cascade model ranges eventually become norm believes Valeo IR driver aid systems still production application infancy become increasingly available optional equipment later standard items costs reduce economies scale Subtle lighting enhance interior nocturnal ambience distracting driver possibly contributing driver efficiency safety likely become increasingly popular Today widening spectrum lighting technology its applications applies companies involved sector once functional set components light way ahead warn vehicles following behind become art form itself art form technologically based its aesthetic elements firmly rooted Automotive Lighting started LED rear lamp production Peugeot 307CC 2003 rear LED lights Valeo's V360 demonstrator vehicle provide optimum visibility design freedom Valeo's V360 research vehicle's headlamps use Beamatic high- low-beam automation Dow Corning Corp tech briefs 36 APRIL 2006 aei aei-online org tech briefs Edited David Alexander BorgWarner Turbo Systems developing its turbocharger technology bring performance efficiency gains variety engine sizes types company worked closely Audi develop world's first gasoline engine use both direct injection turbocharger-- Audi 2 0-L Turbo FSI engine combines advantages fuel stratification ignition FSI combustion process benefits exhaust gas turbochargers result unit offers high power torque moderate fuel consumption--all meeting EU4 ULEV2 exhaust emissions regulations well future onboard diagnostic provisions engine recently introduced Audi A3 Sportback available Audi A4 VW Golf GTI VW Passat collaboration resulted integrated module represents development BorgWarner's K03 turbocharger BorgWarner Turbo Systems continuing expand its business Asia March 2005 series production started Hyundai Korea first product BV43 turbocharger manufactured joint venture company SeohanWarner Turbo Systems BorgWarner Turbo Systems founded together automotive supplier Korea Flange Company February 2004 company chose BorgWarner Engine Group factory Pyongtaek production site BorgWarner MorseTec already producing systems Hyundai turbocharger variable turbine geometry VTG installed diesel engine new Kia Sorento 2 5-L CRDI VGT initially available only Korean market BV43 turbocharged direct-injection diesel engine delivers 25 power its predecessor wastegate development engine focused obtaining higher torque smoother running achieving better fuel economy lower emissions its new BV technology BorgWarner Turbo Systems presenting third generation turbochargers VTG Compared predecessor models latest BV technology offers improved thermodynamics optimized control behavior time ensuring greater reliability Turbocharging important heavy-duty market Commercial vehicle engines need develop high torque allow vehicle pull hill time provide sufficient power low engine speeds maximize fuel economy driving highways Power output fuel consumption Boosting range engines BorgWarner Turbo Systems worked closely Audi develop world's first gasoline engine use both direct injection turbocharger turbocharger variable turbine geometry BorgWarner Turbo Systems installed diesel engine new Kia Sorento initially available only Korean market Fujitsu Microelectronics America, Inc tech briefs 38 APRIL 2006 aei aei-online org briefs briefs emissions control particular extreme demands future turbocharger technology stricter Euro 4 emissions standards force exhaust turbocharger VTG become state art diesel engines passenger cars extent commercial vehicle applications limits single-stage turbocharging reached increase rated power usually leads reduced starting torque BMW 535d adapted commercial vehicle market allows infinitely variable adaptation turbine compressor side engine operating point regulated two-stage turbocharging turbochargers different size large low-pressure turbocharger small high-pressure turbocharger arranged series Unlike system used passenger-car applications regulated two-stage turbocharging commercial vehicles only bypass valve actuator high-pressure turbocharger arrangement turbochargers tuned both active engine operating points boost pressure controlled external bypass allowing continuous control drop pressure Regulated two-stage turbocharging provide commercial vehicles technology meets highest power requirements complies future emissions standards said Hans-Peter Schmalzl Vice President Technology BorgWarner Turbo Systems David Alexander achieving rise rated power engine require use larger turbocharger ensure high boost pressure generated low engine speeds turbine compressor made smaller ideal solution therefore combination both its R2S BorgWarner Turbo Systems developed regulated twostage turbocharging system provides solution technology first its R2S BorgWarner Turbo Systems developed regulated two-stage turbocharger system turbochargers different size arranged series Charge air cooler High-pressure-stage turbocharger Low-pressure-stage turbocharger Wastegate Bosch keeps pressure High injection pressure equates lower particulate emissions diesel engines primary reason researchers pursuing higher higher pressures search clean diesel technology different scenarios following scenario need high-pressure injection HADI Hydraulically Amplified Diesel Injector available other strategies said Stefan Kampmann Senior Vice President Engineering Diesel Systems Robert Bosch Stuttgart Germany Since 2003 Bosch spotlighted common-rail injectors using piezo-inline technology Piezo-inline technology increases 1600 1800 bar 23 2 26 1 ksi year 2000 bar pressure 29 ksi --with 45 engine-out reduction NOx particulate matter-- available 2007 handle 2000 bar 29 ksi injector other associated components must able withstand mechanical forces generated high-pressure advanced-high-strength steel appropriate tolerances injector advanced-high-strength steel otherwise break crack injectors said Kampmann adding quality manufacturing process high-volume production equally important necessity Since emissions regulations moving target Bosch engineers working various pollution-reduction technologies HADI--a technology 2500-bar 36 3-ksi pressure five injections cycle--is example solution under development basic requirements today mean pre-injection keep noise under control second pre-injection keep emissions first pre-injection under control main injection energy powertrain post-injections--the first closed post-injection reduce soot emissions post-injection regeneration after-treatment Bosch manufactures piezo-inline injectors third generation its common-rail injection system Compared previous system injection technology capable lowering diesel engine fuel consumption approximately 3 cutting emissions 20 TenarisDalmine tech briefs 40 APRIL 2006 aei aei-online org devices diesel particulate filter NOx catalyst said Kampmann chosen production solution HADI ready early 2010 biggest challenge HADI basically dynamics injection system-- meaning generating small pre-injections--as well needed processes assure quality system high production numbers Kampmann said three four portions mean 10 injections cycle said Kampmann adding approach totally different combustion strategy require kind injector system Although developed piezo-injection system pan promising application splitinjection concepts HADI split-injection application possibility Kami Buchholz HADI investigated 2 0-L engine advanced development department we're HADI four-cylinder test HADI's performance real engine Kampmann said Bosch engineers evaluating use split-injection use Piezoinline technology basic combustion process homogeneous combustion process chopped-injection--even main injection--would split Getrag expects its dual-clutch transmission DCT hit production overdrive next decade vehicles fitted gearbox Based market study analysis talks OEMs other inputs Getrag officials expect technology reach 29 market share 2015 Europe Asia-Pacific region--minus Japan--the growth dual-clutch transmissions expected reach 13 2015 That's big shift 2005 technology 1 market penetration Europe basically nonexistent Asia-Pacific other Japan Getrag brings its dual-clutch transmission marketplace start production 2007 DCT uses manual gearbox technology transmissions means clutch operates odd-numbered gears other clutch operates even-numbered gears said Stephan Rinderknecht Getrag's Vice President Research Development Getrag release five versions DCT based four different architectures MPS6 SPS6 models transverse layout designs six speeds share hydraulics electronics clutch said Rinderknecht other versions DCT 477 seven-speed transaxle longitudinal design handle 700 N m 516 lb ft DCT 436 seven-speed inline design handles 600 N m 443 lb ft DCT 250 six-speed transverse layout using dry clutches deal 250 N m 184 lb ft DCT--depending design-- uses wet dry clutches employs hydraulic electromechanical actuation adjusts launch behavior via software provides high-speed capability 9000 rpm beyond It's flexible transmission traditional automatic transmission said Rinderknecht adding large variety possibilities dual-clutch transmission built Getrag investing 340 million build new facility Slovakia production transverse transaxle DCTs front-wheel-drive vehicles Production DCTs inline longitudinal transaxle applications occur Getrag's Big expectations dual clutch plant Neuenstein Germany currently producing variety transmissions DCTs mated gasoline well diesel engines four- tencylinder range next-generation DCT likely reach marketplace sometime 2011 already lot ideas improve DCT technology especially terms fuel economy integration all-wheel-drive functions said Rinderknecht Kami Buchholz Getrag's Stephan Rinderknecht stands next company's DCT 477 seven-speed dual-clutch transmission Grammer AG tech briefs 42 APRIL 2006 aei aei-online org Valeo actively developing technology reducing fuel consumption emissions engine cylinder-head design lower electromagnet energizes maintain valve open position valve operates independently others piston position different systems currently developed Valeo including actuators VCU wiring rail electronic control unit specific strategies dedicated new concepts first called full camless manages valves both intake exhaust side engine second called half camless manages inlet valves only controlling residual gases minimizing pumping losses deactivating cylinders valves technology reduce fuel consumption pollutant emissions 20 according Valeo Consumers benefit enhanced performance driving comfort due increase low-end engine torque SVA development program currently undertaken support several leading car manufacturers scheduled volume production 2009 David Alexander uses its Smart Valve Actuation SVA place conventional mechanical operation engine valves cam belt camshaft hydraulic cam followers SVA first innovations Valeo intends actively develop market meet increasing demand better fuel economy reduced pollution following its recent acquisition Johnson Controls' Engine Electronics Division according Chairman CEO Thierry Morin camless engine engine valve operated individually actuator placed upper surface cylinder head directly above valve guides actuator linked engine- mounted valve control unit VCU ensures optimal positioning valves performs power drive function actuator includes upper lower electromagnet valve armature vane connected valve stem upper electromagnet activated vane pulled upward valve moved its closed position upper electromagnet releases vane pulled springs Valeo pushes engine valves Valeo calculates its Smart Valve Actuation technology able reduce fuel consumption pollutant emissions 20 increasing low-speed torque Top-mounted solenoid makes space Starter motors gasoline engines originally designed allow pinion mounted starter motor shaft driven along helix inertial forces created starter motor armature accelerates pinion moves forward along shaft helix engages ring gear attached engine crankshaft motor torque rotates engine spins fast enough ignition system operate Once engine runs under its own power electric power starter motor turned pinion released ring gear recurring problem though pinion accidentally become disengaged engine misfires necessitates restart starter motor Occasionally pinion suffer 'bounce-out' 'pump-out' results pinion oscillating along starter motor shaft causing rapid wear pinion alarming noises problem solved adding magnetic solenoid side starter motor secure starter motor pinion engaged ring gear engine starting engine certain engine compartments become increasingly crowded devices added engines increase efficiency reduce emissions Starter motors side-mounted solenoids valuable space necessary side mounting results solenoid experiencing considerable vibration Engineers Johnson Electric studied problems developed solution called 'Top-Mounted Starter Motor Solenoid changing shape starter motor economize space reduce degree vibration solenoid subjected Johnson Electric engineers decided mount solenoid end cap motor extended shaft along pinion travels design circumferential extensions easier engine compartment designers find space starter motor provides greater flexibility routing other components intake exhaust manifolds Engines horizontally vertically mounted requiring modification solenoid location Engineers Johnson Electric developed top-mounted solenoid save space engine compartment Voss tech briefs 44 APRIL 2006 aei aei-online org new starter motor solenoid located end motor extended shaft carries engagement pinion action solenoid helps push pinion its engagement position holding securely place engine started retracting its rest position un-energized system return spring holds pinion close solenoid coil coil energized current passes starter motor magnetic field generated coil causes pinion move end shaft compress return spring electromagnetic force ensures pinion remains engaged ring gear engine properly started engine fired energy both starter motor solenoid switched return spring forces pinion solenoid armature original position Johnson Electric engineers retained advantages positive-engagement starter positioning solenoid side starter motor thereby creating space-efficient design subjects solenoid vibration article written AEI Darin Bremmer Johnson Electric South Korean automakers VGT South Korea's fourth-largest automaker Ssangyong Motor launched its entry- level five-seat Actyon small SUV four-cylinder 2 0-L diesel XDi200 XVT engine delivers 145 hp 108 kW new engine boosted thirdgeneration turbocharger system improved version XDi270 installed company's Kyron new Rexton models Power torque increased both low high speeds precise electronic controls Compared existing small SUVs South Korea armed second-generation variable-geometry turbochargers VGTs Actyon engine claims higher fuel efficiency automaker said its XDi engine controlled pilot injection system 1600-bar 23 2- ksi high-pressure injection system high-speed 32-bit engine control unit Actyon based platform Ssangyong's larger SUV Kyron According Ssangyong Actyon's diesel engine satisfy EURO 3 4 emissions standards Europe automaker's largest overseas market accounting nearly 50 its total annual exports Ssangyong Motor currently selling Rexton Rodius Kyron its main European markets Spain Italy plan sell Actyon Europe second half next year said Soh Jin-Kwan President Ssangyong Motor selling Actyon fast-growing Chinese market addition new Rexton new Chairman sedan Rodius currently sold country although market currently gasoline-oriented Figuring Chinese market shift diesel future Soh said Ssangyong Motor hopes build lead potential diesel market adding four-cylinder Actyon its lineup China Ssangyong launched Actyon South Korea fourcylinder diesel engine compete Hyundai Tucson Kia Sportage XDi 200 XVT diesel engine featured Ssangyong Motor's Actyon small SUV delivers 145hp 108 kW 1 5 VGT engine used Hyundai's new Avante model Umicore Autocat USA, Inc tech briefs 46 APRIL 2006 aei aei-online org Ssangyong Motor targets 36 000 sales Actyon next 12 months Korean market against segment leaders Sportage Kia Hyundai's Tucson Regarding ongoing discussions Shanghai Automotive Industry Corporation SAIC build Ssangyong Motor plant China Soh said Actyon expected built Chinese market future Although discussions processed step step haven't reached final agreement build plant Compared current gasoline engine 1 5 VGT enhances low-end torque 60 providing significantly better acceleration Engine noise greatly reduced pilot fuelinjection system new transmission enhances stability endurance automaker claims Kia's all-new 1 5 CRDi diesel engine features common-rail technology VGT new engine produces 109 hp 81 kW CO2 rating 116 g km meets Euro 4 emissions criteria Peter Chang producing products-- Kyron Actyon--in potential Chinese plant Soh said Earlier year Ssangyong Motor launched crossover Kyron SUV first product since SAIC joint venture partner China both General Motors Volkswagen took Korean automaker late October year South Korea's top automaker Hyundai meanwhile launched new Avante XD compact 1 5-L VGT engine enhances fuel efficiency 30 previous version delivers enjoyable driving Increased cooling performance Denso Denso developed double-pipe internal heat exchanger automobile airconditioning C systems increases cooling performance 12 Denso claims first develop technology installed limited space new C system introduced recently Middle East Toyota Prado North America Lexus GX 470 double-pipe internal heat exchanger integrates pipes separated conventional refrigeration cycle single pipe inner outer tubes refrigeration cycle low-temperature gaseous refrigerant flows inner tube exchanges heat high-temperature liquid refrigerant flowing gap inner outer tubes Denso's double-pipe internal heat exchanger inner tube wall spiral grooves face outer tube enhancing heat exchange design allows internal heat exchanger achieve high cooling performance short pipe length unique structure Denso's double-pipe internal heat exchanger increase cooling performance 5 12 power level conventional system length only 400 mm 16 C system installed engine compartment pipes need flexible bent fit around other systems components double-pipe internal heat exchanger gap inner outer tubes crushed during bending process making unable function refrigerant path Denso's solution problem spiral grooves inner tube wall structural result tubes crushed bent C systems using Denso's double-pipe internal heat exchanger installed space conventional C system Manufacturing simple process inserting inner tube outer tube fixing tubes both ends David Alexander Denso developed double-pipe internal heat exchanger automobile C increases cooling performance 12 Spiral grooves inner tube Denso's double-pipe internal heat exchanger provide structural support enhance heat exchange Beru AG Sensing change 48 APRIL 2006 aei aei-online org explosion electronic functions creating huge opening sensors link electronic controllers real world growing number sensors prompting engineers re-examine way devices deployed sparking push standardization automakers use additional electronics safety tighter emissions control other features rare sensors central design Virtually new functions use sensors said Alan Amici Director Body Safety Electronics Chrysler Group years shortage sensors mature areas engine management Today growth comes new applications safety variations radar accelerometers gyroscopes cameras helping protect people Usage expected continue growing Ultimately industry cocoon electronic monitoring systems help improve safety said Dave Goff Engineering Supervisor Omron Automotive Electronics Along safety strong push increase comfort comes play primary focus new feature fuel economy variable cylinder management shut three cylinders need low-g accelerometer sense vibration adaptive damping system adjustments said Rich Mannherz Customer Marketing Manager Analog Devices' Micromachined Sensing achange sensor use grows providing input sorts functions engineers responding design challenges standardization shared use signal output Terry Costlow Products Division growth sparking major changes way sensors deployed Engineers must work stylists package position optimally Engineers using networks new architectures reduce costs particularly redundancies occur sensors communicate only control system Design challenges Designing parts vehicles brings challenges Since must interact surrounding environment positioning sensors often difficult expected Nissan testing its redesigned Quest minivan climate-control sensor inside center cluster farthest sunlight HVAC said Carla Bailo Nissan's Assistant Chief Vehicle Engineer test driver long knee-to- Various sensing technologies scattered throughout new Mercedes-Benz S-Class Nissan engineers scrambled avert potential problem sensor placement Quest test driver long knee-tofoot length covered sensor completely moved A&D Technology, Inc Sensing change 50 APRIL 2006 aei aei-online org foot length covered sensor completely move Different types sensors often unique challenges Traits distance speed vary widely cameras key Fellow Visteon Heat dissipation key issue video complicated necessary mounting location camera vehicle headliner difficult eliminate heat said Rob Lyons Manager Combined Active Passive Safety Robert Bosch Heat generated processors removed camera module moved cooled means huge amounts video data must sent relatively long cables adds substantial costs Though engineering challenges trivial often second seat cost Though sensors HVAC systems efficient cruise control adaptive add other features customers want pay extra wipers turn sense rain example key factor sensors categories applications mean sensing technology sees widespread use drives volumes prices Relatively low numbers issue light levels main challenge maintain specific levels performance under conditions ambient light conditions change bright shaded said Paul Zoratti Technical Packing Solid-state sensor manufacturers face electronic challenges attempt gather input tells controller chips real world must deal challenges packaging integrated circuits conventional semiconductors sensor chips small wires sensitive silicon must protected environment high-volume semiconductor packages used safeguard conventional chips openings sensors need gather information temperature pressure Sensor makers must therefore develop custom packages spend lot sensor packaging standard chip packages don't work sensors said Guenter Reiniger Product Sector Marketing Manager Sensors Philips Semiconductors Philips using multichip packaging sensors logic chips sometimes passive components single housing Sensor packages often house multiple chips Although sometimes possible combine logic sensing elements single piece silicon often made using dramatically different processing techniques making level integration impossible DSPs digital signal processors 0 18 0 13 microns sensors several generations behind 3-4 microns said Rich Mannherz Customer Marketing Manager Analog Devices' Micromachined Products Division sensors hidden view factor must considered engineers determine use radar cameras Radar easier conceal behind fascia said Paul Zoratti Technical Fellow Visteon provide superior weather performance Though cameras hidden designers ways viable Cameras often can't hidden behind need pleasing eye said Dave Goff Engineering Supervisor Omron Automotive Electronics sensor packages must designed possible assembly personnel adjustments key challenge presented packaging alignment sensors radar video said Rob Lyons Manager Combined Active Passive Safety Robert Bosch important sensors aligned precisely vehicle field view sensor properly oriented driving axis alignment must place during vehicle production field case vehicle must repaired Radar sensors housed behind plastics Mercedes-Benz S-Class giving edge cameras sensors large moving components X center example Analog Devices difficult logic chip CPU Sensor ranges vary widely Bosch image shows dSPACE, Inc Sensing change 52 APRIL 2006 aei aei-online org units increase price said Gunter Rottner Engineering Manager Driver Assist Systems Bosch Technical challenges cost problem Development costs need distributed piece price low numbers high price generally result lack good business case New SAE protocol emerges Cameras increasingly used give drivers view behind Source DaimlerChrysler number sensors vehicles continues rise Source Analog Devices Airbag Seatbelt pretensioner Gyroscopes Crash detection system Vehicle dynamics control system Navigation driver information system Body chassis control system Satellite sensor Dual-axis airbag sensor Low-g chassis control sensor electronics biggest factors cost reduction emergence standards number leading suppliers hope solution work fragmented world sensors handful OEMs suppliers begun working together SAE International create sensor standard called Single Edge Nibble Transmission SENT point-topoint protocol likely used primarily link sensors controllers technique sends 4-bit nibbles nibble half 8-bit byte repeated eight times telegram provides 12- bit resolution speeds faster 1 ms 12 bits There's security-like error checking don't lose telegrams said Vincent Hiligsmann Product Marketing Manager Melexis SENT makes possible maintain fast data transfer rate two-meter cable critical aspect sensors used throttle steering control combination distance speed 12-bit resolution makes possible maintain tight control needed applications Hiligsmann said SENT uses digital communications analog blocks converted digital cells trimming silicon costs Money drives said Guenter Reiniger Product Sector Marketing Manager Sensors Philips Semiconductors digital shrink cells Analog blocks easy shrink aspect still fine-tuned EMC electromagnetic compatibility protection improve substantially analog techniques Developers say once documentation completed lot effort employ specification digital sensors It's issue silicon need final protocol Reiniger said Slowing growth busy adding new sensors vehicle designers looking ways stem expansion rate addressed part using input sensor use area explosion sensors car OEMs interested combining sensor functions said Kristoff Coddens Business Division Manager Melexis' Sensors Division example wheelspeed sensor send data both ABS speedometer approach replace multiple sensing technologies single approach improve economies scale Canesta developed imaging sensor tell distance detect objects letting handle tasks both radar cam Sensing change aei-online org aei APRIL 2006 53 becoming popular sensor communications Sensor makers already adding devices LIN good candidate Coddens said We're definitely seeing requirements LIN sensors aei eras technology lets machines similar way humans things said Jim Spare Marketing Vice President Canesta noted module used occupant sensing adaptive cruise control design expertise reused unit volumes rise various forms sensor fusion reduce growth rate sensors design engineers working critical components increase error rates other electronic components sensors monitoring own health Component designs changing meet increased diagnostic requirements increased communication schemes information sharing need modules systems increases Amici said Sensor providers system designers must determine sensors fail particularly important sensors impact safety reliability complex multichip packages widespread use diagnostic capabilities must examine aspect module We've added diagnostics capabilities Reiniger said ASIC packaged MR sensor checks itself sensor wire bonds fails defined mode instances vehicle shut avoid damage others system fail-safe mode give drivers time repairs Diagnostic data along information needed normal operation often transferred hierarchy networks controller area network architectures carry data particularly system-level communications high-speed sensors airbag accelerometers sensors need high transmission rates expensive solution Chrysler's Amici noted LIN local interconnect network expensive meets need sensors Omron's sensors housed rugged packages Leading Manufacturers Melting Thermal Processing Production Systems Metals Materials Industry Worldwide Quality parts emerge quality ideas efforts Inductoheat Inductotherm Group Company offers partnership approach process feasibility part design machine design manufacturing installation re performing selective case hardening tempering heating forging thermal process Inductoheat heat need quality parts Inductoheat Inc 32251 North Avis Dr Madison Heights MI 48071 Circle 253 Please visit SAE Booth 2406 focus electronics 54 APRIL 2006 aei aei-online org focus electronics Edited Kevin Jost Freescale STMicro codevelop chips Freescale Semiconductor STMicroelectronics teaming jointly develop chips automotive market cross-license Freescale's PowerPC 32-bit processors ST's power technologies companies jointly develop chips beginning 90-nm processing techniques evolve smaller geometries joint design effort begin roughly 100 employees headquartered near Munich Germany companies augment design group engineers remain existing design teams Though design products share process information sales marketing chips remain separate key focus agreement develop PowerPC architecture addresses fastest-growing segment automotive microcontrollers According Strategy Analytics segment double 1 5 billion year 3 billion 2006 companies both heavily involved automotive applications expecting short-term revenue projects designed combined design project 2009 expect significant impact market said Ugo Carena General Manager ST's Automotive Product Group Strategy Analytics estimates 2004 companies held number number three positions jointly controlling 21 16 billion automotive semiconductor market research house estimated Freescale revenues 1 8 billion ST sales 1 3 billion high-end processors focused applications including engine transmission control well faulttolerant systems drive- brakeby- wire advanced vehicle control driver information systems Carena said ST drop its other CPU central processing unit architectures continue develop ARM processors other automotive applications Freescale feels licensing ST components power MOSFETs metal-oxide semiconductor fieldeffect transistors IGBT insulatedgate bipolar transistors augment its existing product lines letting company easily address system Freescale STMicro agreement targets aspects vehicle electronics Engine control Body gateway Navigation telematics Climate control Brake systems ABS ESP VSC Tire-pressure monitoring Electric parking brake Door window lock Instrument cluster Airbag control Steering Active safety camera radar occupant sensing 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 Market billions 3 5 3 0 2 5 2 0 1 5 1 0 0 5 0 MCU 8-bit MCU 16-bit MCU 32-bit MCU 64-bit 32-bit PowerPC architecture addresses high-growth market Years focus electronics aei-online org aei APRIL 2006 55 designs require power handling includes hybrid vehicles far higher voltages used conventional vehicles license fills gaps said Paul Grimme General Manager Freescale's Transportation Standard Products Group Freescale access products part Motorola segment business lost Motorola spun Semiconductor prior Freescale ST Freescale predict second source electronics key market benefit feel joint development shorten time market offer both companies better capabilities address system-level challenges first time companies joined forces Since 2002 worked along Philips Semiconductors develop CMOS complementary metal oxide semiconductor technology processes 90-nm smaller geometries called Crolles 2 Alliance joint agreements used throughout electronics industry Freescale teamed IBM PowerPC development days announcing linkup ST Motorola joined Power org group begun year promote PowerPC technology 40-member group focuses nonautomotive applications IBM-Freescale joint venture ST current plans join Power org Carena said Terry Costlow FULL-SERVICE SYSTEM INTEGRATOR 36 MANUFACTURING PLANTS PLUS DEVELOPMENT FACILITIES WORLDWIDE PRODUCT FOCUSED TECHNICAL SUPPORT www mclarenperformance com www linamar com CHASSIS ENGINE TRANSMISSION Collaborative product development builds superior products customers ahead Linamar full-service system integrator leading edge design capabilities transform engine transmission chassis requirements concept final product combining innovative uses technology unsurpassed manufacturing expertise add value develop focused program launch systems deliver better products better prices better service customers world leader design manufacture precision-machined components modules systems automotive industry beyond Circle 255 focus electronics 56 APRIL 2006 aei