Detailed FEV study shows the way to major vehicle mass savings
Significant vehicle mass reduction—up to 20%—is achievable if weight reduction is pursued as part of a "full-vehicle approach," according to a study by FEV Inc. released Dec. 13. The company used a 2010 Toyota Venza for its research because that model was used in an earlier, related study. The comprehensive phase-two study by FEV was conducted for the U.S. EPA. The previous study, by Lotus Engineering (go to www.sae.org/mags/aei/8512 to read more), was conducted for the International Council on Clean Transportation. That study did not address mass savings from the powertrain to the extent the new one does, nor did it use advanced CAE tools to judge the impact of mass-savings measures on safety, according to FEV. In both cases, the mass savings were to be achieved with no degradation in safety or other parameters. The new study shows that the body-in-white and closures offered the most mass reduction at 68.32 kg (150.62 lb), followed closely by suspension. Total mass savings of 18.3% (312 kg/688 lb) was achieved, and at a cost savings of $148 from manufacturing efficiencies.
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Advanced CAE tools were used as part of the comprehensive study that resulted in a report of 890 pages.
BMW and Boeing to collaborate on carbon-fiber materials
Two heavyweights in the automotive and aerospace industries are joining minds on lighter materials. BMW and Boeing on Dec. 12 announced they would do joint research on carbon-fiber recycling and share knowledge about the material and its manufacture. As part of the collaboration agreement, the two companies will also share carbon-fiber manufacturing process simulations and ideas for manufacturing automation. BMW in 2013 plans to introduce two models from its new i brand (i3 battery-electric and i8 plug-in hybrid) featuring bodies made of carbon-fiber-reinforced plastic. Boeing's new 787 Dreamliner aircraft is made up of 50% carbon fiber. The collaboration is the first ever between the two companies.
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The bodies of BMW's i brand models will use carbon-fiber-reinforced plastic. (Patrick Ponticel)
GM puts taillights aglow with new LED technology
Working with supplier 3M, General Motors engineers have developed what they claim is an industry-first LED taillight technology that delivers a soft, uniform red glow in a complex and unique shape. It is being deployed first on the MY2013 Buick Enclave, then will be cascaded to other Buick models, the company says. The uniform glow is made possible by 3M's Uniform Lighting Lens technology, which uses a precision engineered, micro-patterned, thermoformable polycarbonate material that provides even illumination around complex shapes with fewer LEDs, reducing both complexity and energy use, according to GM.
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The 2013 Buick Enclave's new taillights use an industry-first Uniform Lighting Lens technology from 3M for a unique look and reduced energy use.
Inteva expands in India
Inteva Products recently opened a new plant in India for manufacture of door latches, window regulators, and associated motors. The 72,000-ft² (6700-m²) facility in Pune's Chakan industrial area was designed for future expansion to about 100,000 ft² (9300 m²). Inteva India has complete execution and operational capabilities with full quality-assurance testing for both closure systems and motors and electronic product lines. The plant is designed to accommodate organic growth and has the potential for future expansion into the company's other product lines (interior systems and roof systems). In addition to the Pune Operation, Inteva has a technical center in Bangalore employing approximately 150 engineers and serving global and India business.
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Pune plant operations includes manufacturing lines for door latches, window regulators, and motors, with in-process testing capabilities.
New IIHS test aims to increase protection in frontal crashes
The Insurance Institute for Highway Safety (IIHS) has raised the bar with its new small overlap frontal crash test. With a 50th percentile male Hybrid III dummy in the driver seat, 25% of the car’s front end on the driver side strikes a 5-ft-tall rigid barrier at 40 mph. These small overlap crashes, which affect the outer edges not protected by crush-zone structures, are responsible for a considerable percentage of the 10,000 deaths in frontal crashes each year. The test utilizes three rating categories: structure, restraints and kinematics, and dummy injury measures. Of the vehicles tested, the Volvo S60 performed the best, permitting only a few inches of intrusion into the occupant compartment due to reinforcement of the upper rails and a steel cross member below the instrument panel. Common problems with other vehicles included high occupant compartment intrusion and unsafe occupant motion, including dummies that missed the airbag or moved too far forward toward the A-pillar. After 2013, the IIHS intends to add the small overlap frontal crash test to its list of evaluations for the Top Safety Pick award.
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Of the 11 midsize luxury and near-luxury cars tested, only three scored good or acceptable in the new small overlap frontal crash test from IIHS.