aei-online org Korean automakers upgrade telematics South Korean automakers led Hyundai Motor its affiliate Kia Motors making cars smarter taking advantage stunning progress South Korea's information technology infrastructure Hyundai developing 512-MB memory telematics known Mozen new sedans debut near future Currently automaker's Vision Innovation Idea Integrators Roof systems modules Door systems modules Access control systems Suspension systems modules Wheels Emissions technologies www arvinmeritor com ArvinMeritor s latest door module technology radically change way OEMs design assemble door systems integrating doorframe window regulator ArvinMeritor increased cockpit space improved fit finish reduced window noise improved glass stability example ArvinMeritor integrating components solutions move world Circle 256 briefs Philips Automotive Playback Modules Visteon demonstrated first car jukebox module concept 2006 Consumer Electronics Show CES January Las Vegas listening disc consumers simultaneously record 10 CDs system's flash memory 4X speeds Visteon's advanced user interface said give ability navigate quickly intuitively music tracks stored system Car Jukebox concept allows users listen 7 h favorite music Once content stored Car Jukebox memory users leave CD collection home addition playback several formats CD DA MP3 WMA files concept record external sources FM satellite radio unit fits half-DIN sized slot reducing interior real estate required current CD changer units 2006 Geneva Motor Show Microsoft Fiat unveiled first production cars featuring Windows Mobile Automotive WMfA in-car infotainment system called Blue enables consumers safely use mobile devices Bluetoothenabled mobile phones digital entertainment devices Its USB universal serial bus port connect variety personal music players other devices software upgradeable refreshed accommodate consumers' changing needs supporting future devices new industry standards low-cost in-car system developed under years costs kept check using standardized platform across multiple models According Frost Sullivan European automotive industry witnessing growing trend towards installing active safety systems vehicles biggest factors propelling demand obstacle-sensing technologies critical role played sensors absence definitive sensor fulfills equally important requirements obstacle sensing classification created attractive market various competing complementing technologies said Research Analyst Karthikeyan Vijayakumar Valued 14 4 million 2004 European market obstacle- sensing technologies likely increase substantially 194 7 million 2015 compound annual growth rate around 26 7 largely due introduction vision short-range sensors well growing penetration long-range radar sensors passenger commercial vehicles new luxury model Grandeur armed 256-MB telematics memory chips compared automaker's initial 96-MB offering better control automaker's powerhouse engines Hyundai trying upgrade its engine control unit ECU 32 bit current 16-bit ECU previous 8-bit examples Various levels telematics technology installed Hyundai's Azera Equus Sonata Santa Fe SUV South Korea Besides route guidance current systems used vehicle-theft tracking company real-time image services drivers its mid- long-term plan working upgrading its current DVD navigation encompass 4 5 million different types information automaker's previous model CD navigation 220 000 Advancements planned SOC system chip applications process driving information Hyundai expects eventually able provide car infotainment information entertainment services South Korean electronics companies including LG Electronics expand investments sector next-generation projects Its customers able enjoy Internet home entertainment music movies cars addition geographical location services provided telematics Kia Motors making its car smarter Its current 30-40 SOCs car 10 chips late 1990s Hyundai's 256-MB telematics system installed company's Grandeur luxury model focus electronics aei-online org aei APRIL 2006 57 Power Steering OUTH CAROLINA perfect place drive growth International Center Automotive Research established network auto-related manufacturers Charleston largest container port South SC Power Team connect strategically located sites buildings state local incentives workforce training largest electric power system state drive next facility location 1201 Main St Suite 1710 Columbia SC 29201 803 254 9211 Rreed SCpowerteam com Representing Electric Cooperatives Santee Cooper www SCpowerteam com Contact Rusty Reed Circle 257 focus electronics 58 APRIL 2006 aei aei-online org automaker planning using 32- bit 4-8 MB memory chips navigation striving its cars moving offices upgrading telematics first installed Optima Legal models November 2004 Telematics upgrades planned Opirus sedan well Sorento Sportage SUVs helping service centers remotely identify problems cars aid engine computer chips past 10 years rapid progress South Korea achieved numerous milestones breakthroughs 1996 country rolled world's first commercial CDMA code division multiple access mobile phones service emerging new force reckoned global mobile communications markets 1998 world's first broadband Internet service launched South Korea other achievements South Korea's industry its own national growth engine Telematics 10 core next-generation technologies South Korea seeking develop part nation's future growth industries other growth engines according government include next-generation mobile communication digital TV home networking ITSoC next-generation PC embedded SW digital contents intelligent robots long-term investment 112 3 billion won spent developing core telematics technologies including driving safety information database development technology expanding sales telematics terminals home abroad government soon launch open-type telematics terminal software upgraded image services pursued mid- long-term upgrading telematics including navigation systems help South Korean car companies upgrade competitiveness against other global giants Mercedes-Benz Daeje Chin Minister Information Communication told SAE added comes automotive telematics South Korean automakers think pretty competitive against major global players Currently Japan accounts 60 global telematics market Europe U S making 30 5 respectively South Korea accounts 1 Peter Chang Hyundai's Mozen telematics system installed Azera top-of-the-range Equus Sonata sedans well Santa Fe SUV Circle 258 focus electronics aei-online org aei APRIL 2006 59 System-level E E design needed complexity automotive electronic electrical E E systems increases expect design processes follow suit reality current design methodologies lagging considerably resulting lower quality increased development time costs Automakers recognize low-tech design methods borrowed time seeking systemlevel design process entire E E architecture designed using topdown approach today's production vehicles loaded high-tech features high-end vehicles containing 80 electronic control units ECUs Furthermore majority ECUs must communicate real-time realize features adhering functional timing requirements Specifying developing highly distributed reliable real-time E E system complex challenge requires specialized practices tools causing automakers try design risk delivering lowerquality products vehicle features typically perceived simple surface contain inherent complexities manageable using traditional engineering methods example consider realworld implementation power door lock's lock-all feature requirements fairly straightforward doors must lock 200 ms locks must actuated 20 ms seem challenging actuality requires four microprocessors three communication buses communication protocols three multiplexed messages well operating systems software drivers application code Using distributed architecture seem overly complex approach implementing relatively simple feature Instead simply hardwire button directly door-lock actuators answer cost Wiring harness costs expensive vehicle components-- second only powertrain Therefore effort made minimize amount vehicle wiring resulted explosion in-vehicle networks based standards J1850 controller area network local interconnect network LIN Today complex vehicles 10 distinct networks obvious trade-off reduction wiring costs increased design complexity Determining optimally allocate vehicle functions limited number resources ensuring solution provides real-time behavior problem thought couldn t Clad metals allow possibly single metal examples mean visit website Weld dissimilar metals using clad transition insert made wide variety bondable metals Robust intermetallic- free joints created using existing joining techniques Intricately formable virtually eliminates galvanic corrosion Reduce brazing costs clad self-brazing materials Eliminate shims pastes powders Braze filler integrated substrate conventional metal forming simplified assembly optimal joint geometry improved quality Learn clad www cladit com call 508-342-2235 STAINLESS STEEL BRAZE ALLOY CLAD TRANSITION INSERT WELDING ELECTRODE STEEL ALUMINUM WELD NUGGETS Circle 259 focus electronics 60 APRIL 2006 aei aei-online org automakers unable solve Implementing door-lock feature requires electrical engineer consider things CPU central processing unit utilization interrupt latencies OS operating system task switching communication latencies LIN communication latencies execution time communication drivers buffer utilization application polling intervals hardware latencies isolation designing validating door-lock feature trivial task problem becomes exponentially complex consider dozens functions competing resources Proper design door-lock feature instance requires precise knowledge worst-case latencies engineer must know other things worst-case interrupt latencies least-optimal OS task switching maximum amount time access bus send message worst-case polling intervals information only known features designed system-level perspective implying feature designed knowledge resource requirements other features system-level design assurance features work brought together System-level failure common problem current methods solving problems next impossible Making changes simple door-lock system requires architecture using LIN vehicle function unknown side effects cause function stop working properly cases engineers end chasing tail quest solve types problems assurance intermittent problems surface hands consumers Fortunately technical solutions exist today allowing automakers incorporate system-level design methods OEMs using sophisticated network scheduling tools design deterministic real-time networks others use advanced microprocessor simulators analyze latencies embedded code technologies alone provide significant benefit merging types technologies industry really solutions horizon important solutions form new set standards AUTOSAR Automotive Open System Architecture consortium focuses improving design processes increasing scalability flexibility leveraging off-the-shelf components optimizing resource usage AUTOSAR basis comprehensive seamless tool-chains allow automakers design robust high-quality E E systems minimizing development time warranty costs resulting increased profitability article written AEI Jason Paskvan Senior Transportation Product Specialist Mentor Graphics explosion electronic content today's production vehicles making complicated systems engineering challenge Vector CANtech, Inc Attacking hybrid cost 62 APRIL 2006 aei aei-online org Attacking hybrid cost OEMs working cost hybrid development design manufacturing Shown Toyota's Prius line Japan Attacking Mention word hybrid room full automotive engineers likely spark high-voltage debate merits hybrid- electric vehicle HEV technologies topic engineers product planners agree Cost significant penalty hybrids due pairing separate power units--an internal-combustion IC engine battery module--within single vehicle hybrids become sustainable high-volume player cost must reduced asserted Floyd Allen consultant FEV Engine Technology former Powertrain Executive Engineer DaimlerChrysler DCX Allen explained reducing hybrid costs significantly require automakers suppliers use proven high-volume production design value-engineering experience protect hybrids base vehicle design must advantage economies scale conventional hybrid powertrain components Slashing costs vehicle side particularly critical U S market considered offer greatest growth potential HEVs high sustained retail fuel prices hybrids' sticker price strongly influence technology moves mainstream said Anthony Pratt Global Powertrain Director industry analysts J D Power Associates hybrid forecast U S admittedly conservative--just 4 Rather outsourcing supply expensive Insulated Gate Bi-polar Transistors IGBTs used power control high-voltage electrical systems Toyota chose manufacture its own Power electronics strategically critical HEVs moving forward minimize black-box costs minimize silicon use Hermance said decided IGBT development in-house Performance criteria bear heavily cost planning its second-generation 2004 Prius Toyota decided drop battery voltage 202 V achieving similar power 272-V first-generation car require pushing current current voltage drives cost HEV power electronics Hermance explained Hybrid-electric vehicle costs must slashed significantly technology become mainstream HEV developers reveal routes cost-reduction crusade hybrid Lindsay Brooke market 2012 said hybrids capture larger share Pratt estimates retail price-premium drop today's 3000- 5000 range 800- 1000--similar cost engine upgrade conventional car industry option 1000 easy hybrids attract broader customer base government subsidies tax credits explained point hybrids realize economic break-even Kieretsu vs strategic alliance industry employing different hybrid development strategies its costreduction crusade believe hybrid pioneers Toyota Honda best positioned reduce system costs both companies tightly control kieretsu suppliers batteries motors power inverters Toyota's goal cut retail price premium its hybrid vehicles half end decade begin using cheaper smaller third-generation hybrid- electric drive 2008 plans increase HEV production 600 000 units year its way stated annual sales target 1 million units 2010 Vertical integration benefits Toyota's HEV program ways explained Executive Engineer Dave Hermance Reducing cost control electronics priority hybrid developers Denso's compact dcdc converter used Toyota cost AR Worldwide Attacking hybrid cost 64 APRIL 2006 aei aei-online org Attacking hybrid cost avoid increasing cost made evolutionary change reduce relative size components desired performance said achieved adding small stage dc inverter boosts 202-V battery 500 V power electronics deal lower current give power Toyota took cost battery added slight cost inverter's extra stage removed cost inverter redesigning chipset boards Hermance explained didn't cost increase motors although they're powerful--50 rather 33 kW--they're physical hardware continuous improvement well cost overall process Toyota's hybrid future fully wedded its kieretsu year automaker began buying hybrid-electric motors Hitachi deal Toyota's first purchase major hybrid component supplier outside its own group Facing Toyota across battlefield General Motors-DCX-BMW Hybrid alliance consortium formed GM DaimlerChrysler late 2004 co-develop GM-Allison dual-mode hybrid transmission lightduty vehicles BMW joined fall Ford said considering joining cent years commodity price nickel tripled rising high 15 kg 2005 Researchers vigorously investigating alternatives NiMH According FreedomCAR battery technology expert Tien Duong aim reduce hybrid battery costs today's roughly 40 kW 20 kW 2010 projected volume 100 000 units leading candidate replace NiMH lithium-ion said Menachem Anderman consultant Advanced Automotive Batteries SAE Hybrid Vehicle Technologies Symposium January noted lithium-ion chemistry potentially double hybrid battery power offering longer life other performance package benefits NiMH Anderman said lithium combined suite widely available moderate-cost materials including cobalt vanadium manganese oxides depending performance requirements experts acknowledge development needed generally bullish moving lithium-ion offer reduced battery costs industry standardize lithium technology cell level develop economies scale manufacturing process improvements said Greg alliance exists reduce cost sharing development production scale well accelerating time-to-market afford develop solutions--and industry need develop proprietary solutions hybrid engineering challenges said Andre Metzner DCX engineer alliance's HEV Development Center Troy MI innovative dual-mode transmission launches late 2007 GM Dodge vehicles potential production scale millions units alliance presents formidable competitor Toyota proven arch-competitors matter collaborative outperform single focused highly capitalized entity Battery big bogey seriously reduce hybrid system costs requires attacking expensive component battery accounts two-thirds cost delta said Ed Wall Program Manager Office FreedomCAR Vehicle Technologies U S Department Energy's automotive R D arm aligned GM Ford DCX Nickel metal-hydride NiMH industry's workhorse battery chemistry suffered severe price increases re- TRW's electrohydraulic EPHS steering system designed both hybrid conventional applications cost hybrid development making allies competitors Chrysler COO Eric Ridenour GM Powertrain VP Tom Stephens discuss companies' codevelopment dual-mode hybrid transmission BMW part alliance aei-online org aei APRIL 2006 65 AAttttaacckkiinngg hhyybbrriidd ccoosstt Sherrill Vice President Johnson Controls' Power Solutions group Mild hybrid bang buck operate battery power alone lower-voltage mild hybrid systems offer attractive cost value proposition certain vehicle segments Toyota sold various mild-HEVs price-sensitive Japan European OEMs developing own types Early GM Dodge Honda efforts replaced flywheel electrical machine create integrated startergenerator ISG Honda chose highpower 144-V electronics GM used 42-V battery enabling use MOSFET Metal Oxide Semiconductor Field Effect Transistor inverter controls rather expensive IGBTs saved cost black box allowed GM use cheaper lead-acid battery instead NiMH ISG-based trucks hardly lit sales charts GM Powertrain VP Tom Stephens explained 42-V belt-alternator starter BAS units likely supercede ISGs become automaker's primary mild hybrid system reason bang buck simpler package BAS enters production year Saturn Vue Green line planned multiple GM vehicle architectures claimed 20 efficiency gain aided tweaks vehicle's aerodynamics rolling resistance coupled portunity systems work well both TRW's EPHS electrohydraulic steering first looked hybrid trend thought 'How easiest car companies ' said Charlie Creguer TRW's Business Director steering driver assistance systems Commonality existing products path resistance choices OEMs working leverage control software compowith sub- 2000 price premium achieved great part using vehicle's existing transmission slightly modified form hybrid duty We've created hybrid deep inside existing powertrain said Engineering Director Pete Savagian work underhood package volume pretty exists helps minimize cost GM said Vue lowest- priced hybrid SUV U S market arrives showrooms summer Commonizing battery cell architectures well complete NiMH module families serve broad bandwidth vehicles focus Cobasys supplier Vue's compact NiMH battery system world packaging often first consideration said Chief Engineer Scott Lindholm learning quickly develop systems fit variety vehicle types Tearing base vehicle structure incur huge cost similar strategy pursued new Continental Temic ZF joint venture hybrid powertrains Its parallel- type hybrid system uses customer's existing automatic transmissions Automakers encouraging systems applied hybrid nonhybrid vehicles little modification Since HEVs due launch 2009 hybrid versions conventional vehicles ample op- Developing technical standards hybrids key reducing hybrid systems costs common industry specifications components Topping list connectors high-voltage safety systems interlocks battery test methods motor system power ratings similar engine standard ratings SAE International already work area June 2005 formed Hybrid Technical Standards committee aimed driving commonality non-competitive areas group's first goal develop standard test required determine HEVs qualify U S federal tax credits explained Committee Chairman Don Anderson engineering executive General Motors-DaimlerChrysler-BMW hybrids joint venture We're working fast said Anderson test critical certifying 2006 hybrid models tax credits Component commonization work follow mild-HEV Saturn Vue Green Line aims capture hybrid buyers its low price high fuel efficiency Advanced nickel metal-hydride battery pack Power electronics Engine control module 12-V battery accessories Electric motor generator Regenerative braking Attacking hybrid cost 66 APRIL 2006 aei aei-online org Attacking hybrid cost Circle 266 nent commonality across applications Algorithms big chunk expense effort GM's Savagian explained great cost other incentives integrate controls battery pack inverter degree control integration expected remain choice Cost-benefit analyses OEMs move hybrid programs second third generations constant opportunities lower costs challenge suppliers stay ahead commodities trap adding value Electric motors item often cited destined lowcost global sourcing challenge keeping abreast rapidly changing technology led new battery chemistries systems control architectures materials performance demands hard keep volumes move new generations said Denso VP Doug Patton company provides Toyota's dc-dc converter electric HVAC system expects cost reduced incrementally falling cost electronics system integration Toyota supplier Yazaki studying major materials change--from copper lower density aluminum its hybrid-systems wiring enormous amount power flowing HEV dictates thick 25-mm 1 0-in cable copper costly currently preferred choice due its flexibility assembly plant said Kevin Pimlott VP High Voltage Systems Components Yazaki North America noted simply switching materials technology depends Yazaki reduce total systems cost customer's performance spec We're cost benefit analyses regarding aluminum Pimlott said consider totality delivery customer material must sufficiently robust survive shipment installation alone deliver performance reliability vehicle hybrid technology curve seems extreme today historical perspective order Hybrids expensive said Denso's Patton we've century building IC engines that's lot time costs We've building hybrids only 10 years time aei Battery makers modularizing product lines broaden applications lower cost Cobasys' Series 1000 NiMH module designed SUV applications Bayer MaterialScience, LLC Engineering enemy 68 APRIL 2006 aei aei-online org Emotions ran high GM Powertrain engineers entering large meeting room late 2002 inside Ford technical facility Dearborn--the heart enemy territory--about kick days deep-dive discussions joint development all-new transmission General Motors visitors thought partnering foes churned mixture nerves caution Taking seats room few attendees joked signs directing check daggers door Ford engineers present equally wary precedent company's 100-year history begin mutual creation GM 6T70 Ford 6F55 state-of-the-art six-speed automatics transverse-mounted engines built common design architecture Collaboration competitors new concept rise auto industry cost developing new vehicles sophisticated technologies increases arch rivals working together save millions quicken time market recently example prospect DaimlerChrysler BMW co-developing hybrid transmission unthinkable project under way part three-way compact GM Volkswagen finally committed minivan North America enlisting DaimlerChrysler's engineering production help industry gets increasingly Engineering enemy program devoid bloodshed General Motors Ford codeveloped new six-speed automatic key both companies' future vehicle plans program managers explain they'd eagerly Lindsay Brooke competitive able leverage other's resources people facilities huge explained Ram Krishnaswami Manager Ford's half six-speed program counterpart GM Assistant Chief Engineer Bob Vargo way success program can't imagine other way shared benefits I've lot people Ram GM Ford reveal program costs--some reports pegged around 750 million--they claim partnership cut investment outlays roughly half compared spent independently similar transmission projects both companies new automatic reflects decisions made prior alliance leapfrog four-speeds six-speeds front- allwheel- drive FWD AWD vehicle architectures partners stated 6T70 6F55 capable handling 315 hp 235 kW 280 lb ft 378 N m makes ideal power 2007 Saturn Aura sedan Ford Edge crossover utility first midsized frontand all-wheel-drive vehicle applications transmission coming both automakers program enjoy strong economies scale Total annual production new six-speeds expected upwards 2 million transmissions both units fully ramped forecast CSM Worldwide GM expected ultimately account roughly 1 2 million 6T70s Ford's 6F55 volume reach 700 000 units year GM's Bob Vargo Ford's Ram Krishnaswami co-managed six-speed program Horiba Instruments Inc Engineering enemy 70 APRIL 2006 aei aei-online org transformation competitor colleague forces side view other terms common goals might sound strange hear say peer pressure significant program noted Vargo don't want Ford Neither succeeds transmission doesn't meet expectations Cost timing synergies actual genesis six-speed partnership remains confidential GM Ford story Vargo Krishnaswami recount senior GM Ford leadership recognized during random conversation similar development paths new sixspeed FWD automatics Though GM farther along its work clear both programs potential realize significant cost timing synergies competitors partners looked win-win idea cascaded powertrain leadership both companies discussions positive yielded code name--Project Eastern Standard--followed months hammering legal framework formal memorandum understanding MOU announced February 2002 hush-hush quite recalled Vargo Manhattan Project reference 1940s atomic bomb development fact probably exciting GM's clutch-to-clutch design time early discussions GM Ford pursuing different design paths GM interested moving its traditional auto transmission architecture based one-way clutch freewheelers automaker maintained key premium shift quality potential replacement GM investigating clutch-to-clutch operation used successfully years Chrysler Mule testing under way Ford other hand considering Lepelletier design currently associated Aisin ZF automatics Both GM Ford strategies aimed improving FWD powertrain packaging reducing transaxle size bring overall performance efficiency improvements fifth gear direct rather overdrive other six-speeds transmission capable flat-towing GM's clutch-to-clutch design predetermined partnership its benefits clear Ford team series post-MOU engineering meetings advantage packaging--nice small lightweight explained Krishnaswami complete unit measures 357 mm 14 1 cylinder block mating face righthand side transmission design slightly complex Lepelletier delivers performance Ford wanted Organizing hundreds engineers specialists effective operational teams challenge given vigorously competitive legacy companies Wariness lingered both sides feeling other trying find working relationship recalled Krishnaswami help feel part single unit Vargo made meetings staggered GM Ford facilities PowerPoint slides GM presenters tried ensure Ford GM vice versa Still warmth fuzziness old rivals slow emerge different Toyota Honda engineers tossed together common project Vargo noted relatively tightknit aspect North American transmission engineering community helped melt ice number people both sides knew other former colleagues felt total sense support senior management via meetings program's steering team GM Ford powertrain VPs Tom Stephens Dave Szczupak regularly stressed importance joint effort Drooling Ford's tools MOU set framework GM Ford working together including managing intellectual property confidentiality team work day-to-day program management basic standard established Three keys joint program 1 Joint ownership problems Generally both partners own problems arise it's specific application-oriented issue said Bob Vargo noted GM Ford took particular ownership powertrain bending analysis transmission-to-cylinder block interface -- areas huge implications customer satisfaction 2 Joint timing critical maintaining sense urgency alliance program sixspeed GM Ford established joint timeline single piece paper lined milestone events noted Ram Krishnaswami milestone event occurred company occurred other pursue together met both companies' requirements 3 Personalities count right personalities clicking critical collaborative program Vargo said sometimes losing person collaborative program said big egos recommended externally mounted controller distinguishes Ford's 6F55 shown its GM 6T70 brother Both six-speeds feature clutch-to-clutch shifting free-wheeler Hengst of North America Inc Engineering enemy 72 APRIL 2006 aei aei-online org time materials worked both ways depending side provided resources lined teams part companies' transmission engineering operations organized similarly teams merged area expertise torque converter gearset clutches pump-filter structures controls NVH hydraulic control module major difference GM Ford transmissions shift control differentiator vehicles equipped 6T70 6F55 automakers chose slightly different control-hardware paths proprietary control logic GM's transmission carries its controller inside case Ford version integrates externally mounted powertrain control unit PCU Base component development handled PDT CPMT--the amalgam GM Ford's existing product component teams met regularly jointly agreed specific component direction primarily technical changes sourcing Validation verification addressed separate level criteria jointly established GM Ford program level entire program team--including Vargo Krishnaswami purchasing functional groups--met weekly issue we'd talk said Vargo We'd decide best path seldom argue path We'd move 'Get mad it' program managers agree crisp decision-making issues except related tooling recognized company brought certain resource advantages party Ford's rapid prototyping facility Dearborn tops AEI January '06 p 26 drooling stereolithography capability said Vargo made first rapid parts external structure It's really upsetting can't laughed heaping similar praise Ford's X-ray facilities Cooperation closest product purchasing supplier quality areas managers agreed Manufacturing clicked bit precisely said Krishnaswami given differences process philosophies Although alliance's MOU defined purchasing guidelines Ford GM lead buyers selected parts set cadence supplier visits ensure quality said Vargo spoke single voice suppliers learned quickly play against other venture CAD CAE data interchange simplified fortuitous event occurred prior MOU Ford's previous CAD system vendor SDRC purchased UGS supports GM made convenient efficient collaborate said Vargo Ford's next software based UG process streamlined effective chagrin we're Ford part numbers prints said actually prefers Ford's 'smart numbering' GM's part information system Keeping confidential early seemed new issues Ford GM arise week close proximity 20 minutes other common language mitigated serious problems expected confidentiality issues arose during development program Vargo recalled meeting Ford guys slip 6T70 launch Aura Sensitive technologies gear geometries addressed purely need-to-know basis Vehicle applications calibration algorithms clearly defined areas kept limits Although vehicles separate companies shared failure information during mule testing finite number units complex system transmission small sample explained Krishnaswami Chances certain failure modes GM find hits field find share failures tell other guy 'Hey problem ' big positive GM Ford maintain collaboration beyond base design product launch post start-of-production actions process improvements scheduled key thing design remain common continue reap benefits worked hard establishing certain framework joint change control said Vargo set safeguards this--a common-drawings kind thing established relationships plants GM Warren Ford Van Dyke six-speed partnership official end date long transmissions remain production neither Vargo nor Krishnaswami believe other grown rely other said Vargo we're best enemies aei jointly developed six-speed debut 2007 Saturn Aura Ford Edge highvolume installations across multiple nameplates platforms follow Emitec GmbH material innovations 74 APRIL 2006 aei aei-online org material innovations Edited Ryan Gehm life static dynamic stiffness acoustics comfort--while reducing weight development teams need find right combination suitable engineering measures modern material manufacturing techniques advanced materials addition increased functionality relentless demand improved fuel efficiency driving dynamics contributed keen focus lightweight BIW solutions month's SAE 2006 World Congress Detroit BMW researchers presented technical paper achieving optimum balance via mixed-material approach making use advanced materials multiphase steel grades aluminum plastics carbon fiber lightweight design solutions tend cost traditional ones important select appropriate lightweight solutions fulfill functional requirements determined customer demands--for example improved driving dynamics BMW researchers referred value proposition offered M6 sports car example philosophy action Weight reduction achieved M6's structure aluminum end aluminum hood thermoplastic side panel According BMW thermoplastic selected side panel only weight purposes due manufacturing limitations metals complex form Due high weight savings structure well achieving equal load distribution rear axle cost- weight-saving measures applied middle rear structure included specifying advanced-high-strength multiphase steels specific components reduce car's center gravity roof manufactured carbon fiber Aluminum doors carbon-fiber bumper carriers provide weight savings challenges manage increased loads keeping weight resulted BMW mixes BIW Challenges manage increased loads keeping weight resulted significant transformation mild steels high-strength advanced-highstrength steels during past decade mixed-material approach used BMW M6 sports car resulted fairly significant mass savings several areas Hood aluminum 2K bonding -11 kg -24 lb end aluminum -20 kg -44 lb rear bumper beam carbon fiber -6 8 kg -15 lb Fenders thermoplastic resin -4 kg -8 8 lb Doors aluminum -10 kg -22 lb Roof carbon fiber -4 3 kg -9 5 lb Trunk lid thermosetting material -2 kg -4 4 lb improve functional properties vehicle's body-in-white BIW --including its requirements passive safety service material innovations aei-online org aei APRIL 2006 75 significant transformation blend steel grades used 3 5 7 Series BIW illustrated image bottom previous page noteworthy result transformation increase average yield strength structure successive structure value represents body structure only excludes hang-on parts doors hoods fenders vehicles upper value segment aluminum polymers replacing steel manufacture hang-on parts materials offer significant weight savings material gauge parts dimensioned strength decreased yield strength available carbon steels increased since functionality certain parts dimensioned stiffness depends modulus elasticity E-Modulus material cross section increasing yield strength material benefit eventual contribution stiffness BIW carbon steel parts dimensioned stiffness meet weight requirements part meet strength requirements alternative materials higher specific modulus need considered According researchers cases present ideal scenario consideration carbon fiber Carbon fiber composites CFC offer significant weight savings improved functionality compared metals researchers noted example three-point bend test conducted various configurations profile 1-mm steel 2-mm steel 1-mm steel carbon-composite laminate reinforced profile force required bend CFC-reinforced profile double required bend 2-mm 0 08 steel profile CFC widely used motorsports aerospace industry high costs remain concern mainstream use automotive applications BMW CFC already provided value proposition use only M6 Hydrogen 7 Series structure resulted overall mass savings 15 kg 33 lb cases dimensions required part stiffness carbon steel part physical dimensions gauge proven lower dimensions required strength part Instead increasing material gauge results higher part weight lightweight-design approach use higher-strength material Materials worth consideration high-strength steel HSS grades advanced-high-strength steel AHSS multiphase steel grades demonstrate lightweight-design potential multiphase steel grades researchers adopted size new 3 Series grown meet market demands previous- generation 3 Series resultant mass BIW 284 kg 626 lb new 3 Series features multiphase steel grades representing 26 total mass its predecessor made use multiphase steel result mass its BIW reduced 267 kg 588 lb time increased functionality stiffness crash behavior etc conclusion researchers reiterated selection appropriate materials results optimized configuration lightweight BIW Lightweight engineering provides basis weight optimization Once load path defined optimum weight distribution vehicle broadly determined prioritize areas vehicle benefit application more-expensive materials--within Circle 275 material innovations aei-online org aei APRIL 2006 75 significant transformation blend steel grades used 3 5 7 Series BIW illustrated image bottom previous page noteworthy result transformation increase average yield strength structure successive structure value represents body structure only excludes hang-on parts doors hoods fenders vehicles upper value segment aluminum polymers replacing steel manufacture hang-on parts materials offer significant weight savings material gauge parts dimensioned strength decreased yield strength available carbon steels increased since functionality certain parts dimensioned stiffness depends modulus elasticity E-Modulus material cross section increasing yield strength material benefit eventual contribution stiffness BIW carbon steel parts dimensioned stiffness meet weight requirements part meet strength requirements alternative materials higher specific modulus need considered According researchers cases present ideal scenario consideration carbon fiber Carbon fiber composites CFC offer significant weight savings improved functionality compared metals researchers noted example three-point bend test conducted various configurations profile 1-mm steel 2-mm steel 1-mm steel carbon-composite laminate reinforced profile force required bend CFC-reinforced profile double required bend 2-mm 0 08 steel profile CFC widely used motorsports aerospace industry high costs remain concern mainstream use automotive applications BMW CFC already provided value proposition use only M6 Hydrogen 7 Series structure resulted overall mass savings 15 kg 33 lb cases dimensions required part stiffness carbon steel part physical dimensions gauge proven lower dimensions required strength part Instead increasing material gauge results higher part weight lightweight-design approach use higher-strength material Materials worth consideration high-strength steel HSS grades advanced-high-strength steel AHSS multiphase steel grades demonstrate lightweight-design potential multiphase steel grades researchers adopted size new 3 Series grown meet market demands previous- generation 3 Series resultant mass BIW 284 kg 626 lb new 3 Series features multiphase steel grades representing 26 total mass its predecessor made use multiphase steel result mass its BIW reduced 267 kg 588 lb time increased functionality stiffness crash behavior etc conclusion researchers reiterated selection appropriate materials results optimized configuration lightweight BIW Lightweight engineering provides basis weight optimization Once load path defined optimum weight distribution vehicle broadly determined prioritize areas vehicle benefit application more-expensive materials--within Circle 275 material innovations aei-online org aei APRIL 2006 77 paint process exposed panels aspect problem-- strengths guaranteed 200 C 392 F during 1 hour degradation particularly important case roof application said researchers complete clamping part body-in-white A-type cheaper lower mechanical polymer behavior high temperature-- strengths guaranteed 160 C 320 F available exposed panels electro-galvanized steel skins 0 25 mm 0 01 DDQ grade maximum width 1600 mm 63 Hot-dip galvanized skins possible non-exposed panels maximum width 1280 mm 50 recycling loop end-of-life vehicles fully investigated early stages product development shredding tests high-temperature tests including melting tests instrumented electric arc furnace pilot plant investigations concluded Usilight allows recycling 100 behavior already-recycled organic coated products life-cycle analysis performed Centro Ricerche Fiat hood approach shows compared traditional steel aluminum designs laminated steel allows lower consumption energy lower emissions CO2 during whole life cycle considered vehicle researchers investigated carmakers' manufacturing processes validate industrial potential Usilight material forming techniques used current steels applied traditional painting processes traditional welding techniques used thick polymer core Assembling technologies selfpiercing rivets bonding must used researchers pointed numerous cases possible main applications product large panels requiring stiffness--e g roof hood rear back-plate sparewheel housing its good mechanical performances extended other specific parts cockpit structure example Valeo developing cross-beam concept integrating both structural air-supply functions high-stiffness sandwich steel structure partnership Arcelor weight module said low magnesium- based solution gain volume 15 L 0 53 ft3 According researchers Usilight able provide weight reduction 20 40 its validated applications associated weight saving cost Ryan Gehm Arcelor's Usilight product three-layer composite provide weight reduction 20 40 its validated applications roof hood Steel skins DDQ grade 0 25 mm 0 01 Polymer core 0 2 2 mm 0 008 0 08 Circle 277 Drivetrain advances 78 APRIL 2006 aei aei-online org Japan predominantly automatic transmission country small proportion manual transmissions enjoyed die-hard driving enthusiasts accepted economy-conscious utilitarian users Accustomed automatic's smooth less-arduous progression narrow roads congested traffic Japanese embraced automatically shifting manual transmissions other hand continuously variable transmission CVT population rapidly growing Nissan Toyota Honda Mitsubishi Fuji Heavy Industries offering large variety cars equipped CVT Subaru R2 1 mini 3 5-L V6-propelled Murano SUV employ VDT Dutch Van Doorne Transmissie pushtype steel belt pulley system Nissan's ambitious extremely smooth responsive Extroid toroidal CVT still listed top option Skyline Infiniti G35 dormant awaiting second awakening Nissan JATCO combine completed updating its CVT range largest type-RE0909A possesses highest torque capacity 350 N m 258 lb ft mated VQ 3 5-L engine Murano SUV RE0F08A latest version original small unit uprated maximum torque capacity 180 N m 133 lb ft suitable 1 5- 1 8- L displacement engines type-RE0F10A represents Nissan JATCO's third-generation CVT maximum rating 250 N m 184 lb ft 2 0- 2 5-L engines first vehicle application Lafesta compact minivan based Nissan-Renault C-platform various mechanical refinement measures including ultra-flat torque converter new chain-driven outrigger vane-type oil pump vs previous integrated gear-type simplified pulley construction Internal friction greatly reduced 30 compared previous midsize CVT measures including optimizing electronic fluid pressure control fewer clutch plates adoption vane-type oil pump Torque converter lockup range CVT's inherent strength expanded powertrain's response efficiency improved notable feature absence typical rubbery feel acceleration associated CVT Nissan claims real-life fuel economy improvement 37 new Lafesta minivan versus previous Liberty realized new engine-CVT combination well other refinements including new air-conditioning compressor RE0F10A allows manual selection seven fixed ratios Japan's leading companies focused development reducing size mass cost Jack Yamaguchi Drivetrain advances combined new MR20DE 2 0-L inline four-cylinder engine RE0F09A 10A employ push-type steel belts 30-mm 1 18-in width small RE0F08A uses 24-mm 0 94-in wide belt supplied VDT updated 08A new 10A Nissan JATCO attained ratio spread 6 0 magic number CVT manufacturers must seeking advantage norm 5 4 5 5 enhanced drivability fuel economy new CVT unit 50 mm 1 97 shorter lengthwise width installed transversely allowing installation kinking subframe's longitudinal member--an important consideration frontal crash energy absorbing capacity shed 4 kg 8 8 lb weighing 90 kg 198 lb closer mass typical stepped-gear fourspeed automatic Mass critical factors influencing broadening CVT applications other remaining issue cost Size mass reduction accomplished small-car CVT Toyota compact light Drivetrain advances Japan's leading companies focused development reducing size mass cost first market new idea doesn t paddling upstream avoid obstacles good view lies ahead DELMIA provides real-time 3-D collaborative environment visually plan define validate optimize manufacturing processes early product lifecycle committing production DELMIA digital manufacturing tools combine knowledge sharing process planning capture reuse best practices throughout extended enterprise Adding DELMIA core component strategy offers revolutionary PLM solution design manufacturing helps achieve high levels innovation quality cost savings - transforming way business CATIA DELMIA - ENOVIA SMARTEAM POWER PLAN POWER BUILD Send email call toll free request free copy CIMdata Digital Manufacturing PLM Environments whitepaper requests website Circle 279 Drivetrain advances 80 APRIL 2006 aei aei-online org Sporty tuning Honda's small CVT first introduced Civic 1996 its startup clutch mounted driven pulley shaft uniquely Honda clutch multiplate wet type unlike super-bike clutch CVT constantly refined Fit Jazz small car well Insight Civic Hybrid transmission employs 24-mm 0 94- push-type steel belt first supplied VDT produced Honda Honda added all-new higher-torque unit 30-mm 1 18-in belt introduced Japanese Odyssey crossover vehicle featuring three-row seating its lower-than-minivan-norm body Odyssey powered K24A 2 4-L inline four-cylinder engine maximum torque 218 N m 161 lb ft enabling driver shift seven gears actually clamping pulley sequentially seven positions transmission's control system ensures seamless shifting optimized particular situations driver's preferred mode progress D1 schedule prioritizes fuel economy engages smaller throttle opening limiting engine speed maximizing torque delivery D2 shift schedule called frequency medium throttle opening increased Engine speed kept higher offering superior acceleration S sport shift schedule engaged larger throttle opening frequently used providing rapid acceleration increased engine-braking effects sportier driving Unique Honda CVT Cornering G shift control uses history lateral acceleration determine vehicle twisty road causes maintain higher engine speed including during deceleration braking smaller type-K410 CVT latest collaborative product Toyota automatic transmission specialist Aisin AW latter undertaking production transmission specifically designed developed mate small-displacement engines Daihatsu-designed 1KR-FE 1 0-L inline three-cylinder 2SZ-FE 1 3- L I4 updated Vitz Yaris small cars undisputed champion CVT mass size scaling scant 59 kg 130 lb 17 lighter previous small CVT heavier manual transmission must certainly represent transmission since adopted Japanese market minivans Unlike smaller unit new CVT employs torque converter drivepulley- side shaft ratio spread medium 5 5 2 47 low 0 45 high transmission compact measuring 385 mm 15 2 length width mounted transversely 65 mm 2 6 shorter Honda's own fourspeed automatic mass 95 3 kg 210 lb drive-side pulley fitted double-piston increasing effective piston area external diameter remains allows reduction pulley control pressure vehicle steady cruise thus lowering oil pump drive torque CVT provides popular fashionable manual ratio selection facility Nissan's new CVT midsize I4 engines attained high ratio spread 6 00 Honda's high-torque CVT I4 engines 30-mm 1 18-in pushtype steel belt introduced Japanese Odyssey other minivans Mitsubishi's Eco-Evo features 50-kW motor wheel JSP Drivetrain advances 82 APRIL 2006 aei aei-online org optimization CVT design includes 190-mm 7 5-in diameter flat torque converter reduction pulley side third retaining 24-mm 0 94-in belt CVT called Super CVT-i small signifying intelligent control applies coordinated engine transmission well pulleyclamping hydraulic pressure transmission ratio spread 5 6 2 386 1 low gear 0 426 1 overdrive compact mini-car specialist Daihatsu said readying ultralightweight compact cost-competitive CVT its front-drive light vehicles displacement under 660 cm3 Its archrival Suzuki tried Aichi Kikai unit composite dry belt its light cars dropped transmission thrives Suzuki's big powerful two-cylinder scooter models Honda's Forza 250-cm3 single-cylinder scooter equipped S-matic electronically controlled rubber-belt pulley CVT allows automatic shifting modes D drive S sport well handlebar switch-operated manual selection six ratios recent automotive sporty CVTs manual mode switch motion relayed transmission electronic control unit ECU actuates shift motor select chosen ratios sequence system automatically downshifts lowest ratio vehicle comes stop manual mode prevents multilink rear suspension HICAS Nissan's rear-wheel steering system joined Honda R D 1986 deciding want pursue Nissan seasoned designer profound theoretician still rookie Honda given free hand want placed upper deck R D 'barn ' speak ladder removed reminisced Shibahata fascinated AWD Existing systems fore-and-aft torque split control still rudimentary only over-revving engine manual selection lower gears high vehicle speeds Honda's third business its power equipment division offers great variety machines Transmission evolution variety motive equipment generators snow throwers quite interesting including friction-disc drive HST hydrostatic transmission internal- combustion engine electric hybrid HST applications mini farm tractor equipped pumps side-by-side hydraulic motors motor drives rear wheel its side HST drive allows two-wheel drive canceling counter-rotation reaction forces farm equipment tractor towing single-cylinder engine drives auger throws snow simultaneously generates electricity motive power in-wheel-motor reduction-gear units installed driving crawler wheels lead-acid secondary storage battery used additional power source Steering accomplished applying right electric motor brake lever new look AWD Honda's 2005 Acura RL Honda Legend equipped SH-AWD short Super-Handling All-Wheel Drive system brain child chassis designer extraordinaire Yasuji Shibahata Working suspension design Nissan 10 years Shibahata created Japan's first patented Honda's drivetrain experience broad rubber-belt CVT Forza scooter CVT Honda Forza scooter allows manual selection fixed ratios Nissan JATCO's ambitious toroidal CVT dormant Rennsteig Werkzeuge GmbH Drivetrain advances 84 APRIL 2006 aei aei-online org Honda's drivetrain designer Yasuji Shibahata developed SH-AWD system provide left-and-right torque split control addition fore-and-aft Honda SH-AWD unit hypoid gears drive right rear wheels via pair direct-electromagnetic clutches planetary geartrains halfway whole system reasoned whole system realized hold tremendous potential attain ultimate vehicle dynamics secluded himself barn theorizing various AWD configurations hit left-and-right torque split control vs addition fore-and-aft split months later experimental vehicle built first Shibahata's super-handling AWD systems Its dynamics truly revealing system incorporated large FSX concept sedan shown 1991 Tokyo Motor Show project considered ambitious business point view shelf Integra coupe modified system extra punch provided highly tweaked DOHC 1 8-L engine boosted Lysholm positive-displacement supercharger car phenomenal its acceleration dynamic behavior around Honda's Tochigi Proving Ground handling course project still deemed expensive small car sporty shelved Shibahata nurtured left-and-rightsplit- and-control concept presented award-winning 'ß beta Yaw Moment' analytical method 1992 since frequently referenced quoted number vehicle dynamics papers ß-method effective analytical comparative tool especially integrated chassis control according Shibahata lateral torque split control system applied production frontwheel- drive model Prelude coupe Called ATTS Active Torque Transfer System endowed sports coupe tremendous road-hugging ability Unfortunately launch 1997 Prelude coincided waning popularity coupe-type cars Japan U S ATTS combined automatic transmission respective sizes deterred prospective buyers Finally production become SH-AWD wait 2004 Acura RL Honda Legend launched won immediate acclaim Japan U S Shibahata revealed system applied front-drive Prelude simply called DYC--dynamic yaw control- -he likened row boat rudder turn outer oar must rowed vigorously inner provide difference right drive force work Think frustum simply paper Styrofoam cup explained Shibahata Pushed its side moves circular line vehicle larger wheel outer side smaller inside naturally turns toward inner side ultimately tracing circle Early experimental SH-AWD systems hydraulically operated multi-plate clutches rear dual-function differential unit resulted delay action well complexity hydraulic pump lengthy piping production SH-AWD unit controlled wire electronically electrically employing direct-action magnetic clutches SH-AWD's ECU monitors driver's intention steering accelerator brake inputs vehicle road conditions determines optimum front-and-rear lateral left-and-right torque distribution Data engine transmission ECUs sent via controller area network information relayed rear drive unit continuously regulates varies frontrear torque split ratios 30 70 70 30 rear-wheel lateral left-to-right split 100 0 0 100 SH-AWD feedback system gathers data surface frictional coefficient vehicle model information slippage angle sends feed-forward system controls rear-wheel acceleration right wheel-control clutches powertrain's torque thus used improve cornering ability stability well vehicle propulsion Viewed top rear drive unit 'T' shaped longitudinal section houses two-speed unit comprising hydraulically actuated high-low clutch planetary gearbox unit increases input speed propeller shaft during cornering maneuvers hypoid gears drive right rear wheels via pair direct-electromagnetic clutches planetary geartrains system applies torque outside rear wheel vehicle accelerating during cornering generating inward yaw moment reducing understeer Sekisui Products, LLC Drivetrain advances 86 APRIL 2006 aei aei-online org SH-AWD employs direct-acting electromagnetic clutches side drive shafts world's first type application according Honda fast precise enabling optimum distribution torque rear right wheels internal planetary gear step-up mechanism increases torque transmission addition making rear drive unit compact lightweight rear drive unit mass 62 kg 136 7 lb slightly median mass comparable advanced AWD systems quite cost-competitive according Shibahata enables Mitsubishi's experimental Eco-Evo sedan's high performance augmented four 50-kW in-wheel motors Honda fit SH-AWD standard equipment Acura RL Honda Legend allow application vehicle types Mitsubishi determined advocate DYC-equipped AWD employed limited-production Lancer Evolution series ultra-high-performance sedans Senior Manager Hiroaki Yoshida charge Advance Vehicle Engineering forth interesting far-reaching concept called Eco-Evo installed four 50-kW in-wheel motors car motors individually controlled theoretically endowing car awesome ecofriendly dynamic characteristics according Yoshida Kanto Automobile Toyota's affiliate vehicle assembly company possesses design development capabilities produced interesting AWD vehicle joystick-controlled electric wheelchair employing unique wheel design allowing wheels side-step steer its multi-cones mounted wheel's periphery angle place conventional tire wheelchair traverse unmade soft surfaces aei Thomas Magnete USA L L C 4465 North 124th Street Unit F Brookfield WI 53005 USA Phone 262 781-2900 Fax 262 783-6845 Mobile Phone 414 364-9012 info usa thomas-magnete com Thomas Magnete GmbH San Fernando 35 D-57562 Herdorf Phone 49 2744 929-0 Fax 49 2744 929-290 info thomas-magnete com www thomas-magnete com METERING PUMPS PROVIDE ESSENTIALS DIESEL TREATMENT MICROLITER ACCURACY DROP DELIVERED crystal clean environment Circle 286 Please visit SAE Booth 1339 Testing rolls aei-online org aei APRIL 2006 87 testing requirements vehicles become complicated rolling road systems taken increased importance Components antilock braking systems ABS require specific tests confirm working correctly testing track practical --and perhaps dangerous Rolling roads typically used validation purposes end production line vehicle completed used R D capacity wind tunnels climatic chambers general development years vehicle produced large volumes Rolling roads developed specifically improve simulation accuracy wind tunnels technology seeing extensive use motorsports market due large amount downforce produced race vehicles MTS developed Single Belt FlatTrac Rolling Road system employs continuous steel belt running beneath wear forcing engineers tune system specific vehicle Vehicles ground effects cause low-pressure area under vehicle tend lift belt surface said Jake Rawn MTS Motorsports Market Manager system pressurebalanced independent vehicle there's longer need finetuning multiple vacuum chambers control belt lift opposed elastomer fabric belts steel belts generate little dust static electricity longer belt life reached 5000 operational hours FlatTrac system offers large road surface running test vehicle well past rear providing moving ground enough length vehicle wake fully form Testing rolls Matt Monaghan new generation rolling road systems helping both vehicle manufacturers race teams better simulate road conditions effect minute changes full-scale Sauber Petronas Formula car undergoes wind-tunnel testing MTS Single Belt FlatTrac Rolling Road system using throughthe- belt measurement technology vehicle simulate road beneath race car traveling course Capable running continuously 180 mph 290 km h system closely approximates speeds encountered series NASCAR Formula F1 Stability major factor belts used aerodynamic measurements continuous steel belt provides superior flatness strength vacuum preloaded air bearing system employed keep system stable Previous systems employing elastomer fabric belts required multiple vacuum chambers pull belt keep lifting areas low pressure generated car chambers pull hard belt causing excessive friction MTS Single Belt FlatTrac Rolling Road system features continuous steel belt running beneath vehicle simulate road beneath racecar traveling course adhesive-backed coating applied belt simulate road textures Testing rolls 88 APRIL 2006 aei aei-online org Drive five addition single-belt design used primarily motorsports applications MTS offers five-belt system used both motorsports passenger- car development differences fivebelt system although doesn't complete ground plane traditional platform balance allows separation rolling resistance aerodynamic drag said Rawn single-belt system using traditional cable restraint measurement system simultaneously measure aero drag rolling resistance According Rawn MTS process completing single-belt system allows separation rolling resistance aerodynamic drag five-belt system wheeldrive unit beneath tire vehicle January 2005 BAR Honda F1 team purchased rolling-road system its headquarters Brackley UK several years BMW Sauber began using system develop aerodynamic performance package its F1 vehicle different drum production vehicles applications other aerodynamics companies employ traditional drum-type rolling road systems systems used test everincreasing number electronic components integrated vehicles including engine-management systems cruise control adaptive cruise control heating air-conditioning systems Cirrus Technologies based Redditch UK 30 years providing systems offers range rolling roads offers systems traditional cradle design vehicle's wheels sit cradle rollers single-roller design vehicle's wheels sit larger-diameter roller company developed range rolling roads large commercial vehicles We've lot work recently companies Caterpillar supply heavy-duty rolling road said Richard Grocott Key Account Manager Cirrus Technologies try complete range only passenger vehicles light- heavy-duty commercial vehicles addition Caterpillar Cirrus' customers include Land Rover Nissan Aston Martin Lotus Peak Industries based Dearborn MI serves Cirrus' North American partner sales single-roller design roller--1 m 3 3 ft diameter--is independently driven accelerated braked disengaged its own synchronized motor controlled system running Cirrus' Stratus5 software ABS provided main reason shift kind design ABS controls vehicle's wheels independently depending conditions road braking systems react designed size tire contact patch flat stainless-steel belts air bearing technology we're able present tire true flat surface said Rawn That's keys system tires act tires ride flat surface Tires don't act normally ride drum roller better simulate actual road surface MTS apply adhesive-backed coating stainless-steel belt surface Special textures applied simulate different road surfaces system car mounted center belt give longer roll-out distance allow vehicle wake occur moving ground plane best simulation possible said Jake Rawn MTS Motorsports Market Manager sport utility vehicle undergoes testing single-roller rolling road system developed Cirrus Technologies testing part combined General Motors Renault project 4x4 SUV delivery van production line smooth material used reduce friction tires Beneath center vehicle runs narrow belt typically 0 9 1 2 m 3 0 3 9 ft wide acts moving ground plane chassis motorsports vehicle heavy ground effect key areas vehicle treated moving ground plane thus preference move toward single belt groundeffect- intensive vehicles said Rawn MTS recently sold its 11th single-belt system NASCAR team plans use aerodynamic testing its Nextel Cup Busch Series vehicles tyco electronics Testing rolls 90 APRIL 2006 aei aei-online org aid power consumption ways transmit energy vehicledriven rollers other roller sets transfer excess energy main supply via common dc bus regenerative power unit Cirrus intrigued MTS's FlatTrac system consider single-belt designs technology worth investing It's interesting development we're aware customers specifically asked invest said Grocott It's comes along future don't personally huge advantage roller large diameter appears practically flat there's slight curvature lot long restrain vehicle exactly apex roller doesn't seem issue aei find customers need extremely flexible said Grocott days customer place production facility build type vehicle its entire life finding different models moved around different factories production facilities adapt quickly accommodate Sequences easily modified customers' engineers quickly happy supply systems open architecture customers changes quickly response production demands placed modifying surface roller Cirrus' rolling roads used NVH studies regulations place govern exactly roller Range Rover Sport Land Rover tested Cirrus RTC6000 rolling road using Cirrus' Cyclone portable test vehicle interface system RTC6000 employs traditional cradle roller design vehicle exits rolling road acoustic enclosure booth Land Rover's production facility Solihull England addition Land Rover Cirrus sold rolling roads Nissan Aston Martin Lotus differently testing needs verified overall system functioning correctly four corners control rollers independently said Grocott duplicating vehicle via its onboard diagnostic connection attempting induce skid telling operator brake vehicle fairly aggressively monitor four independent systems ensure ABS system opening closing braking valve correctly right time wheel skid flexibility Cirrus' design allows mixed operation different vehicle types varying mass simulation Different drive cycles realized variable load characteristics simulate warming uphill downhill driving needs look different road surfaces simulated Typically we'll