Dow expands composite processing capabilities
Dow Automotive Systems has expanded its capabilities in composite processing technology with two new development facilities—one in Freienbach, Switzerland, and the other in Midland, MI. The labs support global automotive and commercial transportation customers with an emphasis on carbon-fiber composites. The 200-m2 (2150-ft2) Composite Technology Center in Freienbach opened in April and is equipped with a large high-pressure resin transfer molding (RTM) machine for prototype production. It also offers development and testing facilities for resins and related adhesives, as well as an Adhesives Training Center. The Midland tech center, which opened in June, accommodates technologies associated with direct long-fiber processing, prepreg, preforming, compression molding, and laminating. This 465-m2 (5000-ft2) site is co-located with key corporate R&D capabilities including analytical sciences, the Materials Engineering Center, and polymer chemistry and processing related expertise. The two new composite technology facilities are part of Dow Automotive Systems’ strategy to support the industry’s push for more lightweight solutions.
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Dow Automotive Systems' new Composite Tech Center in Freienbach is equipped with a large high-pressure resin transfer molding (RTM) machine for prototype production.
NHTSA takes closer look at vehicle compatibility
A voluntary agreement reached among the world's major automakers in 2003 to reduce the risk of injury and death in collisions between passenger cars and larger light vehicles (LTVs) has produced questionable results, according to the NHTSA (U.S. National Highway Traffic Safety Administration). The agency is seeking comment on a technical report that describes the effectiveness of the Enhancing Vehicle-to-Vehicle Crash Compatibility Agreement (EVC), under which automakers agreed on voluntary standards for LTVs to reduce the height mismatches between LTVs and passenger cars. Overall, there was a statistically significant 8% reduction in car occupant fatalities of passenger cars after light trucks self-certified to the agreement. However, for pickup trucks and SUVs separately, the effectiveness is inconsistent. Pickup trucks experienced a nonsignificant increase of 5% likelihood of occupant fatalities of passenger cars, while SUVs were associated with a significant 17% reduction. The studies cited in the report "provide some evidence that the EVC has reduced fatalities, but are not sufficiently strong to permit an unequivocal conclusion that it has been effective in reducing fatality risk to car occupants." NHTSA will study comments received to determine whether to initiate rulemaking. The technical report can be viewed at http://www-nrd.nhtsa.dot.gov/Pubs/811621.pdf.
Phone app enables auto LED lighting design
Osram has developed a Web-based smart phone app for designers of exterior automotive lighting called the Automotive Signal LED Selector. Available for the iPhone, Android, or Blackberry OS, or any device with a Web browser, the tool provides lighting designers and engineers with a mobile, convenient, and easy-to-use tool to select the right LEDs for the application. Designers and engineers can quickly and easily select LEDs by function, color, regulatory requirements, luminosity, and the number of LEDs required. “As demand for LEDs in exterior signal and forward lighting increases, we saw the need for a portable tool that enables simplified calculations for function-specific LED selection,” said Mike Godwin, Director, Visible LEDs, Osram Opto Semiconductors Inc. “The Automotive Signal LED Selector is a mobile extension of Osram’s extensive know-how in automotive LED selection, offering access to the latest advances in LED technology.” Applications in the tool include center high mounted stop lamps, daytime running lights, front fog/park/position/turn lights, high/low beams, rear fog/park/position/stop/turn lights, and reverse and side marker/turn indicators.
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The Web-based smart phone app for designers of exterior automotive lighting—called the Automotive Signal LED Selector—is available for use with the iPhone, Android, or Blackberry OS, or any device with a Web browser.
GM-SAIC JV breathes life into climate wind tunnel in Shanghai
A climate wind tunnel that opened March 27 in Shanghai is notable for several reasons, according to the joint venture behind it, PATAC. According to PATAC (Pan Asia Technical Automotive Center) JV partners General Motors and SAIC (Shanghai Automotive Industry Corp.), it is the first climate wind tunnel in China that can provide rain and snow simulations. Among others that are operating in China, PATAC's is the only one that has a wind-speed deviation of less than 1% and a maximum wind speed of 250 km/h (155 mph). In addition, it has the widest temperature simulation range of -40 to +60°C (-40 to +140°F) and the largest humidity simulation range (5 to 95%). The JV claims that it can replace about 80% of climate road tests.
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PATAC engineers conduct wet weather testing on a Buick LaCrosse at the climate wind tunnel in Shanghai.
Europe toughens truck cab safety test
The United Nations Economic Commission for Europe (UN ECE) on Jan. 4 published the 03 series of amendments to Regulation No. 29 on commercial vehicle cab safety which introduces some significant amendments to the pendulum impact test procedures, according to InterRegs, an online resource for global vehicle safety and emissions regulations. The changes increase the impact energy level for the existing front pendulum impact test from 44 kJ to 55 kJ, specify an additional front pendulum impact test designed to test the cab’s A-pillars, and require that the cab roof be subjected to a lateral pendulum impact prior to the roof crush test being conducted. Compliance with these new requirements becomes mandatory for new types of truck from Jan. 30, 2017.
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