sample test track customer wants simulate reproduce quite precisely said Grocott Keep rolling separate drive motor roller Cirrus' rolling roads offer maintenance power-consumption benefits clutches disc brakes drivetrain fewer parts maintain replace individual motors replaced quickly event failure Maintenance important rolling roads production line depends said Grocott need maintained kept reliable throughout entire life--a life excess 20 years continuous use frequency-controlled drive motors Schaeffler KG testing simulation 92 APRIL 2006 aei aei-online org Renault F1 Team accelerates composites Renault F1 Team longstanding expertise designing composite parts racecars team knows little winning races past fall its R25 racecar all-composite chassis won both FIA Formula Drivers' Constructors' World Championships draped complex surfaces typical racecar components fiber deviation weakens part manufacturing process composite parts mostly manual painstakingly slow Strength vital since composite parts subject FIA Fédération Internationale de l'Automobile impact tests produce strong composite parts quickly possible Renault F1 Team must able verify ply layer correct fiber orientation uses FiberSIM software VISTAGY operating Catia Dassault Systèmes simulate ply lay-up streamline manufacturing team's first major use FiberSIM 2003 pilot project redesign nosebox R23 racecar goals reduce part mass improve structural integrity speed manufacturing engineers used software create library ply specifications nosebox recording material mass sequence lay-up direction fiber orientation ply simulated ply lay-up check fiber deviation caused complex curvature part helped promote manufacturability eliminate potential weaknesses part FiberSIM helped team automatically generate flat patterns plies Previously technicians made ply patterns draping sheets paper completed part tool cutting sheet hand adding necessary darts splices manual process highly time-consuming said Duerden generate cutting data patterns hand new composite nosebox R23 racecar 12 lighter previous design strong due part FiberSIM well design changes previous version Generating lay-up data ply books required minimal time slight reduction hours needed design manufacturing nosebox project gave FiberSIM software operating CATIA simulates ply composite material drapes complex surface representing tool used fabricating R23 racecar nosebox completed nosebox 12 lighter previous designs Given physical demands racing specifications component strength strict meet rigorous deadlines specs first time said Alan Duerden CAD engineer Renault F1 Team Oxfordshire UK we're designing building composite parts Composite materials combine high strength low mass used extensively F1 cars engineers design composite parts face daunting technical challenges Woven unidirectional composite materials shift Renault F1 Team recorded significant reductions time create flat pattern templates lay-up times outer inner skins R25 racecar chassis testing simulation Edited Matthew Monaghan Arkema testing simulation aei-online org briefs Data Physics acquired Gearing Watson UK-based manufacturer electrodynamic shakers underwater acoustic systems Data Physics offers full range shakers 4 50 000 lbf 18 222 000 N under roof Data Physics already markets sells Ling Electronics shakers built Satcon Technology supplies vibration controllers used drive shakers product testing applications Endevco signed OCDM Associates its exclusive sales representative test measurement products Brazil OCDM Endevco direct presence South America first time Lexus GS earned top rating good Insurance Institute Highway Safety crash test simulates side impact sport utility vehicle pickup truck vehicle earned good rating frontal offset test rated Top Safety Pick marginal rating rear test separate releases announced UGS provide product life-cycle management system Nissan Paulstra Nissan use UGS' NX CAD software design build its next generation vehicles both companies implement UGS' Teamcenter collaborative product development management software UGS recently announced technology partnership FunctionBay allows UGS leverage RecurDyn multi-body dynamics solver its NX digital simulation software ANSYS signed definitive agreement acquire Fluent global provider CAE software Under terms agreement valued 565 million ANSYS issue 6 million shares its common stock pay 300 million net cash complete transaction combined company employ 1350 people across 40 direct sales offices 17 development centers Shanghai Automotive Industries Corp SAIC purchased Mentor Graphics' Volcano network design testing tools design automotive vehicle networks SAIC's selfbranded platforms SAIC use Volcano Network Architect development in-vehicle networking systems Volcano TELLUS test validation solutions automatically verify communication parameters vehicle sense gains future composite parts Duerden said 2004 Renault F1 Team drew its experience FiberSIM design build R25 racecar chassis biggest composite component vehicle chassis consists outer inner skins core combination aluminum honeycomb Nomex resincoated paper outer skin itself laminate 200 unidirectional woven carbon-fiber plies needed exact lay-up process chassis said Duerden needed speed automating possible Technicians lay plies sequence following specific instructions placement orientation lay-up starting point Once engineers used software simulate lay-up composite plies determine unwanted deviation checking design minimize fiber deviation created flat patterns directly completed ply data plotted flat-pattern data template film cutting team used FiberSIM create cutting templates three-quarters plies outer skin part software helped engineers model inner mold surface chassis avoid interference fuel-cell ancillaries chassis R25 racecar delivered schedule met design goals weight FIA specifications strength impact performed well season Compared its work previous chassis Renault F1 Team recorded 30 reduction time create flat pattern templates 20 reduction lay-up times chassis outer skin 25 reduction lay-up time inner skin Best using FiberSIM data conjunction laser pattern projection system team able increase ply lay-up speed 62 expect save time next chassis Duerden said Renault F1 Team begins laying R26 chassis using FiberSIM generate both laser projection data electronic ply books team converts ply books JPEG images display screen clean room only paper involved sign-off log plies said Duerden David Alexander Circle 294 Please visit SAE Booth 2133 testing simulation aei-online org Researchers Helsinki Polytechnic University Art Design Helsinki Finland collaborating design produce CityCab taxicab 21st century CityCab single-purpose vehicle urban commuting designed five passengers plus driver option passenger using wheelchair CityCab project inspired part earlier successful joint efforts universities city-car Ibana introduced Paris Motor Show 1994 versions RaceAbout sports car introduced Geneva Motor Show 2000 2005 Additional motivation desire taxicab fuel-efficient environmentally friendly ties used directly customizable ALGOR material library carbon fiber alumina composite material properties manufacturers' data sheets Researching taxicab design CityCab researchers ran initial static stress tests taxicab's frame ALGOR determine distortion frame under maximum-load conditions testing simulated forces encountered Instructor Markku Lavi right Team Manager Harri Santamala led team students Helsinki Polytechnic study taxicab concept fuel-efficient environmentally friendly CityCab incorporates latest hybrid powertrain Toyota Prius conjunction hybrid engine light low-cost frame allow taxicab use fuel produce fewer emissions Researchers project used FEA software ALGOR design efficient frame body goal design testing find lightest configuration materials possible keeping maximum stresses under yield Under direction instructor Markku Lavi Team Manager Harri Santamala students Helsinki Polytechnic used CAD modelers Catia Dassault Systèmes Rhinoceros McNeel North America develop 3-D solid model frame axles frame designed using combination materials including steel alumina composites carbon fiber material proper- eXCELLENCE Automotive thinking helps change mobility manufacturer original equipment automotive industry taking development responsibility initial design prod-uction readiness high-tech products drive systems petrol injection diaphragms fluid technology interior trims air spring systems vibration control modules innovative system-oriented part Continental's capability reliable comfortable mobility long-term customeroriented cooperation style good piece automotive engineering Drive components Chassis components Equipment components ContiTech AG D-30001 Hannover E-Mail service contitech de www contitech de www contitech-online com ContiTech Specialist rubber plastics technology Circle 295 testing simulation 96 APRIL 2006 aei aei-online org vehicle rough terrain Under conditions researchers reasoned taxicab bounce entire weight car its payload wheels brief periods mass engine passengers added load total 2250 kg 4960 lb applied frame around wheels researchers three iterations model arrive optimized combination materials Researchers Helsinki Polytechnic University Art Design Helsinki Finland built model CityCab taxi using Catia Rhinceros ran static stress tests frame ALGOR software static stress testing ALGOR Mechanical Event Simulation MES crashtest simulations run tests consisted 20 km h 12 4 mph collisions model against solid crash wall researchers looked maximum deformation car final permanent displacement frame especially passenger driver seats ensure acceptable ranges October 2005 prototype complete chassis axles built powertrain installed Based results MES crash tests additional changes incorporated design finished prototype introduced Paris Motor Show September 2006 two-week presentation CityCab Paris important trial period international automotive experts analyze vehicle publish findings incorporating changes expert evaluations additional six months virtual testing ALGOR conducted Finally CityCab prototype used service research cab Helsinki metropolitan area Spring September 2007 taxicab's performance evaluated standpoints both passengers drivers gain empirical knowledge CityCab compares taxicabs use David Alexander Circle 296 Please visit SAE Booth 1971 STAR-CD s position leading CFD solution automotive industry built history innovative insight STAR-CD first ease meshing unstructured grids first bring simulation reality together moving geometry full-spectrum physical models reciprocating engines re simulating V6 engine moving pistons valves combustion Talk CD-adapco find innovation enable insight engine design process CAE Partner Success info uk cd-adapco com www cd-adapco com Vist Booth 1927 SAE Congress 2006 Innovative Insight Engine Design Honda Civic aei-online org aei APRIL 2006 97 year's winner Best Engineered Vehicle competition sixth-generation Chevrolet Corvette AEI readers editors rewarded vehicle thought provided best value its segment given excellence its underlying engineering fundamentals gave Honda Civic glowing marks categories reader citing award's criteria including interior accommodation comfort durability economy operation environmental responsibility handling stability manufacturing cost quality safety its class moved engineering along huge way reader wrote Civic innovative exteriors interiors car better ergonomics space similar exterior dimensions great engine options summed car Brilliant engineering fantastic ergonomics futuristic looks outstanding performance--all decent price point recurring theme reader comments editors concur affordable price key Civic embodies thoroughly up-to-date technology including hybrid variant impressive price Though engineering tough lots money resources case high-end luxury sports cars really difficult thing deliver small new emerging markets meet harsh consumer needs work against stiff competition new environment deliver real time OEMs cutting corners Honda Civic eighth-generation model Civic re-established itself benchmark its segment setting new standards safety technology performance save money Honda developed completely new complex ACE Advanced Compatibility Engineering body structure improve safety Civic Clever structural engineering along extensive use high-strength ultrahigh- strength steels body structure made possible true world car Introduced Japan 1972 first-generation Civic launched Honda automaker global significance Civics manufactured 11 countries around world introduction eighthgeneration model 2006 company add three manufacturing bases--in India Vietnam China Civic sold 160 countries accounting 30 Honda's total automobile sales Whereas previous-generation Civic 2001-2005 model years employed single platform body types new-generation model strategy employs unique plat- High-tensile steel content increased adding body's rigidity collision safety body employs Honda's ACE Advanced Compatibility Engineering structure enhances protection frontal collision against larger vehicles Honda Civic 98 APRIL 2006 aei aei-online org forms sedan coupe other European hatchbacks Flexibility regional differentiation Though sedan coupe platform evolution previous Civic its architectural concept its body chassis components 100 new said Large Project Leader Toshiro Morita Japanese-developed sedan IMA Integrated Motor Assist gasoline electric hybrid derivative based 2700-mm 106 3-in wheelbase 80 mm 3 longer predecessors widened tracks 1500 mm 59 1520 mm 59 8 rear interior volume qualifies EPA compact classification exclusively North American coupe its Si derivative developed Marysville OH based shortened 2649-mm 104 3-in wheelbase classified subcompact terms interior volume sedan appears half size larger measuring 4490 mm 176 8 long 1750 mm 68 9 wide 1435 mm 56 5 tall width exceeds Japan's small car limit coupe 4440 mm 174 8 long 1750 mm 68 9 wide 1359 mm 53 5 tall Mono-form design design theme mono-form upper structure wide-stance lower body distinctive cab-forward proportions both sedan coupe latter 100 unique sheet metal windshield rake exotic-car extreme sedan's 23 9 horizontal vs previous model's 29 coupe's windshield laid farther 21 9 horizontal vs previous 28 Honda's design team cleverly differentiated sedan styles cater vehicle's specific market positioning customer preferences combinations bolt-on outer components including rear bumper fascias hoods fenders grilles lamps theme North American Chinese sedans Sporty Youth rest world sedan upscaled Sporty Luxury models feature air dam various undercovers augment body's aerodynamics 1 8-L-powered sedan achieving Cd 0 29 IMA hybrid sedan 0 27 Si coupe features trunk-lid-mounted wing reduces rear lift coefficient 60 well drag 3 Hatchbacks Europe Development new European Civic architecture influenced Fit Jazz small hatchback Europe's preferred body style Civic larger vehicle platform chassis components specific 100 new car European C-segment sized often cited highlight new BMW 3 Series readers its engine engine design sophisticated its lightweight aluminum magnesium composite parts VANOS lift throttle system delivers cleaner emissions power wrote BMW inline six-cylinder engine well-tuned reliable engines Earth Initially depending market 3 Series available four-door sedan form choice three gasoline turbodiesel engine significant 190-kW 255- hp 300-N m 221-lb ft 3 0-L inline six 330i crankcase crankshaft bearings cylinder head cover magnesium--a first volume production power unit indication BMW's determination use technology save weight aid fuel consumption reduce emissions help towards ideal 50 50 weight distribution Weight saving 30 compared aluminum unit engine said BMW powerful lightest six-cylinder its segment Other gasoline engines 160-kW 214-hp 2 5-L six-cylinder 2 0-L 110-kW 147-hp four-cylinder 2 0-L diesel 120 kW 161 hp 340 N m 251 lb ft 2000 rpm uses second-generation commonrail technology variable turbine turbocharger geometry Although 3 Series bodyshell larger steel taking higher level equipment account BMW says body-inwhite 30 kg 66 lb lighter previous model Body stiffness improved Second place BMW 3 Series 25 car's support bar concept provides reinforcement points subject extreme loads including engine mounts points connecting engine longitudinal arms connection points both B-pillars rear new car packs high level technology cascaded its larger costly BMW siblings terms engines transmissions steering chassis control body stiffness safety interior features convenience items 5 Series active steering option electronically controlled variable ratios combining Servotronic vary steering forces Chassis support electronics include dynamic stability control DSC integrating automatic stability traction control ASC Other functions include brake lining wear display pre-charging brake circuit sudden braking anticipated driver's foot movements dry braking function wet weather Soft Stop run-flat tires availability active cruise control car's optional iDrive user interface controls variety functions its operation simplified Voice control covers system's functions ensure increased eyes cockpit time Honda Civic aei-online org aei APRIL 2006 99 hatchback features sharply raked windshield 23 horizontal Honda cites aerodynamic drag coefficient 0 30 interior new Civic features two-tier instrument panel sedan coupe large legible digital speed display placed forward analog tachometer layout made possible extreme windshield-forward position--the lower edge 10 254 mm farther predecessor's 60 40-split rear seat folds completely flat footwell enhancing cargo-carrying capacity Safer structure High-tensile steel content increased accounting 50 vs 32 total body shell 58 vs 11 high-tensile steel 590-MPa ultrahigh- tensile steel adding body's rigidity collision safety Honda claims 35 improvement dynamic rigidity body employs Honda's ACE structure enhances protection frontal collision against larger vehicles Honda crash tests Civic conducted Tochigi R D Center employed fleet Acura RLs prove new car's crashworthiness Better handling suspension evolution previous generation MacPherson struts rear double-wishbone trailing arms sedan coupe its components geometry new geometry incorporates high 7 4 vs 2 6 caster angle caster trail increased 20 mm 0 8 scrub offset reduced 20 resultant improved toe control agile responsive handling well enhanced highway braking stability rear suspension its spring mainstream engine new Civic around world new 1 8-L i-VTEC replaces previous 1 7-L VTEC employs intelligence vary intake charge volume intake valve during part-load operation greatly reduces pumping losses Honda's gasoline electric hybrid drivetrain system upgraded three-stage 1 3-L i-VTEC IMA hybrid system Honda Civic Supplier Highlights Allied Ring 1 8-L engine piston rings Alpine Digital audio tuner navigation system Analog Devices Airbag system accelerometers Bosch Diesel common rail injection system Cooper Standard Automotive NA door seals hood seals headlight seals Nisco its Nishikawa Rubber JV F T Precision 1 8-L engine VTEC rocker arms Honda Foundry Hybrid 1 3-L engine piston Jefferson Industries Tailored blank dashboard lower Johnson Matthey Low precious metal content catalytic converter 1 8-L engine Keihin 1 8-L engine intake manifold throttle body KTH Parts Industries Tailored blank body side frames Kuroda Precision Industries Laminate magnetic steel plates stator subcomponent yoke Lear Carpeting four-door Amtex JV Michelin Tires Nippon Seiki Multiplex two-tier instrument display Nissin Kogyo Hybrid hydraulically assisted brake system Nissin Manufacturing Hybrid 1 3-L engine VTEC rocker arms Matsushita Electric Industrial Hybrid NiMH secondary storage battery Siemens VDO Airbag safety system SKF MacPherson strut bearing units Sumitomo Electric Industries Aluminum inner wiring high-voltage cable three-phase cabling connector Takata Supplemental restraint system including side air-curtain bag Tamagawa Seiki Resolver sensor revolution sensor TDK Compact 12-V dc-dc converter downverter TRW Supplemental restraint system control unit sideimpact sensor crush-zone sensor curtain airbag inflator rain sensors TS-tech Active head restraint noise-absorbent roof lining United Piston Ring 1 8-L engine piston rings Valeo Smart immobilizer keyless entry system Yachiyo Kogyo Composite zero-evaporative AT-PZEV fuel tank hybrid Yutaka Close-coupled dual-bed catalytic converter 1 3-L hybrid engine Honda Civic 100 APRIL 2006 aei aei-online org shock absorber separately mounted departing previous concentric mount practice IMA hybrid Si coupe employ electrically assisted rack-and-pinion steering other models hydraulic assist brake system across board employs advanced-logic fourchannel antilock braking system ABS combined electronic brake distribution EBD Tire wheel sizes range IMA hybrid's low-rolling-resistance P195 65R15 type Si's optional Michelin Pilot Exalto PE2 summer tires 215 45R17 size--the first OE application ultra-high-performance tires European model's suspension specific components different new Civic sedan coupe rear torsion beam located pair trailing arms sprung separately mounted coils shock absorbers Electrically assisted rack-and-pinion steering standard three different ratios suit powertrain variations Braking features ventilated rear solid discs ABS EBD Brake Assist standard Vehicle Stability Assist range powertrains U S Civic range offers three types powertrain new 1 8-L SOHC 16-valve i-VTEC inline four-cylinder engine combined five-speed automatic K20Z3 2 0-L DOHC 16-valve i-VTEC high-performance engine mated new six-speed manual gearbox Si coupe IMA gasoline electric hybrid unit driving via continuously variable transmission CVT Canadian Acura EL sedan powered 155-hp 116-kW version K20 2 0-L DOHC VTEC engine offered five-speed manual five-speed automatic transaxle K20Z3 produces output 197 hp 147 kW 7800 rpm 139 lb ft 188 N m 6200 rpm Intelligent mainstream engine mainstream engine new Civic around world both sedan European hatchback 1 8-L i- VTEC Quoted maximum SAE power torque numbers 140 hp 104 kW 6300 rpm 128 lb ft 174 N m 4300 rpm Japanese European specifications list maximum power 103 kW 138 hp 6300 rpm peak torque new 1 8-L i-VTEC replaces previous 1 7-L VTEC intelligent technology employed engine vary intake charge volume intake valve intake valves cylinder during part-load operation steadystage cruising engine speeds 1000 3500 rpm delays 1 valve's closing timing making engine operate adaptive Atkinson Cycle greatly reducing pumping loss thus improving fuel economy Honda estimates EPA city highway fuel consumption 30 40 mpg five-speed automatic Though based loosely Mazda6 platform Ford improved Mazda6 areas styling handling performance wrote reader Fusion echoed others wrote saying car presents good balance comfort durability economy operation environmental responsibility handling stability manufacturing cost safety performance good value recurrent theme reader comments Good overall package driving dynamics only its class six-speed transmission priced competitive its primary competition return investment 17 995 starting price Fusion buyers return fuel economy 31 mpg Ford executives promise estimable product delivers advertised terms performance comfort convenience other parameter applicable segment Filling open space its lineup Ford sought equip its newest entry technological marvels great balance attributes Fusion Milan Zephyr since renamed MKZ program ushered entirely new way working Ford using standardized tools leveraging new technologies tapping Ford's global product resources company's first fully digital car Fusion completely designed engineered tested manufacture digital environment using advanced design tools available precision quality efficiency Though Mazda first use Ford's CD3 architecture basic underbody structure Third place Ford Fusion Mercury Milan Lincoln Zephyr architecture modified Fusion improvement torsional rigidity 12 7 benefits better handling reduced NVH Although 30 mm 1 18 wider 55 mm 2 17 longer Fusion architecture's mass Ford uses engines Fusion Milan Duratec 23 2 3-L I4 Duratec 30 3 0-L V6 I4 delivering 160 hp 119 kW 6500 rpm 150 lb ft 203 N m 4000 rpm 31 mpg highway 221 hp 165 kW 6250 rpm 205 lb ft 278 N m 4800 rpm V6 Zephyr's sole engine paired its six-speed automatic transmission helps propel Fusion 55 75 mph second faster cars its competitive set according Ford Ford engineers able create three distinct exterior designs Fusion Milan Zephyr using core central body Only middle section three cars terms sheet metal according Zephyr Fusion Milan Chief Engineer Brian Vought A-pillar forward C-pillar unique said Vought noted engineering sheet-metal parts cars better expected during cars' development Ford Fusion aei-online org aei APRIL 2006 101 Honda Civic meeting U S ULEV ultra-low-emissions vehicle Level II Euro 4 Japanese ULEV emissions standards diesel Europe European Civics three engine options include upper-grade engine 1 8-L i-VTEC unit sedan coupe base gasoline engine shared smaller Jazz hatchback 1 4-L i- DSI fast-burn unit employing twin sequentially firing spark plugs cylinder produces 61 kW 82 hp 5700 rpm 119 N m 88 lb ft 2800 rpm Honda quickly expanding application its 2 2-L i-CTDi common-rail turbocharged diesel engine across its European product range DOHC 16-valve diesel puts 103 kW 138 hp 4000 rpm 340 N m 251 lb ft 2000 rpm Standard transmission three engine types six-speed manual gasoline-engine vehicles available AMT automated manual transmission versions six-speed Improved hybrid Honda's gasoline electric hybrid drivetrain system upgraded threestage 1 3-L i-VTEC IMA hybrid system comprises low mid-speed cam profiles high-speed profile variable cylinder management deactivates four cylinders deceleration braking improving energy recovery motor generator replenish storage battery engine IMA drive wheels via Honda's push-type steelbelt pulley CVT wider ratio spread continues employ multi-plate-type starting clutch Civic Hybrid sedan manufactured plant Suzuka Japan Japan Europe select Asian Oceanic countries maximum power torque outputs engine motor 70 kW 94 hp 123 N m 91 lb ft 15 kW 20 hp 103 N m 76 lb ft respectively Maximum U S outputs combined IMA hybrid system 110 hp 82 kW 6000 rpm 123 lb ft 167 N m 1000 2500 rpm New hybrid cooperative regenerative braking system coordinates braking regenerate kinetic energy contribute vehicle's retardation realize power assist resorting conventional vacuum boost integrate hill-start assist importantly realize fully electronic brake-assist system system comprises power unit ABS modulator servo unit includes hydraulic servo hydraulic sensor solenoid valves electronic control unit new Civic Hybrid estimated EPA city highway fuel consumption rates 50 50 mpg improvement its predecessor's 47 48 mpg aei Circle 301 manufacturing solutions 102 APRIL 2006 aei aei-online org manufacturing solutions Edited Patrick Ponticel Welding advanced-high-strength steel AHSS tricky business April 5 technical session welding joining fastening technologies SAE World Congress Detroit Ford researchers studying gas metal arc welding GMAW describe taking trickiness Conventional steel mild steel easily welded said Armando Joaquin Ford researchers AHSS behaves differently due chemistry thermomechanical processes different steel suppliers heat-affected zone weld component greatly affected lead reduced fatigue performance added other Ford researcher Adrian Elliott GMAW process optimized technical presentation based SAE paper Gas Metal Arc Welding Advanced High Strength Steel--Developments Optimized Welding Control Weld Quality Joaquin Elliott along other researchers AET Integration Lincoln-Electric Metro Technologies pursued study 2005 involved welding steel plates--one advanced-high-strength other lowcarbon type--in lap configuration setup represented bracket-to-rail combination proposed truck frame researchers conducted 58-run experiment involving critical process parameters e g wire feed speed travel speed torch angle goal study develop three statistical correlation models Fatigue life weld dimensions Weld dimensions welding variables Fatigue life welding variables researchers' broader goal achieve better comfort GMAW primary single-side welding process advanced-high-strength-steel architectures--in particular use process hydroform-intensive body structures starting emerge said Elliott noted resistance spot welding RSW ineffective heavier-gauge steel used frames Nor RSW established single- side applications although development work area Laser welding suitable only certain applications controlled gap Elliott added said surprised strength statistical correlation models AHSS mild steel material GMAW finds favor Ford high-strength steel Ford Five Hundred Freestyle produced Chicago Assembly Plant shown high AHSS content Although currently used plant Ford proposing GMAW AHSS applications new car architectures Ford researchers Adrian Elliott Armando Joaquin gained better understanding gas metal arc welding via study subject technical paper presentation SAE World Congress month Detroit manufacturing solutions aei-online org aei APRIL 2006 103 GMAW study involved 58 experimental runs under six different welding parameters results varied significantly inadequate welds vertical leg shown image failing tension heat-affected zone Balanced welds typical right resulted joint strength exceeded base metal strength chemistry combinations weld process parameters weld profile fatigue performance Although research undertaken specific future truck frame mind refinements GMAW AHSS derived study applied new car program requires large amount single-side welding said Elliott Changes specifications process parameters already implemented Ford according Elliott Joaquin Patrick Ponticel www crh-group com FUTURE DESIGN IDEAL SEAT looking automotive partner rely expertise ideas alive right place CRH stands innovative development manufacture high-grade adjuster systems seats steering columns variable interior systems company renowned its independent predevelopment technical features components subsequent integration designs adapted clients automotive industry way cutting-edge solutions developed meet customers' requirements safety comfort convenience Benefit flexibility experience CRH set new standards right mass production Visit SAE 2006 COBO CENTRE WAYNE Hall Stand-No 1438 USA-Detroit Michigan Circle 303 Please visit SAE Booth 1438 manufacturing solutions 104 APRIL 2006 aei aei-online org Despite accumulated knowledge tool engineers decades experience process drawing forming sheet metal complex shapes often defied prediction terms knowing certainty metal withstand force die end exact dimensions intended Factors spring-back specific type thickness steel used difficult estimate rework draw re-strike dies built common surface contoured part stamping process design begins high degree accuracy only saves time money during development process eliminates trial-and-error fixes typically made days weeks during die tryout press Synergis phase project called 'die tryout' anymore referred 'die adjustment' simulation work end prevented several major recuts product shape engineers merely making die adjustments die mechanics ondary operations considered Rapid die design simulation different alternatives using AutoForm software modules possible companies Synergis choose robust cost-effective process Trying various part tips trim angles binder configurations computer immediately reveal fracture points wrinkles shock lines excessive thinning might Corrections made tryout phase AutoForm approach software usable shop-floor AutoForm's Incremental module used simulate draw operation subsequent die stations including re-strike flanging trim operations taillight housing Spring-back springforward characteristics simulated software shows wrinkling fracturing tendencies flanging Blue tendency wrinkle Maroon wrinkle Orange excess thinning Yellow risk cracks Gray insufficient stretching faster path die tolerance--without wrinkles fractures-- add weeks substantial costs project largest producers stamping dies automotive progressive die transfer press operations Synergis Technologies Group realized early software tools help simulate factors dies built--better designed far beyond one-step software merely lets die maker unfold customer's part determine size shape blank new generation comprehensive die design simulation software verifies optimizes die ready ship stamping customer's plant Synergis specializes chassis components interior reinforcements Customers include automotive OEMs Tier 1 component suppliers Synergis began using early simulation software mid-'90s upgraded its capability recent years software modules AutoForm AutoForm's calculation speed approximately 10-15 times faster software package Synergis using Process alternatives drawing vs forming tried quickly prototyping Additional die stations secpersonnel considerable die design metal-forming knowledge necessarily background FEA Synergis three six completely different processes job created simulated day job gets simulated helps during cost estimating Reducing amount iron die base reducing number die components reduce cost die continuing pressure customers reduce prices intricate custom- engineered tools simulation lets die tool builder proceed predictability final outcome--within cost parameters affecting ability die good product approach generate substantial savings AutoForm software used Synergis includes Incremental Die Designer manufacturing solutions aei-online org aei APRIL 2006 105 Trim modules Synergis personnel fully productive using software four six weeks beginning training AutoForm currently used Normal displacement reported plus minus values part dimensions Out-of-tolerance areas quickly identified addressed re-striking remodeling recutting product geometry draw die Lighter-weight die base structures fewer die parts substantially reduce die costs Process parameters first verified simulation enhance robust engineering ability manufacturing process accept variables proven die matrix menus missing targets quality tooling costs Simulation helps assure stability predictability stamping process despite variations circles simulation software considered key survival--the price entry today's world stamping Jay Groendyke Synergis Technologies wrote article AEI firms U S Europe Asia die building work automotive industry Synergis AutoForm recently focused developing software tools unlimited virtual mockup lit unlit appearance human visual perception effects interior aspect visualisation color photometry analysis compliance SAE ECE standards perceived quality OPTIS Headquarters Tel 33 494 086 690 OPTIS Central Europe Tel 49 711 674 00 344 OPTIS North America Tel 1 514 620 2099 OPTIS Japan Tel 81 3 3589 1559 Download trial version videos brochures www optis-world com best proven software technology automotive lighting design 100 CAD integrated CATIA SolidWorks standalone version INNOVATIONS AHEAD L G H T LED module headlamp Simulation Courtesy Renault Circle 305 form vs function form function 106 APRIL 2006 aei aei-online org Chris Bangle said believes true Design important leave designers true engineering Chief designer BMW Group Bangle might qualify chief philosopher automotive design community designers fields Bangle Tenet 2 Engineering opinion contemporaries side design-engineering divide quibble seems unanimous support overarching notion conveyed dueling aphorisms groups different must willing work together achieve best results best both worlds Evidence suggests engineers designers indeed working closely together BMW according Bangle borderline designer engineer modeler fading it's really only creating creative car Ford design leaders bringing hundreds engineers styling studio hopes become sympathetic tune styling about--and dispel myth studio country club said Ford's Patrick Schiavone Design Director North America Car engineers understand want future let's say headlamps taillamps features center stack start working toward goals rather backing cost Schiavone said Ford Motor Co President Mark Fields bigger pusher idea form vs function toform function jobs distinctly different engineers design counterparts share end goal best vehicle possible Patrick Ponticel Toyota's Calty Design Research Chief Kevin Hunter said work staffers makes designers rather simply stylists Design important leave designers true engineering said BMW Design Chief Chris Bangle I'm telling folks 'Show bubble roof--something really looks it's floating it's road ' said Ford North American Car Design Director Patrick Schiavone Ford said looking edgy styling handcuffs man Modular Tooling Systems s m p l e e f f e c t v e Re v o l u t o n n Wo r k h o l d n g Recognizing customers need improve competitive edge proven solution facilitating production intent prototype environments improving quality saving time saving money Results positive major automotive manufacturers identify implementation PATCO Reusable Modular Tooling Systems priority revolutionizing time honored tooling traditions customers realized reductions tooling time 40 Capitalizing investment reusable components saved 60 cost expendable tool program early identification production intent process development saving time reducing cost long-term business plan visit web site www patcoae com call 586 795-3690 35835 Stanley Drive Sterling Heights MI 48312-2663 USA sales patcotooling com Please visit Exhibit 946 2006 SAE World Congress April 3-6 Circle 307 form vs function form function 108 APRIL 2006 aei aei-online org everybody company page it's happening I've mean truly added addition promoting synergy groups company leaders promoting exciting overall vehicle design well Design leadership Chairman Bill Ford's mandates- -part company's strategic plan moving forward said Ford Design Chief J Mays design major priority that's great complete partnership parallel vehicle engineering partnership begins early vehicle project Ford Director Strategic Design Freeman Thomas meets Ford Director Advanced Product Creation Hau Thai-Tang negotiate dimensions crashworthiness other considerations made design part vehicle architecture process Thomas said learned important protect features added designers work closely product planners engineers package protection helps disciplines later kind collaboration engineering delivers design department architectures lot bandwidth--flexibility wheelbase track common hard points said Mays wide bandwidth Mazda6 platform CD1-3 example allows Lincoln offer 18- 20- wheels new Aviator wheelhouse flexibility vehicle engineering guys worked closely ensure execution said Vehicle architecture counted generate contention design engineering according Joel Piaskowski Hyundai's North America design chief example Designers want really fast windshield transitioning roof profile said Engineering comes head clearance upward visibility drive header forward higher we're fighting Tumblehome area apt generate disagreement Piaskowski added Except model initiated design side development process Hyundai new vehicle programs begins engineering giving design package related general architecture said Piaskowski early stage opportunity challenge engineering push design try modern progressive possible engineering head start said case company Piaskowski asserted negotiations design engineering throughout development project common years past engineering hand design box style new vehicle sometimes still happen said Toyota North American Design Chief Kevin Hunter Certainly starting point presented Toyota moving strongly toward designers involved vehicle architecture earlier stage Hunter added It's longer satisfactory designers only styling it's holistic approach said word designer appropriate stylist people main responsibility vehicle's aesthetic appeal Mazda Global Design Director Moray Callum said industry whole moved box approach although cases still slightly extent automakers consider design afterthought they're danger offered Giving ground Regardless discipline gets leg other start program subsequent disagreements engineering design inevitable Sometimes disagreements escalate point company president must arbitrate happened twice during development Honda Ridgeline pickup truck involved company's name presented tailgate H company named spelled capital letters case turned Ridgeline Chief Engineer Gary Flint said says HONDA tailgate guess won compelling argument Honda data Flint Although skirmishes relationship Toyota design engineering marked common objective producing aesthetically appealing high-quality vehicles according Calty Design Research Chief Kevin Hunter Greg Bernas Executive Program Director Toyota Technical Center compelling argument Honda data said Gary Flint Chief Engineer Automotive Design Honda North America served Chief Engineer Ridgeline Camcraft form vs function form function 110 APRIL 2006 aei aei-online org continued brought competitive data showing other single truck industry spelled name we're trying consistent theme Flint lost other appeal concerned trim plating wasn't passionate said Flint's view focus winning debates it's making customer wins That's litmus test use decision said Flint believes mistake engineering give compromise times stylists tend passionate sculpture sometimes forget we're making sculpture we're making piece transportation said functionality issues form follows function opinion Flint said it's appealing sculpture not--honestly couldn't care long it's functional Flint few rhubarbs time including different employer pulled shirttails contentious meeting manager manager basically told sit shut example engineering giving ground said cost issue little debate design engineering according Mazda's Callum Given unending resources engineering find ways implement styling feature 'Is worth spending money want ' question said That's real issue time debate won lost well sides terms communication education--that biggest stick Callum said kidding cohesive team makes resolving disputes easier territorial Callum puts himself former camp I'm engineer-hater colleagues said General Motors' Darren Post Vehicle Line Director Global Rear-Wheel- Drive Compact Performance Cars believes teamwork result ever-increasing number challenges industry especially most-recent decades underlying business need work smarter said Today's highly competitive environment taught think outside traditional box time work smarter together cohesive team means engineering design manufacturing purchasing marketing others become open-minded understanding roles organization Pontiac Solstice Saturn Sky healthy tension spirited discussions considering form vs function decisions Customers demanding intuitive innovative designs current market due increased number choices growing expectations refined execution Post continued customer cares end results sometimes can't predict drives perceptions 'blah' design home run sometimes several seemingly small styling innovations add larger favorable perception tension factor BMW's Bangle mind Callum relationship man wife Bangle said tension part deal design-engineering relationship comes bringing child car world offer different skill sets similar passions joint interest said adding things bit testy deciding DNA dominant Design fight well Bruce Campbell Vice President Design Nissan Design America downplays tension aspect Mazda's Callum believes budget adversary engineering Tension happens create different people disagree can't resolution said important design engineering finance Hyundai U S Design Chief Joel Piaskowski said designers visionaries company sky limit designers wheel size said Mazda Global Design Director Moray Callum Engineers sane voice tells limits Nissan Design Chief Bruce Campbell Chief Engineer Bob Sump agree working different parts country conducive contemplation case design engineering collocated form vs function form function aei-online org 111 APRIL 2006 aei aei APRaIeL i2-o00n6lin1e 1or1g SMALLEST SIZE volume channel nearest competitor BEST VALUE Based system purchase annual maintenance FLEXIBLE DAS easily moves in-dummy on-vehicle crash wall HIGHEST SAMPLING RATE 5 times maximum sampling rate competitors SUPERIOR SUPPORT experienced crash test support engineers industry Actual Size need black box DTS proud partner Visit SAE World Congress 2006 Booth 420 www dtsweb com Circle 311 Please visit SAE Booth 420 other disciplines involved early program Bob Sump Vice President Vehicle Engineering Nissan Technical Center North America says Nissan worked collaborative way since joined company 16 years good rapport Nissan's engineering operations Michigan its design operations California according Sump know well enough give design production vehicle impossible said know real out-of-bounds stakes other hand working together we're able push envelope little bit Campbell Sump agree tension factor Nissan otherwise might engineering design worked building since engineering based Michigan design California looking other's shoulders Plus separation promotes sense urgency importance meetings held improving focus efficiency Pushing envelope Knowing boundaries enabled engineers turn established engineering guidelines head development Pontiac Solstice according GM's Post relates fit wheel wheelhouse designer heaven wheel fill opening entirely tough sell engineering suspension considerations early-on agreement importance car engineering bent rules fit tight although tight Solstice unveiled concept 2002 North American International Auto Show related set rules bent push wheels beyond accepted practice time meeting called engineering design talk issues didn't answer achieve wheel fit knew work together Post said end both sides relaxed criteria achieve world-class result terms fit combination far wheels pushed Lindsay Brooke contributed article Engineering bent rules optimize wheel fit inside wheelhouse Pontiac Solstice said Darren Post GM Vehicle Line Director Global Rear-Wheel-Drive Compact Performance Cars Wired safety 112 APRIL 2006 aei aei-online org Wired safety Dan Carney Carmakers suppliers collaborate augment drivers' skill judgment electronics 100 years automotive travel weak link safety equation continues nut behind steering wheel Half century machines themselves needed serious safety improvements today low-hanging safety fruit picked bare means rather installing restraint systems designing improved impact-absorption properties cars engineers pursuing ways prevent mistakes lead crashes first place Robert Bosch cites research predicting market driver-assistance systems blossom 1 3 billion 2010 new cars drawing board CAD workstation means new generation electronic systems infrared night vision blindspot monitoring improves driver's powers perception brake assist quicken reflexes stability-control rollover-prevention devices augment skills lane-departure warning offers correction inattentive crashmitigation systems attempt rescue oblivious considered 'accidents' yesterday simply happen tomorrow technology solutions entering marketplace staggering pace observed Dean McConnell Director Occupant Safety Driver Assistance Systems Continental Automotive Systems North America engineering standpoint exciting using available technology prevent crash happening giving drivers control primary obstacle systems know-how cost course increasing scale manufacturing cuts costs newly developed technologies become commonplace semiconductor industry's axiom called Moore's Law predicts available computing power doubles 18 months cost manufacturers confident expensive technology cost-effective eventually Antilock brakes example become 80 lighter 90 expensive since 1984 introduction according Continental Systems integration challenge overcome initial high cost consumers' corresponding reluctance pay lot new technologies avalanche new devices help problem emerging systems pool resources bringing cost individual devices part package individual products individual product piece bigger puzzle said Bob Rivard Vice President Advanced Technology Robert Bosch Today automakers often choose alternative sensing technologies safety applications Bosch combining systems future only improve performance today's applications enable additional capabilities Carmakers struggle balance cost performance choosing sensors driver-assistance systems Radar provides longer range fewer crash-vulnerable sensors ultrasonic sensors Delphi backup assist system Laser Radar Si PIN Photodiode Si APD Steering Wheel Angle Sensing Infrared LED Photo IC Information Systems VICS Light-Emitting Receiving Module Climate Control Si Photodiode Sunsensor Assembly Thermopile Headlight Control Si Photodiode Anti-glare Mirrors Photo IC Diode Rain Sensor Si Photodiode Infrared LED Driver Interface Encoder Module Fully Loaded Load leading opto-semiconductors Hamamatsu options information visit online sales hamamatsu com search SAE USA 800 524 0504 designing next big thing four wheels head straight latest optics technology leader photonics 50 years Hamamatsu provides wide variety opto-semiconductors designed demanding automotive applications help stay fast lane Hamamatsu offers complete line compact flexible reliable optical sensors Vehicle Safety Systems laser radar detection steering angle sensing Information Systems AMI-C1394 networks VICS Automatic Climate Control sun load sensing Driver Assistance automatic headlight control automatic anti-glare mirrors rain sensing Driver Interface jog dials automotive opto-semiconductors Hamamatsu represent milestone long road innovations photonics learn leading products need custom solution please visit website call directly Information Systems AMI-C1394 Networks Transmitter Photo IC Receiver Photo IC Optical Touch Panel Switch Phototransistor Infrared LED Si PIN Photodiodes Si APDs Infrared LEDs Photo ICs FOT Transmitters Receivers Light-Emitting Receiving Modules Encoder Modules SAE Booth 1913 Circle 313 Wired safety 114 APRIL 2006 aei aei-online org roadmaps start stability control end emergency braking Systems grow incorporate additional functions include adaptive cruise control convenience feature forward-looking radar serve crash-mitigation collision-warning systems Stability-control systems expand encompass rollover-prevention technology trailer-sway control Today's common stability-control systems reduce incidence single- vehicle crashes SUVs 63 according National Highway Traffic Safety Administration NHTSA Adding anti-rollover technology help top-heavy off-roaders Cheaper alternatives approach rollover prevention direct measurement demonstrated Ford's Volvo-developed Roll Stability Control RSC system debuted Swedish manufacturer's first SUV XC90 2002 directly measures vehicle's angular acceleration tips wheels intervenes brake application reduce chance tipping Ford proliferating technology its corporate SUV lineup installing vehicles heavily revised 2006 Ford Explorer system works well adds cost additional sensor other manufacturers developed anti-rollover technology uses sensors already place stability-control antilock brake systems Continental Teves Electronic Roll Mitigation system used Chrysler Group SUVs 2006 Jeep Commander example indirect measurement approach Half new vehicles sold U S equipped stability-control technology 2008 according Continental providing solid foundation proliferation rollover prevention technology rollover prevention other new technologies explored alternative routes goal seeking balance performance cost Suppliers testing manufacturer interest systems use cameras radar infrared sensing warn drivers presence car vehicle's blind spot Lower-frequency 24-GHz radar costs one-fifth 77-GHz radar works fine short-range applications blind-spot detection according Derrick Zechmair Vice President Siemens VDO Automotive's Restraint Systems Safety Electronics Division Using beams side car lets system detect object's presence size speed computer decide warning appropriate Delphi working lower-cost passive infrared detection systems watch pair spots road adjoining lane detect interruptions vehicle present LIDAR light detection ranging CCD charge coupled device video camera preferable alternatives suggested Douglas Patton Senior Vice President Engineering Denso International America Candid cameras CCD might best way sideobject detection radar costeffective cost computing power needed interpret data CCD Patton said Video cameras needed lanedeparture warning used applications collision warning pedestrian avoidance high cost remains obstacle video camera robust reliable affordable challenge said Robert Bosch's Rivard durability improving affordability laggard added Combining both long-range 77-GHz radar--with range 150 m 490 ft --and 24-GHz short-range radar covering objects 30 m 100 ft Mercedes Brake Assist Plus system possesses enough information objects ahead perform automatic modulated braking rather only performing all-out emergency stops Using forward-looking radar determine crash imminent systems Bosch's Predictive Brake Assist perform emergency braking independent driver input helping vehicles stop short colliding car ahead Hall ICs Bus ICs Intelligent Drivers Actuators RF RFID Automotive ICs CMOS Imaging Silicon MEMs IR Temperature Growing BUS Family Simplicity Integration - defining phrase Melexis IC development benefited only TH8056 GM-LAN Transceiver Melexis industry benchmark LIN Transceivers BUS product family Melexis provides LIN bus architects new high-integration slave transceiver ICs TH8062 TH8065 TH8080 TH8082 LIN transceivers significantly cut component counts possible simple powerful expensive LIN bus slave nodes connected directly DC supply Melexis LIN Transceivers conform LIN J2602 - produced rigorous ISO TS16949 standards BUS Systems Melexis addressed need dedicated economical fully integrated Slave Node devices based unique dual core MLX4 processor Melexis LIN interface firmware ROM memory board IC eliminates need customers' reinvent LIN protocols available development tools versatile products greatly speed development application specific firmware switch actuator sensor interface LIN bus Right Performance - Right Price Inspired customers requirements cost effective high performance Automotive networking ICs Melexis expanded its industry leading family Bus Transceivers Slave Node ICs Melexis Speaks GM-LAN Melexis announces best performing economical GM-LAN transceiver available TH8056 GM-LAN Transceiver TH8056 approved GM-LAN 2 3 applications Wherever GM Module application requires GM-LAN 2 3 GMW3089 TH8056 Transceiver gives right performance - right price CanYou Speak GM-LAN GMW3089 2 3 compatible 100 Drop-in replacement Freescale MC33897 Available GMT-900 Epsilon 2 Global-A platforms Fully compatible J2411 Single Wire Class B Available Lead-Free Undervoltage lock-out Operating voltage range 5V 27V Low RFI due output wave shaping Production Volumes Available Today Contact samples technical assistance 603 223 2362 visit website Circle 315 Wired safety 116 APRIL 2006 aei aei-online org Data acquisition Cameras watch road ahead lanedeparture- warning systems radar scans ahead adaptive cruise control infrared cameras look road people animals illuminated invisible light infrared emitters monitors well-suited its own task using combination better job enable new applications collision warning crash preparation e g Mercedes-Benz Pre-Safe Lexus Pre-Collision systems emergency crash-mitigation braking e g Mercedes-Benz Brake Assist Plus system systems work own information available base decisions result false alarms helpful information driver greater integration systems trusted greater responsibility capability ability completely stop restart car traffic said Richard Lind Director Advanced Engineering Delphi next ACC stop said vehicle ahead comes stop system automatically recognizes brings vehicle stop computer smart enough know stop comparatively easy part said Lind 'go' part still under development Mercedes-Benz already 2006 S-Class featuring Distronic Plus adaptive cruise control Brake Assist Plus emergency braking technology systems combine information Adaptive lighting Visteon already shines around corners response information steering wheel position sensor future lights respond information car's navigation system pre-aiming lights curves navigation system knows approaching near-infrared night-vision system 2006 Mercedes-Benz S-Class employs pair fog-light-like emitters shine invisible infrared light road detected windshield-mounted infrared video camera human-machine interface significant factor determining value driver-assistance systems night vision Carmakers wrestling choice in-dash displays Mercedes S-Class head-up displays Siemens VDO prototype right possibility substitution cheaper CMOS complementary metal oxide semiconductor cameras CCD cameras manufactured millions cell phones only slashed cost improved durability said Tim Tiernan Senior Manager Advanced Electronics Visteon CMOS cameras point job well robust said CCD cameras better low-light conditions provide superior image quality CMOS cameras continue improve image quality tolerance low light ferocious rate semiconductors CMOS silicon-based technology expect bigger gains cost Tiernan concluded Similarly LIDAR substitute radar forward-looking tracking systems variety applications said Siemens VDO's Zechmair fewer cheaper components LIDAR adaptive cruise control systems cost 30 radar systems said Compared radar far easier commented Zechmair only laser diodes receivers simplicity affordable cost aftermarket vendors approached Siemens VDO developing add-on aftermarket versions product said application cameras watching driver rather helping driver watch road instance Volvo developing system monitors driver drowsiness impairment Total Electronics, LLC Wired safety 118 APRIL 2006 aei aei-online org both long-range 77-GHz radar shortrange 24-GHz radar gain complete picture objects ahead car improved information gathering only increases braking authority cruise control system 0 2 0 4 g permits automatic braking event imminent collision according Jorg Breuer Senior Manager Active Safety Mercedes-Benz event emergency braking system full brake authority vary pressure needed avoid collision- -a first according company Systems original Pre - S f e read driver's intent examining speed brake application trigger release pre-charged maximum brake power Pre-Safe Plus eliminate possibility rear-end collisions Mercedes-Benz' research driving simulator shown dramatic reduction likelihood crashes--and occur reduced speed Breuer said Mercedes-Benz' solution 'go' portion automatic stop speed control driver initiate movement touching accelerator cruise control lever system resume following car ahead automatically Delphi collaborated General Motors real-world test cars equipped collision-warning systems preparation production learned quite bit field trials requirements sensors human-machine interface you'll reflected products said Lind critical part human-machine interface elimination false alarms undermine usefulness warning systems collisions lane departure Adding information radar camera data used today's lane-departure- warning system Infiniti M45 help system better determine car really leaving lane said Lind systems remain four years North American roads uniformly marked European Japanese roads according Zechmair making task difficult market Vision correction Rather finding ways help car better ahead driver aid aims help driver better road Adaptive lighting systems steer headlights curves night vision systems dark ways systems introduced met tepid consumer interest far way improve adaptive forward lighting connect navigation system suggested Visteon's Tiernan Adaptive forward lighting launched expensive luxury cars its way mainstream Visteon's system appearing Ford Focus sold Europe other existing systems points headlights based information steering wheel position sensor new system consult navigation system map data point headlights knows road leads system Tiernan calls predictive lighting Better map data starting look interesting product said fog headlights point road helping guide drivers road commonly drivers can't well enough dark Raytheon's farinfrared system available Cadillac DeVilles remains option Hummer H1 SUVs expensive unpopular customers Lexus offers near-infrared system calls Night View uses fog-light-like emitters bathe road ahead invisible light illuminate picture head-up night vision display windshield Mercedes said its research drivers distracted head-up display company chose use 8-in dashboard display show nightvision image according Breuer Mercedes worked supplier Bosch develop proprietary image programming reduces tendency nearinfrared systems dazzled oncoming headlights rain-slicked roads Breuer said company chose nearinfrared technology far infrared work effectively temperatures above 30 C 86 F crisp image quality possible near infrared Siemens VDO developed both near- far-infrared systems investigating adding ability identify highlight pedestrians driver's display company say pedestrian identification ready market says its night vision systems production 2008 aei Automakers employed variety electronic vision sensors date hearing sensors Siemens microphone listens distinct sounds crushing sheet metal car's safety systems alert faster deployment Rapid response especially critical side impacts short crush space Dassault Systemes performance aftermarket 120 APRIL 2006 aei aei-online org performance aftermarket Edited Ryan Gehm SAE-certified hp aftermarket SAE-certified power torque program its feature witnessed testing automotive aftermarket manufacturers sell products systems promise significant performance improvements assurance offers seem major appeal--for companies ready financially able prove promises result SAE introduced its program presentation aftermarket industry's leading trade association SEMA Specialty Equipment Market Association panel original equipment OE engineers explained program testing performed engine dynamometer updated differed significantly typical aftermarket practices SEMA technical consultant Frank Bohanan participant said meeting both applicable SAE standards--J1349 engine testing J2723 qualified witnesses observe procedures--would provide credibility aftermarket manufacturers pointed SAE J2530 recommended practice wheels example already drawing aftermarket interest first engine certified vehicle manufacturer new SAE regime General Motors' Chevrolet Corvette Z06 engine 7 0-L small block V8 designated LS7 rated 505 hp 377 kW 6200 rpm 470 lb ft 637 N m 4800 rpm DaimlerChrysler's 2006 Dodge Viper 8 3-L V10 510 hp 380 kW 5600 rpm 535 lb ft 725 N m 4100 rpm SAE horsepower standards date 1917 laboratory gross horsepower rating standard J606 introduced 1963 widely used OE level years SAE J1349 net horsepower standard introduced 1980 revised three times current version intended reduce opportunities creatively interpret procedures best results well provide coverage latest electronic controls statement intent asks interpretation reflect typical in-service performance number examples cited Dr David Lancaster GM Technical Fellow Engineering Group Manager Base Engine Architecture GM Powertrain major ones Peak torque measurement added test procedure selective fitting finishing allowed refers techniques machining cylinder head gasket surfaces raise compression ratio selecting throttle body manifolds heads peak airflow end manufacturing tolerance scales polishing cylinder head ports select-fitting bearings production engine oil pan specified factory fill engine oil must used windage losses production vehicle accurately replicated Unlike other engines concern oil pan windage LS7 dry sump lubrication system noted David Hill former Corvette chief accessories standard equipment-- power steering alternator air conditioning compressor air pump--must installed driven laboratory exhaust system used instead vehicle's production version laboratory example must include specific restriction replicates restriction catalytic converter vehicle previous version J1349 Corvette LS7 7 0-L V8 first engine SAE-certified Ansoft Corporation Cost power safety 124 APRIL 2006 aei aei-online org third year row relentless cost pressures top list issues facing automotive engineers jobs according 2006 SAE DuPont Engineering Survey Alternative powertrain development vehicle safety advanced electronic electrical programs fuel efficiency technologies round top five areas professional focus noted engineers surveyed annual SAE DuPont Engineering Survey its 12th year conducted first quarter year SAE members planning attend SAE World Congress target sample roughly 100 engineers broad range Cost power safety andmore Automotive engineers heading year's SAE World Congress sound hottest trends greatest challenges facing industry Lindsay Brooke lenges noted engineers cost declined steadily year Three years 44 respondents listed cost greatest concern figure declined 33 2004 26 3 year auto engineers longer view cost-reduction mandate external factor finally consider integral element product development moving forward Competition Chinese automakers major force end decade said survey respondent summing outlook colleagues Others noted increased electrical content new safety regulations rollover pedestrian-protection requirements well meeting Federal Motor Vehicle Safety Standard 208 outof- position vehicle occupant standards U S driving per-vehicle costs engineer countered Safety competitive issue Warranty costs need reduce highlighted companies across automotive value chain interviewed primarily telephone year 103 engineers participated survey 69 67 employed supplier companies 34 33 work automakers supplier engineers 93 2 employed Tier-1 companies Cost China threat Cost cited 1 challenge facing automotive design engineering community works remain competitive according 23 7 surveyed percentage chal ARi ARi ARi ARi Cost power safety aei-online org aei APRIL 2006 129 surveyed cost employee health care affects productdevelopment engineering costs older workforce can't compete younger Japanese workforce lower health-care costs asserted engineer only solution change national policies regarding health care Hybrids set powertrain pace surveyed 35 expect alternatively powered vehicles greatest impact major automotive technology trend next decade engineers say optimized internal-combustion engine ICE continue lead industry's powertrain focus its prominence steadily declined 55 2003 28 3 2006 Diesel engines hybrids increasingly grabbing engineers' attention diesels leaping 1 4 2003 7 9 year Hybrid-electric vehicles HEVs vastly outpacing diesels terms engineers' professional focus 40 surveyed say HEVs industry's greatest technology impact influence fuel cells 21 5 year's respondents listed top technology dropped slightly 19 7 2006 Besides advanced powertrains next technologies impact advanced electronic electrical innovations 19 7 advanced collision avoidance 14 5 Fiber optics distributed networks smaller smarter electrical components real-time sensing current engineering trends expected drive next generation safety systems well hybrid drivetrains other subsystems according engineers safety-systems development challenges collision-avoidance systems hot topic engineers asked technology mainstay area majority surveyed 47 primary winning technology mind Cameras 19 1 radar 17 4 IR vision systems 13 noted Steel stands tall Cost dominates ultra-competitive materials arena according engineers 2006 SAE DuPont survey asked rank tall list materials-selection criteria 1-5 scale terms Cost reduction Alternative powertrain issues Vehicle safety Advanced electrical electronic issues Fuel economy CAFE Emissions regulations Alternative fuel Alternative fuel Emissions regulations Fuel economy CAFE Advanced electrical electronic issues Vehicle safety Alternative powertrain issues Cost reduction Top Engineering Challenges 2003-2006 Percent 100 80 60 40 20 0 2006 2005 2004 2003 Top Engineering Challenges 2006 Percent Surveyed 23 7 14 5 18 3 13 6 1 4 6 3 8 Top Environmental Issues 2006 Percent Surveyed Light weighting CAFE Recycling recyclability Lower emissions clean air Hybrids hybrid system development Alternative fuels Bio materials Waste reduction Eliminating hazardous materials Plant pollution Fuel cells 24 5 12 6 11 9 8 4 7 0 2 8 2 8 2 1 1 4 0 7 8 4 Cost power safety 130 APRIL 2006 aei aei-online org 21 5 plastics 17 8 advanced composites 11 1 magnesium 5 2 Steel low-cost proven reasoned engineer lightweight materials plastics magnesium become attractive light rising fuel prices said Meeting new regulations Engineers asked weigh impacts U S Transportation Bill specifically its influence vehicle-rollover side-impact performance California's emissions regulations apply product design Transportation Bill influence short term five years engineers believe 2010 time frame changes safety standards requiring new highstrength materials rollover protection changed materials mix expected cause increase vehicle development costs noted survey emissions engineers split California Air Resources Board CARB regulations challenge industry future OEMs grappling observed engineer stated number hybrids continues grow meeting CARB regulations becomes attainable comments appear explain few engineers ranked categories emissions fuel economy CAFE top challenge facing industry 2006 three years 15 surveyed ranked emissions greatest challenge percentage fell steadily 4 6 year reason dramatic shift perceptions next round U S emissions regulations socalled Tier 2 standards fully understood industry Engineers' confidence technologies meet regulations likely risen three years Fuel economy 2003 considered leading challenge 7 surveyed rising 11 2005 year's survey only 6 1 engineers believe main challenge Perhaps industry learned relatively short period yesterday's challenges longer pressing--except cost aei importance engineers cost top priorities ranked narrowly ahead other key factors including durability high-performance physical properties warranty simplified design reduced wear friction weight reduction Brand new materials welcome lower cost commented survey respondent Asked pick materials species believe gain automotive share next decade engineers chose aluminum 25 9 steel Top Safety Technologies Priority Order Engineers Surveyed 2006 2005 2004 Occupant detection systems Side rear airbag systems Collision-avoidance systems Improved airbags Collision-avoidance systems Side rear airbag systems Collision-avoidance systems Occupant detection systems Advanced seatbelts Electronic stability control Electronic stability control Electronic stability control Top Safety Issues 2006 Percent Surveyed Engineering Emphasis Powerplants 2004-2006 Percent Surveyed Occupant detection Collision avoidance Improved airbags Stability control Body structure Pedestrian safety Rollover Active seatbelts Interior safety By-wire systems Inflatable belts Hybrid safety systems New materials 12 0 11 1 11 1 7 9 6 9 6 5 6 0 5 1 4 2 3 2 2 3 1 4 1 4 100 80 60 40 20 0 2006 2005 2004 Developing fuel cells developing HEVs Optimizing diesel ICEs Optimizing gasoline ICEs PCB Piezotronics AEI 2006 Tech Awards 132 APRIL 2006 aei aei-online org editors Automotive Engineering International highlight innovative new products technologies display SAE 2006 World Congress based latest information provided exhibiting companies Suspension module suspension module Benteler designed application commercial vans light trucks firm provides full-service supplier capabilities application development just-in-time sequenced delivery addition manufactures central component parts including crossmember control arms highlight suspension module use composite leaf spring spring provides 15-kg-per-module 33 lb weight reduction compared previous steel spring improving sprung semi-sprung mass information circle 21 visit Booth 1473 Product management Dassault Systèmes' 3D XML documentation tools www 3ds com 3dxml real-time product data available management engineering suppliers via interfaces already comfortable Microsoft Office released firm V5R16 supports Microsoft Windows 64-bit operating system hardware platforms enabling customers create analyze manage large amounts data complex products automobiles capability reduces product development cycles accelerating design enhancing design reviews product optimization decision support product life-cycle management solutions leverage set product development technologies best practices based CATIA V5 ENOVIA SMARTEAM DELMIA SIMULIA 3D XML information circle 22 visit Booth 1959 Direct-injection gasoline engine TurboDISI engine FEV 1 8-L turbocharged gasoline direct-injection engine offers impressive low-end torque fuel economy typically associated only diesel engines engine replace larger heavier naturally aspirated engines promises reduced emissions compared naturally aspirated port-fuel-injected turbocharged engines Compared larger 2 6-L naturally aspirated engine replaces TurboDISI engine produces peak torque power reaches peak torque quickly offering better specific fuel consumption throughout engine map minimizes traditional turbo-lag drawback experienced conventional turbocharged engines characterized delay torque rise during acceleration applies technologies variable valve timing integrated charge air cooler intake manifold advanced charge air devices information circle 20 visit Booth 1817 Kistler Instrument Corp AEI 2006 Tech Awards 134 APRIL 2006 aei aei-online org Multi-application sensor Alasca XT Ibeo Automobile Sensor multi-application sensor high-resolution laser technology combine seven different applications space- cost-saving unit sensor features scan frequency 12 5 Hz 25 Hz 240 field view 0 3 200 m 1 656 ft range multi-echo multi-target technology Four-echo technology flexible angular resolution increased 1 10 help unit meet needs applications including pedestrian protection ACC stop lanedeparture warning automatic emergency braking pre-crash warning traffic jam assistant low-speed collision avoidance information circle 24 visit Booth 1435 Electronic test software PROVEtechTA test software MBtech Group helps identify errors early stage increase performance quality electrical electronic components serves interface tester test system validates both hardware software system enables testing ECUs virtual vehicle hardware-in-the-loop testing embedded software software-in-the-loop testing models model-in-the-loop testing Four main modules include workpage contains required manual execution tests stimulation visualization signals test manager real-time engine automated execution tests diagnostic area displays internal control unit information allows users read error log perform diagnostics ECU coding flash ECU fault simulation module faults injected test system behavior information circle 23 visit Booth 2413 Powertrain simulation ITI-SIM ITI GmbH modeling simulation environment contains only physical domains vehicle engineering model libraries powertrain vehicle components Multi-domain modeling features domains including mechanics pneumatics hydraulics control systems simulation model Hierarchical model structure allows construction complex models clear manner hierarchy representing different logical layers model user defines model complexity degree detail Object-oriented models use physical entities base part describe interactions via physical state flow quantities Libraries base elements lowest hierarchical level provided component modeling collection prebuild validated model objects powertrain components includes items engines clutches gear stages synchronizers information circle 25 visit Booth 1439 Wheel motor TM4's liquid-cooled wheel motor offers 14 kW peak power 300 N m 221 lb ft motor uses envelope previous air-cooled version produced 2 5 kW continuous power 7 kW peak power 100 N m 74 lb ft direct-drive permanent-magnet brushless wheel motor suited hybrid configurations using conventional internal-combustion engine electric propulsion rear vehicle single electronic module independently controls motors setup replaces mechanical differentials provides real-time accurate all-wheel-drive capability transforming vehicle hybrid vehicle information circle 26 visit Booth 1833 Visit on-line www intermark-usa com full product list 1310 Tully Rd Ste 117 San Jose CA 95122 INTERMARK USA INC subsidiary KITAGAWA INDUSTRIES CO www kitagawa-ind com 408 971 2055 fax 408 971 6033 www intermark-usa com sales intermark-usa com MG-02A MAB MSF High performance EMI noise absorption sheets Custom cutting processing adhesive backing available Ferrites High Shield Gaskets offer variety EMI ferrites assortment shapes sizes Low-cost versions available INTERMARK USA solution Available variety shapes sizes customizable virtually application EMI Problems Grounding Contacts OG series contacts extremely effective reducing EMI noise level PC board Tape reel packaging SMT applications Circle 334 AEI 2006 Tech Awards aei-online org aei APRIL 2006 135 Particulate filter PUREM's PMF CPMF particulate filter systems active passive regeneration techniques ensure filtration efficiencies excess 90 diesel engine applications various sizes sintered metal filter substrate manufactured large filtration areas exhibits high ash storage capacity High heat conductivity allows high soot loading maintaining backpressure targets New cleaning methods developed product reduce life-cycle costs particle NOx cleaner combines selective catalytic reduction system using aqueous urea solution PMF CPMF meet future emission standards EPA 2010 EURO 6 Nitrogen oxides particulate matter hydrocarbon reduction 90 achieved components integrated stainlesssteel housing noise-attenuation optimization options offered information circle 27 visit Booth 2258 Active stabilizer Aisin's electric active stabilizer system jointly developed Toyota improves vehicle posture stability driveability roll control Lightweight compact size electric actuator responsive electric motor installed middle stabilizer bar high level ride comfort roll control curves achieved advanced type vehicle posture control technology new system next-generation version hydraulic active suspensions used 1989 Toyota Celica stabilizer currently use Lexus GS information circle 30 visit Booth 2069 Antenna integration Hirschmann integrating antennas antenna structures integrated receiving systems plastic roofs car boot lids wings systems only implemented glass additional packaging space allows only trouble-free integration new services vehicle digital satellite radio digital audio broadcast improvement reception quality existing services method enables vehicle manufacturer standardize integrated antenna systems across car lines technology introduced Smart For-Four 2006 onward technology discrete packaged car body entire model range require subsequent assembly steps separate adhesive bonding information circle 28 visit Booth 1238 Laser scanning NVision's MobileScan HD high-definition version its laser scanning system name scanner provides resolution point spacing 0 002 0 05 mm accuracy 0 0005 0 01 mm collecting measurements rate 30 000 points second sensor two-axis servocontrolled swivel head integrated turntable Movement three axes programmable system uses only servo rotary encoder time sensor moved manually controlled automatically follow predefined measurement strategy projects laser light surface object measured camera continuously triangulates laser's changing distance profile density resulting point cloud enables object replicated accurately information circle 29 visit Booth 2306 IFP Services Powertrain Engineering Delivering engine vehicle designs meet targets performance fuel consumption emissions Circle 335 AEI 2006 Tech Awards 136 APRIL 2006 aei aei-online org Multi-fuel engine Schoell Cycle Cyclone Heat Regenerative External Combustion Engine Cyclone Technologies multi-fuel capacity contains petroleum lubricants releases fewer emissions internal-combustion engines runs quietly low exhaust temperatures Mark II develops 18 hp 13 kW configured stand-alone generator package marine other uses Cyclone Engine operates interrelated system heat exchangers conserve deliver maximum heat piston combustion chambers form vapor under high pressures temperatures behaves fluid Mark V Cyclone six-cylinder radially configured engine 100 hp 74 kW intended off- on-road applications Unlike spark- compression-ignition engines requires starter motor external radiator muffler transmission multi-fuel capacity self starting self cooling 350-lb 159 lb engine 38 in3 623 cm3 displacement develops 700 lb ft 949 N m starting torque engine scaled develop 4000 hp 2980 kW information circle 31 visit Booth 2233 Sporty engine sound Symposer MANN HUMMEL developed DaimlerChrysler Ford provides rich sound sporty vehicles turbocharged engines Original acoustic performance turbocharged supercharged engines damped compressor air intake system engine noise generally independent charge engine speed Thus engines require additional sound systems acoustic feedback corresponds driving dynamics Symposer transfers engine-generated pulsations air intake passenger compartment create engine noise high-frequency sounds predominate directly behind turbocharger dynamic pressure signal downstream intercooler nearly equals characteristics naturally aspirated engine Connecting Symposer directly throttle body produces characteristic charge-dependent sound information circle 32 visit Booth 1532 Energy absorption INDUS Concepts Engineering introduces knee bolster energy absorber using LATTICELL energy absorber technology Multiple cells arranged concisely crush progressively dissipate energy efficiently during knee impact frontal collision minimize load occupant femurs Openings cell's curved walls allow crush initiation occur suitable locations correct timings range occupant sizes 5th percentile female 95th percentile male protected Other product features include mass 0 5 lb 0 23 kg low tooling cost tunability targeted performance information circle 35 visit Booth 1138 Thermal simulation SC Tetra V6 Software Cradle general-purpose 3-D fluid thermal simulation software uses mesh generation diagnostics repair functionality reduce time required construct complex fluid thermal models Features include simple operation improved analytical functions easier integration other commercial software SC Tetra V6 incorporates automated hybrid mesh generation using tetrahedron pentahedron hexahedron elements improve accuracy reducing number elements Other benefits include automatic control boundary layer improved discontinuous mesh function additional analytical functions use COM technology information circle 34 visit Booth 2133 Production code testing variant dSPACE's modular RapidPro System testing production code stand-alone electronic control unit MPC5554 microcontroller Copperhead system used test production code early function prototyping stage developing automotive functions chassis control transmission control body electronics code C code generated automatically models firm's TargetLink code generator other sources hand coding system provides 4 MB external SRAM memory 16 MB external flash memory Its modular design enables adaptability individual requirements system connects via USB CalDesk measurement calibration software information circle 33 visit Booth 1701 AEI 2006 Tech Awards aei-online org Safety systems Mercedes-Benz S-Class equipped Continental's networked active passive safety components including intelligent electronic brake driver assist systems advanced tire expertise hose lines well antilock brakes traction control electronic stability control driver assistance system adaptive cruise control maintains distance vehicle ahead ensures necessary safety interval ESC MK25E5 brake control system uses four pressure sensors addition master cylinder pressure sensor infinitely variable valves provide sensitive brake pressures resulting improved forward side-to-side dynamics electronic ignition starter switch central control unit key interlock system recognizes its driver instantly approaching vehicle seat control unit seamlessly connected control information circle 37 visit Booth 2059 Climate control system Behr BHTC collaborated DaimlerChrysler create Physio-Control climate control system allows vehicle occupants select own personal climate settings Featured Mercedes-Benz S-Class system computes key data occupant sensitivity uses information program climate control system key design component HVAC module contains aluminum heat exchanger output 9 8 kW Independent temperature settings provided floor head area air volume control system uses computer-simulated model HVAC module determine real time current volume air required air vent system considers outside air intake well individual vent jet unventilated inside temperature air outlet temperature sensors four-quadrant solar sensor provide data C control unit information circle 36 visit Booth 1259 Infrared lighting Hella's new ADILIS Advanced Infrared Lighting System infrared night vision system designed improve traffic safety dark Capable detecting objects far 500 ft 152 m system uses CMOS camera IR headlamp head-up display driver Three different prototype IR headlamps used system H7 halogen bulb interference filter projection modules LEDs act IR light sources headlamp IR laser light hits angled reflector beamed road Illuminating distant objects normally invisible naked eye head-up display shows driver gray-scale image camera detects information circle 38 visit Booth 1345 Circle 337 New SAE 2006 138 APRIL 2006 aei aei-online org AEI continuing its preview coverage month's issue takes detailed look products services technologies displayed SAE 2006 World Congress scheduled April 3-6 Cobo Center Detroit New Robotic measurement Battenberg's robotic measurement systems provide measurement testing movement functions robotic sensors image processors RobFlow software system measures haptic qualities control panels switches knobs key pads air conditioning systems information entertainment communications centers car interior Sensors grippers tactile tools used measure evaluate document characteristics force displacement torques angles special application car manufacturers enables complete automobile analysis measurement car interior's control panels Applications system used measure offsets surfaces color accuracies RobPoint software allows robot taught leading hand sending defined robot positions PC via speech module information circle 40 visit Booth 1441 Mechatronic design Synopsys' Saber family design verification tools contains enhancements allow implementation robust design methodologies across range automotive mechatronic designs Design verification throughput increased allow time test verify system under operational environmental conditions In-vehicle networking hybrid vehicle design power system solution packages supported application-specific mechatronic components encompass 30 000-plus model library Recent additions include variable valve timing models sensors planetary gears automatic transmission model sets battery models Hardware software co-simulation MathWorks' Simulink Saber simulators continues enhanced System support standard modeling languages includes VHDL-AMS MAST language Saber Harness wiring harness design tool improved interfaces CATIA V5 Unigraphics NX3 design environments information circle 41 visit Booth 2500 Electric oil pump electric oil pump Aisin features reduced size weight resulting integration driver motor pump Long life achieved sensorless brushless motor design system currently installed Toyota Vitz information circle 42 visit Booth 2069 Crash sensor Miniature Model 52 accelerometers Measurement Specialties developed improve measurement reliability test professionals particularly space-restricted environments limited mounting options flexible conductor cable winds channels obstructions instrumentation power supplies Operating 2 10 V dc Model 52 available ranges 50 2000 g frequency response 400 7000 Hz depending range fourarm Wheatstone Bridge device measures 0 4 x 0 15 10 x 3 8 mm operating temperature range -40 85 C -40 185 F information circle 43 visit Booth 2208 Force sensor Piezoelectric force sensors Force Torque Division PCB Piezotronics measure dynamic force compression tension impact modes feature necessary response follow fastrising short-duration force events including crimping stamping New SAE 2006 aei-online org aei APRIL 2006 139 punching forming drop impact testing Various force sensors offered including ring three-component ring link impact penetration strain styles Applications include tensile fatigue testing press force machine process monitoring package drop testing force limited vibration testing modal analysis information circle 44 visit Booth 601 virtual circuit compound avoid sharp edges damage wires during cable assembly process External closure allows high cable fill rates wraparound side-entry jacketing system permits modular design reduce installation costs closure method ensures cables exposed outside contaminants D-Track suitable automotive applications cable bundles must protected rugged road use Sizes range 0 375 9 5 mm diameter low-temperature version offered information circle 46 visit Booth 2421 provide maximum data transfer rate 50 Mbps optical fiber links photo ICs heat-resistant operating temperatures ranging -40 95 C -40 203 F maximum storage temperature 110 C 230 F L8628 transmitter photo IC set operating mode reduces optical output level half S8627-01A features dynamic range resistance noise shift operation low-power sleep mode normal operating mode detection light trigger information circle 48 visit Booth 1913 Optical design software TracePro Bridge add-in Lambda Research mechanical design software SolidWorks allows users include optical components light sources detectors sensors optical effects properties directly software's mechanical models Completed opto-mechanical models exported TracePro optical simulation software ready optical ray tracing analysis Users able assign save optical properties SolidWorks view properties objects surfaces comprising model transition models design analysis meet criteria including output distribution flux levels detection patterns information circle 49 visit Booth 1813 Testing card TZ Mikroelektronik's FlexCard flexible monitoring analyzing device used configuring testing monitoring time-triggered FlexRay serial bus system FlexCard Cyclone II compliant version 2 1 offers transmission reception symbols display existence network synchronization error status communication controller monitoring network startup report data transmission time Data transmission reception speed doubled card offers synchronization input well output information circle 45 visit Booth 2309 Cable management D-Track complete cable management system Zippertubing manufactured flexible permanent Data validation TDAS Data Validation Engine DaVE Diversified Technical Systems software package automatically validates crash-test data identifying common data quality issues caused sensor wiring problems setup mistakes other anomalies generates report Automated validation tests include signal saturation inverted signal broken sensor wire sensor separated body shifts zero level redundant channel verification consistency integrated speeds TDAS DaVE used conjunction TDAS control software stand-alone system information circle 47 visit Booth 420 Optical communication Hamamatsu's L8628 transmitter photo integrated circuit IC S8627-01A receiver photo IC designed MOSTcompliant vehicle networks Torque Flange Sensors In-Line Transducers torque range 0 1 N m 150 000 N m Several price performance options Non-contact Maintenance-free Ideal active torque monitoring Excellent noise EMC immunity High torsional rigidity Speed measurement 50 000 rpm Torque Measuring Options Circle 339 New SAE 2006 140 APRIL 2006 aei aei-online org Seat heating Constant-wattage heaters Total Electronics heat average 50 faster conventional seat-heating technologies using 30 power Heating zones shaped deliver heat exactly occupants feel Target temperatures reached minutes robust systems customized fit seating applications present safety fire hazard damaged puncture wear conventional heaters information circle 50 visit Booth 1911 Thermal expansion joint Advanced Energy Technology joined automotive exhaust tubing fabricator develop thermal expansion joint high-temperature exhaust systems primarily diesel engines thermal expansion joints used tubing routes exhaust gasses exhaust manifold turbochargers ERG valves joints use GRAFOIL diemolded seals create sliding seal exhaust tubes expand contract heat engine products provide thermal stability resilience compressibility natural lubricity easy cutability formability information circle 51 visit Booth 738 Low-profile antenna GPS 18 90 LP GPS cellular combination antenna Hirschmann designed use fleet management systems asset tracking car navigation other telematics applications antenna mounted via adhesive magnetic pad screw mounting various surfaces including glass plastic metal features low profile dimensions 100 x 66 mm 3 9 x 2 6 19 mm 0 75 tall classified IP66 waterproof outdoor installation Broadband tuning covers European GSM U S American cellular phone frequencies information circle 52 visit Booth 1238 catalysts Inspection times 10 s achievable providing 360-part-perhour inspection rate configurations 20 different inspections possible software part traceability optional bar code printer implemented identify substrate inspection time information circle 53 visit Booth 2348 Substrate inspection CatPro 6000D HD Image Labs International designed around need inspect large-scale ceramic silicon carbide exhaust system catalysts filters system images surface substrate providing 360 view outside skin well both faces system looks substrate detect optical leaks diesel particulate filters plugs flow-through Electric drive simulator hybrid powertrain engineers develop components switching frequencies beyond traditional 10-20 kHz range Opal-RT's RT-Lab electric drive simulators expanded megahertz allow development accurate virtual hybrid powertrains Engineers motor power electronics models Simulink field-programmablegate array based hardware model computations O completed 1 microsecond information circle 54 visit Booth 1910 EPA protocol gases Scott Specialty Gases' Emission Credit Class EPA protocol gases provide 0 7 analytical accuracy help eliminate calibration errors translate lost SO2 emissions allowances sold banked Emission Credit Class EPA Protocols available SO2 components dual blends becoming available soon Scott maintains extensive Calibration Systems CS18 accelerometers Microphones Calibrators Measuring Equipment Primary- Calibration System CS18P STF accelerometers SPEKTRA developing agent manufacturer service provider complete calibration systems range Sound Vibration Primary- absolute- Secondary- comparison- calibration systems CS18 accelerometers conform ISO 16063 displayed Measurement uncertainties evaluated according GUM SPEKTRA Schwingungstechnik und Akustik GmbH Dresden www spektra-dresden de sales spektra-dresden de Circle 340 New SAE 2006 aei-online org aei APRIL 2006 141 inventory low-uncertainty Standard Reference Materials SRMs NIST-Traceable Reference Materials firm produces gaseous SRM candidates NIST information circle 55 visit Booth 1745 units include fault-tolerant digital O analog inputs transient suppression multiple communication protocol support RS232 background debugging mode interface real-time clock Front-panel diagnostics LEDs userprogrammable information circle 57 visit Booth 2409 low weight allow fit roll-around case ease transportation information circle 59 visit Booth 317 Metal-forming solutions Hess Engineering offers 30 years experience variety metal-forming technologies process solutions firm supplies equipment applications spinning flowforming straightening wheel rim manufacturing supplies manufacturing solutions fabricate automotive truck wheels rims catalytic converters other exhaust components pinion gears axle drive shafts crank cam shafts brake shoes dozens other applications information circle 60 visit Booth 549 Fuel control valves HUSCO Automotive launching fuel control valves year first product used diesel application second gasoline direct-injection system Key features valve include operation -40 150 C -40 302 F response time 1 ms response time 1 ms durability greater 1 billion cycles zero leak 200-bar 2900 psi operating pressure information circle 61 visit Booth 1933 Balances Sartorius Extend Series balances feature powerful processor monolithic weighing system fast accurate results series consists analytical four milligram eight top-loading balances Features include RS-232C port built motorized calibration weight large draft shield chamber large readouts high-contrast display User-friendly operation plain English text prompts provides easy navigation fast learning curve information circle 56 visit Booth 1940 Rapid prototyping hardware Tiger555 565 rapid prototyping system Pathway Technologies features MPC555 40 MHz MPC 565 56 MHz respectively 7 5 60 V power input fully protected against transients reverse-battery load dump conditions Electromechanical design tool Infolytica's MagNet ElecNet OptiNet ThermNet software applications include both 32-bit 64-bit versions 32-bit versions 1 2 times faster increased memory key ingredient 64-bit applications speed-ups significant own right 64-bit solvers 30 faster 32-bit versions information circle 58 visit Booth 870 Surface-quality measurement NanoFocus' Usurf CM mobile system allows high-resolution measurement surface topographies exposed bodyin- white panels lab shop floor robust system withstand harsh environment production provide resolution laboratory machine optical technology based usurf c laboratory system Three stabilizing feet position system large parts hood panel measured desktop system system's compact size www test-dummies com sales frostproducts com 888 437 6780 713 960 8556 Body Weight 175 lbs Use Simulate Body Weight Mass tests Braking Acceleration Road Handling Tire Traction Seat Abrasion used accident Re-enactment M WBE Certified Circle 341 New SAE 2006 aei-online org Structured foil substrates Structured foil substrates Emitec suited both gasoline diesel markets offer reduced backpressure increased conversion efficiency reduced costs substrates break straight-line laminar flow pattern resulting turbulent radial sections flow increase conversion performance Perforated Design product made using perforated foil provides possibility mixing radial flow substrate Longitudinal Structure foil uses counter corrugation technique interrupt laminar flow profile enhance effectiveness 300-cell-persquare- inch cpsi substrate perform 600-cpsi substrate Combination foils allow improved flow mixing mass transfer properties reduced thermal mass information circle 62 visit Booth 2821 percentage EGR Lambda AFR oxygen pressure engine's intake exhaust rugged compact instrument improves shortens engine development calibration times information circle 63 visit Booth 2120 as-cast parts conventional HPDC parts heat treated blistering distortion occurs parts heated making unfit service process makes part performance equivalent better higher-cost wrought parts information circle 65 visit Booth 2713 EGR oxygen analysis ECM's EGR O2 4830 analyzer fast nonintrusive exhaust gas recirculation oxygen meter suitable spark-ignition diesel HCCI engine development calibration Sensors placed engine's intake exhaust used measure Rib deflection measurement Denton's RibEye measurement system monitors rib deflections provides simultaneous noncontact measurement X Y positions 12 points rib cage anthropomorphic test dummy prototype model proportioned 5th female ribcage Future versions provide X Y Z positions side-impact dummies system incorporates sensor heads mounted sides spine box located rear dummy's rib cage LEDs mounted selected measuring points ribs dummy sensors spine box cover view includes entire field measurement interest information circle 64 visit Booth 413 Heat treatment CSIRO's heat-treatment process high-pressure aluminum die castings HPDC gives large improvements strength ductility compared TPMS sensor mounting Band-It Tie-Lok clamping system Band-It-Idex used mount tire pressure monitoring system TPMS sensors system specified leading North American automaker its domestic TPMS requirements beginning 2006 permanent tamperproof OEM-approved banding system secures sensor inside wheel drop well significantly reducing potential sensor damage during tire mounting repair replacement information circle 66 visit Booth 826 Weathering testing facility Atlas Weathering Services Group expanding its services creating claims world's largest advanced global benchmark weathering testing facility Miami FL expansion made possible purchase 18 acres 7 3 ha land close proximity current South Florida Test Service Everglades site located 56 km 35 mi southwest Miami International Airport combining existing site additional acreage firm offer single consolidated weathering exposure center Miami expanded facilities serve firm's worldwide headquarters consisting accelerated weathering laboratory outdoor weathering services sample evaluation facilities information circle 67 visit Booth 627 SHEREX INDUSTRIES SHEREX INDUSTRIES LTD 1400 COMMERCE PKWY LANCASTER NY 14086 TOLL FREE 866 374-3739 FAX 716 681-0270 E-MAIL info sherex com WEBSITE www sherex com Download Sherex Catalog www sherex com Leakproof Sealing Solution Koenig proven leader sealing fluid passages automotive industrial off-road hydraulics aerospace applications low high pressures right fit tight fit 30 YEARS Reliable easy use wide range applications Eliminates taps threads sealants reamed holes Wide selection low high pressure applications Sizes inch metric Special sizes available request Tested 40 000 PSI TS 16949 Koenig Expander Sealing Plugs Koenig Expander Sealing Plugs Circle 342 Please visit SAE Booth 1727 New SAE 2006 aei-online org Airless dosing system airless dosing system PUREM makes possible inject reducing agent urea use air exhaust creating ammonia during process NOx reduction selective catalytic reduction systems system consists dosing pump controller cooled nozzle control valve well pressure lines Integrated sensors control fluid density pressure controller interfaces engine electronic control unit define correct quantity urea accuracy 5 life information circle 68 visit Booth 2258 surface complex contoured deformable support surfaces seats Individual sensing elements mat move directions eliminating sensor hammocking enabling sensor match contour loaded seat rather stretching artificially support body change seat's reaction CONFORMat only creates pressure artifacts cross talk loaded regions information circle 70 visit Booth 1026 unit laser tracks reports 3-D position handheld probe using angular encoders XtremeADM feature allows continuous measurement path beam interrupted Other features include immediate measuring capability temperature management information circle 72 visit Booth 1407 Laser welding improve manufacturing process formed profiles reduce piece costs increase number profiles used Weil Engineering offers various laser welding methods pre-formed blanks technology reduces mass dimensional tolerances car body structures side rails roof railings B-pillars engine mounts Additional efforts under way increase number hydroformed components used information circle 73 visit Booth 2137 Vehicle stabilizer Hamm vehicle stabilizer 24 7 Technology automatically activates SUV truck high-speed turn nullifying upward force vehicle's rear springs diminishing shock absorbing flexibility four suspension springs unit redirects 1000 lb ft 1356 N m upward force mass rear frame undercarriage prevent vehicle propelled upward centrifugal force rolling information circle 69 visit Booth 1942 Sensor mat CONFORMat nonhammocking pressure-sensing mat Tekscan conforms Rolling resistance Calspan's tire rolling resistance machine RRM offers precise rolling resistance values using existing flat track tire test machines instead collecting data drum testers RRM features continuous steel belt simulates flat-surface roadway hydrostatic water bearing supports tire contact patch three-axis load cell designed measure low fore aft lateral forces RRM evaluate rolling resistance free-rolling applied wheel torque conditions information circle 71 visit Booth 513 Laser tracker 230-ft 70-m range Laser Tracker X FARO Technologies uses laser technology measure large parts assemblies 0 001 0 025 mm accuracy Surface protection VentureShield 7503 3-mil 76 2-µm surface-protection film Circle 343 Please visit SAE Booth 1727 New SAE 2006 144 APRIL 2006 aei aei-online org Venture Tape designed less-demanding automotive applications including interior touch screens instruments expanding product line offers surface protection meets aesthetic needs sensitive displays electronics according company information circle 74 visit Booth 1152 modules mounted rack various hardware interfaces available addition FlexRay digital O Configurations offered 4 64 nodes information circle 75 visit Booth 1317 non-ferrous metal painted powder-coated clean prior rivet nut installation Benefits include increased spin-out resistance rivet nut information circle 76 visit Booth 1727 test equipment environmental test chamber joint analysis software controlled fastening tools ultrasonic test equipment presses sample preparation equipment various testing consulting services help manufacturers improve joint product designs concept production according company information circle 78 visit Booth 328 Development system TTAutomotive Software's ready-to-run Development Cluster system FlexRay projects consists system hardware TTX configuration tool time-triggered operating system driver network management component transport protocol hardware based four Powerlink Bonding adhesive Sherex Locsert Sherex Fastening Solutions adhesive pre-applied under head rivet nut insert installed pressure ruptures Loctite microcapsules activating bonding process Base materials must ferrous Generator system TGAR Transient Generator System AR Worldwide RF Microwave Instrumentation flexible system capable generating custom pulses handling large percentage existing specifications Features include base current rating 32 built-in oscilloscope pulse verification built-in auxiliary power supply downloadable software updates LabViewbased software built-in arbitrary waveform generators creation custom waveforms Higher current models available information circle 77 visit Booth 1014 Joint design Archetype Joint offers range testing capabilities analytical laboratory equipment support joint design selection fastener joining methods including mechanical Particle analyzer microscope-based particle analysis system Carl Zeiss designed analysis documentation surfaces cleaning liquids gels powders suitable inspection technical cleanliness round filter membranes One-step evaluation specimen occurs target magnification eliminating manual searching large particles Familiar directives company-specific standards used evaluate measuring results AxioVision software aids system setup configuration information circle 79 visit Booth 1328 Simulation software STAR-Pro ENGINEER Pro E simulation software CD-adapco features solver embedded Pro E environment CFD solution becomes integral part CAD model Simulations set run entirely framework Pro E allowing users work people uncommon commitment membership SAE International entrée industry s great engineering alliance world colleagues world advanced technology 051457 Members www sae org membership Share Serve Advance Join SAE International automotive aerospace commercial vehicle New SAE 2006 aei-online org aei APRIL 2006 145 model using shortcuts visualize results understand flow mechanics CFD functionality presented additional items Pro E menu mesh created directly Pro E model information circle 80 visit Booth 1927 built-in O port Linux 2 6 offers improved memory processor speeds S-3 provides instant nodes network reading writing data logging suitable network development end-of-line testing system service data acquisition unit operate remote PC 9 32 V dc temperature ranges -10 80 C 14 176 F information circle 81 visit Booth 2501 obtain extinction images spray six view angles SETscan patternator performs tomographic inversion provide local distribution drop surface area density spray Images obtained speeds 4000 Hz thereby freezing interior distribution droplets fast-moving spray Typical applications include quality assurance programs fuel injectors information circle 82 visit Booth 2216 Designed comfort P3000 immune untrained operation minimizing operator error avoiding potential missed leaks unit detect leaks distance leak location leak rates displayed refrigerant-equivalent rates accounting difference fill pressure helium refrigerant charge dilution helium Wise technology eliminates filament changes need turbo molecular pump information circle 83 visit Booth 623 Bus analyzer Dearborn Group S-3 automotive bus analyzer features Hercules user interface V 4 0 standard independent 100 Mbps ethernet connection Optical patternator optical patternator En'Urga based Statistical Extinction Tomography SETscan Leak detector INFICON offers Protec P3000 helium sniffer leak detector Roller bearing Koyo Corporation USA JTEKT Group company developed line singlerow tapered roller bearings Optimization internal Honda R D Americas Inc ll involved projects only excite turn heads entire industry engineers designing testing using talents create motorcycles ATVs automobiles power equipment concepts future process rediscover chose profession power turn today s dreams tomorrow s products s high-performance highly rewarding opportunity invite along ride life success built hands-on approach beginning concept generation continuing finished vehicle made easier proximity accessibility Honda s manufacturing facility part excitement interested career Honda send resume Human Resources Honda R D Americas Inc 21001 State Route 739 Raymond OH 43067-9705 Fax 937-645-6337 Email emp oh hra com equal opportunity employer www hondaresearch com Honda R D Americas Inc ThePower Dreams New SAE 2006 146 APRIL 2006 aei aei-online org geometry bearings reduces heat generation frictional losses 50 highway speeds decrease durability rigidity enabling performance axle pinions low frictional torque applications information circle 84 visit Booth 2353 optional remote control information circle 86 visit Booth 645 Distributed computing Distributed Computing Toolbox 2 Distributed Computing Engine 2 MathWorks enable engineers develop distributed MATLAB applications execute cluster computers Together products leverage MATLAB language algorithm development accelerate computation via distributed parallel execution Features include support third-party schedulers inter-process communication capabilities communication functions based message passing interface Distributed Toolbox 2 covers parallel execution finer-grained applications information circle 85 visit Booth 1170 Detecting helium leaks SmartTest portable helium leak detector Pfeiffer Vacuum designed user-selected backing pump match application available vacuum sniffer standard operating modes detectable leak rate helium 5 10-12 mbar l s inlet pressure 25 mbar users begin testing soon startup SmartTest designed integrated test leak selfcalibration work surface Meshing software Gridgen Version 15 09 CFD meshing software Pointwise features solid modeling solid meshing Importing solid data directly assembling solids Gridgen enables mesher distill geometry implicit CAD topology eliminating proximity computation improving efficiency software supports quilts topologically linked surfaces meshed single unit Other features include deformation-based scheme pyramid cell generation hybrid meshes native interface information circle 87 visit Booth 1926 Wire-bondable plating AIR Tech Sumco electroplated coating allows large-diameter aluminum wire ultrasonically bonded lead frame surface AIR Tech applied overall selected stripes stamping etching operation plating system designed alternative aluminum inlay strip material Features include bondability 3000 h exposure temperatures 85 C 185 F 150 C 302 F dry bake information circle 88 visit Booth 2241 Stress measurement MAX Miniature Advanced X-ray Diffraction System Technology Energy Corporation TEC features measurement head fits space 6 152 mm diameter uses X-ray diffraction measure surface residual stresses onsite common engineering materials single exposure technique prevents head moving during measurement measurements made 2 3 min system consists hardware software plus laptop PC information circle 89 visit Booth 641 Octane analyzer ZX-101 portable octane cetane analyzers Zeltex accurately analyze fuel ZX-101XL offers automatic fuel selection detect type fuel analyzed reduce operator error optional GPS locator Delron sense head firmly position sample holder instrument two-piece sealed optical filter tray extend filter life Other features include warm-up time 1 min analysis time 20 sec information circle 90 visit Booth 2229 Hydrogen refueling station U S Army Tank Automotive Research Development Engineering Center TARDEC National Automotive Center highlights innovative vehicles based alternative energy programs forefront military industrial development including Quantum HyHauler Plus Aggressor vehicle Eaton's Hydraulic Launch Assist bus HyHauler Plus transportable hydrogen refueling station encapsulated lightweight trailer specifically designed fast-fills fuel-cell vehicles information circle 91 visit Booth 701 Simulation methodology Ansoft offers simulation methodology predict electromagnetic induction electromagnetic compatibility insulated-gate bipolar transistor IGBT packages used hybridelectric vehicles Based data exchange links Q3D Extractor used create import 3-D solid model physical layout complete IGBT package extracting partial inductance resistance capacitance Engineers construct models entire system Simplorer calculating power input source HFSS calculates electric field user-defined distance information circle 92 visit Booth 2009 aei-online org aei APRIL 2006 147 late 1990s time frame Chrysler Group engineers evaluate 200 000 computer-generated elements typically consumed four five days advancements computing power computer-aided engineering CAE analysis particular subject takes 36 h covers million elements evercloser correlation virtual real worlds--enabled large part amount detail math models--is reducing need physical vehicle testing We're phase we're close eliminating physical prototypes development work said Ram Bhandarkar Supervisor Durability Start Production Analysis Methods Chrysler Group's Advance Vehicle Engineering Prior start production CAE helped engineers investigate array issues Computer simulations example give engineers better understanding specific vehicle structure individual parts perform during impact instance particular part compromised pealing bumper other layer said Shan Haq Chrysler's Group's Supervisor Safety CAE-Start Production Analysis Methods CAE X-ray vision that's different view during vehicle crash barrier test Chrysler Group programs uses combination com- validation OEMs developing tools engineers around world validate vehicles regulations conformity other objective subjective aspects Kami Buchholz puter simulations physical testing develop validate vehicle said Mark Chernoby Vice President Advance Vehicle Engineering Chrysler Group early stages program computer simulation computer-aided design CAD dominant tools develop vehicle design combines discrete set components vehicle system meets targeted customer requirements Computer simulations enable General Motors' engineers accomplish various tasks validating vehicle structural characteristics virtual assessment process used provide assurance engineering solutions meeting performance requirements prior engineering releases virtual build process prior physical builds explained Bill Alfaro General Motors Quality Strategist Physical builds hardware testing used math models capable sufficient validate design themselves Ford computer simulations used aspects product creation--from early aerodynamic occupant package analysis manufacturing assembly service noted Dan Arbitter Chief Engineer Vehicle Engineering Small Wheel Drive Rear Wheel Drive Platforms CAE laboratory testing vehicle testing interwoven today five years Using durability testing example Arbitter said Today able capture vehicle loads real-world street using highpower in-vehicle computers transducers acquire data instance utilize loads analytically develop shock absorber profile validate full vehicle rig test utilizing exact loads boundary conditions changes role full-size hardware definitely evolving Physical vehicles provide value CAE need evaluate wide variability human vehicle environmental interactions Arbitter said interface include driver passenger assembly plant employee environmental conditions rain snow altitude dust temperature Although evaluating factors analytically grasp interactions permutations real world difficult model analytically solve today's computing power Physical prototypes utilized demonstrating regulatory compliance governmental organizations accept analytical data Chrysler use prototype vehicles validation purposes vehicle program specifically plan use physical properties answer specific compelling questions noted Chernoby physical properties range validation 148 APRIL 2006 aei aei-online org bolting single component existing production vehicle full-skin prototype components represents intended production design usage physical prototypes grows parallel scope program Product validation relying proving grounds testing General Motors use computer simulation laboratory-based evaluations gain favor GM compresses product development process full vehicle testing impacted large extent greater emphasis reliance component subsystem validation Utilization re-use strategies implementation design best practices reduced need physical tests said Alfaro expect trend continue future increased focus identifying potential design issues earlier vehicle development process Physical builds essential validate vehicle-level interactions validated subsystem component levels New frontiers Innovations existing technologies continued mobility advancements create new testing procedures New technologies--including alternate propulsion systems new safety requirements increased use electronic controls information integration increased demands customer reliability durability--will continue drive changes product validation methods said GM's Alfaro case point work relative radio frequency RF interference Chrysler Group example developing virtual RF interference simulation companion current testing It's 100 correlated we're working said Richard Bradshaw Chrysler's Group's Product Engineer Electronic Electrical System Compatibility Chrysler conducts types RF testing involving radiating vehicle other confirming vehicle radiate RF outward Canadian law requires outdoor test confirm vehicle radiating RF Depending vehicle program supplier handle substantial validation duties suppliers comprehensive in-house testing methods equipment example program dictates Behr provide HVAC heating ventilation air conditioning modules workers conduct validation tests performance heating cooling airflow NVH well durability thermal cycle door life cycle vibration system programs additional validation tests overall system performance Behr's responsibility responsibility specific validation tests vary program program said Philip Stephenson Chief Engineering Validation Behr America Inc adding case validation testing ranges individual component tests module tests vehiclelevel tests performed climatic wind tunnel road factors determine validation test uses full vehicle decision perform vehicle-level testing typically driven availability test vehicles type testing required cost considerations explained Stephenson addition customer standards durability perfor- Test engineer Chris Leitz installs acoustic measurement head test vehicle Behr's semi-anechoic test cell acoustic measurement head helps engineers optimize sound quality airconditioning unit vehicle mance testing drive specifications tests instance certain performance tests address occupant safety validation testing meet defrosting defogging targets NVH development HVAC modules key aspect validation process Behr Customers expect excellent sound quality HVAC module noted Stephenson result concentrate only lowering overall sound level eliminating types sound--for example whistling whining noises particularly objectionable customers Behr employs global standards testing methods equipment test performed Behr locations compared 'apples apples' high confidence according Stephenson other hand customers different parts world local validation requirements number type tests vary region use term 'validation' define test evaluation cycle associated vehicle design released tooling said Chrysler's Mark Chernoby tooling prototype actual productiontooled version depending scope program Validation begins CAE modeling level design Validation concludes final test evaluation conducted production-tooled vehicles occurs prior releasing shipments customers 2006 U S -market Ford Focus underwent validation broadly categorized Design Verification Production Verification Actual start times vary based amount new content vehicle program generally speaking Design Verification begins approximately mid-point program start Job said Ford's Dan Arbitter During phase ensure fundamental design meets requirements Production Verification begins three months Job ensure requirements met utilizing production manufacturing processes variability Analytical modeling system vehicle level begins program start assure compatibility targets shape designs supplier's role validation validation aei-online org aei APRIL 2006 149 outward Chrysler conducts tests its Chelsea MI proving grounds expectation increasing pervasiveness two-way communications undoubtedly alter status quo Eventually background noise gets great we'll somewhere said Bradshaw RF interference cause electronics malfunction year-to-year gain electronics vehicles presents gateway potential problems main challenges product validation evaluate possible operating condition customer experience according Chrysler's Chernoby difficult examples today's complex electrical systems challenge engineers making electrical electronic modules work cohesively system--regardless operating environment event sequence conduct statistical analysis potential number conditions quickly realize virtually impossible evaluate physical test reasonable period time explained Chernoby five years Chrysler began using computers conduct hardware-in-the-loop testing electrical systems covering possible scenarios fraction time human beings physical test Chernoby added different worldwide requirements validation strategies continue revamped Shared vehicle designs architectures subsystems components different markets require new revised validation methods procedures offered GM's Alfaro illustrate point Alfaro cited circumstances durability evaluations North America falling short meeting vehicle performance needs developing countries Simply durability tests severe enough Evaluation procedures revised place address global durability reliability requirements Alfaro said Market motivators Ford relies total program plan wraps multiple market requirements including validation internally developed tool optimizes test planning prototypes prevents replication provides efficient robust validation plan said Ford's Arbitter result needs unique markets addressed driven customer needs expectations regulatory compliance possible entire validation process twist turn predict reliance global validation vehicle programs said Arbitter Imagine single vehicle program North America managed United States validation process performed parallel throughout globe envisions possible scenario supplier system validation China vehicle validation executed New Zealand Australia Northern Canada Arizona Europe CAE performed India powertrain calibration development North American environmental labs global approach optimize resources facilities time market environmental exposure Arbitter said GM's formation global product process teams represents push common global requirements design margins family parts approach leverage re-use robust designs minimize need repeat product validation said Alfaro GM global proving grounds test labs correlated step supporting validation product designs different markets Although repeat testing specific validation tests performed demonstrate compliance regional regulatory requirements Chrysler Group vehicle validation relies total understanding wanted component system during specific operating conditions think 'scripting' play said Chernoby Once understand 'script ' develop vehicle ever-improving set computer simulation physical testing tools meet exceed customer requirements Predicting future continues difficult task likely scenarios find method using similar artificial intelligence automate portions develo p - ment process run parallel CAD Product validation starts prior Vehicle Program Initiated stage understanding customer needs wants translating engineering requirements determining validation methods used verify design meets customer requirements said GM's Bill Alfaro Product validation concludes approximately weeks prior Manufacturing Validation Builds- Saleable reassessment Ship Commerce once Manufacturing Validation completed additional design changes understood PT Cruiser tested Chrysler Group's Electromagnetic Compatibility Test Cell uses antenna cart radio frequency transmission According Mark Chernoby competitors consumers influence product validation primary impact continuous improvement expectations product said basically means functional requirements become stringent category--from appearance seat material noise characteristics during wide-open throttle acceleration Durability testing Chrysler Group replicate life cycle passenger car weeks versus typical 16 18 weeks Chelsea Proving Ground road simulation lab usually used times-- manufacturing pilot vehicle pre-launch vehicle--to address development work validation needs early skin prototype road simulator radically different vehicle image shows Dodge Ram truck tested Chrysler Group's road test simulator product briefs 150 APRIL 2006 aei aei-online org Testing Spotlight product briefs Edited Matthew Newton Leak finder portable Leak Finder Cincinnati Test Systems used find small leaks chambers connections parts device features rechargeable container helium gas spray nozzle similar aerosol Helium sprayed suspected leak location part chamber observed mass spectrometer system continuously measures helium concentration part under vacuum leak immediately identified helium drawn part chamber vacuum inside mass spectrometer responds concentration change caused new helium drawn part chamber timing response corresponds location helium sprayed time response indicate leak location information circle 1 Component testing Schaffner EMC's automotive electronic component testing system claimed first internal 100- coupler system includes NSG 5500 testing capacitive discharge transient immunity NSG 5600 testing supply voltage variation PA 5840 battery simulator NSG 5500 contains internal 100-A battery switch feature allows four times equipment-under-test supply current industry-standard 25-A couplers provides greater waveform accuracy standard external couplers information circle 2 Impact measurement Dynatup 9250 Instron impact testing instrument designed measure energy absorption related impact properties polymers metals composites resulting final components drop tower features complete computer control impact velocities 20 m s 66 ft s rigorous testing fields R D quality control system captures plots analyzes entire impact event enabling user determine important characteristics incipient damage ductile-to-brittle transition point maximum load total energy absorbed addition test materials extreme temperatures harsh environments information circle 3 Custom electrical sets Staco Energy Products' Power Provider System line custom electrical test sets monitors controls range variables allow electrical product manufacturers test products accuracy Common uses include testing electrical motors compressors pumps power supplies lighting variables accelerated service life testing motor startup run efficiency inrush amps locked rotor amps capacity RS-232 interface allows computer control downloading data customer's computer system information circle 4 Modular power supply Agilent Technologies added four modules mainframes its N6700 modular power system extend its range 1200 W mainframes offer 600- 1200-W capability join currently available 400-W mainframe mainframes accommodate four modules system-ready 1U package size Four 300-W basic programmable power supply modules added system extend its range coverage system automatically senses power available ac line scales available output power accordingly allowing high-power mainframe plugged standard outlet information circle 5 Test management software NI TestStand 3 5 test management software National Instruments offers native integration NI LabVIEW 8 well requirements management tools XML-based reporting Engineers use software design prototype deploy automated test systems using test code modules developed legacy latest programming environments including LabVIEW 8 graphical development environment NI LabWindows CVI 8 0 ANSI C development well Microsoft Visual Studio 6 0 NET package integrates LabVIEW 8 project library improve organization deployment files large automated test systems expands connectivity other industry standards tools delivering Automated Test Markup Language reporting interface integration information circle 6 product briefs aei-online org aei APRIL 2006 151 Automatic contact generation NEiNastran V9 0 Noran Engineering contains fully automated interface handle surface contact weld-element generation assembly models Previously users required specify surfaces contact time consuming models contact areas V9 0 adds single command interface specify type contact general welded bi-directional sliding rough user meshes individual parts entire assembly NEiNastran V9 0 rest Welded contact allows movement parts model redefine ideal design optimization information circle 7 Crash simulation ESI Group demonstrated capabilities its 64-bit Open VTOS solution ESI's crash simulation solution PAM-CRASH integrates Microsoft Message Passing Interface Job Scheduler technologies Microsoft Windows Compute Cluster Server 2003 Open VTOS encompasses Visual Environment ESI Group solvers version allows customers use Distributed Memory Processing version PAM-CRASH clusters industry-standard 64-bit hardware allows work interactively large models 4 5 million elements require 4 GB memory information circle 8 Faster multiphysics COMSOL released version 3 2 COMSOL Multiphysics--the previous version known FEMLAB 3 1 software reads geometry files created major CAD packages v3 2 introduces COMSOL Script standalone product featuring command-line modeling graphical user interface encourages use consistent system engineering units moving-mesh feature allows models simulate moving parts parametric geometries Improved solvers handle models millions degrees freedom information circle 9 Air velocity temperature measurement Advanced Thermal Solutions' ISD-232 board provides simultaneous high-speed measurements air velocity temperature independent sensors board directly assesses airflow temperature computer feedback control measurement systems using mobile sensors placed anywhere test domain board used control devices laboratory wind tunnels HVAC regulators provide read-out data display systems measures temperatures -30 150 C -22 302 F air velocities 0 50 m s 0 164 Image Volkswagen Convergence guiding principle automotive innovation coming decades Convergence 2006 explore powerful convergence advanced electronics propulsion materials telematics synergy realized key technologies paradigm shifting industry enabling reinvention automobile setting stage truly sustainable mobility signifi cant industry growth October 16-18 2006 Cobo Center Detroit Michigan USA 060157 2006 Theme Convergence Reinvents Automobile Connect infl uential technologies people involved vehicle electronics mechanics communications Larry Burns Vice President GM Research Development Strategic Planning General Motors Corp Convergence 2006 General Chair www sae org convergence CustomerService sae org outside U S Canada 1-724-776-4970 Register save 200 Exhibit Sponsor Advertise CustomerSales sae org 1-724-772-4086 product briefs 152 APRIL 2006 aei aei-online org ft s changing sensors board 3 34 x 1 44 85 x 37 mm platform 0 55 14 mm tall information circle 10 Simulated light Lighting Scenery latest simulation software OPTIS allows designers automotive lighting systems test designs virtual world 3-D scene generated importing designs CAD CAM software application Entering surface properties environmental data time place weather sunlight provides users projected illuminance luminance levels--represented 3-D view both false real color primary benefit technology allow user test efficiency system building casting molds building prototypes information circle 11 High-reliability parts Automotive Plus Series parts AVX qualified Automotive AEC-Q200 standard manufactured quality assurance-tested high reliability requirements aerospace industry series features Base Metal Electrode BME System X7R ceramic range part numbers includes X7R dielectric components containing BME electrode copper terminations Ni Sn-plated overcoat X7R dielectric components featuring BME electrode soft terminations Ni Sn-plated overcoat X7R hybrid applications epoxy-finished components NP0 dielectric components containing Pd Ag electrode silver termination Ni Snplated overcoat information circle 12 Lockable slide latch molded thermoplastic body push-to-close convenience flexible locking options Southco A3 push-to-close slide latch solution secure latching sheet metal thin thermoplastic door panels Its integrated lockplug housing provides added security sacrificing latch's small envelope size eliminates need separate key cam lock security Both locking non-locking versions snap position identical-size rectangular installation holes lock housing offered 500 key code options information circle 13 Marketing Solutions SAE International SAE qualified audience 300 000 mobility engineering professionals around world re trying reach mobility engineering professionals Print Advertising E-marketing Exhibits Sponsorships List Rental Customized Marketing Solutions premier society dedicated advancing mobility engineering worldwide Automotive Aerospace Commercial Vehicle SAE Marketing Solutions Toll-free U S Canada 1-888-875-3976 Telephone 1-724-772-4086 Fax 1-724-776-3087 E-mail CustomerSales sae org waiting spend penny marketing resources contact SAE s knowledgeable regional market managers find rich offering Marketing Solutions including 051572 Attention mobility industry Marketing Professionals aei-online org aei APRIL 2006 153 Receive FREE literature featured suppliers www aei-online org click PRODUCT INFO menu bar enter circle number listed advertise company's literature call 888-875-3976 1-724-772-4086 tech-lit file Circle 353 RF Power Amplifier Brochure revised RF Power Amplifier Brochure AR Worldwide RF Microwave Instrumentation features wide range RF power amplifiers available brochure highlights W series amplifiers cover 1 -- 10 000 watts dc- 1 GHz Product photographs descriptions specifications performance graphs included model AR Worldwide RF Microwave Instrumentation 160 School House Road Souderton PA 18964 215-723-8181 Circle 358 PATCO Modular Tooling Systems Prototype Systems Tier design build inspection services facility offering PATCO Reusable Modular Tooling dedicated tooling services celebrating 20th year anniversary year information please call 586 795-3690 visit web site www prototype-systems com Circle 355 Circle 359 Austempering Applied Process 8-page brochure information-packed guide Austempering process high performance heat treatment steel gray iron ductile iron delivers improved toughness wear-resistance fatigue strength Learn Austempering boost product performance reduce manufacturing costs Applied Process offers brochure - expertise application engineers - show information contact Applied Process Inc 12202 Newburgh Road Livonia Michigan 48150 TEL 734-464-8000 FAX 734-464-6314 www appliedprocess com Circle 357 Circle 356 Circle 354 Retrofit-able DPF-EGR system Achieves Emissions Goal affordable costs GreenPower Muffler system newly patented DPF-EGR system worldwide helps meet future 2007-10 diesel PM NOx emissions standards economically Urea-SCR system save fuel use catalytic water solution EGR-Accumulator system OEM's retrofit market simplified GreenPower system developed recently certified Japan DPF trap units fuel additive offered retrofitting heavy-duty diesel engines engine capacities varying 8 24 liters GreenPower DPF retrofit kit includes canned ceramic filters modular design Green FBC catalytic additive engine-Oil Borne catalyst OBC additive optionally Patented technology licenses available OEM's Visit website www dieselnet com dr rim Contact dieseltrap aol com Doubletree Tech Intmet Ltd 522 Hupp Ave Jackson MI 49204 734 414-1414 734 414-1415 fax Buhrke Industries offers 20 page brochure detailing its high-volume metal stamping automated assembly services major automotive supplier Buhrke produces parts sub-assemblies electronic industrial equipment OEM's worldwide Competencies include in-house tooling design fabrication application engineering prototype services Buhrke member company IMS group Plants U S Mexico ISO TS 16949 2002 ISO 9001 2000 ISO 14001 1996 Metal Stampings Automated Assembly Since 1949 BUHRKE INDUSTRIES IMS COMPANY 511 W Algonquin Rd Arlington Heights IL 60005 Ph 847 981 7550 Fax 847 981 0772 info buhrke com www buhrke com HANDBOOK DESIGN ENGINEERS its new 320-page catalog Suhner introduces components improve efficiency automate drilling milling tapping operations unique system offers conventional CNC machining units slide assemblies including multiple spindle heads comprehensive modular product range ideal designing building customized self-made machines assisted 2D 3D CAD component layouts SAE Congress booth 2155 Suhner Industrial Products Corporation Rome GA Phone 706 235-8046 Fax 706 235-8045 www suhner com DANA INTRODUCES NEW DRIVETRAIN PRODUCTS BROCHURE Dana Corporation announces availability brochure featuring its drivetrain products including full line axles driveshafts torque couplings literature offers detailed information Dana's complete drivetrain systems thermalmanagement products drivetrain products brochure component four-part series building block brochures includes chassis engine structural products information request building block brochures visit www dana com auto Exhibit World Congress April 16-19 2007 Cobo Center Detroit Michigan USA Host Company Reserve booth location SAE 2006 advantage reduced deposit fee only 10 Visit SAE Corporate Sales Offi ce located next SAE Store Wayne Hall fi nd Ultimate Technical Information Exchange World Class Networking Customers re 060283 aei-online org aei APRIL 2006 155 Company Page 24 7 Technology 143 Acura 84 99 Advanced Automotive Batteries 64 Advanced Energy Technology 140 Advanced Thermal Solutions 151 AET Integration 102 Agilent Technologies 150 Aichi Kikai 82 Aisin 70 80 135 138 Alfa Romeo 33 ALGOR 95 Allied Ring 99 Allison 13 64 Alpine 99 American Motors 158 Analog Devices 48 50 99 Ansoft 146 ANSYS 94 AR Worldwide RF Microwave Instrumentation 144 Arcelor 76 Archetype Joint 144 ASC 28 158 Aston Martin 88 Atlas Weathering Services Group 142 Audi 6 34 36 AutoForm 104 Automotive Components Holdings 12 Automotive Lighting 33 Automotive Resources Asia 160 AUTOSAR 60 AVX 152 BAR Honda 88 Ballard Power Systems 159 Band-It-Idex 142 Battenberg 138 Behr 30 137 148 Benteler 132 BHTC 137 BMW 34 38 64 65 68 74 98 106 BMW Sauber 88 BorgWarner MorseTec 36 BorgWarner Turbo Systems 36 Bosch 14 33 38 50 99 112 Cadillac 33 118 Calspan 143 Canesta 52 CARB 130 Carl Zeiss 144 Cars Concepts 158 Caterpillar 88 CD-adapco 144 Centro Ricerche Fiat 77 Chevrolet 12 24 97 120 158 Chevron 157 Chrysler 48 70 114 147 158 159 Cincinnati Test Systems 150 Cirrus Technologies 88 Citroen 30 Cobasys 65 Collins Aikman 159 COMSOL 151 Continental 112 137 Continental Temic 65 Cooper-Standard Automotive 99 Cord 30 Crolles 2 Alliance 55 CSIRO 142 CSM Worldwide 68 Cyclone Technologies 136 Daihatsu 80 DaimlerChrysler 14 52 62 65 68 120 136 137 Dassault Systèmes 92 95 132 Data Physics 94 Dearborn Group 145 Delphi 114 Denso 46 66 114 Denton 142 Detroit Diesel 158 Diversified Technical Systems 139 Dodge 10 13 16 64 120 159 dSPACE 136 Duke University 8 DuPont 124 Eaton 146 eBay 159 ECM 142 Emitec 142 En'Urga 145 Endevco 94 EPA 6 98 157 ESI Group 151 F T Precision 99 FARO Technologies 143 FAW 160 FAWER 160 FEV Engine Technology 62 132 FIA 92 Fiat 30 56 Fluent 94 Ford 12 18 24 64 68 100 102 106 114 136 147 158 159 160 Formula 87 FreedomCAR 64 Freescale Semiconductor 54 Frost Sullivan 56 Fuji Heavy Industries 78 FunctionBay 94 GE Plastics 28 159 Gearing Watson 94 General Motors 6 12 46 64 65 68 88 110 118 120 147 159 Getrag 40 GM Powertrain 68 Halla Climate Control 160 Hamamatsu 139 Harley 159 HBPO 30 Hella 30 33 137 Helsinki Polytechnic 95 Hess Engineering 141 Hirschmann 135 140 Hitachi 64 Honda 16 24 62 70 78 97 108 Honda Foundry 99 Hummer 28 118 159 HUSCO Automotive 141 Hyundai 16 18 24 36 46 56 108 157 160 Ibeo Automobile Sensor 134 IBM 55 Image Labs International 140 INDUS Concepts Engineering 136 Indy Racing League 6 INFICON 145 Infiniti 78 118 Infolytica 141 INSA 18 Instron 150 Insurance Institute Highway Safety 94 International 13 InterRegs 157 ITI 134 J D Power Associates 62 JATCO 78 Jeep 24 114 Jefferson Industries 99 Johnson Controls 42 65 Johnson Electric 42 Johnson Matthey 99 JTEKT Group 145 Kanto Automobile 86 Keihin 99 Kia 14 16 36 46 56 Korea Flange Company 36 Koyo Corporation USA 145 KTH Parts Industries 99 Kuroda Precision Industries 99 Lambda Research 139 Land Rover 88 Lear 99 Lexus 14 46 94 116 135 LG Electronics 57 Lincoln 12 18 108 Lincoln-Electric 102 Lotus 88 Lumileds Lighting 32 Magna 158 Magna Steyr 159 Magneti Marelli 33 MANN HUMMEL 136 Massachusetts Institute Technology 159 MathWorks 138 146 Matsushita Electric Industrial 99 Mazda 26 100 108 MBtech Group 134 McLaren Performance Technologies 28 McNeel North America 95 Measurement Specialties 138 Melexis 52 Mentor Graphics 60 94 Mercedes-Benz 14 32 33 48 116 137 160 Metro Technologies 102 Michelin 99 100 Microsoft 56 132 150 151 Mini 27 companies mentioned Mitsubishi 16 20 78 158 Motorola 55 Motorsport Industry Association 6 MTS 87 NanoFocus 141 NASCAR 87 Nash 159 National Academy Sciences 157 National Automotive Center 146 National Instruments 150 NHTSA 114 Nippon Seiki 99 Nissan 14 18 48 78 88 94 110 159 Nissin Kogyo 99 Nissin Manufacturing 99 Noran Engineering 151 NVision 135 OCDM Associates 94 Oldsmobile 30 Omron Automotive Electronics 48 50 Semiconductor 55 Opal-RT 140 Opel 34 OPTIS 152 Pathway Technologies 141 Paulstra 94 PCB Piezotronics 138 Peak Industries 88 Peugeot 33 Pfeiffer Vacuum 146 Philips 56 Philips Semiconductors 50 52 55 Plastic Omnium 30 Pointwise 146 Pontiac 110 Porsche 160 Power org 55 PSA Peugeot Citroën 160 PSA 160 PUREM 135 143 Raytheon 118 Renault 18 78 88 Renault FI Team 92 Ricardo 160 Ricardo Japan 159 Rockford 16 Roush 158 SAE International 6 8 52 58 64 65 74 76 100 102 120 124 Sartorius 141 Satcon Technology 94 Saturn 65 68 110 Schaffner EMC 150 Scott Specialty Gases 140 SDRC 72 Seima 33 SEMA 120 SeohanWarner Turbo Systems 36 Shanghai Automotive Industry Corporation 46 94 Sherex Fastening Solutions 144 Siemens VDO 99 114 160 SKF 99 Skoda 160 Smart 135 Software Cradle 136 Solutia Automotive 12 Southco 152 Ssangyong Motor 44 Staco Energy Products 150 Stanley Electric 32 STMicroelectronics 54 Strategy Analytics 54 Subaru 78 Sumco 146 Sumitomo Electric Industries 99 Suzuki 28 82 Synergis Technologies 104 Synopsys 138 Takata 99 Tamagawa Seiki 99 TDK 99 Technology Energy Corp 146 Tekscan 143 Business Motorsports 6 TM4 134 Total Electronics 140 Toyota 10 22 28 46 62 70 78 95 108 135 138 158 160 Triumph 30 TRW 65 99 160 TS-tech 99 TTAutomotive Software 144 Tucker 30 TZ Mikroelektronik 139 U S Army Tank Automotive Research Development Engineering Center 146 U S Department Energy 64 157 U S Department Transportation 157 UGS 72 94 United Piston Ring 99 United States Advanced Battery Consortium 157 University Art Design 95 University Detroit 158 University Michigan 158 University Waterloo 159 UTC Power 157 Valeo 34 42 77 99 VDT 78 Venture Tape 144 VISTAGY 92 Visteon 50 56 116 160 Volkswagen 32 36 46 68 159 160 Volvo 114 Weil Engineering 143 Xiali 160 Yachiyo Kogyo 99 Yazaki 66 Yutaka 99 Zeltex 146 ZF 65 70 Zippertubing 139 Inquire online aei-online org ad index 156 APRIL 2006 aei aei-online org Advertiser Circle Page Website 3M Automotive Division 217 17 www 3M com FFCe D Technology Inc 249 49 www aanddtech com AIN global 229 29 www koaashow com AR Worldwide 263 63 www ar-worldwide com ARi 125-128 ari sae org Adobe Systems Inc 4 5 adobe com 3D Ansoft Corporation 321 121 www ansoft com solve Applied Process Inc 354 153 www appliedprocess com Arkema 293 93 www arkemagroup com ArvinMeritor Inc 256 56 www arvinmeritor com Atlas Fahrzeugtechnik GmbH 337 137 www aft-detroit com Automotive Lighting 231 31 www al-lighting com Bayer MaterialScience LLC 267 67 www bayermaterialsciencenafta com visionworks Advertiser Circle Page Website Publisher's Office SAE International Thomas J Drozda General Manager Corporate Sales Publisher 400 Commonwealth Drive Warrendale PA 15096-0001 V 1-724-772-8591 F 1-724-776-3087 thomasdrozda sae org Melissa R Mishler General Manager Global Sales V 1-281-374-7135 F 1-281-251-7101 meliss sae org William Lauppe Director Automotive Sales SAE Automotive Headquarters 755 West Big Beaver Road Suite 1600 Troy MI 48084 V 248-273-4088 F 248-273-4082 billlauppe sae org Arlene Sloan Director International Sales V 724-772-8546 F 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Kemet Electronics Corp 209 9 www kemet com Kistler Instrument Corp 333 133 www kistler com Kolbenschmidt Pierburg Inc 213 13 www usa kolbenschmidt-pierburg com Lee Company 322 122 www TheLeeCo com imh4 Linamar Corp 255 55 www linamar com MACSTEEL 398 cover 3 www macsteel com Magtrol Inc 339 139 www magtrol com MathWorks Inc 215 15 www mathworks com mbd Melexis 315 115 www melexis com OPTIS 305 105 www optis-world com PCB Piezotronics 331 131 www pcb com Palmetto Economic Development Corp 257 57 www SCpowerteam com Prototype Systems Inc 307 107 www patcoae com 359 153 Radiall 275 75 www radiall com Rennsteig Werkzeuge GmbH 283 83 www rennsteig com Schaeffler KG 291 91 www ina com Sekisui Products LLC 285 85 Sherex Industries Ltd 342 142 www sherex com 343 143 Siemens VDO Automotive 397 cover 2 www siemensvdo com Simtec 277 77 www simtec-silicone com Software Cradle Co Ltd 294 94 www sctetra-usa com Spektra Schwingungstechnik Akustik GmbH 340 140 www spektra-dresden de SUHNER Manufacturing 356 153 www suhner com TenarisDalmine 239 39 www tenaris com Thomas Magnete USA LLC 286 86 www thomas-magnete com Total Electronics LLC 317 117 www totalems com Tyco Electronics 289 89 www tycoelectronics com Umicore Autocat USA Inc 245 45 www automotivecatalysts com www umicore com Vector CANtech Inc 261 61 www vector-cantech com Voss 243 43 www voss de Yazaki North America Inc 207 7 www yazaki-na com ZF Friedrichshafen AG 219 19 www zf com aei-online org aei APRIL 2006 157 regulations standards Edited Patrick Ponticel briefs fed money fuel efficiency big President Bush's proposed budget increases research nextgeneration auto fuel battery engine technologies still drawn carping couple sources president's proposed fiscal 2007 budget starts October 1 singles biofuels hydrogen fuel plug-in battery initiatives U S Department Energy significant increases increases instances way short Congress directed president spend 2005 energy bill Moreover key House committee chairman says technology research great results long term Short-term measures tougher Corporate Average Fuel Economy CAFE standards U S Department Transportation proposed needed right said Key auto programs DOE hydrogen fuel cell FreedomCar programs hydrogen program receive 195 8 million increase 26 fiscal 2006 FreedomCar fall 166 million 182 million 2006 reduction comes eliminating 20 million projects Congress insisted including 2006 budget essentially flat FreedomCar Hybrid Electric Propulsion R D subprogram increase 7 million 51 million Run conjunction United States Advanced Battery Consortium USABC automotive manufacturers participate effort aimed reducing volume production cost high-power 25-kW battery use passenger vehicles 3000 1998 500 2010 Possible candidates include advanced high-energy lithium-ion systems gel polymer electrolytes biomass funding program 91 million 150 million increases significant context big federal deficit budget cuts other federal domestic programs auto industry officials want increases view Judith Bayer Director UTC Power's government business development UTC manufacturer fuel cells working Chevron Hyundai four teams participating DOE's National Hydrogen Learning Demonstration Project Bayer said budget technology validation increase 33 million 39 million Bayer pointed Energy Policy Act Congress passed summer set authorization level entire DOE hydrogen program 500 million fiscal 2007 Bush's proposed 198 million budget increase far short Bayer noted company others trying convince House Senate appropriations committees increase Bush's hydrogen program proposed numbers other end spectrum influential Republican Rep Sherwood Boehlert R-NY Chairman House Science Committee worried excessive technology funding Energy Secretary Samuel Bodman Science Committee February present proposed budget Boehlert told need beyond illusion pouring money technology development--which need do--is enough transform energy portfolio Joe Pouliot spokesman Boehlert said congressman thinks equally important maximize use fuelefficiency technologies already developed Specifically Boehlert wants Department Transportation toughen CAFE standards proposed late August September 2005 Boehlert introduced legislation H R 3762 nearly 70 cosponsors both parties technology cars trucks farther gallon gasoline already developed Pouliot said 2002 National Academy Sciences identified dozen technologies currently 'on shelf ' government implemented policies force technologies marketplace Stephen Barlas European Union recently published amendment EC Directive rear underrun protection devices known rear impact guards United States doubles load devices must capable withstanding introduces provisions allow gaps devices accommodate platform lifts according InterRegs new requirements 2006 20 EC apply new vehicle types September 11 2007 new vehicles March 11 2010 U S EPA Environmental Protection Agency issue new vehicle emissions standards toxic fumes gasoline new standards along existing ones help reduce toxic emissions passenger vehicles 80 below 1999 levels according EPA other things rule set new benzene standards gasoline hydrocarbon emissions standards passenger vehicles proposed standards effect 2010 passenger vehicles 2011 fuel requirements harmonize federal California evaporative emissions standards light-duty vehicles U S EPA proposed rule removal oxygen content requirement reformulated gasoline RFG produced sold throughout United States addition rule prohibit combining VOC-controlled RFG blended ethanol nonoxygenated VOC-controlled RFG January 1 September 15 Federal rules governing mixing already approved California InterRegs reports European Union published Directive requiring frontal protection systems referred bull bars United States pedestrian-friendly applies both original equipment aftermarket systems fitted cars multipurpose passenger vehicles trucks gross vehicle weight 3500 kg 7716 lb apply new vehicle types November 2006 new vehicles March 2007 insiders insights 158 APRIL 2006 aei aei-online org insiders insights Edited Patrick Ponticel Young engineers note career product development lead serious addiction love creating new vehicles longer worse addiction proof look Chris Theodore new Vice Chairman ASC American Specialty Cars Southgate MI-based design house niche vehicle manufacturer joining ASC November Theodore struggling retirement leaving Ford Vice President Advanced Product Development spearheaded GT supercar other programs 10 months immersed himself family teaching master's level courses engineering business University Detroit love spending time kids couldn't escape number passion developing new vehicles Theodore 55 recalled ideas cars still wanted head felt explode Six years injecting excitement Ford's product line top three decades various engineering management roles Ford first job University Michigan 1972 Detroit Diesel American Motors AMC Chrysler couple suppliers lost much-publicized battle Phil Martens Ford's top product development post 2004 Theodore realized return industry company maximize proven talents looked around find right place design total vehicles said basically three players field ASC Magna Roush AMC specialty car business Cars Concepts main competitor ASC founder Heinz Prechter greatly respected experience side industry Theodore knew ASC President Paul Wilbur both worked Chrysler struck deal seems heaven-sent both Theodore's responsibilities include ASC's product creation manufacturing plus purchasing live future said able stuff satisfies functional emotional needs can't quite conceive fun interview Theodore North American International Auto Show NAIAS illustrates deep industry connections are--and valuable new employer prepared regular interruptions Roger Penske makes detour say hello Barry Meguiar car-wax mogul creator popular TV show Car Crazy hunts Theodore guided tour ASC's latest concepts can't walk 10 paces stopping Theodore said exciting world's automakers pallet creative team throw great ideas different manufacturers meet needs Theodore's first project reorganizing ASC's operational model crossfunction system purchasing design engineering manufacturing engineering working together company develops new products grow its manufacturing operation set data shared real time--you call 'Chris's Law said That's we're moving Theodore believes product lifecycle management PLM process linking data analysis production suppliers used Ford bring GT production 28 months difficult implement larger older companies larger company effective communication becomes challenge PLM said Size means likelihood fixes applied correct problems ultimate creates bureaucracy ASC right-sized employ PLM effectively said part product-development process Theodore labels unique company process blends best practices GT program lessons learned Chrysler's ultra-lean 12 person Research Safety Vehicle program 1980s system Chrysler eventually built industry benchmark Chrysler 1990s Theodore built reputation platform- team revolution minivan program Chrysler under Engineering Vice President Francois Castaing pushing fast collaborative vehicle development Dassault Systèmes' CATIA tools both inherited pioneering AMC Theodore brought essential elements lean product development Ford 1999 ASC little 'Petri dish' apply I've learned years said grin really lean product development bring innovative products market faster ASC's current book business includes assembly Chevrolet SSR convertible systems Toyota Camry Solara Mitsubishi Eclipse various appearance packages Chrysler's SRT range Viper company employs 1000 people 10 facilities U S including California ad- Theodore brings 'Chris's Law' ASC Theodore sits ASC's Helios concept convertible based Chrysler 300C insiders insights aei-online org aei APRIL 2006 159 briefs vanced design studio Theodore explained ASC's future portfolio includes four main elements InfiniVu flexible roof systems unveiled year's NAIAS traditional convertible market total vehicle integration somewhat quixotic business noted appearance packages InfiniVu power-folding roof system concepts show ASC's innovation capabilities said Theodore offer OEMs solutions differentiate product lines Cosmos TriLite concepts based Hummer H3 Toyota Sienna respectively showed potential applications InfiniVu roof-system architecture InfiniVu based set common components electronic hardware controls helps keep costs low said Theodore key functional enabler horizontal header located D-pillar tracks way roof slides forward provides rear-loading access Theodore noted InfiniVu system scalable across vehicle sizes currently targeted SUV crossover minivan segments Offered durable fabric folds accordion-style three depending vehicle size stackable hard panels bidirectional roof units fold front-to-back back-to-front exposing interior's occupants varying degrees sky push button TriLite concept minivan roof panels Lexan GLX polycarbonate latest InfiniVu materials choice Developed collaboration GE Plastics Automotive clear Lexan offers weight savings 50 potentially greater shatter resistance compared glass panels ASC offers its InfiniVu materials suite Theodore's passion cars creativity stop ASC's headquarters During brief retirement kicked project veteran auto writer old friend Brock Yates developing kit convert classic 1970s Chrysler E-body Challenger Cuda modern muscle cars using independent suspension steering systems Hemi V8s Chrysler's current LX models day job quite provide enough automotive stimulation Theodore simply home open garage door choose eclectic fleet including Dodge Viper R T Nash Metropolitan Harley Softtail 1957 Ford Crown Victoria Skyliner retractable hardtop purchased eBay Lindsay Brooke InfiniVu powerroof system shown ASC's 2006 concept vehicles H3-based Cosmos above Sienna-based TriLite John Sheridan appointed President Chief Executive Officer Ballard Power Systems served roles interim basis since October previously served Chairman Board director since 2001 Sheridan earned bachelor's environmental studies degree University Waterloo Recently elected National Academy Engineering Priya Prasad Davor Hrovat Ford Gary Cowger Alan Taub General Motors Previously General Manager Magna Steyr's Graz Engineering Center Werner Wilhelm named Vice President Engineering Austrian company Volkswagen join Magna Steyr 2004 Byron Kearney Chrysler Group Vice President Product Development Core Components Process given 2006 Dean's Award annual Black Engineer Year Awards Conference attended 10 000 African- American executives mechanical engineer MBA Massachusetts Institute Technology Akio Okamura appointed President Ricardo-Japan worked Nissan early career Mary Ann Wright Ford Director Sustainable Mobility Technologies Hybrid Vehicle Programs appointed Executive Vice President Commercial Program Management Collins Aikman emerging markets Edited Patrick Ponticel Ricardo-Prague outpost sees growth Czech nationals office Ricardo's diverse--on par Detroit office Hill said--employing engineers countries Sri Lanka Bulgaria Turkey Jordan Slovakia Italy Proficiency English job qualification official business conducted English Czech nationals often use native language communicate themselves Hill said company considering relaxation its English language requirement Czech hierarchy takes shape allowing engineers ranks speak Czech themselves supervisors turn speak English superiors employees including outside Czech Republic must able speak Czech Hill noted said told Czech difficult learn only Mandarin Chinese Hill's Czech coming along Salaries vary greatly discipline overall one-third one-half offered Ricardo's UK office Work Ricardo's only outpost Central Europe supports work company's other offices Opportunities establish new business Ricardo continuing expand its presence Czech Republic company's engineers perform level matching its longerestablished operations according Manager Ricardo-Prague Martin Hill Western Europe Czech graduates leading universities tend quite useful day Hill said Graduates UK Hill bit academic need lot training become useful side Czech graduates weaker soft skills related things presentations time management Prague office limited according Hill only OEM significance country Skoda break Skoda depends relationship Volkswagen Skoda's parent company Germany said Hyundai planning open major manufacturing plant Czech Republic look promising terms new business Ricardo Hill said new Toyota PSA joint-venture plant uses little engineering content Czech Republic added Ricardo-Prague five distinct departments engine transmission vehicle software control electronics Hill doubles head engine department year Hill hiring department heads hiring responsibilities Although initially developed other offices several Ricardo software packages including PISDYN sole responsibility Prague office Ricardo- Prague working sister facilities develop new software packages bigger challenges future recruiting according Hill said great amount demand engineers local competitors engineering arms Skoda Porsche Mercedes-Benz well major suppliers including Siemens VDO Plus Czech engineers opting better-paying fields information technology banking Hill said result Ricardo-Prague's growth slow compared its early highgrowth years Hill said Patrick Ponticel China--Domestic brands including new top-seller Charade FAW unit Xiali surpassed sales foreign brands first time according Automotive Resources Asia Domestics captured 28 7 car market TRW begun operations commercial steering joint venture Changchun Chinese company FAWER 85 engineers Ricardo- Prague Czech nationals office undergoing expansion 1400 m2 15 000 ft2 Ricardo-Prague Manager Martin Hill says Czech Republic great highway system transporting product highly viscous governmental bureaucracy Slovakia--French company PSA Peugeot Citroën soon begin operations new compact vehicle assembly plant 300 000- unit annual capacity near capital Bratislava Thailand--Ford gave journalists dealers look new Ranger pickup truck March 7 planned officially unveil Bangkok International Motor Show March 23 1-ton 0 9-t truck built Thailand shipped 130 countries excluding U S Turkey--Visteon begun production climate control modules Gebze via its Korean affiliate Halla Climate Control installation Accents Hyundai's car assembly plant Izmit briefs Despite weakness integration Ricardo-Prague larger organization better anticipated Hill's opinion Communications barriers overcome relatively quickly said Hill Ricardo-Prague since opened March 2000 85 nearly 100 engineers employed Ricardo-Prague 160 APRIL 2006 aei aei-online org MACSTEEL Dana Corporation